Ingersoll-Rand SMB030 User's Manual
Contents
1. section on page 7 Welded Area Wear in these areas Dwg MHP0102 4 CAUTION The full extent of chain wear cannot be determined by visual inspection At any indication of chain wear inspect chain and load sheave in accordance with instructions in Periodic Inspection A worn load chain may cause damage to the load sheave Inspect the load sheave and replace if damaged or worn 5 Load Chain Reeving Refer to Dwg MHP0042 on page 9 Make sure welds on standing links are away from load sheave Reinstall chain if necessary Check that the last link of the load chain is securely connected On 2 3 and 5 ton hoists make sure chain is not capsized twisted or kinked Adjust as required Periodic Inspection According to ASME B30 16 frequency of periodic inspection depends on the severity of usage NORMAL HEAVY yearly semiannually SEVERE quarterly Disassembly may be required for HEAVY or SEVERE usage Keep accumulative written records of periodic inspections to provide a basis for continuing evaluation Inspect all items in Frequent Inspection Also inspect the following MHD56391 Edition 2 1 Fasteners Check rivets capscrews nuts cotter pins and other fasteners on hooks and hoist body Replace if missing and tighten or secure if loose 2 All Components Inspect for wear damage distortion deformation and cleanliness If external evidence indicates the need disassemble C2. IT Approvato da NL Goedgekeurd door NO Godkjent av PL Zatwierdzone przez PT Aprovado por SK Schv lil SL Odobril SV Godk nt av ard John T Perkins IREP Annandale New Jersey USA Engineering Manager 18 MHD56391 Edition 2 WARRANTY LIMITED WARRANTY Ingersoll Rand Company warrants to the original user its Hoists and Winches Products to be free of defects in material and workmanship for a period of one year from the date of purchase Ingersoll Rand will repair without cost any Product found to be defective including parts and labor charges or at its option will replace such Products or refund the purchase price less a reasonable allowance for depreciation in exchange for the Product Repairs or replacements are warranted for the remainder of the original warranty period If any Product proves defective within its original one year warranty period it should be returned to any Authorized Hoist and Winch Service Distributor transportation prepaid with proof of purchase or warranty card This warranty does not apply to Products which Ingersoll Rand has determined to have been misused or abused improperly maintained by the user or where the malfunction or defect can be attributed to the use of non genuine Ingersoll Rand parts Ingersoll Rand makes no other warranty and all implied warranties including any warranty of merchantability or fitness for a particular purpose are limite
3. Load Chain 1 Remove cotter pin from anchor hanger Push anchor pin into one of the side plates 2 Position end link of load chain on anchor pin Reposition anchor pin to engage both side plates 4 Install cotter pin in anchor pin on either side of load chain and bend ends apart Ww On 2 3 and 5 ton hoists ensure load chain is not twisted kinked or capsized Refer to Dwg MHP0043 on page 9 Capsized Hook Make certain the bottom block has NOT been flipped through the chain falls Dwg MHP0043 General Disassembly The following instructions provide the necessary information to disassemble inspect repair and assemble the hoist Parts drawings of the hoist assembly are provided in the parts section If a hoist is being completely disassembled for any reason follow the order of the topics as they are presented It is recommended that all maintenance work on the hoist be performed on a bench In the process of disassembling the hoist observe the following 1 Never disassemble the hoist any further than is necessary to accomplish the needed repair A good part can be damaged during the course of disassembly 2 Never use excessive force when removing parts Tapping gently around the perimeter of a cover or housing with a soft hammer for example is sufficient to break the seal 3 Do not heat a part with a flame to free it for removal unless the part being heated is already worn or damaged bey
4. and 70 35 Shoulder Screw 36 Idle Sheave 1 Not sold separately 37 Bottom Block Plate 2 Gear Assembly includes items 38 39 1 45593399 45593563 45593829 45593977 45594215 45594371 41 38 Gear 1 45593456 45593647 45593886 45594033 45594272 45594546 39 Retainer Ring 1 Not sold separately 40 Pinion 1 45593480 45593670 45593910 45594066 45594306 45594579 41 Reduction Gear 2 45593449 45593639 45593878 45594025 45594264 45594538 43 Gear Cover 1 45593472 45593662 45593902 45594058 45594298 45594561 44 Capacity Label 1 45514551 45514569 45514577 45514585 45514593 45514601 Bottom Hook Assem bly includes items 18 45 31 33 34 36 37 67 1 45519063 45519071 45519105 45519113 45519121 45519139 68 70 74 amp 75 46 Capscrew 2 Not sold separately 47 Washer 2 62 Anchor Hanger 1 45593498 45593688 45593928 45594082 45594314 45594587 63 Retainer Ring 64 Pawl 2 Only available as item 75 65 Pawl Spring 66 Ring 1 67 Locknut 1 68 Capscrew 1 Not sold separately 70 Locknut 3 74 Locknut 1 Brake Kit includes 75 items 3 4 8 9 63 64 2 45518743 45518750 45518768 45518784 45518792 45518800 amp 65 76 Adjusting Nut 1 77 Bevel Spring 1 82 Friction Disc 1 Order item 5 87 Hand Chain Wheel 1 91 Seal 1 92 Bearing 1 Not sold separately 93 Bearing 1 Not Shown 16 MHD56391 Edition 2 ACCESSORIES AND KITS PARTS LIST DESCRIPTION OF PART PART NO Chain Lubricant LUBRI LINK GREEN PARTS ORDERING INFORMATION
5. on page 5 7 Lubricate the hoist regularly Refer to the LUBRICATION section on page 7 8 Do not use hoist if hook latch 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 Refer to the SPECIFICATIONS section on page 3 MHD56391 Edition 2 12 When using two hoists to suspend one load select two hoists 23 Always ensure that you and all other people are clear of the each having a rated capacity equal to or more than the load path of the load Do not lift a load over people This provides adequate safety in the event of a sudden load 24 Never use the hoist for lifting or lowering people and never shift allow anyone to stand on a suspended load 13 Never place your hand inside the throat area of a hook 25 Ease the slack out of the chain and sling when starting a lift 14 Never use the hoist load chain as a sling Do not jerk the load 15 Never operate a hoist when the load is not centered under the 26 Do not swing a suspended load hook Do not side pull or yard 27 Never weld or cut on a load suspended by the hoist 16 Never operate a hoist with twisted kinked capsized or 28 Never use the hoist chain as a welding electrode damaged load chain 29 Do not operate hoist if chain jumping excessive noise 17 Do not force
6. supporting or transporting people or lifting or supporting loads over people The National Safety Council Accident Prevention Manual for Industrial Operations Eighth Edition and other recognized safety sources make a common point Employees who work near cranes or assist in hooking on or arranging a load should be instructed to keep out from under the load From a safety standpoint one factor is paramount conduct all lifting operations in such a manner that if there were an equipment failure no personnel would be injured This means keep out from under a raised load and keep out of the line of force of any load Ingersoll Rand hoists are manufactured in accordance with the latest ASME B30 16 standards The Occupational Safety and Health Act of 1970 generally places the burden of compliance with the user not the manufacturer Many OSHA requirements are not concerned or connected with the manufactured product but are rather connected with the final installation It is the owner s and user s responsibility to determine the suitability of a product for any particular use It is recommended that all applicable industry trade association federal state and local regulations be checked Read all operating instructions and warnings before operation Rigging It is the responsibility ofthe operator to exercise caution use common sense and be familiar with proper rigging techniques Refer to ASME B30 9 for rigging information American Soci
7. to the part before assembly Gears 38 and 41 1 Remove nuts on gear cover 2 Remove old grease and replace with new For temperatures 20 to 50 F 29 to 10 C use EP 1 grease or equivalent For temperatures 30 to 120 F 1 to 49 C use EP 2 grease or equivalent MHD56391 Edition 2 Load Chain Failure to maintain clean and well lubricated load chain may result in chain failure causing injury death or substantial property damage 1 Lubricate each link of the load chain weekly Apply new lubricant over existing layer 2 In severe applications or corrosive environments lubricate more frequently than normal 3 Lubricate hook and hook latch pivot points with the same lubricant used on the load chain 4 remove rust or abrasive dust build up clean chain with acid free solvent After cleaning lubricate the chain 5 Use Ingersoll Rand LUBRI LINK GREEN TROUBLESHOOTING This section provides basic troubleshooting information Specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety operation and maintenance of this equipment The chart below provides a brief guide to common hoist symptoms probable causes and remedies CAUSE REMEDY Hoist will not operate Hoist is overloaded Reduce load to within rated capacity Slip clutch not adjusted Adjust slip clutch Refer to MAINTENANCE section Load continues to mo
8. without 20 foot lift minus 2 ft 050 5 metric ton 5 000 kg load chain Specify length General Specifications Hand Chain Hoist Net Weight with Rated 2 Load i No of Capacity Pull to Lift Rated Load Overhauled to Lift 0 Standard 10 ft 3 m Model No metric Chain Size Load 1 ft 0 3 m Chain Lift t mm Falls ons Ib kg ft m Ib kg 5 005 1 2 55 5 25 5 15 31 5 9 6 23 5 10 7 5 010 1 64 29 6 18 53 1 16 1 26 8 12 2 5 015 1 1 2 69 31 7 21 71 6 29 38 5 17 5 5 020 2 77 35 8 24 84 6 26 i 42 4 19 3 SMB030 3 100 45 10 x 30 99 4 30 70 4 22 5 050 5 83 5 38 9 27 213 2 65 2 90 2 41 One metric ton 2 200 lbs INSTALLATION Prior to installing the hoist carefully inspect it for possible shipping damage Hoists are supplied fully lubricated from the factory Lubrication of the load chain is recommended before initial hoist operation Hook Latch Hand Chain MI y Dwg MHP0832 Top Hook Bottom Hook A falling load can cause injury or death Before installing read SAFETY INFORMATION CAUTION Owners and users are advised to examine specific local or other regulations including American Society of Mechanical Engineers and or OSHA Regulations which may apply to a particular type of use of this product before installing or putting hoist to use Hoists are designed to provide a 4 1 safety factor The supporting structures and load attaching devi
9. 5593423 45593613 45593852 45594009 45594249 45594512 Top Hook Assembly 17 includes 18 30 31 1 45518933 45518941 45518958 45518974 45518982 45518990 35 67 68 amp 70 Latch Kit includes 18 items 18 32 67 amp 68 1 45519006 45519014 45519022 45519030 45519048 45519055 19 Guide Roller 1 45593514 45593704 45593944 45594108 45594330 45594603 20 Load Chain bulk As Req d LCCF005 LC618 G10 LCCFO15 LCCV020 LC1030 G10 LCCF025 Bearing Kit includes items 10 21 39 and 1 45593407 45593571 45593837 45593985 45594223 45594389 92 21 Bearing 1 Not sold separately 22 Stripper 1 45593506 45593696 45593936 45594090 45594322 45594595 Assembly 23 Hand Chain bulk As Req d HCSM005ZP 24 Hand Chain Guide 1 Not sold separately 25 Chain Guide 1 26 Load Sheave 1 45593431 45593621 45593860 45594017 45594256 45594520 27 Hub Back 1 Order item 5 28 Hub Front 1 29 Warning Tag 1 71301097 30 Top Hook 5 ton 1 Order item 17 Not Shown MHD56391 Edition 2 HOIST ASSEMBLY PARTS LIST CONTINUED ITEM DESCRIPTION QTY PART NO NO OF PART TOTAL 1 2 ton 1 ton 1 1 2 ton 2 ton 3 ton 5 ton 31 Spring 1 32 Anchor Pin 1 Not sold separately 33 Capscrew 1 34 Bottom Hook 5 ton 1 Order item 45 Hardware Kit includes items 31 46 47 67 1 45594611
10. Form MHD56391 PARTS OPERATION AND MAINTENANCE MANUAL for MANUAL CHAIN HOIST MODELS 5 005 5 010 5 015 SMBO020 1 2 ton 1 ton 1 1 2 ton 2 ton SMBO030 SMBO050 3 ton 5 ton Dwg MHP0831 Unless otherwise noted tons in this manual are metric tons 1 metric ton 2 200 Ib READ THIS MANUAL BEFORE USING THESE PRODUCTS This manual contains important safety installation operation and maintenance information Make this manual available to all persons responsible for the operation installation and maintenance of these products Do not use this hoist for lifting Supporting or transporting people or lifting or supporting loads over people Always operate inspect and maintain this hoist in accordance with American Society of Mechanical Engineers Safety Code ASME B30 16 and any other applicable safety codes and regulations Refer all communications to the nearest Ingersoll Rand Office or Distributor Form MHD56391 Edition 2 45518578 Ingersoll Rand 2008 Ingersoll Rand Company SAFETY INFORMATION This manual provides important information for all personnel involved with the safe installation operation and proper maintenance of this product Even if you feel you are familiar with this or similar equipment you should read this manual before operating the product Signal person person who observes load and relays directions to winch operator Operation Manuals documentation that is
11. The use of other than genuine Ingersoll Rand replacement parts may adversely affect the safe operation of this product When ordering replacement parts please specify the following 1 Complete model number and lot number as it appears on the capacity label 2 Part number s and part description s as shown in this manual 3 Quantity required The hoist capacity label is located on the gear cover Example shown is for a 1 1 2 ton SMB hoist model SMBO15 Label is shown smaller than actual size SER NO 1 1 2 ton Silver Series US White House TN 37188 irtools com EU Wigan WN2 4EZ U K For your convenience and future reference it is recommended that the following information be recorded Hoist Model Number Hoist Lot Number Date Purchased MHD56391 Edition 2 Return Goods Policy Ingersoll Rand will not accept any returned goods for warranty or service work unless prior arrangements have been made and written authorization has been provided from the location where the goods were purchased Hoists returned with opened bent or twisted hooks or without chain and hooks will not be repaired or replaced under warranty NOTICE Continuing improvement and advancement of design may cause changes to this hoist which are not included in this manual Manuals are periodically revised to incorporate changes Always check the manual edition number on the front cover for the late
12. a chain or hook into place by hammering jamming overloading or binding occurs 18 Never insert the point of the hook into a chain link 30 Only operate the hoist with manual power 19 Be certain the load is properly seated in the saddle of the 31 After use or when in a non operational mode the chain hoist hook and the hook latch is engaged should be secured against unauthorized and unwarranted use 20 Do not support the load on the tip of the hook 32 Do not leave a load suspended when the hoist is unattended 21 Never run the load chain over a sharp edge Use a sheave or not in use 22 Pay attention to the load at all times when operating the hoist WARNING TAG Each hoist is supplied from the factory with a multi language warning tag If the tag is not attached to your unit order a new tag Failure to follow these warnings may result in and install it Refer to the parts list for the part number Read and death severe injury or property damage obey all warnings and other safety information attached to this Read manual before using this product x Do not lift lower or pull more than hoist Tag may be shown smaller than actual size rated load Do not lift people or loads over people Do not operate with twisted or damaged chain or kinked frayed or cut rope or strap Do not operate lever hoist or puller with handle extension cheaters Do not operate if damaged or malfunctioning Do not operate when ch
13. ain rope or strap cannot form straight line with load Do not operate with other than manual power Do not operate with open latch twisted hook or without a latch Always keep minimum of 3 wraps of wire rope or 2 wraps of strap on drum Do not remove or obscure warning labels SPECIFICATIONS General Model Code Explanation Manual Chain Hoists can be mounted to the suspension shaft of a Example SMB 005 10 8 V trolley or a permanent mounting structure The hoist is designed to lift and lower loads up to rated capacity with minimal hand chain Series effort To determine your basic hoist configuration refer to capacity and Capacity lot number label located on gear end cover for model number information Lift Hand Chain Slip Clutch MHD56391 Edition 2 3 Hoist Lift Hand Chain Sli Series Capacit Hoist load chain Hand chain is 2 ft CI h apacity hook travel less than lift uic SMB Silver Series 005 1 2 metric ton 500kg 10 10 ft 3 m 8 8 feet standard V Slip Clutch Manual 010 1 metric ton 1 000 kg standard 10 foot lift minus 2 ft standard Chain Hoist 015 1 1 2 metric ton 15 15 ft 5 m 13 13 feet 1 500 kg 20 20ft 6m 15 foot lift minus 2 ft 020 2 metric ton 2 000 kg Specify length 18 18 feet 030 3 metric ton 3 000kg Hoist
14. ain moves freely without binding or excessive drag Load chain travel should stop when hand chain stops moving 2 Hooks Check for wear or damage increased throat width bent shank or twisting of hook Replace hooks which exceed the throat opening discard width 1596 shown in Table 1 refer to Dwg MHP0040 on page 6 or exceed a 10 twist refer to Dwg 111 on page 6 If the hook latch snaps past the tip of the hook the hook is sprung and must be replaced Check hooks swivel easily and smoothly Repair or lubricate as necessary 10 yy Twisted Normal DO NOT USE Can Be Used Dwg 0111 gt Throat Width b Dwg MHP0040 Normal Discard Model No in mm in mm 5 005 0 94 24 1 09 27 6 SMBO010 1 00 26 1 18 30 5 015 1 10 33 1 50 38 SMB020 SMB030 1 50 39 1 76 44 8 SMB050 1 89 48 2 17 55 2 3 Hook Latches Check operation of the hook latches Replace if broken or missing 4 Chain Refer to Dwg 102 on page 6 Examine each link for bending cracks in weld areas or shoulders transverse nicks and gouges weld splatter corrosion pits striation minute parallel lines and chain wear including bearing surfaces between chain links Replace a chain that fails any of the inspections Check lubrication and lubricate if necessary Refer to Load Chain in LUBRICATION
15. apart 4 Wrap hand chain around handwheel and feed ends through slots provided in hand chain wheel cover Install the handwheel cover Secure with three nuts and screws Bottom Hook Assembly 2 3 and 5 ton hoists only 1 Grease and install the rollers in the groove provided in the bore of the idler sheave 2 Install idler sheave shaft through the idler sheave bore Ensure rollers remain in position 3 Carefully place the assembled parts between the plates 4 Install hook between plates and clamp plate halves together with capscrews lockwashers and nuts Gear Timing For proper operation timing marks on the gears must be in the correct positions The timing marks are circular impressions on the faces of gears Refer to Dwg MHP0833 on page 11 FN fh Urn Se of S 3 j A NS C gt VAI Models Dwg MHP0833 11 Hand Chain Adjustment Replacement 4 CAUTION When cutting the weld side of a hand chain link do not cut or nick the opposite side A damaged link must be replaced to prevent premature failure A falling hand chain can cause injury weld cut C Link Dwg MHP0016 1 To create link cut the welded side of the link with a hack saw Clamp one side of the C link in a vise and bend it open by using a pliers to gri
16. ces used in conjunction with this hoist must provide adequate support to handle all hoist operations plus the weight of the hoist and attached equipment If in doubt consult a registered structural engineer The SMB manual chain hoist must be used in a vertical position to provide a straight line pull from top hook to bottom hook The hoist must be positioned so that it does not contact the support members when in use When operating in limited areas suitable lifting attachments or slings must be used to prevent the hoist body and hand chain from being obstructed MHD56391 Edition 2 Initial Operating Checks CAUTION Ensure the hoist top hook is properly installed on the support member and the hook latch is engaged Operate the hoist with a test load 1096 of rated capacity by raising and lowering this load several times Verify the brake operation by lowering the same load to check load does not slip when lowering stops NOTICE Each time a load is lifted the operation of the load brake should be checked by raising the load slightly and stopping to ensure the brake will hold the load before proceeding to lift the load Familiarize operators and people responsible for hoist installation and service with ASME B30 16 specifications prior to placing the unit into service All the requirements of this specification including testing should be met before approving the hoist for operation OPERATION The four most imp
17. ch norem DA ved at v re 1 overensstemmelse med f lgende hovedstandard er DE Unter Anlehnung die folgenden Grundnormen entsprechen EL ia np runa ES conforme a los siguientes est ndares FI esitetyt vaatimukset seuraavia perusnormeja k ytett ess FR En observant les normes de principe suivantes HU A k vetkez elvi szabv nyok alkalmaz sa mellett IT Seguendo i principi standard indicati di seguito NL overeenkomstig de volgende hoofdstandaards NO Ved bruke f lgende prinsipielle standarder PL Spetniajac wymogi nastzpujacych g wnych norm PT observando as seguintes Normas Principais SK Pri dodrZan nasledovnych SL Uporabljeni osnovni standardi SV Genom att anvanda foljande principstandard Date February 2007 CS Datum nor 2007 DA Dato Februar 2007 DE Datum Februar 2007 EL Huepounv a 2007 ES Fecha Febrero 2007 FI P iv ys Helmikuu 2007 FR Date F vrier 2007 HU D tum 2007 Febru r IT Data Febbraio 2007 NO Dato Februar 2007 NL Datum Februari 2007 PT Data Fevereiro 2007 PL Data luty 2007 SK D tum Febru r 2007 SL Datum februar 2007 SV Datum Februari 2007 Approved By CS Schv lil DA Godkendt af DE Genehmigt von EL ES Aprobado por FI Hyv ksytty FR Approuv par HU J v hagyta
18. chain movement when attempting to lift a load greater than the capacity of the hoist To adjust the slip clutch you will need a weight that is known to be 150 of hoist capacity or a scale that will read at least 150 of hoist capacity Attach hoist to a suitable support and then attach load scale to load hook MHD56391 Edition 2 Adjusting with a Weight Remove handwheel cover from hoist Using hand chain hoist up the load If load does not rise tighten nut 1 4 turn Attempt to raise the load Continue tightening nut in 1 4 turn increments until load raises 3 Then lower the load and back the nut off 1 4 turn The slip clutch is now adjusted 4 Reinstall handwheel cover to hoist Ne Adjusting with a Scale 1 Remove handwheel cover from hoist 2 Using hand chain hoist up Needle on scale should only go up to 150 of hoist capacity then the clutch will slip 3 Ifclutch slips prior to 150 capacity hoist down to remove tension and tighten nut 1 4 turn Continue this hoist up hoist down procedure adjusting the nut in 1 4 turn increments until the scale reads 150 of rated load The slip clutch is now adjusted 4 Reinstall handwheel cover to hoist NOTICE Due to the nature of the design an exact precision clutch setting may be difficult to obtain Repeated slipping of the clutch in an attempt to obtain an exact setting may reduce the life of clutch components Attaching End of
19. clarons sous notre seule responsabilit que le produit HU Kiz r lagos felel ss g nk tudat ban kijelentj k hogy term k IT Dichiariamo sotto la nostra unica responsabilit che il prodotto NL Verklaren onder onze uitsluitende aansprakelijkheid dat het produkt NO Erklaerer og samvittighet at produktet PL Przyjmuj c pe n odpowiedzialno o wiadczamy ze produkt Declaramos sob a nossa exclusiva responsabilidade que o produto SK Z v zne prehlasujeme Ze vyrobok SL Pod polno odgovornostjo izjavljamo da je izdelek SV Intygar enligt vart ansvar att produkten Model 5 005 5 010 5 015 5 020 5 030 5 050 Serial Number Range 07 and up CS Model Rozsah v robn ch sel DA Model Serienummeromrade DE Modell Seriennummernbereich EL oeipiak v api8uov ES Modelo N meros de serie FI Malli Sarjanumeroalue FR Mod le Gamme de num ros de s rie HU Modell Gy rt si sz m tartom ny IT Modello Gamma delle matricole NL Model Serienummer NO Modell Serienr PL Model Zakres numer w serii PT Modelo Gama de Nos de S rie SK Model Rozsah vyrobnych Cisiel SL Model Obmo je serijskih tevilk SV Modell Serienummer mellan To which this declaration relates is in compliance with provisions of Directive s 98 37 EC machinery CS Ke kter m se t
20. d by personnel trained in safety operation and maintenance of this hoist to ensure safe operation at rated specifications before placing hoist in service Frequent and periodic inspections should be performed on hoists in regular service Frequent inspections are visual examinations performed by operators or service personnel and include observations made during routine hoist operation Periodic inspections are thorough inspections conducted by personnel trained in the safety operation and maintenance of this hoist ASME B30 16 states inspection intervals depend upon the nature of the critical components of the hoist and the severity of usage Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the early stages allowing MHD56391 Edition 2 corrective action to be taken before the condition becomes dangerous Deficiencies revealed through inspection or noted during operation must be reported to designated personnel trained in safety operation and maintenance of this hoist A determination as to whether a condition constitutes a safety hazard must be decided and the correction of noted safety hazards accomplished and documented by written report before placing the hoist in service Records and Reports Inspection records listing all points requiring periodic inspection should be maintained for all load bearing equipment Written reports based on severity of service should be made on t
21. d 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 Measure the thickness of the brake discs If brake discs do not have uniform thickness or are less than the discard dimension shown in Table 3 Brake Disc Chart replace brake discs Table 3 Brake Disc Chart 1 2 5 ton in mm Normal 0 10 2 5 Discard 0 075 1 875 5 Inspect ratchet pawls and springs on side plate assembly Replace parts if pawls and or springs are damaged or fail to operate MHD56391 Edition 2 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 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 3 Smooth out all nicks burrs or galled spots on shafts bores pins and bushings 4 Examine all gear teeth carefully and remove nicks and burrs 5 Polish the edg
22. d to the duration of the expressed warranty period as set forth above Ingersoll Rand s maximum liability is limited to the purchase price of the Product and in no event shall Ingersoll Rand be liable for any consequential indirect incidental or special damages of any nature rising from the sale or use of the Product whether based on contract tort or otherwise Note Some states do not allow limitations on incidental or consequential damages or how long an implied warranty lasts so that the above limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state IMPORTANT NOTICE It is our policy to promote safe delivery of all orders This shipment has been thoroughly checked packed and inspected before leaving our plant and receipt for it in good condition has been received from the carrier Any loss or damage which occurs to this shipment while enroute is not due to any action or conduct of the manufacturer Visible Loss or Damage If any of the goods called for on the bill of lading or express receipt are damaged or the quantity is short do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt Concealed Loss or Damage When a shipment has been delivered to you in apparent good condition but upon opening the crate or container loss or damage has taken place while in trans
23. e load end of EQUIPMENT BEING REPAIRED the load chain is anchored to suspension plates To Only allow personnel trained in the operation and service of disconnect load chain from suspension plates remove this product to perform maintenance anchor bolt assembly After performing maintenance on the hoist test to 125 of 2 Make a link in new load chain by grinding through one its rated capacity before returning to service Testing to 150 side of the end link Refer to Dwg MHP0817 on page 8 To of rated capacity will be required to set overload clutch and avoid twisting the load chain on 2 3 and 5 ton units must might be required to comply with standards and regulations have an odd number of links not counting the C link set forth in areas outside of the USA ican A dimension Installing New Load Chain To prevent a falling load which can cause death injury or property damage the hook must be on left fall of load chain and right fall must be attached to hoist body with anchor pin and anchor hanger Right and left designations are as viewed from the hand chain side of the hoist NOTICE Do not remove the old load chain from the hoist The old load chain can be used to install the new load chain C Link Dwg MHP0817 8 MHD56391 Edition 2 3 Using a link join the old load chain to the new load chain If the old load chain was installed correctly the C link assures end link of ne
24. es of all shaft shoulders to remove small nicks which may have been caused during handling 6 Remove all nicks and burrs caused by lockwashers Assembly Load Sheave Assembly 1 Apply grease to roller bearings and position them the groove of the bearing race located on the gear end of the load sheave 2 Install load sheave in side plate ensure roller bearings remain in position 3 Install two chain guides chain stripper assembly anchor hanger assembly and top hook assembly in side plate 4 Apply grease to the second set of roller bearings and position them in groove ofthe bearing race located on the plain end of the load sheave The same number of roller bearings must be used on either side of the load sheave 5 Carefully install side plate assembly to engage the locating diameters of parts installed in steps 3 and 4 Ensure all roller bearings remain in position 6 Install lockwashers and nuts and tighten Slip Clutch Assembly 1 Place double cone onto pins in handwheel and press until seated 2 Insert screws through double cone and tighten 3 Insert single cone into double cone along with spring 4 Insert support through backside of double cone Thread nut onto support loosely 5 Slide this assembly onto pinion shaft and secure with nut and cotter pin 6 Refer to Adjusting Slip Clutch for adjustment procedures Gear End Assembly Follow steps 1 through 6 described in Load Sheave A
25. ety of Mechanical Engineers Three Park Avenue New York NY 10016 SAFE OPERATING INSTRUCTIONS The following warnings and operating instructions have been adapted in part from American Society of Mechanical Engineers ASME B30 16 Overhead Hoists and are intended to avoid unsafe operating practices which might lead to injury or property damage Ingersoll Rand recognizes that most companies who use hoists have a safety program in force in their facilities In the event 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 are not necessarily limited to the following list Refer to specific sections in the manual for additional safety information 1 allow people trained in safety and operation of this product to operate the hoist N 2 Only operate hoist if you are physically fit to do so 3 When a DO NOT OPERATE sign is placed on the hoist 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 use a hoist which inspection indicates is worn or damaged 6 Periodically inspect the hoist thoroughly and replace worn or damaged parts Refer to the INSPECTION section
26. he condition of critical parts as a method of documenting periodic inspections These reports should be dated signed by the person who performed the inspection and kept on file where they are readily available for review Load Chain Reports Records should be maintained documenting the condition of load chain removed from service as part 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 Table 1 Hook Throat Opening Frequent Inspection Manual Chain Hoists should be inspected at the beginning of each shift Visual inspections should also be conducted during regular service for any damage or evidence of malfunction which appears between regular inspections 1 Operation Check for visual signs or abnormal noises which could indicate a potential problem Do not operate a hoist unless the load chain feeds through the hoist and hook block smoothly Listen for clicking binding or malfunctioning The clicking sound of the pawl on the ratchet gear is normal when a load is being raised If chain binds jumps or is excessively noisy clean and lubricate the chain If problem persists the chain and load sheave may have to be replaced Do not operate the hoist until all problems have been corrected Check that hand ch
27. heck gears shafts bearings sheaves chain guides springs and covers Replace worn or damaged parts Clean lubricate and reassemble 3 Hooks Inspect hooks for cracks Use magnetic particle or dye penetrant to check for cracks Inspect hook retaining parts Tighten repair or replace if necessary Refer to the latest edition of ASME B30 10 Hooks for additional hook inspection information 4 Chain Sheaves Check for damage or excessive wear Replace if necessary 5 Brake Ensure proper operation Brake must hold hoist rated capacity If load test indicates the need disassemble Brake discs must be free of oil any grease unglazed and uniform in thickness Refer to MAINTENANCE section for allowable brake disc wear Check all other brake surfaces for wear deformation or foreign deposits Inspect gear teeth pawl and pawl spring for damage Check that brake pawl stops counterclockwise rotation of ratchet gear Clean and replace damaged components as necessary 6 Supporting Structure If a permanent structure is used inspect for continued ability to support load 7 Labels and Tags Check for presence and legibility Replace if necessary 8 End Anchor Ensure end anchor is installed and unbent Replace if missing or damaged Refer to Attaching End of Load Chain in the MAINTENANCE section 9 Load Chain Measure the chain for stretching by measuring across five link sections all along the chain length Refer to D
28. it notify the carrier s agent immediately MHD56391 Edition 2 Damage Claims You must file claims for damage with the carrier It is the transportation company s responsibility to reimburse you for repair or replacement of goods damaged in shipment Claims for loss or damage in shipment must not be deducted from the Ingersoll Rand invoice nor should payment of Ingersoll Rand invoice be withheld awaiting adjustment of such claims as the carrier guarantees safe delivery You may return products damaged in shipment to us for repair which services will be for your account and form your basis for claim against the carrier 19 Printed in China Ingersoll Rand
29. move retainer ring and replace damaged parts mcus 10 Slip Clutch Disassembly Remove cotter pin and nut Pull handwheel slip clutch assembly off of pinion shaft 3 Remove nut from support and separate support spring and single cone 4 Remove screws and carefully pry double cone off of handwheel NOR Accessing Load Sheave Follow steps 1 through 5 in Accessing Gear End and steps 1 through 6 in Accessing Brake End then steps below 1 Remove nuts and lockwashers from side plate 2 Pull side plate away from studs in side plate 3 Remove the top hook assembly roller bearings two chain guides chain stripper and anchor hanger 4 Lift load sheave from side plate Being careful to catch roller bearings as they become free Bottom Hook Disassembly 2 3 and 5 ton Remove three capscrews lockwashers and nuts Separate plates and remove hook 3 Lift out sheave assembly Carefully slide idler sheave shaft from idler sheave and remove rollers NR Cleaning Inspection and Repair Use the following procedures to clean and inspect the components of the hoist Cleaning Clean all hoist component parts in an acid free solvent except for the brake disc 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 inspecte
30. ond repair and no additional damage will occur to other parts In general the hoist is designed to permit easy disassembly and assembly The use of heat or excessive force should not be required 4 Keep the work area as clean as practical to prevent dirt and other foreign matter from getting into bearings or other moving parts 5 When grasping a part in a vise always use leather covered or copper covered vise jaws to protect the surface of the part and help prevent distortion This is particularly true of threaded members machined surfaces and housings 6 Donotremove any part which is press fit in or ona subassembly unless the removal of that part is necessary for repairs or replacement Disassembly Accessing Gear End Remove the three nuts from gear cover Remove gear cover Remove nuts along with lockwashers from support plate Remove support plate gears and bearings Remove retainer ring from load sheave and pry off gear eo Accessing Brake End Remove the three nuts and screws from handwheel cover Remove handwheel cover Remove cotter pin and nut from pinion shaft Secure load sheave to prevent rotation and unscrew handwheel from pinion shaft Handwheel is left hand counterclockwise threaded 5 Remove brake discs and ratchet disc 6 Secure load sheave to prevent rotation and unscrew brake hub from pinion shaft NOTICE If ratchet pawls or springs are damaged or not functioning then re
31. ortant aspects of hoist operation are 1 Follow all safety instructions when operating the hoist 2 Allow only personnel trained in safety and operation of this hoist to operate hoist 3 Subject each hoist to a regular inspection and maintenance procedure 4 Be aware of hoist capacity and weight of load at all times Hoist is not designed or suitable for lifting lowering or moving persons Never lift loads over people Hoist Operation When facing hand chain side of hoist 1 Pull down on the right hand chain clockwise to raise load 2 Pull down on the left hand chain counterclockwise to lower load NOTICE The clicking sound of the pawl on the ratchet gear is normal when a load is being raised Slip Clutch Operation Hoists are equipped with a slip clutch When trying to lift a load that exceeds capacity of hoist the hand chain will rotate in the hoist body but the load will not be lifted It is important to keep the slip clutch properly adjusted Refer to the MAINTENANCE section on page 8 for the proper procedure Storing the Hoist Always store hoist in a no load condition Wipe off all dirt and water Oil the chain hook pins and hook latch pins Hang in a dry place Before returning hoist to service follow instructions for Hoists Not in Regular Use in the INSPECTION section on page 5 pni dS cbr INSPECTION All new altered or modified hoists should be inspected and teste
32. oto prohl en vztahuje odpov daj ustanoven m sm rnic DA som denne erkl ring vedr rer overholder bestemmelserne 1 f lgende direktiv er DE auf das sich diese Erkl rung bezieht der folgenden Richtlinie entspricht EL onoio auth Odnyiac ES los que se refiere la presente declaraci n cumplen con todo lo establecido en las directivas FI johon tama vakuutus viittaa t ytt direktiiveiss FR Objet de ce certificat est conforme aux prescriptions des Directives HU Amelyekre ezen nyilatkozat vonatkozik megfelelnek a k vetkez ir nyelvek el r sainak IT a cui si riferisce la presente dichiarazione conforme alle normative delle direttive NL waarop deze verklaring betrekking heeft overeenkomt met de bepalingen van directieven NO som denne erkl ringen gjelder for oppfyller bestemmelsene i direktivene PL Kt rego dotyczy niniejsza deklaracja jest zgodny z wymogami dyrektyw PT Ao qual se refere a presente declara o est de acordo com as prescri es das Directiva SK Na ktor sa toto prehl senie vztahuje je v s lade s ustanoveniami Smernice Smern c SL Na katerega se ta izjava o skladnosti nana a v skladu z dolo ili smernic SV Som detta intyg avser verensst mmer med f ljande direktiv By using the following Principle Standards EN 292 VBG 9a CS Pou it m n sleduj c ch z konn
33. p the exposed part of the link C Link Vise Dwg MHP0014 12 2 Ifthe hand chain is being replaced disconnect it at link and carefully remove the hand chain 3 When replacing a hand chain cut a length 2 times the required hand chain drop plus about one foot 305 mm For adjustments remove or add a length of chain twice the difference in hand chain height To prevent the hand chain from twisting maintain an even number of links by removing or adding an even number of links 4 Ifyou are replacing the hand chain run the new hand chain up through the left hand chain guide around the handwheel making sure the hand chain is seated in the handwheel pockets and back down through the right hand chain guide 5 Connect the hand chain ends with the link s making the total number of links even and bend the C link s shut 6 Make sure the hand chain is not twisted If twisted untwist or open link and remove one hand chain link Refer to Dwg MHP0015 on page 12 Twisted Do Not Use Untwisted Dwg MHP0015 Load Test Prior to initial use all new extensively repaired or altered hoists shall be load tested by or under the direction of a person trained in the operation and maintenance of this hoist and a written report furnished confirming the rating of the hoist Test hoist to 125 of the rated hoist capacity Testing to more than 125 will be required to se
34. provided with the winch that contains installation parts information maintenance lubrication and related service instructions Danger Warning Caution and Notice Safety Summary Throughout this manual there are steps and procedures which if not followed may result in a hazard The following signal words are used to identify the level of potential hazard Indicates an imminently hazardous DANGER situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation amp WARNING which if not avoided could result in death or serious injury Indicates potentially hazardous situation CAUTION which if not avoided may result in minor or moderate injury or property damage Indicates information or a company NOTICE policy that relates directly or indirectly to the safety of personnel or protection of property The words shall and should are used throughout this manual in accordance withdefinitions in the ASME B30 standards as follows Shall this word indicates that the requirement is mandatory and must be followed Should this word indicates that the requirement is a recommendation The advisability of the recommendation depends on the facts in each situation Also used in this manual and other manuals are the following words with definitions Owners users these words also refer to winch operators Do not use this hoist for lifting
35. ssembly 1 Install gear on load sheave Ensure recessed side of gear face is outward Install retainer ring on load sheave to secure gear 2 Install pinion shaft through the center of load sheave 3 Install gears so gear teeth are correctly timed and end shafts are located in bearing sleeves in side plate Refer to Gear Timing section on page 11 4 Apply a thick coat of grease as recommended in the LUBRICATION section to all gear teeth Install support plate over gears to engage gear end shafts 5 Secure support plate with nuts and lockwashers 6 Install the gear cover Secure with three nuts and screws MHD56391 Edition 2 Brake End Assembly Follow steps 1 through 6 described in Load Sheave Assembly and steps 1 through 6 described in Gear End Assembly then below steps amp CAUTION The brake will not operate properly if there is oil on the brake discs 1 Thread brake hub onto pinion shaft until snug Stepped side of brake hub must face out 2 Install first brake disc followed by ratchet disc and second brake disc Ratchet disc teeth must engage the two pawls mounted on side plate assembly Counterclockwise rotation of the ratchet disc must be possible 3 Secure load sheave to prevent rotation and thread handwheel onto pinion shaft and secure with nut Tighten nut until snug and then back nut off until first slot is aligned with pin hole in pinion shaft Install cotter pin and bend ends
36. st issue Disposal When the life of the hoist has expired it is recommended that the hoist be disassembled degreased and parts separated as to materials so that they may be recycled For additional information contact Ingersoll Rand 510 Hester Drive P O Box 618 White House TN 37188 Phone 615 672 0321 Fax 615 672 0801 17 DECLARATION OF CONFORMITY CS PROHL EN SHOD DA FABRIKATIONSERKLARING DE KONFORMITATSERKLARUNG EL AHAQZH ES DECLARACI N CONFORMIDAD FI VAKUUTUS NORMIEN TAYTTAMISESTA FR CERTIFICAT DE CONFORMITE HU MEGFELELOSEGI NYILATKOZAT IT DICHIARAZIONE DI CONFORMIT NL SCHRIFTELIJKE VERKLARING VAN CONFORMITEIT NO KONFORMITETSERKLARING PT DECLARACAO DE CONFORMIDADE PL DEKLARACJA ZGODNOSCI SK PREHL SENIE ZHODE SL IZJAVA SKLADNOSTI SV FORSAKRAN OM OVERENSSTAMMELSE Ingersoll Rand 529 Avenue Roger Salengro 59450 Sin Le Noble France Declare under our sole responsibility that the product Manual Chain Hoist CS ProhlaSujeme na svou zodpov dnost Ze produkt DA Erkl rer som eneansvarlig at nedenst ende produkt DE Erkl ren hiermit gem unserer alleinigen Verantwortung da die Ger te EL AnAovoups pe 00 ro npoi v ES Declaramos que bajo nuestra responsabilidad exclusiva el producto FI Vakuutamme ja kannamme yksin t yden vastuun siit ett tuote FR D
37. t overload clutch and may be necessary to comply with standards and regulations set forth in areas outside of the USA MHD56391 Edition 2 SERVICE NOTES MHD56391 Edition 2 13 HOIST ASSEMBLY PARTS DRAWING BRED fe J JEJ Dwg MHP2915 14 MHD56391 Edition 2 HOIST ASSEMBLY PARTS LIST ITEM DESCRIPTION QTY PART NO NO OF PART TOTAL 1 2 ton 1 ton 1 1 2 ton 2 ton 3 ton 5 ton x Coyet Bil eludes 1 45593381 45593555 45593811 45593969 45594207 45594363 items 1 10 and 43 1 Hand Wheel Cover 1 45593464 45593654 45593894 45594041 45594280 45594553 2 Top Hook Support 1 Order item 17 Plate 3 Nut 1 Order item 75 4 Cotter Pin 4 Hand Wheel Slip su Ieeh Assembly 1 50002 100002 150002 200002 300002 500002 includes items 27 28 76 77 82 amp 87 6 Support Plate 1 Not sold separately 7 Friction Disc 2 45518826 45518859 45518883 45518891 45518909 45518917 8 Ratchet Disc 1 Order item 75 9 Brake Hub 1 10 Nut 6 Not sold separately 11 Capscrew 3 Order item 45 12 Side Plate 1 45593415 45593597 45593845 45593993 45594231 45594397 1 45519261 45519279 45519287 45519295 45519303 45519311 items 33 amp 74 15 Support Plate 1 4
38. ve when hoist is stopped Brake is slipping Check brake adjustment and brake disc wear Check brake discs are clean Hoist is overloaded Reduce load to within rated capacity shaft gears load chain sheaves Load chain binds Damaged load chain pinion shaft gears or Disassemble hoist inspect and repair or replace sheaves damaged components Refer to MAINTENANCE section Load chain not installed properly twisted Remove load chain and reinstall kinked or capsized Hand chain binds Damaged hand chain hand chain wheel pinion Disassemble hoist inspect and repair or replace damaged components Hand chain not installed properly twisted or kinked Remove hand chain and reinstall Load hook latch does not work Latch broken Replace hook latch Load hook bent or twisted Inspect load hook as described in INSPECTION section Replace if necessary MAINTENANCE 1 Remove end of load chain from anchor pin 4 WARNING a 1 2 to 3 ton units are single fall hoists The load end of the load chain is anchored to the bottom hook assembly Never perform maintenance on the hoist while it is To disconnect the load chain from the bottom hook supporting a load assembly remove anchor pin and nut On bottom hook Before performing maintenance tag hoist remove spring and pin DANGER DO NOT OPERATE b 5 ton units are double chain fall hoists Th
39. w load chain will be correctly reeved through the hoist Be sure welds of standing links on the new load chain are facing away from the hoist load sheave Refer to Dwg MHP0042 on page 9 Load Chain Load Sheave Standing Link Chain Weld Dwg MHP0042 4 Run the new chain to its anchor point On smaller units use the hand chain to move the load chain On larger units load chain installation can be speeded up by removing gear cover support plate and taking out gears With the gears removed the load chain can be pulled by hand through the hoist body and hook blocks Reinstall gears support plate and gear cover 5 Remove C link and old chain 6 On 1 2 1 and 1 1 2 ton hoists anchor load chain to bottom hook assembly On 2 3 and 5 ton units secure load chain to suspension plates using anchor bolt assembly For information on connecting unloaded end of load chain refer to Attaching End of Load Chain section 7 Check for the following a Load chain did not become twisted when reeving the load chain between the idler sheave on the bottom hook assembly and the hoist load sheave Refer to Dwg MHP0020 on page 9 b Make sure load chain is reeved between load sheave and chain guides Appearance of chain that is Not Twisted Dwg MHP0020 Appearance of chain that Is Twisted Slip Clutch The slip clutch is designed to slip handwheel rotates but no load
40. wg MHP0041 on page 7 When any five links in the working length reach or exceed the discard length shown in Table 2 replace the entire chain Always use a genuine Ingersoll Rand replacement chain Table 2 Load Chain Length Inspection Chain Normal Length Discard Length Model No Size mm in mm in mm 5 005 5 15 2 95 75 3 03 77 5 010 6 18 3 54 89 9 3 63 922 5 015 4 17 106 4 28 108 7 5 020 8 24 4 72 119 9 4 84 122 9 SMB030 10 30 5 91 150 1 6 03 153 2 SMB050 5 35 136 5 47 139 Hand Chain No discard length needed Dwg MHP0041 Hoists Not in Regular Use 1 Hoists which have been idle for a period of one month or more but less than one year should be given an inspection conforming with the requirements of Frequent Inspection before being placed in service 2 Hoists which have been idle for a period of over one year should be given a complete inspection conforming with the requirements of Periodic Inspection before being placed in service 3 Standby hoists should be inspected at least semiannually in accordance with the requirements of Frequent Inspection LUBRICATION General Thread lubricant or an antiseize compound use is recommended for threaded shafts capscrews and nuts Unless otherwise stated remove old lubricant clean the part with an acid free solvent and apply a new coating of lubricant
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