26
Trolley Removal
1.
Remove locknut (47) and nut (48) from only one side of
trolley.
2.
Slowly and very carefully separate side plate assemblies
(59 and 52), catching the spacers and washers (63 and 64)
as they slide off shaft (105).
3.
Lower trolley from beam and move to work bench.
Trolley Disassembly
1.
Remove capscrews (57) and lockwashers (58), lift off
counterweight (62).
2.
Using special tool, pull wheels (53) and (54) from side
plates. Remove retainer rings (56) and bearings (55) from
wheels.
3.
Remove locknut (47) and nut (48) from shaft (105). Note
how many spacers (63) are on each side of side plate (59 or
52), this will be used during assembly.
4.
Remove capscrews (49) and lockwashers (50).
5.
Remove side plate (52).
Brake Disassembly (optional feature)
Refer to Dwg. MHP1075.
1.
Remove the four capscrews (70 and 71) and lockwashers
(16) from brake cover (72). Remove cover and gasket (73).
Gasket (73) is rubber and should not be glued to either
cover (72) or brake housing (90).
2.
Remove retainer (84). Push down on brake lever (82),
while pulling brake pin (83) out of lever block (80).
Carefully release pressure on brake lever (82).
3.
Remove locknut (97, not available separately, part of 85)
on solenoid (85) end of brake lever (82). Remove brake
lever (82), spring (87), spring guide (88) and spring (98,
not available separately, part of 85).
4.
Remove cup disc (74), brake washer (75) and brake discs
(76 and 77).
5.
Remove retainer ring (29) and brake hub (92) depending on
position of rotor shaft (31), key (93) might fall out also.
Remove key (93).
6.
Record how control cable wires are connected to solenoid
(85) through terminal block (89). This will be used during
reassembly.
7.
Disconnect control cable wires from terminal block (89)
and ground (earth) connection (items 81 and 16).
8.
Separate cable connector (95) and pull control cable out of
housing (90).
9.
Remove plug (94).
10. Going through access holes in housing (90) remove
capscrews (86) and washers (16). Slide solenoid (85) out of
housing.
Trolley Motor Disassembly
1.
Position motor assembly with the gear cover (40) facing up
(cavity in gear housing (33) is full of lubricant). Remove
four capscrews (42) and lockwashers (34). Remover gear
cover (40) by tapping around sides with a polyurethane
hammer. Once cover is off remove retainer ring (36).
2.
Pull out gear assembly group (32, 37, 39, 44, 45 and 46).
3.
Disassemble the gear group consisting of bearing (32),
bearing (37), gear (39), retainer ring (44), key (45) and
pinion shaft (46).
a.
Remove bearing (37) with two small pry bars or small
gear puller, this bearing is pressed on.
b.
Remove gear (33) and key (35).
c.
Remove bearing (27).
d.
Remove retainer ring (44).
4.
Remove capcrews (35) with lockwashers (34). Remove
gear housing (33).
5.
Remove retainer ring (36) from gear housing (33).
6.
Rotor (31) may come out with gear housing (33) if it does
then tap rotor (31) out of housing (33).
7.
Pull rotor (31) out of stator (28).
8.
Remove retainer ring (29) from opposite end of rotor (31).
Remove bearings (30 and 32).
9.
Remove motor cover (27) by removing capscrews (26) and
lockwashers (16). If unit has no brake.
Control Housing Disassembly
1.
Disconnect the following lettered or numbered wires from
terminal strip (part of item 5).
a.
Motor wires (U1, V and W).
b.
Housing ground (earth)(PE).
c.
Pendant (50, 41, 42, 44, 1, 2, 3 and 4 depending on
options)
d.
If equipped, brake (PE, U1 and 49).
2.
Remove screws (4) from control assembly (5) mounting
plate.
3.
Loosen cable connectors (19 and 22) and pull out control
cables.
4.
Remove screws (17) and washers (16). Remove relay box
(18) and gasket (24).
5.
Remove screw (81) and washer (16) pull out ground (earth)
wire.
Cleaning, Inspection and Repair
Use the following procedures to clean, inspect, and repair the
components of the trolley.
Cleaning
• Bearings that are loose, worn or rotate in the housing must
be replaced. Failure to observe this precaution will result in
additional component damage.
• Do not use trichloroethylene to clean parts.
Clean all trolley components parts in solvent. The use of a stiff
bristle brush will facilitate the removal of accumulated dirt and
sediments on the gears and frames. Dry each part using low
pressure, filtered compressed air.
Inspection
All disassembled parts should be inspected to determine their
fitness for continued use. Pay particular attention to the
following:
1.
Inspect all gears for worn, cracked, or broken teeth.
2.
Inspect shafts for ridges caused by wear. If ridges caused
by wear are apparent on shafts, replace the shaft.
3.
Inspect all threaded items and replace those having
damaged threads.
4.
Check bearings for wear and ability to freely rotate.
Replace bearings if rotation is rough or bearings are
excessively worn.
Repair
Actual repairs are limited to the removal of small burrs and
other minor surface imperfections from gears and shafts. Use a
fine stone or emery cloth for this work.
1.
Worn or damaged parts must be replaced. Refer to the
applicable parts listing for specific replacement parts
information.
2.
Inspect all remaining parts for evidence of wear or damage.
Replace or repair any part which is in questionable
condition. The cost of the part is often minor in comparison
with the cost of redoing the job.
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