Ingersoll-Rand Hercu-Link HA1-005 Installation guide

Form MHD56298
• A copy of our “Safe Operating Practices” Manuals are always available free of charge either by downloading it from our
Technical Publications website @ www.airwinch.com or by contacting the Factory at [phone] for North America and
[phone] for International. The Safe Operating Practices manual must be read prior to anyone operating a
Ingersoll-Rand winch or hoist. The manual form numbers are as follows:
“Safe Operating Practices Non-Man Rider™ Winches” Manual, Form No. MHD56250
“Safe Operating Practices for Man Rider™ Winches” Manual, Form No. MHD56251
“Safe Operating Practices for Pneumatic, Hydraulic and Electric Hoists” Manual, Form No. MHD56295
• Available winch options may require additional supplements to the basic winch manual.
• For Man Rider™ winches ensure a copy of the Man Rider™ supplement is made available to the operator prior to winch
operation.
• We strongly recommend that ALL maintenance on Ingersoll-Rand equipment be carried out by personnel certified by
Ingersoll-Rand, or by Ingersoll-Rand Authorized Service Centers.
• Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions.
• Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist.
• ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested
prior to being placed into service:
Winch Man Rider™Supplements:
Model: Publication No. Model: Publication No.
FA2, FA2.5,
FH2, FH2.5 MHD56046 LS500RLP SAM0011
LS1000RLP SAM0012
FA5 MHD56042 and
MHD56220
LS150RLP SAM0082
LS150RLP/500/
1000 SAM0115
FA10 MHD56252
FA2.5A MHD56236 LS150RLP and
LS150PLP-PH SAM0120
FA2B and
HU40A MHD56207 LS500RLP-E SAM0122
FH10MR MHD56212 LS150RLP-
DP5M-F SAM0184
Fulcrum Electric MHD56277
LS500HLP/
LS1000HLP SAM0004 LS150HLP SAM0222
*Winches-ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
*Hoists - ANSI / ASME B30.16 (OVERHEAD HOISTS - UNDERHUNG) Refer to section 16.2.2 - Testing.
Form MHD56298
Edition 2
November 2004
71441844
© 2004 Ingersoll-Rand Company
IMPORTANT INFORMATION:

Form MHD56075
PARTS, OPERATION AND MAINTENANCE MANUAL
for
AIR HOIST
MODELS
HA1-005 HA1-010 HA1-015 HA1-020
5 ton 10 ton 15 ton 20 ton
Tons in this manual are metric tons (2,200 tbs.)
READ THIS MANUAL BEFORE USING THESE HOISTS. This manual con-
tains important safety, installation, operation and maintenance informa-
tion. 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, inspectand maintain this hoist in accordance with American National
Standards Institute S
regulations. afety Code (ASME 830.16) and any other applicable safety codes and
Refer all communications to the nearest Ingersoll-Rand Material Handling Products Office
or Distributor.
Form MHD56075
Edition 1
September 1993
71123053
©1993 Ingersoll-Rand Company MATERIAL HANDLING

Description Page No.
Safety Information
Danger, Caution, Warning and Notice.. ......................................................................................................................... 3
Safe Operating Instructions ............................................................................................................................................ 4
Warning Labels and Tags .............................................................................................................................................. 5
Specifications
Description of Hoist Operation ...................................................................................................................................... 6
Specification Chart.. ....................................................................................................................................................... 6
Model Code Explanation ............................................................................................................................................... 7
Installation
Hoist and Trolley Installation ........................................................................................................................................ 8
Air Supply.. .................................................................................................................................................................... 9
Motor.. .......................................................................................................................................................................... 10
Initial Operating Checks .............................................................................................................................................. 11
Air Schematics ............................................................................................................................................................. 12
Operation
Hoist Controls .............................................................................................................................................................. 13
Inspection
Records and Reports .................................................................................................................................................... 15
Frequent Inspection ...................................................................................................................................................... 1.5
Periodic Inspection.. ..................................................................................................................................................... 16
Hoists not in Regular Use ............................................................................................................................................ 17
Inspection and Maintenance Report ............................................................................................................................. 18
Lubrication
Motor.. .......................................................................................................................................................................... 19
Load Chain ................................................................................................................................................................... 20
Reduction Gear Assembly ........................................................................................................................................... 21
Troubleshooting
Troubleshooting Chart ................................................................................................................................................. 22
Maintenance
Maintenance Intervals .................................................................................................................................................. 24
Load Chain Replacement ............................................................................................................................................. 24
Hoist Disassembly ........................................................................................................................................................ 27
Cleaning, Inspection and Repair .................................................................................................................................. 30
Hoist Assembly ............................................................................................................................................................ 3 1
Load Test ..................................................................................................................................................................... 36
Index of Exploded View Parts Illustrations ................................................................................................................. 39
Hoist Parts Section ....................................................................................................................................................... 40
Parts Ordering Information
Return Goods Policy ....
................................................................................................................................................ 78
Warranty ...................................................................................................................................................................... 79
2

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
and understand this manual before operating the product.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures
which, if not followed, may result in a injury. The follow-
ing signal words are used to identify the level of potential
hazard.
Safety Summary
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 mainte-
nance information which is impor-
tant but not hazard-related.
l Do not use this hoist for lifting, supporting, or trans-
porting people or lifting or supporting loads over
people.
l Air powered hoists are designed to provide a 5 to 1
safety factor and are factory tested to 125% of the rated
load. 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.
l Lifting equipment is subject to different regulations in
each country. These regulations may not be specified in
this manual.
The National Safety Council, Accident Prevention Manual
for Industrial Operations, Eighth Edition and other recog-
nized 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 Material Handling 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 owner/employer,
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 responsibility and user’s responsibility to deter-
mine the suitability of a product for any particular use. It is
recommended that all applicable industry, trade associa-
tion, federal, state and local regulations be checked. Read
all operating instructions and warnings before operation.
Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper
rigging techniques. See ASME B30.9 for rigging informa-
tion, American National Standards Institute, 1430 Broad-
way, New York, NY 10018.
This manual has been produced by Ingersoll-Rand to
provide dealers, mechanics, operators and company
personnel with the information required to install, operate,
maintain and repair 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:
1. Proper and safe use and application of mechanics
common hand tools as well as special Ingersoll-Rand
or recommended tools.
2. 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 repairs may be
conducted and the hazards and/or results of each method. If
operation or maintenance procedures not specifically
recommended by the manufacturer are conducted, it must
be ensured that product safety is not endangered by the
actions taken. If unsure of an operation or maintenance
procedure or step, personnel should place the product in a
safe condition and contact supervisors and/or the factory
for technical assistance.

The following warnings and operating instructions have
been adapted in part from American National (Safety)
Standard ASME B30.16 and are intended to avoid unsafe
operating practices which might lead to injury or property
damage.
An operator should be physically competent. The operator
should have no health condition which might affect his
ability to react, and he should understand the operation of
the hoist, including reading the manufacturer’s literature.
The operator should have a working knowledge of hitching
loads. The operator should have a good attitude regarding
safety and should refuse to operate the hoist under unsafe
conditions.
Ingersoll-Rand recognizes that most companies who use
hoists have a safety program in force at their facility. If
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 dangerous practices to avoid and are not
necessarily limited to the following list. Refer to specific
sections in the manual for additional safety information.
1. Only allow personnel trained in, safety and operation
on this product to operate and maintain 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
controls, do not operate the hoist until the sign has been
removed by designated personnel.
4. Before each shift, the operator should check the hoist
for wear or damage.
5. Never use a hoist which inspection indicates is warn or
damaged.
6. Do not use hoist if hook latch on a hook has been
sprung or broken.
7. Check that the hook latches are engaged before using.
8. Never splice a hoist chain by inserting a bolt between
links.
9. Only lift loads less than or equal to the rated capacity
of the hoist. See warning labels attached to the hoist.
10. When using two hoists to suspend one load, select two
hoists each having a rated capacity equal to or more
than the load. This provides adequate safety in the
event of a sudden load shift.
11. Never place your hand inside the throat area of a hook.
12. Never use the hoist chain as a sling.
13. Only operate a hoist when the load chain is centered
over the hook. Do not “side pull” or “yard”.
14. Never operate a hoist with twisted, kinked, “capsized”
or damaged load chain.
15. Do not force a chain or hook into place by hammering.
16. Never insert the point of the hook into a chain link.
17. Be certain the load is properly seated in the saddle of
the hook.
18. Do not support the load on the tip of the hook.
19. Never run the load chain over a sharp edge. Use a
sheave.
20. Pay attention to the load at all times when operating
the hoist.
2 I. Make sure all people are clear of the load path. Do not
lift a load over people.
22. Never use the hoist for lifting or lowering people, and
never allow anyone to stand on a suspended load.
23. Ease the slack out of the chain and sling when starting
a lift. Do not jerk the load.
24. Do not swing a suspended load.
25. Never suspend a load for an extended period of time.
26. Never leave a suspended load unattended.
27. Never weld or cut a load suspended by the hoist.
28. Never use the hoist chain as a welding electrode.
29. Do not operate hoist if chain jumping, excessive noise,
jamming, overloading, or binding occurs.
30. Keep the load from hitting the load chain.
3I. Do not use the up and down emergency stop limit
protection as a normal means of stopping the hoist.
32. Avoid unnecessary jogging of hoist and/or trolley
controls.
33. Always rig the hoist properly and carefully.
34. Shut off air supply before performing any mainte-
nance.
35. Avoid collision or bumping of hoist.
36. After use, properly secure hoist and all loads.
4

Each hoist is supplied from the factory with the warning
tags and labels shown. If the tags or labels are not attached
to your hoist, order new tags or labels and install them. See
Labels and Tags parts list in parts section. Read and obey
all warnings and other safety information attached to this
hoist. Tags and labels may not be shown actual size.
Tag part number 7104212l/B is attached to the inlet air
supply components.
Tag part number 7 1042 147/A is attached to the lubricator
in the inlet air supply line .
Tag part number 7 1107 155 is attached to the power head Label part number 71107130/A is attached to the inlet air
reduction gear assembly fill plug. supply components.
Tag part number 71059612/B is attached to the pendant
assembly.
Tag part number 7 1107 148 is attached to the power head
reduction gear assembly.

Description of Hoist Operation
The HA 1 air powered hoist primarily consists of a power
head assembly which acts as the control for the lower hook
block movement. The power head assembly is made up of
three main sections. They are the motor and first gear
reducer section, the brake and second gear reducer section
and the sheave section.
The input shaft cannot rotate in either direction until the
brake has been released. The brake is released by air
pressure applied to the annular brake piston. The piston
compresses the brake springs, releasing the brake discs.
There are five sintered bronze type brake friction discs and
six stationary brake discs.
The brake piston is actuated by air from the main control
valve. When the control pendant “UP” or “DOWN” button
is pushed it moves the main control valve spool. The spool
is designed to send air to the brake.
The output shaft from the piston motor is connected to the
first planetary reducer assembly. The output from the first
planetary reducer assembly is connected to the brake by the
input shaft which passes through the center of the sheave
section. The input shaft also acts as the sun gear for the
second stage planetary reducer. The output from the
secondary planetary reduction assembly is transmitted
directly to the load chain sheave.
When the pendant “UP” or “DOWN” button is released,
quick exhaust valves allow the brake to set quickly and
avoid downward load drift.
Table 1
Capacity
(metric tons)
I
Std.. Lift Speed Air Supply
ft Lift Lower Lower HP I
m Lift
(fpm) cfm cu.m/min
(m/min) (fpm) (m/min)
10 3 15 4.6 3.8 165 4.67
1.5 2.3 3.8 4.67
5 10
10 10
15 10
20 10
3
3
3
3
5 7-l/2 165
3-l/4 5 1.5 3.85
1.14 3.8
165 4.67
4.67
2-l/2
1
0.76 3-314 165
Model No.
HA l-005
HAl-010
HAl-015
HAL020
Table 2
Load Head Room* Unit Weight with
Capacity Unit Weight
Model No. (metric Chain Hook Mount Trolley Mount Hook Mount Trolley
tons) Size (Piston Motor)
(mm) in mm in mm lbs kg lbs kg
HAl-005 5 16 27-5/8 702 23-9116 598 685 311 905 411
HAl-010 10 16 35-l/2 902 30-l/2 775 765 348 1105 502
HAl-015 15 16 41-7/8 1064 35-l/4 895 875 398 1315 590
HAl-020 20 16 42-l/2 1080 34-9/16 878 975 443 1425 640
* Head room dimensions are for hoists without limit switches. Refer to sales brochure for head room dimensions of hoists with limit switches.
6

Model Code Explanation
Model Code Example HA1 - 0l0M- A3 -30-27FLM
Series HA = Hercu-Link Air Powered Hoist
Frame Size
1 = 16 mm Load chain
Capacity 005 = 5 metric ton (11,000 lbs)
010 = 10 metric ton (22,000 lbs)
015 = 15 metric ton (33,000 lbs)
020 = 20 metric ton (44,000 lbs)
Suspension
H = Hook mount
C = Clevis mount*
D = Deck Mount*
P = Plain trolley
G = Geared trolley
V = Vane motor driven trolley
M = Piston motor driven trolley
Trolley Flange Adjustment
M = No trolley used with hook
A = Standard
B = 2 in. (51 mm) extension
C = 4 in. (102 mm) extension
D = 6 in. (152 mm) extension
Control 1 = Pull rope 5 = 1 motor with emergency stop
2 = 1 motor pendant (2 button) 6 = 2 motor with emergency stop
3 = 2 motor pendant (4 button) 7 = 3 motor with emergency stop
4 = 3 motor pendant (6 button)
Lift xx = Length of lift. (XX = Specify length (ft). Max. 60 ft. (18 m))
Control Drop
xx = Control Drop Pendant or Hand chain length
Options C = Corrosion resistant coating (SBCZ and Marine 812 top coat)
L = Upper and lower limit switch
N = Corrosion resistant load chain (zinc plated)
M = Marine protection package
T = Galvanized chain container (not available on 5 ton hook mounted models)
Y = Hull bumper (for hook mounted shipyard hoists only)
R = Copper plate S*COR*E package
t
= Solid bronze S*COR*E package (12-l/2 ton models only)
= 60 psi application package
Trolley
B = Trolley bumper
G = Trolley guide rollers
Control
F = Push button main air shutoff
A = Accu-Trol® pendant
* Features not covered in this manual. For additional information contact your nearest Ingersoll-Rand Material Handling
office or distributor.

Prior to installing the hoist, carefully inspect it for possible
shipping damage.
l Before installing hoist read “SAFETY INFORMA-
TION” section.
Hoists are supplied from the factory with the correct grade
and quantity of lubricating oil. Before operation all oil
levels must be checked and/or topped off with the proper
type of oil recommended in the “LUBRICATION” section.
Lubricate load chain before operating hoist.
l Owners and users are advised to examine specific,
local or other regulations, including American
National Standards Institute and/or OSHA Regulations
which may apply to a particular type of use of this
product before installing or putting hoist to use.
Remove cover from the shipping crate. Carefully remove
steel straps. On units equipped with a trolley, carefully
position wire rope sling around the hoist trolley side plates
and slowly lift hoist assembly. Constantly monitor the
position of the hoist and trolley to ensure the load is
balanced and secure. On hook mounted units lift into
position by using top hook of the hoist.
Attach chain container to hoist with chain container pin
and connect the container suspension hook as required.
Hook Mounted Hoist Installation
Place hook over mounting structure. Make sure hook latch
is engaged. Ensure the supporting member rests completely
within the saddle of the hook and is centered directly above
the hook shank.
l Do not use a supporting member that tilts to one side
or the other.
Trolley and Hoist Installation
l A falling load can cause injury or death. Before
installing trolley and hoist, read “SAFETY INFORMA-
TION”.
l Depending on the size of hoist selected it could weigh
as much as 1425 lbs. (640 kg). If parts of the trolley or
hoist are dropped, they could cause injury or damage
property. Adequately support the hoist and trolley
when lifting them into place on the beam.
Installing Over the End of the Beam
Preadjust trolley width for the beam flange measurement.
Refer to “Installing from Underneath the Beam.” Remove
the rail stop and slide trolley on end of the beam. Reinstall
rail stop. If this procedure cannot be used, due to insuffi-
cient space or fixed limit stops, the trolley must be installed
from underneath the beam using the procedure which
follows.
Installing from Underneath the Beam
(Ref. Dwgs. MHTPA0511 and MHTPC0532)
1. Measure beam flange width and compare with
measurement between trolley wheel flanges. The
correct total clearance between the beam and the
trolley wheel flanges is l/16 to 3/16 in. (2 to 5 mm).
To adjust trolley wheel spacing remove cotter pins
(178) and pins (177) at side plate. Remove adjusting
spacers (157) and side plate and add or subtract an
equal number of adjusting spacers (157) on suspension
shafts (174) between top frame and side plates. Longer
spacers (175) and (176) are used on trolleys which will
be mounted to wider beam flange widths. Ensure that
the same spacer configuration is used on either side of
the hoist top frame.
2. When desired trolley wheel spacing measurement is
achieved, carefully position wire rope sling around the
hoist trolley side plates and slowly lift hoist and trolley
assembly into place beneath the beam flange. Press
side plates together on beam. Trolley wheels must rest
on top of the beam flange.
l To avoid an unbalanced load which may damage the
trolley, the hoist must be centered under the trolley by
the spacers (157).
3. Slide remaining adjusting spacers (157) over the free
end of the suspension shafts (174). Insert pins (177)
into the holes in the suspension shafts (174). Secure by
installing cotter pins (178) and bending ends apart.
4. The pin (177) and outside spacers (157) must hold the
trolley to the adjustment in step 1. If the side plates
can be spread farther apart, install more outside
spacers (157) between side plate and the pin (177).
8

(Dwg. MHTPA0511)
Trolley Installation
(Dwg. MHTPC0532)
l Trolley wheels ride on the top of the lower flange of
the beam.
5. If trolley is equipped with guide rollers measure beam
flange width and compare with measurement between
guide rollers. Side roller spacing measurement should
be l/16 to 3/16 in. (2 to 5 mm) greater than beam
flange width.
6. Ensure beam stops are installed prior to operating hoist
and trolley.
7. Prior to placing into service test the trolley. Check that
the trolley side plates are vertical. Raise a load equal to
the rated capacity of the hoist 6 to 7 ins. (130 to 180
mm) off the floor and operate the trolley along the
entire length of the beam.
Chain Container (optional feature)
l Do not pile chain carelessly 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 chain stopper (241) to the last link of the load
chain free end.
3. Attach the chain container to the hoist.
4. Run bottom block to lowest point and run hoist in up
direction to feed the chain back into the container.
l When feeding chain into the chain container begin
with the chain stopper end of the chain so that it piles
naturally.
Attaching Free End of Load Chain
1. Install chain stopper (241) on the end of the load chain.
2. Attach the free end of the load chain to the hoist or
bottom hook assembly. See Chaining Drawings in the
“MAINTENANCE” section.
After installing load chain, make sure it is not twisted or
kinked. Fix before using hoist.
Air Supply
The air supply must be clean and free from moisture. Due
to efficiency losses in the air lines and air line components,
air pressures should be checked at the hoist motor. A
minimum of 105 psi (7.2 bar/724 Kpa) at the hoist motor is
required to provide rated hoist capacity. Due to efficiency
losses in air lines, pressures of up to 130 psi (8.9 bar/896
Kpa) at the air supply may be required to achieve the
required operating pressure. (Contact the Technical
Support Department for operating requirements with
optional 60 psi system).

Air Lines
The inside diameter of the hoist air supply lines must not
be smaller than 1 in. (25 mm) based on a maximum of 50
ft. (15 m) between the air supply and the hoist. Contact the
factory for recommended air line sizes for distances greater
than 50 ft. (15 m). Before making final connections, all air
supply lines should be purged before connecting to unit
inlet. 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.
Regulator
Air Out
Lubricator Filter
Air In
(Dwg. MHTPA0191)
Air Line Lubricator
(Ref. Dwg. MHTPA0191)
Always use an air line lubricator with these motors. Use a
lubricator having an inlet and outlet at least as large as the
inlet on the motor. Install the air line lubricator as close to
the air inlet on the motor as possible.
motor or an aftercooler at the compressor that cools the air
prior to distribution through the supply lines, are also
helpful.
Motor and Reducer Assemblies
Remove shipping ‘0’ Ring (360) from breather on hoist
motor and trolley motor if equipped.
l Failure to remove shipping ‘0’ Ring(s) on the motor
breather(s) may result in premature failure of the
motor seals.
Hoist and Trolley Motors
For optimum performance and maximum durability of
parts, provide an air supply to operate hoist and trolley
motors with 105 psig at 165 scfm (7.2 bar/724 kpa at 4.67
cu.m/m). The air motor should be installed as near as
possible to the compressor or air receiver. (Contact the
Technical Support Department for operating requirements
with optional 60 psi system)
Hoist Pendant
The pendant control is installed at the factory. Hose fittings
on the pendant are color coded to ensure correct assembly.
Check all hose connections are tight and that hoses are not
twisted or crimped. Refer to Dwg. MHTPA0095 and
MHTPA0510 for correct pendant hose connections.
If the optional Accu-troll® pendant is used refer to Accu-
trol pendant manual form number MHD56014 for correct
pendant hose connections.
l Lubricator must be located no more than 10 ft. (3 m)
from the motor.
The air line lubricator should be replenished daily and set
to provide 4 to 6 drops per minute of SAE 10W oil. A fine
mist will be exhausted from the throttle control valve when
the air line lubricator is functioning properly.
Air Line Filter
(Ref. Dwg. MHTPA0191)
It is recommended that an air line strainer/filter be installed
as close as practical to the motor air inlet port to prevent
dirt from entering the motor. The strainer/filter should
provide 20 micron filtration and include a moisture trap.
Clean the strainer/filter periodically to maintain its operat-
ing 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 and other methods, such as an air
receiver which collects moisture before it reaches the
l Disconnect air supply before performing any mainte-
nance.
l Do not attempt to reverse air lines either at the
pendant station or hoist. This will give a false indication
of operation which may result in serious damage to the
hoist.
PENDANT CONTROL BLOCK
(Looking Down On Top of Block)
(Blue)
*Plug for Hook Mounted or non-powered Trolley Units
(Dwg. MHTPA0095)
10

Check strain relief chain (188) is properly connected to the
hoist and pendant body. The chain is connected to the hoist
at the piston motor assembly with capscrew (63 1). Ensure
pendant is supported by the chain and not hose assemblies.
Hoist Motor and Valve
(Dwg. MHTPA0510)
l To avoid damaging the pendant hose, make sure the
strain relief chain, not the pendant hoses, is supporting
the weight of the pendant.
Emergency Air Shutoff (optional feature)
If supply air is wet and unfiltered, and/or the hoist is
operated in a dirty environment, the hoist or trolley control
valves may malfunction and become stuck “on”. As a
safeguard, an emergency main line shutoff valve is
provided at the pendant. The emergency valve shuts off
the air supply to the entire unit when the red pull/push
button is depressed (pushed in).
Initial Operating Checks
Hoists are tested for proper operation prior to leaving the
factory. Before the hoist is placed into service the follow-
ing initial operating checks should be performed.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
After installation of trolley mounted hoists, check to
ensure the hoist is centered below the trolley.
Check for air leaks in the supply hose and fittings to
pendant, and from pendant to manifold.
When first running the hoist or trolley motors some
light oil should be injected into the inlet connection to
allow good lubrication.
When first operating the hoist and trolley it is recom-
mended that the motors be driven slowly in both
directions for a few minutes.
Operate the trolley along the entire length of the beam.
Inspect hoist and trolley performance when raising,
moving and lowering test load(s). Hoist and trolley
must operate smoothly and at rated specifications prior
to being placed in service.
Check that trolley (if equipped) and hook movement is
the same direction as arrows or information on the
pendant control.
Raise and lower a light load to check operation of the
hoist brake.
Check hoist operation by raising and lowering a load
equal to the rated capacity of the hoist a few inches
(cm) off the floor.
Check operation of limit devices,
On trolley units check ‘0’ ring (360) on breather plug
(362) in trolley drive piston motor has been removed.
Storing the Hoist
For hoists that have been in storage for a period of more
than one month the following start-up procedure is
required.
1. Give the hoist an inspection conforming to the
requirements of “Hoists Not in Regular Use” in the
“INSPECTION” section.
2. Pour a small amount of 10W oil in the motor inlet
ports(s).
3. Operate the motor for 10 seconds to flush out any
impurities.
4. The hoist is now ready to work.
Trolley Drive Assembly Run In Period
Maximum efficiency of the trolley drive worm gear is
obtained after a “run-in” period. The length of time
required will depend on the load applied and will be two to
four hours at rated load and considerably longer at lighter
loads. (Overloading will not decrease the “run-in” time
and it may damage the worm gear.)
During “run-in” higher than normal temperature rise, and
lower efficiency and output torque can be expected.
If is in necessary to use the emergency air shut off valve,
then the malfunctioning control valve should be disas-
sembled, cleaned, and/or repaired as required to clear the
malfunction before resuming operation.
11

Hoist without air
I
Hoist with air powered
vane or piston motor
trolley.
Lubricator
(Accessory) Filter/
Separator
(Accessory)
(Dwg. MHTPA0535)
12

The four most important aspects of hoist operation are:
1. Follow all safety instructions when operating the hoist
and trolley.
2. Allow only people instructed in safety and operation of
this product to operate the hoist and trolley.
3. Subject each hoist to a regular inspection and mainte-
nance procedure.
4. Be aware of the hoist capacity and weight of load at all
times.
l Only allow personnel instructed in safety and opera-
tion of this product to operate the hoist and trolley.
l The hoist is not designed or suitable for lifting,
lowering or moving persons. Never lift loads over
people.
Operators must be physically competent. Operators must
have no health condition which might affect their ability to
act, 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 thoroughly understand 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 perform the
initial operating checks described in the “INSTALLA-
TION” section.
Hoist Controls
Refer to Dwgs. MHTPA0094 and MHTPA0095 in the
“INSTALLATION” section for correct pendant hose
connections.
Pilot Pendant Throttle with Emergency Stop
(Ref. Dwg. MHTPA0395)
The pendant control throttle is equipped with two separate
levers for hoist operation. Pilot pressure from the pendant
throttle activates the hoist control valve. Direction of hook
travel is controlled by whichever lever is depressed.
(Dwg. MHTPA0395)
Pilot Two Lever Pendant
(Ref. Dwg. MHTPA0396)
The pilot two lever pendant is standard on hook mounted
hoists without the emergency stop option.
Load
(Dwg.
MHTPA0427)
13

Accu-Trol® Pendant (Push Button Type) Optional
The Accu-Troll® pendant is available with 2,4 or 6
buttons. Refer to Accu-Trol® Pendant manual form
number MHD56014 for additional information. (4 button
pendant shown).
(Dwg. MHTPB0434)
Attaching the Load
Power “ON”
Power “OFF”
Hoist “RAISE”
Hoist “LOWER”
Trolley “RIGHT”
Trolley “LEFT”
l The hook latch is intended to retain loose slings or
devices under slack conditions. Hook latches are not
intended to be an anti-fouling device, so caution must
be used to prevent the latch from supporting any of the
load.
14

l 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 inspections are
visual examinations performed by operators or personnel
trained in safety and operation of this equipment and
include observations made during routine equipment
operation. Periodic inspections are thorough inspections
conducted by personnel trained in the safety, operation and
maintenance of this equipment. ASME B30.16 states
inspection intervals depend upon the nature of the critical
components of the equipment and the severity of usage.
Frequent and periodic inspection intervals for equipment
use under various operating conditions are listed below:
1. Frequent Inspection:
NORMAL HEAVY
monthly weekly SEVERE
daily
2. Periodic Inspection:
NORMAL
yearly HEAVY semi-annually SEVERE quarterly
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 designated personnel trained
in safety, operation and maintenance of this equipment. 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 equipment 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 the condition of critical parts as a
method of documenting periodic inspections. These
reports should be dated, signed by the person who per-
formed the inspection, and kept on file where they are
readily available for review.
l The external placement of coded marks on equipment
identifying completed inspections and operationally
certified equipment is an acceptable method of docu-
menting periodic inspections in place of written
records.
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.
Frequent Inspection
On hoists 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.
I. OPERATION. Check for visual signs or abnormal
noises (grinding etc.) which could indicate a defect.
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 defects have been corrected.
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
specified in Table 3 (see Dwg. MHTPA0040) or
exceed a 10° twist (see Dwg. MHTPA0l11). If the
hook latch snaps past the tip of the hook, the hook is
sprung and must be replaced. Refer to the latest
edition of ASME B30.10 “HOOKS” for additional
information.
15

Table 3 Hook Throat Opening
NewHook Discard Hook
Hoist Model
in. mm in. mm
HA l-005 (Steel) 1.87 47.6 2.15 54.6
HA l-005 (Bronze) 2.25 57.2 2.58 65.5
HAl-010 (Steel) 2.50 63.5 2.87 73.0
HAl-010 (Bronze) 3.37 85.7 3.88 98.5
HAl-015 (Steel) 3.37 85.7 3.88 98.5
HAl-015 (Bronze) 4.15 105.4 4.77 123.1
HA l-020 (Steel) 4.00 101.6 4.60 116.8
HA l-020 (Bronze) 4.50 114.3 5.17 131.3
UPPER AND LOWER LIMIT DEVICE. Test
operation with no load. Upward travel must stop when
the bottom block or stop buffer on chain hits hoist
limit arm.
AIR SYSTEM. Visually inspect all connections,
fittings, hoses and components for indication of air
leaks. Repair any leaks found.
CONTROLS. During operation of hoist, verify
response to pendant is quick and smooth. If hoist
responds slowly or movement is unsatisfactory, do not
operate hoist until all defects have been corrected.
MAX
Twisted
DO NOT USE
(Dwg. MHTPA0lll)
Normal
Can Be Used
6. HOOK LATCH. Make sure the hook latch is present
and operating. Replace if necessary.
7. CHAIN. Examine each of the links for bending, cracks
in weld areas or shoulders, traverse nicks and gouges,
weld splatter, corrosion pits, striation (minute parallel
lines) and chain wear, including bearing surfaces
between chain links (see Dwg. MHTPA0102). Replace
a chain that fails any of the inspections. Check chain
lubrication and lubricate if necessary. Refer to “Load
Chain” in “LUBRICATION” section.
(Dwg. MHTPA0102)
l It may not be possible to determine the full extent of
chain wear or stretching by visual observation. At any
indication of wear or stretching inspect the chain in
accordance with instructions in “Periodic Inspection”.
8. CHAIN REEVING. Ensure welds on standing links
are away from load sheave. Reinstall chain if neces-
sary. Make sure chain is not capsized, twisted or
kinked. Adjust as required.
Periodic Inspection
l Refer to “INSPECTION AND MAINTENANCE
REPORT” for guidance on documenting periodic
inspection items.
Disassembly may be required as a result of initial indica-
tions of inspections or in order to properly inspect the
individual components. Disassembly steps are described in
the “MAINTENANCE” section. Maintain written records
of periodic inspections to provide an accumulative basis for
continuing evaluation. Inspect all items listed in “Frequent
Inspection.” Also inspect the following:
1. FASTENERS. Check all rivets, split pins, capscrews
and nuts. Replace if missing or tighten if loose.
2. ALL COMPONENTS. Inspect for wear, damage,
distortion, deformation and cleanliness. If external
evidence indicates the need, disassemble. Check
gears, shafts, bearings, sheaves, chain guides, springs
and covers. Replace worn or damaged parts. Clean,
lubricate and reassemble.
16

3.
4.
5.
6.
7.
8.
9.
HOOKS. Inspect hooks carefully for cracks using
magnetic particle or other suitable non-destructive
method. Inspect hook retaining parts. Tighten or
repair, if necessary.
CHAIN SHEAVES. Check for damage or excessive
wear. Replace if necessary.
MOTOR (Hoist and Trolley). If performance is poor,
disassemble the motor and check for wear or damage
to bearings and shafts. The parts should be cleaned,
lubricated and reassembled. Replace worn or damaged
parts.
BRAKE. Raise a load equal to the rated capacity of
the hoist a few inches off the floor and check ability of
hoist to hold the load without drift. If drift occurs,
disassemble. Check rotating disc lining thickness as
noted in the “MAINTENANCE” section.
SUPPORTING STRUCTURE. Check for distortion,
wear and continued ability to support load.
TROLLEY. Check that the trolley wheels track the
beam properly and clearance between side rollers and
beam is correct, l/16 to 3/16 in. (2 to 5 mm). Check
side plates for spreading due to bending.
LABELS AND TAGS. Check for presence and
legibility. Replace if necessary.
10. LOAD CHAIN END ANCHORS. Ensure and of load
chain is securely attached to the hoist or bottom block.
Secure if loose, repair if damaged, replace if missing.
Check chain stopper is correctly installed and func-
tional.
11. LOAD CHAIN. Measure the chain for stretching and
wear by measuring across five link sections all along
the chain paying particular attention to the most
frequently reeved links. When any five links in the
working length reaches or exceeds the discard length,
replace the entire chain (see Dwg. MHTPA0041).
Always use a genuine Ingersoll-Rand Material
Handling replacement chain for regular and nickel-
diffused load chains.
Size
(mm)
16.0
Normal Discard
Length Length
in. (mm) in. (mm)
8.86 225 9.02 229
Gauge Length
(Dwg. MHTPA0041)
12. CHAIN CONTAINER. Check for damage or exces-
sive wear and that chain container is securely attached
to the hoist. Secure or replace if necessary.
13. LIMIT ASSEMBLY. Check limit arm moves freely
and activates limit switches for maximum upper and
lower hook travel.
Hoists Not in Regular Use
1. Hoists which have been idle for a period of one month
or more, but less than six months shall be given an
inspection conforming with the requirements of
“Frequent Inspection” before being placed into service.
2. Hoists which have been idle for a period of over six
months shall be given a complete inspection conform-
ing with the requirements of “Periodic Inspection”
before being placed into service.
3. Standby hoists shall be inspected at least semi-
annually in accordance with the requirements of
“Frequent Inspection”. If abnormal operating condi-
tions apply hoists may require a more frequent
inspection.
l A worn load chain may cause the load sheave to wear
rapidly. Inspect the load sheave and replace if damaged
or worn.
17

Model Number:
INSPECTION AND MAINTENANCE REPORT
MODEL HA1 AIR CHAIN HOIST
Date:
serial Number:
II__.
Inspected by:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection ( _ Monthly _ Quarterly _ Yearly).
2. Discrepancy(s) noted during Frequent Inspection.
3. Discrepancy(s) noted during maintenance.
4. Other:
Refer to the Parts, Operation and Maintenance Manual “INSPECTION” section for general inspection criteria. Also, refer to appropriate National Standard
and codes of practice. If in doubt about an existing condition contact the nearest INGERSOLL-RAND Distributor or the factory for technical assistance.
COMPONENT CONDITION
Pass Fail
CORRECTIVE
ACTION
Repair Replace
NOTES
Fasteners
Gears
Shafts
Bearings
Working length(s) maximum wear/stretch:
Supporting Structure
Labels and Tags
Other Components
list in NOTES section)
inches / mm (ref. load chain dimensions for maximum acceptable wear/stretch).
Testing: Fail
Pass
I Operational (No Load) I I I- I
Operational (10% Load)
Operational (Maximum Test Load *)
* Refer to the Parts, Operation and Maintenance manual “Testing” in the “MAINTENANCE” section to determine Maximum Test Load.
18

To ensure continued satisfactory operation of the hoist, all
points requiring lubrication must be serviced with the
correct lubricant at the proper time interval as indicated for
each assembly. Correct lubrication is one of the most
important factors in maintaining efficient operation.
The lubrication intervals recommended in this manual are
based on intermittent operation of the hoist eight hours
each day, five days per week. If the hoist is operated almost
continuously or more than the eight hours each day, more
frequent lubrication will be required. Also, the lubricant
types and change intervals are based on operation in an
environment relatively free of dust, moisture, and corrosive
fumes. Use only those lubricants recommended. Other
lubricants may affect the performance of the hoist. Ap-
proval for the use of other lubricants must be obtained from
your Ingersoll-Rand Technical Support Department or
distributor. Failure to observe this precaution may result in
damage to the hoist and/or its associated components.
INTERVALINTERVAL
Start of each shift
LUBRICATION CHECKS
Check flow and level of air line
lubricator (approximately 4 to 6
drops per minutes required at
maximum motor speed).
Check oil levels in the hoist and
trolley piston motors.
MonthlyMonthly Lubricate all grease fittings.
Clean air line filter.
Check oil level in the brake and
reduction gear assembly.
6 Monthly6 Monthly Drain and replace oil in trolley
and hoist piston drive motors.
YearlyYearly Drain and refill oil in the hoist
brake and reduction gear assem-
bly.
Pivot Points and Bushings
Lubricate grease fittings monthly with 2 or 3 pumps from a
grease gun or more frequently, depending on severity of
service. For temperatures -20° to 50° F (-29° to 10° C) use
a multipurpose lithium-based EP 1 grease. For tempera-
tures 30° to 120° F (- 1° to 49° C) use a multipurpose
lithium-based EP 2 grease.
Hoist Motor
The motor is splash lubricated by the oil in the motor
housing and has no other means of lubrication. It is
therefore important to use only high quality, non-detergent
hydraulic oil to insure maximum performance and mini-
mum down time for repairs. Allow oil to settle prior to
topping off. Oil capacity for the HA 1 hoist motor is 0.1
gals. (0.38 ltrs.).
Below 32° F (0° C) SAE 10W Hydraulic Oil
32° to 80° F (0° to 27° C) SAE 20W Hydraulic Oil*
Above 80° F (27° C) SAE 30W Hydraulic Oil
* Hoists are shipped from the factory with this oil
Trolley Drive Motor (piston)
The motor is splash lubricated by the oil in the motor
housing and has no other means of lubrication. It is
therefore important to use only high quality, non-detergent
hydraulic oil to insure maximum performance and mini-
mum down time for repairs. Allow oil to settle prior to
topping off. Oil capacity for the HA1 trolley drive motor is
0.1 pints (65 ml).
Below 32° F (0° C) SAE 20W Hydraulic Oil
32° to 80° F (0° to 27° C) SAE 30W Hydraulic Oil*
Above 80° F (27° C) SAE 40W Hydraulic Oil
* Hoists are shipped from the factory with this oil
Bottom Hook Block Assembly
To prevent moisture entering the bottom block assemblies
they should periodically be disassembled and repacked
with grease. For temperatures -20° to 50° F (-29° to 10° C)
use a multipurpose lithium-based EP 1 grease. For tem-
peratures 30° to 120° F (-1° to 49° C) use a multipurpose
lithium-based EP 2 grease. Add grease to bottom hook
assemblies through grease fittings (39).
Hoist Capacity
HAl-005 (5 ton)
HAl-010 (10 ton)
HAl-015 (15 ton)
HAl-020 (20 ton)
Grease Required to
Pack Hook Assembly
ozs. grams
0.33 31
1.1 204
1.1 468
7.2 873
19