OPERATION AND PARTS MANUAL

ML500
THIS MANUAL MUST
ACCOMPANY THE
EQUIPMENT AT ALL TIMES.
Manufacturer Address: Sales Office:
Esquire Machines Pvt. Ltd. 10, Haribhakti Colony Extension,
Plot No. 316/317 301 – 302, 3rd Floor,
G.I.D.C., Por, Ramangamdi, Old Padra Road,
Vadodara – 391243, Gujarat, Vadodara – 390015
(INDIA)
Mobile: Email : ema@esqmach.com
Domestic : +91-9662023744 Website : www.esqmach.com
Export : +91-9825466353

® Registered trademark of Esquire Machines Pvt. Ltd, Vadodara

NOTES
 TABLE OF CONTENT
Mini Lift Specifications………..............................................................1
General Information............................................................................2
Safety Message Alert Symbols...........................................................3
Rules for Safe Operation....................................................................4
Mini Lift Basic Components................................................................6
Pre-Inspection…………......................................................................7
Mini Lift Operation..............................................................................8
Maintenance (Machine)......................................................................9
Mini Lift Trouble Shooting...................................................................10
Ordering Spares.................................................................................11
Main Assembly...................................................................................12
Tripod Assembly.................................................................................14
Bearing Housing Assembly with Bracket............................................15
Idler Gear Assembly............................................................................16
Drum and Gear Assembly...................................................................17
Boom Assembly..................................................................................19
Tool Kit List………………....................................................................21
Manufacturer's Warranty.....................................................................22
 ML500 – SPECIFICATIONS
Table 1. Specifications (Geared Motor)
Model Helical Gear Brake Motor
Motor Brake Motor
Power (kw/hp) 2.25/3.0
Motor Frame 100
Brake Electromagnetic Type Disc Brake With Manual Release
Brake Torque (Nm) 38
Gear Ratio 18.79
Out Put Speed (rpm) 76.6
Out Put Torque (Nm) 280.64
Weight of Geared Motor 70
(kg)
Geared Motor overall Length – 772, Width – 250, Height – 282
dimensions (mm)

Table 2. ML500 Specifications

Height (mm/in) 2582/101.65
Width (mm/in) 2990/117.72
Length (mm/in) 3791/149.25
Lifting Capacity (kg) 500 Net.
Max. Lifting height (m) Up to 100
Rotation (degree) 360
Wire Rope Dia. (mm) 8
Speed (meter/minute) 20
Boom Length (mm) 1650
Feature Non Rotating Wire Rope

1
 MINI LIFT MACHINE – GENERAL INFORMATION
Congratulations for buying the “ESQUIRE” make 500 kg machine and we are sure that our
workmanship and craft of the machine will make your Mini Lift task easy. At Esquire we
construct machines for the construction people and this Mini Lift machine is addition to the
already growing family of construction machines.

This manual is prepared with a view to assist operator and owner to get best results from our
Mini Lift machine.

Before machine is commissioned and put in use, read the manual thoroughly to minimize the
down time.

We request to read gearbox manual, circuit diagram and rope lubrication properly before
starting machine.

2
MINI LIFT MACHINE – SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND be injured if you do

SAFETY OF OTHERS!
Safety precautions should be followed
at all times when operating this
equipment. Failure to read and
understand the Safety Messages and
Operating Instructions could result in
injury to yourself and others.
not follow directions.
Potential hazards associated with the
Esquire mini lift machine operation will
be referenced with Hazard Symbols
which appear throughout this manual,
and will be referenced in conjunction
with Safety Message Alert Symbols.

This Owner's HAZARD SYMBOLS

Manual has been
developed to Rotating Parts
provide complete NEVER operate
instructions for the equipment with
safe and efficient operation of the covers, or guards
Mini Lift. Before using this machine, removed. Keep
ensure that the operating individual fingers, hands, hair
has read and understood all and clothing away
instructions in this manual. from all moving parts
to prevent injury.
SAFETY MESSAGE ALERT SYMBOLS
Equipment Damage Messages
The three (3) Safety Messages shown Other important messages are provided
below will inform you about potential throughout this manual to help prevent
hazards that could injure you or others. damage to your machine, other
The Safety Messages specifically property, or the surrounding
address the level of exposure to the environment.
operator, and are preceded by one of
OP ERATOR’S
three words: DANGER, WARNING, or
SAFETY:
CAUTION.
DANGER: You will
be killed or seriously Operator must
injured if you do not wear safety belt
follow directions. attached to anchor
bolt properly grouted on
slab or with pillar while operating mini
WARNING: You can lift.
be killed or seriously
injured if you do not
follow directions.

CAUTION: You can

3
 MACHINE SAFETY WITH LIMIT
SWITCH:
Limit switch provided for safe operation
of machine in case weight reaches top
limit.
Limit switch will cut off motor power
supply and machine will be stopped to
avoid further damage and accident.

4
 MINI LIFT MACHINE –
RULES FOR SAFE
OPERATION
DANGER: medicine.
Failure to follow  NEVER operate this
instructions in this equipment under the
manual may lead to influence or drugs or
serious injury or even
alcohol.
death! This equipment
is to be operated by  ALWAYS check the machine for
trained and qualified loosened threads or bolts before
personnel only! This equipment is for starting.
industrial use only.  ALWAYS wear proper hearing and eye
The following safety guidelines should protection equipment when operating
always be used when operating the the machine.
Esquire Lifting:  NEVER! Place hands inside the
GENERAL SAFETY: machine while working.
 DO NOT operate or  NEVER operate the machine in
service this an explosive atmosphere. An
equipment before explosion or fire could result
reading this entire causing severe bodily harm or death.
manual.  Never use accessories or
 This equipment attachments which are not
should not be recommended by Esquire for this
operated by persons equipment. Damage to the
equipment and/or injury to user
under 18 years of
may result.
age.
 Manufacturer does not
 NEVER operate this assume responsibility for any
equipment without accident due to equipment
proper protective modifications.
clothing, shatterproof
glasses, steel-toed  ALWAYS read, understand and
follow procedures in Operator's
boots, safety belt and Manual before attempting to
other protective operate equipment.
devices required by  ALWAYS be sure the operator is
the job. familiar with proper safety
 NEVER operate this precautions and operations
equipment when not techniques before using machine.
feeling well due to  ALWAYS store equipment properly
when it is not being used. Equipment
fatigue, illness or taking

5
 should be stored in a clean, dry
location out of the reach of children.  Before starting any maintenance,
 NEVER leave the machine remove all electrical connection.
unattended, unplug switch board  Bring machine from edge of floor to
when unattended. center of floor.
 CAUTION must always be observed  Keep counter weight placed in its
while servicing the machine. Rotating position.
parts can cause injury if contacted.  Wire rope swivel hook to be
 Unauthorized equipment clamped in c-shape rode welded in
modifications will void all warranties. boom support.
 This machine is intended for lifting  NEVER lubricate components or
the materials. Mini lift must be used attempt service on a running
only for its intended purpose. machine.
 This machine is not suitable for lifting  ALWAYS allow the machine a
of materials beyond mentioned proper amount of time to cool before
capacity. servicing.
 Keep the machinery in proper
 NEVER operate the machine in an running condition.
explosive atmosphere.  Fix damage to the machine
 Before starting the machine, check immediately and always replace
that all guards are in position and broken parts.
correctly fitted.  Gearbox supplied with long-life
 Keep area around the machine clear synthetic oil and do not require any
of obstructions which could cause maintenance.
persons to fall onto moving parts.
 ALWAYS ensure machine is on level
ground before lifting.
 Become familiar with the controls of
the machine before operating.
 ALWAYS ensure the drum is
rotating while winding and
unwinding wire rope.
 ALWAYS use safety belt while lifting
material.
 NEVER look down from top if no
parafit wall available.
 After loading material at ground,
before lifting move away from falling
area.
 Machine must be installed having
proper space for accessories
movement, no abstraction allowed in
its moving path.

MAINTENANCE SAFETY:

6
 MINI LIFT MACHINE –
BASIC COMPONENTS(F

Fig.1
Major Mini
Lift

Components

1. Tripod Base Support: - It consist of for wire rope clamping when machine
fabricated light duty structure on which is in
counter weights are kept. There are 3 maintenance. Welded pipe is used for
Tripod base supports for balancing easy
whole rotation of boom assembly for
machine. unloading
the material on given height.
2. Vertical Support: - It consists of
vertical
shaft on which bearing housing is
placed
through taper roller bearing at upper 5. Boom Assembly: - It consist of
side. pulley
and limit switch. Limit switch is for
3. Drum and Gearbox Assembly: - It is safe
the operation of machine.
main assembly of whole machine
which 6. Handle Assembly: - Handle
consists of bearing housing, wire rope assembly is
drum,brake motor & gearbox and used for moving Radially upper
Gear portion of
drive. machine.

4. Boom support Assembly: - It 7. Counter Weight Bucket: - It is

consist of used to
fabricated light duty structure which put counter weights for balancing
support whole
boom assembly. It consist of c-shape machine before lifting the material.
hook It is

7
 folded type , so easy to transport
from
one place to another.

MINI LIFT MACHINE – PRE-INSPECTION

Before Starting:

1. Check assembly as per figure.

2. Check all electrical connections.
3. Check limit swich functionality.
4. Check fastening nuts and bolts for
tightness.
5. Ensure oil level in gear box.
6. counter weight to be placed as
given.

Gear box Oil Check:

1. Using the level plug window, verify

periodically the correct quantity of
lubricant.
2. Verify the breather plug hole is
clean. Regularly make sure that
there are no lubricant leaks.
3. To verify and check above two
points, you have to remove middle
cover of machine.

8
 MINI LIFT MACHINE – OPERATION
must be in locked position(Fig 2).
Pre-Operation: Attach
1. Give electrical connection for start hook to material carrying accessory
up. and
2. Counter weights should be placed lift the material at appropriate
at tripod base before starting. required
3. Check direction of wire rope. Wire height.
rope should go upward when After that release lock (Fig. 3) and
upward command given and rotate
down when downward command boom assembly and put accessory at
given. If it is wrong, change motor floor
poles. level. Now release hook from
4. Check limits switch functionality. If accessory
it is not proper working, then move to required placed.
check electrical connection of limit Repeat this action for lifting material
switch or replace limit switch. at required height.
5. When machine is in operation,
drum and gear box assembly
should be in locking position to
vertical support (Fig. 2). Then
release lock after material
reaching at required place for
rotation (Fig. 3).

Operation
:
Bring
down the wire rope hook for lifting
material. At this stage boom Fig. 3 Unlocking Position
assembly
Fig. 2 Locking Position

CAUTION:
NEVER stand below lifted material
while machine is working.

9
 MINI LIFT MACHINE – MAINTENANCE
Flange Bearing Grease Fittings:
There are 2 grease fittings that will require lubrication. Lubricate these fittings
once a month. Use suitable bearing grease.

Use Multipurpose Grease or equivalent lubricant. Clean grease fitting, apply

grease gun to fitting (1/2 shot). Remember too much grease or injecting grease
too quickly can cause premature bearing failure. Slowly apply the recommended
amount of grease, taking a minute or so to apply.
Taper Roller Bearing of Bearing Housing:
1. After every 3 months of operation, remove the dust cap and inspect the
Taper roller bearing. Once a 6 month, or when required, remove the old
grease and repack the bearings forcing grease between rollers, cone and
cage with a good grade of high speed bearing grease.
Gear-drive Lubrication:
1. For smooth functioning of gear-drive, proper lubrication should be used.
2. Refer multipurpose grease no. 3 for lubrication.

Gearbox Maintenance:

Please read the manual properly before working/maintenance on Gearbox.

Gearbox manual is given with machine.
1. Replace oil after 15,000 hours.
2. While replacing oil, first drain out old one.
Add new oil 0.3 litre
3. Type of oil
Mobil SHC 630
Shell Tivela S220
Klubersynth GH6-220
4. Check oil level through available site glass.
5. When it is necessary to fill the oil but there is no space for the new oil inside of
the
gearbox, We sugget to empty the gearbox from its oil before putting the new
one.
Rope Lubrication:

Rope need to be properly lubricated as it gets dry, this is required for rope to be
kept in
good condition and avoid rusting and its life.
Use lubricant of grade USHA WRL-55 make -Usha Martin OR equivalent.

10
11
 MINI LIFT MACHINE – TROUBLE SHOOTING
Practically all breakdowns can be prevented by proper handling and maintenance
inspections, but in the event of a breakdown, please take a remedial action
following the diagnosis based on the Troubleshooting (Table 3) information shown
below and on the next page. If the problem cannot be remedied, please leave the
unit just as it is and consult our Company's business office or service plant.

TABLE 3. MINI LIFT TROUBLE SHOOTING

SYMPTOM POSSIBLE PROBLEM SOLUTION
Loose electrical
Check all electrical connection.
connection?
Damage brake motor? Replace brake motor.
Gearbox noisy? Replace gearbox.
Material not lifting.
Worn drive, idler, driven
Replace drive, idler, driven Gear.
gear?
Loose pulley? Tighten or replace pulley.
Drum flange bearing jam? Replace flange bearing.
Loose limit switch
Motor is not getting connection? Check limit switch connection.
stop
Damage limit switch? Replace limit switch.
Lock not release? Check lock and release it.
Boom not rotate
360 degree Damage taper roller
Replace taper roller bearing.
bearing?

12
 MINI LIFT MACHINE – ORDERING SPARES
In all cases, while ordering spares, the reference number of the machine must be
given. The reference number will be found on one of the ends of the machine.

When ordering spares, please quote the following:

• Machine number
• Capacity
• Year of Manufacturing

Please state how parts are to be forwarded i.e. by post, passenger or goods train.
Please keep orders for parts on a sheet separate from other correspondence.
Particulars given in this list are subject to withdrawal and alteration without any
notice.
All quotations are subject to confirmation before acceptance of order.
All goods supplied on the condition that we shall not be liable for any direct or con-
sequential damage arising from delay in delivery or from defective material or
workmanship other than is covered by our usual from of guarantee.
Parts will be dispatched from ex – works, Vadodara.
The list has been most carefully compiled. No liability however can be undertaken
for any error.

13
 MINI LIFT MACHINE – MAIN ASSEMBLY

SR. PART
DESCRIPTION QTY.
NO. NUMBER
1 SF210/047 TRIPOD ASSLY-500 1
2 SF210/038 DRUM AND GEAR BOX ASSLY-500 1
3 MC210/280 THREADED ROD-500 1
4 HD21/012 PLAIN WASHER M30 2
5 HD18/010 HEX. NUT NYLOCK PLATED M30 2
6 SF210/049 BOOM AND PULLY ASSEMBLY-500 1
7 FC210/118 BOOM SUPPORT ASSLY-500 1
8 FC210/111 GEAR SIDE COVER WITH HINGE-500 1
9 FC210/112 MOTOR SIDE COVER WITH HINGE-500 1
10 FC210/113 MIDDLE COVER WITH HINGE-500 1
11 MC210/279 HANDLE FLAT-500 4
12 FC210/114 HANDLE ASSEMBLY 2
13 HD21/053 PLAIN WASHER M6 PLATED 14
14 HD05/053 FT HEX BOLT M6X20 8
15 HD05/052 FT HEX BOLT M6X15 6
16 HD21/010 PLAIN WASHER M20 4
17 HD18/019 HEX. NUT M20 NYLOCK HT GR.8.8 2

14
18 HD06/125 FT HEX BOLT M20X90 HIGH TENSILE 8.8 2
19 MC210/246 BEARING HOUSING LOCK 1
20 HD21/006 PLAIN WASHER M12 1
21 HD05/206 FT HEX BOLT M12 X 40 L 1
22 WR02/201 STEEL WIRE ROPE 8mmx18x7 1
23 MC210/079 DEAD WEIGHT 1
24 SP01/055 COMPRESSING SPRING DEAD WEIGHT 1
25 MC210/074 WIRE ROPE WASHER 1
26 WR09/004 SWIVEL HOOK 1 TON CAPACITY 1
27 WR05/004 THIMBLE 10 mm 1
28 WR04/005 WIRE ROPE CLAMP FORGED 10 mm 3
29 HD01/222 HT HEX BOLT PLATED M15 X 50 L 4
30 MS04/252 GREASE CUP 1/8” BSP 2 NO. 1

15
 MINI LIFT MACHINE – TRIPOD ASSEMBLY

TRIPOD ASSEMBLY
SR. PART
DESCRIPTION QTY.
NO. NUMBER
1 FC210/061 VERTICAL SUPPORT ASSEMBLY-500 1
2 FC210/095 TRIPOD BASE ASSLY LH 1
3 FC210/096 TRIPOD BASE ASSLY RH 1
4 FC210/126 TRIPOD BASE REAR ASSLY-500 1
5 MC210/231 TRIPOD BASE SUPPORT PIPE-1 2
6 MC210/197 TRIPOD BASE SUPPORT PIPE 1
7 HD21/006 PLAIN WASHER M12 18
8 HD01/104 HT HEX BOLT M12 X 60 L 7
9 HD18/006 NYLOCK NUT M12 9
10 HD01/107 HT HEX BOLT M12 X 75 L 2

MINI LIFT MACHINE – BEARING HOUSING ASSEMBLY

WITH BRACKET

BEARING HOUSING
ASSEMBLY WITH
BRACKET

SR. PART
DESCRIPTION QTY.
NO. NUMBER
1 FC210/115 BEARING HOUSING WITH GUSSET-500 1
2 BR03/008 TAPER ROLLER BREARING 30209J 1
3 MC210/206 BEARING HOUSING TOP COVER 1
4 MC210/128 SPRING ROD 1
5 HD23/039 SLOTTED SPRING PIN Ø 4 X 25 L 2
6 HD21/006 PLAIN WASHER M12 1
7 HD10/053 ALLEN BOLT FT M8 X 30 L 16
6
8 SP01/056 COMPRESSING SPRING LOCKING 1
 MINI LIFT MACHINE - IDLER GEAR ASSEMBLY

IDLER GEAR
ASSEMBLY

SR. PART
DESCRIPTION QTY.
NO. NUMBER
1 MC210/265 IDLER GEAR-500 1
2 BR01/301 DEEP GROOVE BALL BEARING 16005 2
3 BR07/002 INTERNAL CIRCLIP 47 1
4 MC210/271 IDLER SHAFT SUPPORT BRACKET 1
5 MC210/272 IDLER SHAFT-500 1
6 BR08/004 EXTERNAL CIRCLIP 25 1

17
MINI LIFT MACHINE – DRUM AND GEAR ASSEMBLY

18
 DRUM AND GEAR ASSEMBLY

SR. PART
DESCRIPTION QTY.
NO. NUMBER
1 FC210/108 WINCH PLATE WELDED LH-500 1
2 FC210/109 WINCH PLATE WELDED RH-500 1
3 FC210/107 MINI DRUM ASSLY-500 1
4 BR04/014 BEARING FLANGE UCF 208 2
5 HD01/229 HEX HEAD BOLT 9/16”- 1 7/8" L 8
6 HD21/067 PLAIN WASHER PLATED 9/16” 16
7 HD18/008 NYLOCK NUT ZINC PLATED 9/16” 8
8 FC210/117 DISTANCE PIECE WITH BUSH-500 3
9 PM20/006 HELICAL GEAR MOTOR 3HP(2.2 Kw) 1
10 HD02/055 HT HEX BOLT HIGH TENSILE 8.8 M12 X 60 L 4
11 SF210/040 BEARING HOUSING ASSLY-500 1
12 HD05/206 FT HEX BOLT M12 X 40 L 8
13 HD21/006 PLAIN WASHER M12 16
14 HD18/006 HEX. NUT NYLOCK PLATED M12 12
15 MC210/312 SPACER DRIVEN GEAR SIDE-500 1
16 MC210/313 SPACER DRIVE GEAR SIDE-500 1
17 MC210/266 DRIVEN GEAR-500 1
18 SF210/037 IDLER GEAR ASSLY-500 1
19 MC210/264 DRIVE GEAR-500 1
20 HD01/049 HT HEX BOLT M10 X 30 L 8
21 HD21/005 PLAIN WASHER M10 8
22 HD18/005 HEX. NUT NYLOCK PLATED M10 2
23 KY05/009 KEY 10 X 8 X 28 L 1
24 MC210/179 GEAR LOCKING WASHER 2
25 HD05/204 FT HEX BOLT M12 X 30 L 2

19
MINI LIFT MACHINE – BOOM ASSEMBLY

20
 BOOM ASSEMBLY

PART
SR. NO. DESCRIPTION QTY.
NUMBER
1 FC210/110 BOOM ASSLY FABRICATED-500 1
2 MC210/059 6" PULLY MINILIFT 1
3 BR01/008 BALL BEARING 6005 ZZ 2
4 MC210/192 PULLEY SPACER 2
5 BR07/002 INTERNAL CIRCLIP 47 2
6 EL06/511 PIN TYPE 1 TON LOAD CELL FOR MINI LIFT 1
7 MC210/189 LOAD CELL LOCKING PLATE 1
8 HD21/004 PLAIN WASHER M8 6
9 HD05/100 FT HEX BOLT M8 X 15 L 2
10 MC210/155 LIMIT SWITCH CLAMP MNTG.PIN 1
11 HD22/019 COTTOR PIN 3 x 15 PLATED 1
12 FC210/042 LIMIT SWITCH CLAMP ASSLY 1
13 MC210/092 LIMIT SWITCH MOUNTING BRACKET 1
14 HD05/001 FT HEX BOLT M5 X 25 L 2
15 HD21/002 PLAIN WASHER PLATED M5 4
16 HD18/002 NYLOCK NUT M5 2
17 HD21/005 PLAIN WASHER M10 1
18 EL04/409 LIMIT SWITCH JO1RTPB 1

21
TOOL KIT LIST:

SR. PART
DESCRIPTION QTY.
NO. NUMBER
1 TL01/003 FIX SPANNER 10 X 11 1
2 TL01/015 FIX SPANNER 18 X 19 1
3 TL01/006 FIX SPANNER 16 X 17 1
4 TL01/010 FIX SPANNER 24 X 26 1
5 TL01/002 FIX SPANNER 8 X 9 1
6 TL03/005 ALLEN KEY 8 mm 1

22
 MANUFACTURER’S WARRANTY
1. In the event of any defect being discovered within the period of six months
from the date of delivery, provided that the alleged defective part/s is/are
returned back to Dealer/Works (Freight Paid).We shall examine such part or
parts carefully and on satisfaction, if the defect is found due to faulty material
or bad workmanship, the same will be repaired/replaced with a new one free
of cost.
2. The defective part which has to be repaired / replaced will become property of
the company that is Esquire Machines Pvt. Ltd., Vadodara.
3. The transit will be on the buyer’s account.
4. The benefit of the warranty is to the first owner and cannot be transferred.

WE ARE NOT RESPONSIBLE FOR:

1. In the case of motor & gearbox as they are manufactured by the other
companies. But on the behalf of customer, company will take up that
complaint and will transfer to those respective manufacture, Which customer
may have regarded as the bad workmanship or material.
2. Defect due to wear and tear, accident, improper adjustment, misuse or
negligence of maintenance, etc.
3. Spare parts manufactured by third parties or by the customer.
4. Esquire shall not be liable hereunder for damages in excess of the purchase
price of the item with respect to which damages are claimed, and in no event
shall Esquire be liable for loss of profit or good will or for any other special,
consequential or incidental damages.
Warranty is for following Equipment:
Machine No. :________________________
Motor Serial No. :________________________, ____HP
Invoice No. & Date :________________________
Customer Name & Address
:_____________________________________________

_____________________________________________

_____________________________________________

23
Dealer Name, Date & Address
:_____________________________________________

_____________________________________________

_____________________________________________

For & on behalf of

ESQUIRE MACHINES PVT. LTD

24