HCJ END TRUCKS

SERVICE AND INSTALLATION MANUAL

CATALOG 436A 1203 TECHNICAL PUBLICATIONS OAK CREEK, WI 53154 1-800-933-3001

Dangers, Warnings, Cautions, Notices

Dangers, Warnings, Cautions, and Notices are used throughout this manual to emphasize important and critical instructions. Dangers, Warnings, and Cautions always precede the paragraph or item to which they apply; Notices always follow the paragraph or item to which they apply. For the purpose of this manual Dangers, Warnings, Cautions, and Notices are dened as follows:

! DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is limited to the most extreme situations.

! WARNING DANGER
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTION DANGER
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTICE
Notice is used to notify people of installation, operation, or maintenance information which is important but not hazard-related.

COPYRIGHT
Under the copyright laws, this document may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form, in whole or part, without the prior written consent of Morris Material Handling, Inc. Copyright 2003 Morris Material Handling, Inc., Oak Creek, Wisconsin, USA 53154 All rights reserved. Printed in the United States. Published by: MMH Publications Department

Morris Material Handling, 1-800-933-3001

TABLE OF CONTENTS
Section 1 INTRODUCTION GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 TUBE END TRUCK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Section 2 MAINTENANCE AND REPAIR GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAINTENANCE . . . . . . . . General . . . . . . . . . . . Periodic Inspection . . . . . Lubrication . . . . . . . . . Bolt and Capscrew Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . 2-1 . 2-1 . 2-1 . 2-1 . 2-1 . 2-1 . 2-3 . 2-4 . 2-4 . 2-4 . 2-6

END TRUCK REPAIR . . . . . . . General . . . . . . . . . . . . . Removal . . . . . . . . . . . . Disassembly . . . . . . . . . . Cleaning, Inspection and Repair Assembly . . . . . . . . . . . . Installation . . . . . . . . . . . Section 3 PARTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSTRUCTIONS FOR ORDERING REPAIR PARTS . . . . . . . . . . . . . . . . . 3-1 RETURN OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSPECTION OF SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 8-INCH WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 10-INCH WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 12-INCH WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 RAIL SWEEP AND BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Section 1 Introduction
GENERAL
This manual provides lubrication, service, par ts information for the Morris Material Handling HCJ Tube End Trucks. This introduction section includes general infor mation about the Tube End Tr ucks, and a description of the end trucks themselves. The information, specications, and illustrations in this publication are based on the information for the tube end trucks that was in effect at the time this manual was printed. Continuing improvements and advancement of product design may cause changes to the components which may not be included in this manual. Each publication is periodically reviewed and revised to update and include these changes in later editions. Any questions regarding the information in this document should be directed to Morris Material Handling, Milwaukee, Wisconsin. With loads in excess of the maximum rated loads stated in the end truck product bulletin. Side pulling. With accessories not designed and furnished or approved by Morris Material Handling. With modications which will affect the operation or capacity of the end truck. Unsafe operating conditions. Operations for which the end truck is not rated or designed.

TUBE END TRUCK DESCRIPTION

Morris Material Handling manufactures several sizes of tube end trucks. These tube end trucks consist of a truck frame, an idler wheel assembly, a drive wheel assembly, and two bumper and rail sweep assemblies. See Figure 1-1. The tube end truck frames are manufactured using rectangular structural steel tubes.

WARRANTY
The warranty for these end trucks is void if the end trucks are operated under any of the following conditions:

Figure 1-1. CJ End Truck Assembly

Rev. Date 12/3/03

Section 1

1-1

Revised 12/3/03 The tube end truck wheel assemblies consist of a anged wheel made of high carbon steel, an axle, and a set of bearings with their associated bearing retainers. The drive and idler wheel assemblies use the same size wheels and bearings, however the drive wheel assembly is provided with an extended axle drive shaft that engages the end truck speed reducer or line shaft.

STORAGE
The tube end truck assemblies should be stored in a clean dry area and covered with heavy plastic to help prevent corrosion. Any bare metal should be prime painted before placing the end truck into storage, and the drive wheel shaft should be covered to protect it from dirt and other contaminants.

NOTICE
Optional speed reducers are not covered in this manual. Refer to the manufacturers service literature for ser vice, repair, and par ts information covering the applicable speed reducer. Depending on the size of the tube end truck, the wheel assemblies size will differ. The tube end truck wheel sizes include 8-inch (200mm), 10-inch (250mm), and 12-inch (300mm) wheel assemblies. All double wheel assemblies use double row spherical roller bearings to support the axle.

NOTICE
At initial assembly, end trucks are cleaned and furnished with one coat of conventional prime paint and are ready for subsequent nal painting. Special preparation and coatings are available through Morris Material Handling.

INSTALLATION
Due to the number of ways the end trucks can be installed, this manual does not cover the installation procedure in detail. For information regarding a particular installation, contact your Morris Material Handling sales or service representative.

1-2

Introduction

Section 2 Maintenance and Repair

GENERAL
This section provides the necessary information to inspect, lubricate, and repair the tube end trucks. Inspection and lubrication instructions are included under the maintenance topic followed by the repair instructions covered under the topic, End Truck Repair. Wheel oat is the amount the wheel can move across the rail from ange to ange. Wheel oat is approximately 3/4 to 1 inch for straight tread wheels. If any of the above conditions exist, repair or replace damaged parts as described under the topic, End Truck Repair.

! WARNING DANGER
When working at heights, full protective precautions should be used in accordance with OSHA regulations.

Lubrication
Lubrication of the end truck wheel assemblies is required periodically. The frequency of lubrication will depend on the operating environment of the end trucks. However, it is recommended that the lubrication period never exceed three months. The bearing housings on each side of the wheel assemblies are provided with lube ttings to allow application of grease to the wheel bearings. Apply multipurpose grease to each lube tting at three month intervals, or shorter periods if usage dictates the need. Refer to Table 2-1 for recommended lubr icant specications.

MAINTENANCE General
The following topics cover the general inspections that should be performed periodically on the tube end trucks. Lubrication information and specications, and bolt torques are also provided under this topic.

Periodic Inspection
Periodic inspection of the end truck assemblies is recommended to ensure proper operation and lubrication of the wheel assemblies. The frequency of inspection depends on the operating environment of the end trucks. Inspection of the end truck assemblies should include, but not limited to, the following: 1. Check for loose or missing mounting hardware. 2. Check wheel anges for wear and indications of the ange rubbing against the rail. 3. Inspect the wheels for at spots and any unusual wear patterns or markings. 4. Inspect the bumper and rail sweep assemblies for damage or wear. 5. Inspect the wheel bearings for proper lubrication and excessive wear. 6. Inspect the wheels for excessive oat.

Bolt and Capscrew Torques

Recommended bolt and capscrew torques are listed in Table 2-2. These torque values apply to all component mounting bolts and capscrews. It is recommended that all mounting bolts and capscrews be checked for tightness at least annually.

END TRUCK REPAIR General

Repair of the HCJ end truck assemblies is limited to replacement of wor n or damaged dr ive wheel assemblies, idler wheel assemblies, or rail sweep and bumper assemblies. Removal and installation of the end truck as an assembly is not covered in this manual due to the variety of end truck installation arrangements. Therefore, the following procedures cover only the removal, disassembly, repair, assembly, and installation
Section 2 2-1

Rev. Date 12/3/03

Revised 12/3/03

Table 2-1. Multipurpose Grease (MPG)

P&H spec no. 472A (NLGI #0 EP) Approximate Ambient Temperature Range *Below - 10F (-12C) Military Spec. No. Not Available

Equivalent Lubricants

Manufacturer

Alvania EP#0 Amolith Grease No. O EP Conolith EP #0 Dura-Lith Grease EP#0 Kendall L-406 Lidok EP#0 Mobilux EP #0 Multifak EP #0 Prestige 740 EP Unoba EP NLGI #0 Alvania EP #1 Amolith Grease #1 EP Conolith EP #1 Dura-Lith Grease EP #1 Gulf Crown Grease EP-1 Kendall L-416 Litholine H EP 1 Mobilux EP #1 Multifak EP #1 Philube EP-1 Prestige 741 EP Rolubricant 1 or Lidok EP #1 Unoba EP NLGI #1 Alvania EP #2 Amolith Grease #2 EP Conolith EP #2 Dura-Lith Grease EP #2 Gulf Crown Grease EP-2 Kendall L-426 Litholine H EP 2 Mobilux EP #2 Multifak EP #2 Philube EP-2 Prestige 742 EP Rolubricant 2 or Lidok EP #2 Unoba EP NLGI #2

Shell Oil Co. Amoco Oil Co. Continental Oil Co. Chevron USA, Inc. Kendall Rening Co. Exxon Co. Mobil Oil Corp. Texaco, Inc. Sun Co. Union Oil Co. of Calif. Shell Oil Co. Amoco Oil Co. Continental Oil Co. Chevron USA, Inc. Gulf Oil Co. Kendall Rening Co. Arco Petroleum Product Co. Mobil Oil Corp. Texaco, Inc. Phillips Petroleum Co. Sun Co. Exxon Co. (A) Union Oil Co. of Calif. Shell Oil Co. Amoco Oil Co. Continental Oil Co. Chevron USA, Inc. Gulf Oil Co. Kendall Rening Co. Arco Petroleum Product Co. Mobil Oil Corp. Texaco, Inc. Phillips Petroleum Co. Sun Co. Exxon Co. Union Oil Co. of Calif.

472B (NLGI #1 EP)

*-20 to 40F (-29 to 4C)

Not Available

472C (NLGI #2 EP)

*+20 to 125F (-6 to 52C)

Not Available

*Pumpability tests also required when used in centralized lubrication systems. Consult manufacturer of system. (A) Rolubricant for steel mill applications. P115

ISSUE NO. 10, 2/1/93

2-2

Maintenance and Repair

Morris Material Handling, 1-800-933-3001

Table 2-2. Recommended Bolt and Capscrew Torques

RECOMMENDED CAPSCREW TORQUE REQUIREMENTS IN FOOT-POUNDS.

GRADE OF BOLT
Capscrews & Trolley Rodbolts Capscrews & Trolley Rodbolts

BOLT SIZE and Threads / Inches

SAE GRADE 2

METRIC GRADE 5.8

SAE GRADE 5

METRIC GRADE 8.8

SAE GRADE 8

METRIC GRADE 10.9

5.8 Clean Dry Threads Motor Oil as New Plated Lubricant No Lube 4.50 5.40 9.90 11.70 16.20 18.00 25.20 27.00 35.10 36.90 45.90 49.50 74.70 85.50 94.50 103.50 144.00 157.50 211.50 225.00 4.00 4.80 8.80 10.40 14.40 16.00 22.40 24.00 31.20 32.80 40.80 44.00 66.40 76.00 84.00 92.00 128.00 140.00 188.00 200.00 Clean Dry Threads 8.00 10.00 17.00 19.00 31.00 35.00 49.00 55.00 75.00 85.00 110.00 120.00 150.00 170.00 270.00 295.00 395.00 435.00 590.00 660.00

8.8 Motor Oil as New Plated Lubricant No Lube 7.20 9.00 15.30 17.10 27.90 31.50 44.10 49.50 67.50 76.50 99.00 108.00 135.00 153.00 243.00 265.50 355.50 391.50 531.00 594.00 6.40 8.00 13.60 15.20 24.80 28.00 39.20 44.00 60.00 68.00 88.00 96.00 120.00 136.00 216.00 236.00 316.00 348.00 472.00 528.00 Clean Dry Threads 12.00 14.00 24.00 27.00 44.00 49.00 70.00 78.00 105.00 120.00 155.00 170.00 210.00 240.00 375.00 420.00 605.00 675.00 910.00 990.00

10.9 Motor Oil as New Plated Lubricant No Lube 10.80 12.60 21.60 24.30 39.60 44.10 63.00 70.20 94.50 108.00 139.50 153.00 189.00 216.00 337.50 378.00 544.50 607.50 819.00 891.00 9.60 11.20 19.20 21.60 35.20 39.20 56.00 62.40 84.00 96.00 124.00 136.00 168.00 192.00 300.00 336.00 484.00 540.00 728.00 792.00

1/420 1/4-28 5/1618 5/16-24 3/816 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-4

5.00 6.00 11.00 13.00 18.00 20.00 28.00 30.00 39.00 41.00 51.00 55.00 83.00 95.00 105.00 115.00 160.00 175.00 235.00 250.00

NOTES: 1. Always use the torque values listed above when specic torque values are not listed. 2. Do no used above values in place of those specied on illustrations and drawings. 3. For stainless Steel Bolts multiply torque values of SAE Grade 2 clean and dry by 1.1 4. For bolt sizes represented the unshaded values represent UNC threads, shaded represent UNF threads.

Section 2

2-3

Revised 12/3/03

of the truck wheel assemblies. The rail sweep and bumper assemblies are not repairable, and if damaged must be replaced as a complete assembly.

! WARNING DANGER
Working on an overhead crane bridge or trolley wheels without rst blocking the structure to prevent movement is hazardous, and may result in injury or death. Install wheel chocks or other blocking devices at each wheel location prior to servicing a wheel assembly. 4. Install wheel chocks on the wheel assemblies opposite the wheel being serviced. Secure chocks to the rail to prevent movement of the crane during the following procedures. 5. If a drive wheel assembly is being removed, remove the drive speed reducer, or line shaft coupling, as explained in the manufacturers service publication. 6. Using a suitable jack, raise the end truck assembly off its supporting rail to provide adequate clearance to remove the applicable wheel assembly. Use suitable blocking to support the end truck in its raised position. 7. Remove the nuts, lockwashers, and bolts which secure the rail sweep and bumper assembly to the end truck, and remove the rail sweep and bumper assembly. 8. Refer to Figure 2-1. Remove the capscrews (04) and lockwashers (05) which secure the bearing retainers (03) to the side plates (10). 9. While adequately supporting the wheel assembly using a suitable lifting device, carefully jack up the end truck to allow the wheel assembly to roll free from its mounting. Then remove the wheel assembly from the supporting rail. Move the wheel assembly to a suitable work area before continuing any repair work.

NOTICE
Removal of the entire end truck assembly should never be required unless the end truck has been structurally damaged. If the end truck has suffered structural damage, contact your local Morris Material Handling sales or service representative. The following topics describe the removal, disassembly, cleaning, inspection and repair, assembly, and installation of the drive and idler wheel assemblies used on the HCJ tube type end trucks. The drive and idler wheel assemblies are basically the same with the exception of the extended drive shaft provided on the drive wheel assembly. Due to this similarity, the topics cover both the drive and the idler wheel assemblies with the minor differences noted where applicable.

Removal
Proceed as follows. 1. Move the end truck to a suitable maintenance area away from personnel and machinery.

! WARNING DANGER
Working on or near an overhead crane while in operation is hazardous, and could result in injury or death. Shut down operation of the end truck, lock out and tag out the o p e r a t o r s c o n t r o l s a n d t h e p o w e r disconnect switch prior to working on the wheel assemblies.

2.

Shut down operation of the end truck, lock out and tag out the operators controls and the power disconnect switch prior to working on the wheel assemblies.

NOTICE
Protect the drive end of drive axle (02) during removal and disassembly to prevent damage.

3. Disconnect or remove the drive gear case or line shaft coupling as necessary, as described under the applicable procedures outlined in the service instructions specic to the drive gear.

Disassembly
Refer to Figure 2-1, and proceed as follows: 1. Capscrews (04) and lockwashers (05) have already been removed during end truck removal.

2-4

Maintenance and Repair

Morris Material Handling, 1-800-933-3001

Figure 2-1. HCJ End Truck Wheel Installation

Section 2 2-5

Revised 12/3/03

2. Support the truck assembly on suitable blocking. Pull bearing retainers (03) from spherical bearings (07) on the axle ends. 3. For the drive axle only, remove V-ring seal (09). 4. Pull spherical bearings (07) from idler axle (01) or drive axle (02). 5. Support truck wheel (06) on suitable blocking and press respective axle (01 or 02) from the wheel. 6. If lube ttings (11) are damaged, replace them with new ttings.

3. Repeat preceding step 2 for the opposite end of the axle for each axle (01 or 02). For the drive axle, install V-ring seal (09) on the drive end of the axle. 4. Install new lube ttings (11) in bearing retainers (03) as needed. 5. Install bearing retainers (03) over the spherical bearings (07) on the axles. Lubricate the bearing with multipurpose grease. Refer to Table 2-1. 6. Capscrews (04) and lockwashers (05) will be used during installation.

Cleaning, Inspection and Repair

Installation
Install a new or repaired drive or idler wheel assembly onto the tube type truck. Proceed as follows:

! CAUTION DANGER
Compressed air will cause debris to y in the air and can cause face or eye injury. Be sure you are wearing appropriate face and eye protection. Thoroughly clean each part of the wheel assembly in a suitable solvent. Dry each part using low pressure, ltered compressed air. Do not spin bearings when drying them, or the bearing will be damaged. Nicks and burrs on the shaft or the wheel may be removed by polishing. Remove any nicks caused by handling using ne sandpaper or oil stone.

! WARNING DANGER
Working on or near an overhead crane while in operation is hazardous, and could result in injury or death of personnel. Shut down the operation of the end truck, open, lock out and tag out the operators controls and the power disconnect switch prior to working on the wheel assemblies. 1. Shut down the operation of the end truck, lock out and tag out the operators controls and the power disconnect switch prior to working on the wheel assemblies. 2. Check the mating surfaces of the bearing retainers with the mounting side plates making sure that the surfaces are free of burrs and dirt. 3. Position the wheel assembly underneath the end truck making sure that the extended drive axle is facing in the proper direction. 4. Lower the end truck or raise the assembly until the bearing retainers can be slid into position on the side plates. 5. Install capscrews (04, Figure 2-1) and lockwashers (05) to attach the bearing retainers to the side plates. Tighten the capscrews to the torque specied in Table 2-2 for the applicable capscrew size being used. 6. Raise the end truck off the blocking using a suitable jack and remove the blocking. Lower the end truck onto its supporting rail.

! CAUTION DANGER
Rotating parts can cause injury to ngers. Be aware and use caution. Inspect the bearings for freedom of rotation. If the bearings are excessively worn or do not rotate freely, replace them with new bearings.

Assembly
Refer to Figure 2-1, and proceed as follows: 1. Support truck wheel (06) on suitable blocking and press idler axle (01) or drive axle (02) into the truck wheel until the wheel is centered on the large OD of the axle between the shoulders. 2. Place a spring disc (08) on one end of axle (01 or 02). Press a spherical bearing (07) onto the axle ush with the disc. Make sure to press only on the inner race of the bearing.

2-6

Maintenance and Repair

Morris Material Handling, 1-800-933-3001 7. If necessary, install the drive speed reducer, or line shafting, as instructed in the manufacturers installation publication. 8. Install the rail sweep and bumper assembly using the bolts, lockwashers and nuts provided. Securely tighten the bolts and nuts. 9. If necessary, lubricate the bearings multipurpose grease. Refer to Table 2-1. 10. Remove any wheel chocks. 11. Test crane for proper operation to verify work has been done correctly. with

Section 2

2-7

Revised 12/3/03

NOTES

2-8

Maintenance and Repair

 2003, MORRIS MATERIAL HANDLING, INC. Technical Publications Oak Creek, WI 53154 1-800-933-3001 Catalog 436A