Ingersoll-Rand MLK Series Bedienungsanleitung

MHD56093

INSTALLATION AND OPERATION MANUAL

for AIR CHAIN HOIST

MODELS MLK and HLK

MONTAGE- UND BEDIENUNGSANLEITUNGEN

für DRUCKLUFTBETRIEBENE KETTENZÜGE

MODELLE MLK und HLK

INSTALLATIONS- OG BETJENINGSHÅNDBOG

for LUFTSTYREDE KÆDETALJER

MODEL MLK og HLK

MANUAL DE INSTALACION Y OPERACION

para los POLIPASTOS NEUMATICOS DE CADENA

MODELOS MLK y HLK

MANUEL D’INSTALLATION ET D’UTILISATION pour

LES MODELES DE PALANS A CHAINE

PNEUMATIQUES MLK et HLK

MANUALE DI ISTRUZIONI PER L’INSTALLAZIONE

E IL FUNZIONAMENTO DEI PARANCHI A CATENA

PNEUMATICI MODELLI MLK e HLK

HÅNDBOK for MONTERING OG BRUK AV

TRYKKLUFTSDREVNE KJETTINGTALJER,

MODELL MLK og HLK

HANDLEIDING VOOR INSTALLATIE EN BEDIENING

van PNEUMATISCHE KETTINGTAKELS

MODELLEN MLK en HLK

INSTALLATIONS- OCH INSTRUKTIONSBOK för

TRYCKLUFTSDRIVET LYFTBLOCK MED KÄTTING

MODELL MLK och HLK

ASENNUS- JA KÄYTTÖKÄSIKIRJA

PAINEILMAKÄYTTÖISET NOSTOTALJAT

MALLIT MLK ja HLK

MHD56093

Edition 2

4/95

71153480

1995 Ingersoll-Rand Company

SAFETY INFORMATION

Thismanualprovidesimportantinformationforallpersonnelinvolvedwiththesafeinstallationand

operation of these products. Even if you feel you are familiar with this or similar equipment, you

should read this manual before operating the product.

Danger, Warning, Caution and Notice

Throughoutthismanualtherearesteps and procedureswhich,if not followed,mayresult in ainjury.

The following signal words are used to identify the level of potential hazard.

Danger is used to indicate the presence of a hazard which will

cause severe injury, death, or substantial property damage if the

warning is ignored.

Warning is used to indicate the presence of a hazard which can

cause severe injury, death, or substantial property damage if the

warning is ignored.

Caution is used to indicate the presence of a hazard which will or

can cause minor injury or property damage if the warning is

ignored.

Notice is used to notify people of installation, operation, or

maintenance information which is important but not hazard-

related.

Safety Summary

WARNING

•Do not use this hoist or attached equipment for lifting, supporting, or transporting people

or lifting or supporting loads over people.

•The supporting structures and load-attaching devices used in conjunction with this hoist

must provide adequate support to handle all hoist operations plus the weight of the hoist and

attached equipment. This is the customer’s responsibility. If in doubt, consult a registered

structural engineer.

NOTICE

•Liftingequipment is subjectto different regulations.These regulations maynot be specified

in this manual.

ENGLISH

READ THIS MANUAL BEFORE USING THESE PRODUCTS.

This manual contains important safety, installation and

operation information.

DANGER

WARNING

NOTICE

CAUTION

ENGLISH

This manual has been produced by Ingersoll-Rand to provide dealers, mechanics, operators and

company personnel with the information required to install and operate the products described

herein.

It is extremely important that mechanics and operators be familiar with the servicing procedures of

these products, or like or similar products, and are physically capable of conducting the procedures.

These personnel shall have a general working knowledge that includes:

•Proper and safe use and application of mechanics common hand tools as well as special

Ingersoll-Rand or recommended tools.

•Safety procedures, precautions and work habits established by accepted industry standards.

Ingersoll-Rand can not know of, nor provide all the procedures by which product operations or

repairsmay beconductedandthehazardsand/orresultsof eachmethod.If operationormaintenance

proceduresnotspecificallyrecommendedbythemanufacturerareconducted,itmustbeensuredthat

product safety is not endangered by the actions taken. If unsure of an operation or maintenance

procedureorstep,personnelshouldplacetheproductinasafeconditionandcontactsupervisorsand/

or the factory for technical assistance.

SAFE OPERATING INSTRUCTIONS

Ingersoll-Rand recognizes that most companies who use hoists have a safety program in force in

their plants. In the event you are aware that some conflict exists between a rule set forth in this

publication and a similar rule already set by an individual company, the more stringent of the two

should take precedence.

Safe Operating Instructions are provided to make an operator aware of unsafe practices to avoid and

arenotnecessarilylimitedtothefollowinglist.Refertospecificsectionsinthemanualforadditional

safety information.

1. Only allow people, trained in safety and operation of this product, to operate the hoist.

2. Only operate a hoist if you are physically fit to do so.

3. When a “DO NOT OPERATE” sign is placed on the hoist or controls, do not operate the hoist

until the sign has been removed by designated personnel.

4. Before each shift, the operator should inspect the hoist for wear or damage.

5. Never us a hoist which inspection indicates is worn or damaged.

6. Periodically, inspect the hoist thoroughly and replace worn or damaged parts.

7. Lubricate the hoist regularly.

8. Do not use hoist if hook latch on a hook has been sprung or broken.

9. Check that the hook latches are engaged before using.

10. Never splice a hoist chain by inserting a bolt between links.

11. Only lift loads less than or equal to the rated capacity of the hoist. See “SPECIFICATIONS”

section.

12. Whenusingtwohoiststosuspendoneload,selecttwohoistseachhavingaratedcapacityequal

to or more than the load. This provides adequate safety in the event of a sudden load shift.

13. Never place your hand inside the throat area of a hook.

14. Never use the hoist load chain as a sling.

15. Neveroperateahoistwhentheload isnotcenteredunderthehook. Donot“sidepull”or“yard.”

16. Never operate a hoist with twisted, kinked, “capsized” or damaged load chain.

17. Do not force a chain or hook into place by hammering.

18. Never insert the point of the hook into a chain link.

19. Be certain the load is properly seated in the saddle of the hook and the hook latch is engaged.

20. Do not support the load on the tip of the hook.

21. Never run the load chain over a sharp edge. Use a sheave.

22. Pay attention to the load at all times when operating the hoist.

ENGLISH

23. Always ensure that you, and all other people, are clear of the path of the load. Do not lift a load

over people.

24. Never use the hoist for lifting or lowering people, and never allow anyone to stand on a

suspended load.

25. Ease the slack out of the chain and sling when starting a lift. Do not jerk the load.

26. Do not swing a suspended load.

27. Never leave a suspended load unattended.

28. Never weld or cut on a load suspended by the hoist.

29. Never use the hoist chain as a welding electrode.

30. Do not operate hoist if chain jumping, excessive noise, jamming, overloading, or binding

occurs.

31. Do not use the up and down stops as a means of stopping a hoist. The up and down stops are

emergency devices only.

32. Always rig the hoist properly and carefully.

33. Be certain the air supply is shut off before performing maintenance on the hoist.

34. Do not allow the chain to be exposed to extremely cold weather. Do not apply loads to a cold

chain.

WARNING LABEL

Eachhoistissuppliedfromthe factorywith the

warninglabelshown.Ifthelabelisnotattached

to your hoist, order a new label and install it.

WARNING

•Do not use hoist for lifting, supporting or

transporting people.

DESCRIPTION

Hoistsdescribedinthismanualarepoweredbyair,andwiththeuseofapendantcontrol,aredesigned

to lift and lower loads. The hoists can be bolted or hook mounted to a trolley or permanent mounting

structure.

The air hoists are equipped with vane motors which act as the drive for the gear section. The output

from the gear section is transmitted directly to the load chain drive sheave.

Each air hoist contains a brake which is released by air pressure applied to an annular brake piston.

Whenthe“UP”or“DOWN”controlpendantbutton/leverispressedairissenttothebrake.Thebrake

piston compresses the brake springs, releasing the brake. When the pendant “UP” or “DOWN”

button/lever is released the air is exhausted and the brake is applied.

ENGLISH

SPECIFICATIONS

Hoist Model

No.

Rated

Capacity

(kg)

No.

Chain

Falls

Air Flow

m³/min

Sound

Pressure

Level

dBA

Sound

Power

Level

dBA

Speed with

Rated Load

m/m

Speed with

No Load

m/m

Hook

Mount

Hoist

Weight

3 m (10 ft)

lift

Overload

nominal

limit

up down up down

ML250KS-E

250 1

1,27

90 100

12,2 27,4 21 16

21,8

- - -

ML250K-E 1,98 30,8 35,7 52 30

ML250KR-E 1,27 7,9 11,6 12,8 9,1

ML500KS-E

500 16,7 20,1 13 10

ML500K-E 1,98 16,8 29,6 32 18

ML500KR-E 2

1,27

4,0 6,1 6,4 4,6

27,7ML1000KS-E 980 23,4 10,0 6,7 4,9

ML1000K-E 8,5 14,9 16 9

HL1000K-E 1000 1

1,98 87 97

7,9 11,3 12,2 7,9 38,1 1250

HL1000KR-E

HL1500K-E 1500 4,9 7,9 8,5 4,9 1875

HL2000K-E 2000 245,5 6,1 456,6 2500

HL3000K-E 3000 2,4 44,3 2,4 58,5 3750

HL4500K-E 4500 31,4 33,2 287,5 5625

HL6000K-E 6000 4 1 2,3 2,6 1,5 112,5 7500

* Sound measurements have been made in accordance with ISO 11201, ISO 3744-3746 and ISO 4871

test specifications for sound from pneumatic equipment. Readings shown are based on the average noise

level of each hoist configuration, proportionate to the utilized time in a regular cycle.

* Lpc (Peak Sound Pressure) does not exceed 130 dB.

* Performance based on 6,3 bar operating pressure.

INSTALLATION

Prior to installing the hoist, carefully inspect it for possible shipping damage.

Hoists are supplied fully lubricated from the factory.

Lubricate load chain before initial hoist operation.

CAUTION

•Owners and users are advised to examine specific, local or other regulations which may

apply to a particular type of use of this product before installing or putting hoist to use.

WARNING

•A falling load can cause injury or death. Before installing, read “SAFE OPERATING

INSTRUCTIONS”.

ENGLISH

Hoist

The supporting structures and load-attaching devices used in conjunction with this hoist must

provide adequate support to handle all hoist operations plus the weight of the hoist and attached

equipment.Thisisthecustomer’sresponsibility. Ifindoubt,consultaregisteredstructuralengineer.

On HLK hoists remove the solid plug located on top of the hoist and install the attached vent plug

priorto usingthehoist.Whenthe hoistisin itsnormallevelpositioncheckthatthegear caseoillevel

is at the check plug on the side of the gear box.

Hook Mounted Hoist Installation

Place hook over mounting structure. Make sure hook latch is engaged.

Ensurethesupportingmemberrestscompletelywithinthesaddleofthehookandiscentereddirectly

above the hook shank.

CAUTION

•Do not use a supporting member that tilts the hoist to one side or the other.

Trolley Mounted Hoist Installation

Refer to trolley manufacturers installation information to safely install the trolley and attach the

hoist.

Chain Container

When installing a chain container, refer to the manufacturers installation Instructions for Chain

Containers.

CAUTION

•Makecertaintoadjustthebalancechainsothatthechaincontainerdoesnotcontacttheload

chain.

•Allow chain to pile naturally in the chain container. Piling the chain carelessly into the

container by hand may lead to kinking or twisting that will jam the hoist.

1. Check the chain container size to make sure the length of load chain is within the capacity of

the chain container. Replace with a larger chain container, if required.

2. Attach the chain container to the hoist.

3. Run bottom block to lowest point and run hoist in up direction to feed the chain back into the

container.

Air System

The supply air must be clean, lubricated and free from water or moisture. A minimum of 6.3 bar/

630 kPa (90 psig) at the hoist motor is required, during operation to provide rated hoist performace.

Air Lines

The minimum allowable hose size is 13 mm (1/2 in). Hose size is based on a maximum of 15 m

(50ft)betweentheairsupplyandthehoistmotor.Contactyournearestdistributor forrecommended

air line sizes for distances greater than 15 m (50 ft). Before making final connections to hoist inlet,

all air supply lines should be purged with clean, moisture free air. Supply lines should be as short

and straight as installation conditions will permit.

Long transmission lines and excessive use of fittings, elbows, tees, globe valves etc. cause a

reduction in pressure due to restrictions and surface friction in the lines. If quick-disconnect fittings

are used at the inlet of the hoist, they must have at least a 10 mm (3/8 in) air passage. Use of smaller

fittings will reduce performance.

ENGLISH

NOTICE

•Always use an air line filter and lubricator with the hoist.

Air Line Lubricator

Alwaysuse an air line lubricatorwiththese hoists. Use a lubricatorhavingan inlet and outlet at least

as large as the inlet on the hoist motor. Install the air line lubricator as close to the air inlet on the

hoist motor as possible.

NOTICE

•Lubricator must be located no more than 3 m (10 ft) from the hoist motor.

•Shut off air supply before filling air line lubricator.

The air line lubricator should be replenished daily and set to provide lubrication at a minimum rate

of 1 to 3 drops per minute adjusted at maximum hoist speed, of SAE 10W oil or a good grade of

hydraulic oil.

NOTICE

•Do not use automotive type detergent oil. Detergents will delaminate the MLK and HLK

hoist motor vanes and cause premature failure.

Air Line Filter

Itisrecommended that an air line strainer/filter be installed as closeas practicalto themotor air inlet

port to prevent dirt from entering the motor. The strainer/filter should provide 10 micron filtration

and include a moisture trap. Clean the strainer/filter monthly to maintain its operating efficiency.

Moisture in Air Lines

Moisture that reaches the air motor through the supply lines is the chief factor in determining the

length of time between service overhauls. Moisture traps can help to eliminate moisture. Other

methods,suchas an air receiver whichcollectsmoisturebeforeit reaches the motororanaftercooler

at the compressor that cools the air prior to distribution through the supply lines, are also helpful.

Overload Device

Anoverloaddeviceisrequiredonallhoistswitharatedcapacityofover1metricton(2,200lbs)used

for lifting applications.

The overload device is integrated into the hoist air motor and prevents the hoist from lifting a load

greater than the overload value listed in the specifications chart. If an overload is detected, inlet

supply air is stopped and the hoist will not operate.

Iftheoverloaddeviceisactivatedtheloadmustbeloweredandreduced.Alternativemethodsshould

be used to accomplish the task. To lower the load reset the hoist by pressing the “ON” button of the

emergency stop device and press the hoist control lever to lower.

Adjustment of Bleed Screws on MLK and HLK Pendent Control Hoists

The two bleed adjustment screws, located under the valve chest, used on MLK and HLK hoists with

a pendent control are factory adjusted to provide optimum control and performance at 6.3 bar/

630 kPa (90 psig) air pressure. If the hoist is used with other air supply pressures, the bleed

adjustment screws may require readjustment.

For maximum performance and control, adjust the bleed screws as follows:

1. Loosen the adjustment screw locknut.

2. Back out the adjustment screw approximately one third (1/3) of a turn.

ENGLISH

3. While fully depressing the pendent throttle lever and holding it in that position, turn in the

adjustmentscrewuntilthepistonrodfullyretracts.Thisadjustmentwillprovideagoodbalance

of spotting control and maximum hoist speed. If better spotting control is desired, slowly back

out the adjustment screw a little at a time until the spotting control is suitable.

4. Tighten the adjustment screw locknut.

Storing the Hoist

1. Always store the hoist in a no load condition.

2. Wipe off all dirt and water.

3. Oil the load chain, hook pins and hook latch.

4. Place in a dry location.

5. Plug hoist air inlet port.

6. Before returning hoist to service follow instructions for Hoists not in Regular Service in the

“INSPECTION” section.

OPERATION

The four most important aspects of hoist operation are:

1. Follow all safety instructions when operating hoist.

2. Allow only people trained in safety and operation on this hoist to operate the hoist.

3. Subject each hoist to a regular inspection and maintenance procedure.

4. Be aware of the hoist capacity and weight of load at all times.

Always operate, inspect and maintain this hoist in accordance with any applicable safety codes and

regulations.

Operators must be physically competent. Operators should have no health condition which might

affect their ability to react, and they must have good hearing, vision and depth perception. The hoist

operator must be carefully instructed in his duties and must understand the operation of the hoist,

including a study of the manufacturer’s literature. The operator must be aware of proper methods of

hitching loads and should have a good attitude regarding safety. It is the operator’s responsibility to

refuse to operate the hoist under unsafe conditions.

Initial Operating Checks

Hoists are tested for proper operation prior to leaving the factory. Before the hoist is placed into

service the following initial operating checks should be performed.

1. After installation of trolley mounted hoists, check to ensure the hoist is centered below the

trolley.

2. Check for air leaks in the supply hose and fittings to pendant, and from pendant to manifold.

3. Whenfirstrunningthehoistortrolleymotors,asmallamount ofnon-detergent, lightoil should

be injected into the inlet connection to allow good lubrication.

4. When first operating the hoist and trolley it is recommended that the motors be driven slowly

in both directions for a few minutes.

5. Operate the trolley along the entire length of the beam.

6. Check operation of limit devices.

7. Check that trolley (if equipped) and hook movement is the same direction as arrows or

information on the pendant control.

8. Check to see that the hoist is securely connected to the overhead crane, monorail, trolley or

supporting member.

9. Check to see that the load is securely inserted in the hook, and that the hook latch is engaged.

10. Raise and lower a light load to check operation of the hoist brake.

ENGLISH

11. Check hoist operation by raising and lowering a load equal to the rated capacity of the hoist a

few centimeters off the floor.

12. Check to see that the hoist is directly over the load. Do not lift the load at an angle (side pull

or “yard”).

13. Inspecthoistandtrolleyperformancewhenraising,movingandloweringtestload(s).Hoistand

trolley must operate smoothly and at rated specifications prior to being placed in service.

WARNING

•Only allow personnel instructed in safety and operation of this product to operate the hoist

and trolley.

•The hoist is not designed or suitable for lifting, lowering or moving persons. Never lift loads

over people.

Hoist Controls

Two Lever Pendant

Two lever pendants provide operation of the hoist only. For units with powered trolleys a four lever

pendantis required. Refer to manufacturers informationonPendantThrottle Handle Assemblies for

two and three motor functions.

The pendant control throttle uses two separate levers for hoist operation. Direction of hook travel is

controlled by whichever lever is depressed.

1. To start hoist operation, press the “ON” button.

2. To operate hoist, press the “UP” or “DOWN”

control lever.

3. Intheeventofanemergency,allhoistoperation

can be stopped by pushing the emergency stop

button. This will prevent air from reaching the

hoist motor which will stop any movement.

4. The “OFF” button willalso stop hoist operation

if pressed.

5. The “ON” button must be pushed to restart the

hoist after the “Emergency Stop” or “OFF”

button have been used.

WARNING

•The hook latch is intended to retain loose slings or devices under slack conditions. Caution

must be used to prevent the latch from supporting any of the load.

"ON" and "OFF"

Buttons

Hoist

Control

Levers

Pendant

Handle

Emergency

Stop Button

(Dwg. MHTPA0671)

ENGLISH

INSPECTION

WARNING

•All new, altered or modified equipment should be inspected and tested by personnel trained

in safety, operation and maintenance of this equipment to ensure safe operation at rated

specifications before placing equipment in service.

Frequent and periodic inspections should be performed on equipment in regular service. Frequent

inspectionsarevisualexaminationsperformedbyoperatorsorservicepersonnelduringroutinehoist

operation.Periodicinspectionsarethoroughinspectionsperformedbypersonneltrainedininspection

and maintenance of the hoist.

Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the

early stages, allowing corrective action to be taken before the condition becomes dangerous.

Deficiencies revealed through inspection, or noted during operation, must be reported to an

appointed person. A determination must be made as to whether a deficiency constitutes a safety

hazard before resuming operation of the hoist.

Records and Reports

Some form of inspection record should be maintained for each hoist, listing all points requiring

periodic inspection. A written report should be made monthly on the condition of the critical parts

ofeachhoist.Thesereportsshould bedated, signedby thepersonwhoperformedtheinspection,and

kept on file where they are readily available for review.

NOTICE

•Theexternalplacementofcodedmarksonequipmentidentifyingcompletedinspectionsand

operationally certified equipment is an acceptable method of documenting periodic inspec-

tions in place of written records.

Load Chain Reports

Recordsshouldbemaintaineddocumentingtheconditionofloadchainremovedfromserviceaspart

of a long-range load chain inspection program. Accurate records will establish a relationship

between visual observations noted during frequent inspections and the actual condition of the load

chain as determined by periodic inspection methods.

Frequent Inspection

On a hoist in continuous service, frequent inspection should be made at the beginning of each shift.

In addition, visual inspections should be conducted during regular service for any damage or

evidence of malfunction.

1. OPERATION. Check for visual signs or abnormal noises (grinding etc.) which could indicate

a potential problem. Make sure all controls function properly and return to neutral when

released. Check chain feed through the hoist and bottom block. If chain binds, jumps, is

excessively noisy or “clicks”, clean and lubricate the chain. If problem persists, replace the

chain. Do not operate the hoist until all problems have been corrected.

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