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Lodestar AIR XL Operating, Maintenance & Parts Manual

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O P E R AT I N G ,
M A I N T E N A N C E
& PA R T S
M A N U A L
A I R
C H A I N H O I S T
A A I I R R X X L L C C H H A A I I N N
Before installing hoist, fill in
the information below. Refer
to the hoist identification
plate.
Model No. __________________
Serial No. __________________
Purchase Date ______________
Rated Capacity______________
53031
H H O O I I S S T T
Rated capacities 2 through 7½ tons/
2000 through 7500 kg
Follow all instructions and warnings for
inspecting, maintaining and operating this hoist.
The use of any hoist presents some risk of personal
injury or property damage. That risk is greatly
increased if proper instructions and warnings are not
followed. Before using this hoist, each operator
should become thoroughly familiar with all warnings,
instructions and recommendations in this manual.
Retain this manual for future reference and use.
Forward this manual to operator.
Failure to operate equipment as directed
in manual may cause injury.
®
Manual No. A652-D

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Summary of Contents for Lodestar AIR XL

  • Page 1 O P E R AT I N G , M A I N T E N A N C E & PA R T S M A N U A L A I R C H A I N H O I S T A A I I R R X X L L C C H H A A I I N N ®...
  • Page 2 XL AIR HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES AND IN CANADA As a XL Air Hoist user, you are assured of reliable repair and parts services through a network of Master Parts Depots and Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.

  • Page 3: Safety Precautions

    SAFETY PRECAUTIONS Each XL Air Hoist is built in accordance with the specifications contained herein and at the time of manufacture com- plied with our interpretation of applicable sections of the *American Society of Mechanical Engineers Performance Standard for Air Chain Hoist HST-5M, “Overhead Hoists B30.16,” and the Occupational Safety and Health Act. Check each installation for compliance with the application, operation and maintenance sections of these articles.

  • Page 5: Table Of Contents

    FOREWORD This manual contains important information to help you properly install, operate and maintain your hoist for maximum performance, economy and safety. Please study its contents thoroughly before putting your hoist into operation. By practicing correct operating proce- dures and by carrying out the recommended preventative maintenance suggestions, you will experience long, depend- able and safe service.

  • Page 6: General Information

    GENERAL INFORMATION SPECIFICATIONS Shielded, lifetime lubricated ball bearings at all rotating points. Open bearings are used in gear case. The XL Air Chain Hoist is a highly versatile material han- Three stage gear reduction. dling device that can be used to lift loads that are within its rated load capacity.

  • Page 7: Repair/Replacement Policy

    REPAIR/REPLACEMENT POLICY LUG SUSPENSIONS Lug suspensions are required to suspend the XL Air Hoist All XL Air Chain Hoists are thoroughly inspected and perfor- from plain, geared or motor driven trolleys described mance tested prior to shipment. If any properly maintained below.

  • Page 8: Installation Unpacking

    INSTALLATION UNPACKING After opening the carton, carefully inspect the hoist, control line, pendant, suspension, trolley and chain con- tainer for damage that may have occurred during ship- ment. If there is damage, refer to instructions on the packing slip envelope. INSPECT FOR SHIPPING DAMAGE MOTOR DRIVEN TROLLEY...
  • Page 9 b. If it is necessary to position the hook so that the If a swivel type hook is required, remove and discard plane of the hook is perpendicular to the long the keeper plate screw and keeper plate. Then axis of hoist, first convert to a swivel type hook as using ahammer, drive the hook nut pin into nut so described above.

  • Page 10: Lug Suspensions

    B. LUG SUSPENSIONS MOUNTING TROLLEY ON HOIST The following instructions are provided to cover The following instructions are provided to cover mount- installing the lug suspension after the hoist has been ing plain, geared and motor driven trolleys after the hoist reassembled following inspection and/or repair.

  • Page 11: Installing Trolley Suspended Hoist On Beam

    4. On geared trolleys, make sure the handwheel is on the loose end/chain container side of the hoist. On motor driven trolleys make sure the motor is located on the loose end/chain container side of the hoist. INSTALLING TROLLEY SUSPENDED HOIST ON BEAM QUANTITY OF QUANTITY OF INSIDE WASHERS...

  • Page 12: Installing Breather

    Units with anti-tipping rollers should be adjusted to pro- INSTALLING BREATHER vide 1/8” maximum gap between the bottom of the After the hook suspension is assembled to the hoist or after the beam and the roller. Run the trolley the length of the hoist and trolley are mounted on the beam, remove the upper beam to check for tight places.

  • Page 13: Checking For Twist In Load Chain

    WARNING OPERATING INSTRUCTIONS Allowing the hook block to run into the bottom of the hoist when raising a load or allowing the dead GENERAL end stop to run into the frame when lowering a 1. The Protector is designed to allow the first reduction gear load may break the chain and allow the load to to slip on an excessive overload.

  • Page 14: Hoist With Plain Trolley

    hook block has been capsized between the strands of chain. Reverse the capsize to remove the twist. 3. Take up a slack load chain carefully and start the load easily to avoid shock and jerking of the hoist load 10. Do not allow the load to bear against the hook chain.

  • Page 15: Hook Inspection

    LOAD CHAIN Records of periodic inspections are to be kept for continuing evaluation of the condition of the hoist. Periodic inspections Cleaning and Inspection are to be performed yearly for normal service, semi-annually First clean the load chain with a non-acid or non-caustic for heavy service and quarterly for severe service, and they are to include those items listed in Table 3.
  • Page 16 Table 3. Minimum Frequent Inspections TYPE OF SERVICE ITEM Severe Normal Heavy Brake for evidence of slippage. Control functions for proper operation. Hooks for damage, cracks, twists, excessive throat opening. latch engagement and latch operation–see page 13. Load chain for adequate lubrication, as well as for signs of wear, damaged links or foreign matter–see page 15.
  • Page 17 Notes...

  • Page 18: Lubrication

    LUBRICATION Service Air Line Lubricator. The air line filter and lubricator is the only source of lubrication for control valves and air motor. Fill lubricator with a good grade WARNING air tool oil or 10W machine oil Feed one drop of oil for every 50 to 75 cubic feet of air going through the air The lubricants used in and recommended for the XL Air Hoist may contain hazardous materials that mandate specific han-...

  • Page 19: Trolley Brake

    TROLLEY BRAKE (2 THRU 7½ TON UNITS) RECOMMENDED SPARE PARTS (Optional Accessory) To insure continued service of the XL Air Hoist, the Horton/Nexen Brake Information: following is a list of parts that are recommended to be kept on hand at all times to replace parts that The brake can be ordered with the trolley or it is avail- have worn.

  • Page 20: Trouble Shooting

    TROUBLE SHOOTING TROUBLE PROBABLE CAUSE REMEDY 1. Hoist does not operate. a. Insufficient air pressure at source. a. Check and adjust air pressure. b. Insufficient air supply at hoist b. Use correct size air supply hose. c. Clogged air intake filter or muffler. c.

  • Page 21: Air Data

    HOIST DISASSEMBLY Refer to pages 24 through 39 for exploded views and 9. Remove the limit switch gear (652-149) from the parts list. The following are general guide lines for dis- limit switch input shaft (652-104) and remove the assembling the XL Air Hoist. Prior to disassembly: shaft from the intermediate plate.

  • Page 22: Valve Disassembly/Reassembly

    Down Pilot Tube (Blue) Up Pilot Tube (Red) Spool Body Spool Body Screws Adapter Block Quick Connect Quick Exhaust Valve Fitting Collar Motor End View VALVE REASSEMBLY VALVE DISASSEMBLY Lubricate the return end caps, springs, and spool cavity with a layer of EP grease as listed on page 14. Be sure Turn off the air supply and bleed off the stored air by the vents on the end caps are exposed.
  • Page 23 VALVE Exhaust Block Spool Body Intake Block Spool Adapter Block Spool End Block SPOOL 70 Durometer o-rings Vent Spool Spool End Cap MOTOR REBUILD (see exploded view, page 39) Remove the end cap. Remove the dead end plate bolts Remove the dead end plate. Do not use a screwdriver to remove the end plate.

  • Page 24: Removal And Replacement Of Load Chain

    13. Install the vane spring lip into the notch at one end of the vane and place in the rotor vane slot with the spring facing the pushpin. 14. Place the proper end plate gasket on the body of the dead end.

  • Page 25: Reeving Load Chain

    hoist frame. Turn the dead end bolt by hand to thread liftwheel pockets. If the chain is not properly placed it into the dead end block. Then tighten dead end bolt on the liftwheel, it will not be possible to install the to a seating torque of 120 pound feet (160 NM).

  • Page 26: Cutting Chains

    Hoistaloy  load chain is hardened and it is difficult to CUTTING CHAINS TESTING Before using, all altered, repaired or used hoists that have cut. The following methods are recommended when cutting a not been operated for the previous 12 months shall be length of new chain from stock or cutting off worn tested by the user for proper operation.
  • Page 27 Repair Parts Hoists that have been in service for a long period or under adverse conditions may require disassembly for adjustment and replacement of parts. The drawings on the following pages are of the exploded type to indicate order of assembly and relative position of parts.
  • Page 41 PART NUMBER REF. 3 TON 2 & 3 TON 5 - 7 1/2 TON PART DESCRIPTION REQ’D PLAIN GEARED MOTOR PLAIN GEARED MOTOR DRIVEN DRIVEN SIDE PLATE ASSEMBLY FOR: 4” TO 6 1/4” FLG. AND PATENTED TRACK 700T-1400 700T-1700 BET-2800 700T-1501 700T-1801 BET-3801 6 3/8”...
  • Page 42 3 THRU 7½ TON MOTOR AND GEAR BOX ASSEMBLY 2 THRU 7 1/2 TON MOTOR AND GEAR BOX ASSEMBLY TROLLEY BRAKE (OPTIONAL) page 39 *SEE PAGE 39 FOR TROLLEY BRAKE ASSEMBLY Ref. No. No. Req’d Part Description Part Number Gear Box Assembly BET-3003 Air Brake Contact Factory...
  • Page 43 Air Motor Components Ref. Qty. Description Drive End Cap Seal O-Ring Locknut Lockwasher Drive End Bearing Spacer Drive End Plate Dowel Pin Spacer Gasket Body Rotor Assembly Push Pin Vane Spring Vane Dead End Plate Dead End Bearing End Cap Gasket Dead End Cap Dead End Plate Bolts Dead End Plate Cap Bolts...
  • Page 44 Note: When ordering parts, always furnish Hoist Model and Serial Number, Motor Horsepower, Voltage, Phase, Frequency and Rated Capacity of hoist on which the parts are to be used. For the location of the nearest Master Parts Depot, see the list located on the inside front cover.

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