Ingersoll-Rand MLK Series User manual

MHD56093
INSTALLATION AND OPERATION MANUAL
for AIR CHAIN HOIST
MODELS MLK and HLK
MONTAGE- UND BEDIENUNGSANLEITUNGEN
für DRUCKLUFTBETRIEBENE KETTENZÜGE
MODELLE MLK und HLK
INSTALLATIONS- OG BETJENINGSHÅNDBOG
for LUFTSTYREDE KÆDETALJER
MODEL MLK og HLK
MANUAL DE INSTALACION Y OPERACION
para los POLIPASTOS NEUMATICOS DE CADENA
MODELOS MLK y HLK
MANUEL D’INSTALLATION ET D’UTILISATION pour
LES MODELES DE PALANS A CHAINE
PNEUMATIQUES MLK et HLK
MANUALE DI ISTRUZIONI PER L’INSTALLAZIONE
E IL FUNZIONAMENTO DEI PARANCHI A CATENA
PNEUMATICI MODELLI MLK e HLK
HÅNDBOK for MONTERING OG BRUK AV
TRYKKLUFTSDREVNE KJETTINGTALJER,
MODELL MLK og HLK
HANDLEIDING VOOR INSTALLATIE EN BEDIENING
van PNEUMATISCHE KETTINGTAKELS
MODELLEN MLK en HLK
INSTALLATIONS- OCH INSTRUKTIONSBOK för
TRYCKLUFTSDRIVET LYFTBLOCK MED KÄTTING
MODELL MLK och HLK
ASENNUS- JA KÄYTTÖKÄSIKIRJA
PAINEILMAKÄYTTÖISET NOSTOTALJAT
MALLIT MLK ja HLK
MHD56093
Edition 2
4/95
71153480
©
1995 Ingersoll-Rand Company
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SAFETY INFORMATION
Thismanualprovidesimportantinformationforallpersonnelinvolvedwiththesafeinstallationand
operation of these products. Even if you feel you are familiar with this or similar equipment, you
should read this manual before operating the product.
Danger, Warning, Caution and Notice
Throughoutthismanualtherearesteps and procedureswhich,if not followed,mayresult in ainjury.
The following signal words are used to identify the level of potential hazard.
Danger is used to indicate the presence of a hazard which will
cause severe injury, death, or substantial property damage if the
warning is ignored.
Warning is used to indicate the presence of a hazard which can
cause severe injury, death, or substantial property damage if the
warning is ignored.
Caution is used to indicate the presence of a hazard which will or
can cause minor injury or property damage if the warning is
ignored.
Notice is used to notify people of installation, operation, or
maintenance information which is important but not hazard-
related.
Safety Summary
WARNING
•Do not use this hoist or attached equipment for lifting, supporting, or transporting people
or lifting or supporting loads over people.
•The supporting structures and load-attaching devices used in conjunction with this hoist
must provide adequate support to handle all hoist operations plus the weight of the hoist and
attached equipment. This is the customer’s responsibility. If in doubt, consult a registered
structural engineer.
NOTICE
•Liftingequipment is subjectto different regulations.These regulations maynot be specified
in this manual.
ENGLISH
1
READ THIS MANUAL BEFORE USING THESE PRODUCTS.
This manual contains important safety, installation and
operation information.
DANGER
WARNING
NOTICE
CAUTION

ENGLISH
This manual has been produced by Ingersoll-Rand to provide dealers, mechanics, operators and
company personnel with the information required to install and operate the products described
herein.
It is extremely important that mechanics and operators be familiar with the servicing procedures of
these products, or like or similar products, and are physically capable of conducting the procedures.
These personnel shall have a general working knowledge that includes:
•Proper and safe use and application of mechanics common hand tools as well as special
Ingersoll-Rand or recommended tools.
•Safety procedures, precautions and work habits established by accepted industry standards.
Ingersoll-Rand can not know of, nor provide all the procedures by which product operations or
repairsmay beconductedandthehazardsand/orresultsof eachmethod.If operationormaintenance
proceduresnotspecificallyrecommendedbythemanufacturerareconducted,itmustbeensuredthat
product safety is not endangered by the actions taken. If unsure of an operation or maintenance
procedureorstep,personnelshouldplacetheproductinasafeconditionandcontactsupervisorsand/
or the factory for technical assistance.
SAFE OPERATING INSTRUCTIONS
Ingersoll-Rand recognizes that most companies who use hoists have a safety program in force in
their plants. In the event you are aware that some conflict exists between a rule set forth in this
publication and a similar rule already set by an individual company, the more stringent of the two
should take precedence.
Safe Operating Instructions are provided to make an operator aware of unsafe practices to avoid and
arenotnecessarilylimitedtothefollowinglist.Refertospecificsectionsinthemanualforadditional
safety information.
1. Only allow people, trained in safety and operation of this product, to operate the hoist.
2. Only operate a hoist if you are physically fit to do so.
3. When a “DO NOT OPERATE” sign is placed on the hoist or controls, do not operate the hoist
until the sign has been removed by designated personnel.
4. Before each shift, the operator should inspect the hoist for wear or damage.
5. Never us a hoist which inspection indicates is worn or damaged.
6. Periodically, inspect the hoist thoroughly and replace worn or damaged parts.
7. Lubricate the hoist regularly.
8. Do not use hoist if hook latch on a hook has been sprung or broken.
9. Check that the hook latches are engaged before using.
10. Never splice a hoist chain by inserting a bolt between links.
11. Only lift loads less than or equal to the rated capacity of the hoist. See “SPECIFICATIONS”
section.
12. Whenusingtwohoiststosuspendoneload,selecttwohoistseachhavingaratedcapacityequal
to or more than the load. This provides adequate safety in the event of a sudden load shift.
13. Never place your hand inside the throat area of a hook.
14. Never use the hoist load chain as a sling.
15. Neveroperateahoistwhentheload isnotcenteredunderthehook. Donot“sidepull”or“yard.”
16. Never operate a hoist with twisted, kinked, “capsized” or damaged load chain.
17. Do not force a chain or hook into place by hammering.
18. Never insert the point of the hook into a chain link.
19. Be certain the load is properly seated in the saddle of the hook and the hook latch is engaged.
20. Do not support the load on the tip of the hook.
21. Never run the load chain over a sharp edge. Use a sheave.
22. Pay attention to the load at all times when operating the hoist.
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ENGLISH
23. Always ensure that you, and all other people, are clear of the path of the load. Do not lift a load
over people.
24. Never use the hoist for lifting or lowering people, and never allow anyone to stand on a
suspended load.
25. Ease the slack out of the chain and sling when starting a lift. Do not jerk the load.
26. Do not swing a suspended load.
27. Never leave a suspended load unattended.
28. Never weld or cut on a load suspended by the hoist.
29. Never use the hoist chain as a welding electrode.
30. Do not operate hoist if chain jumping, excessive noise, jamming, overloading, or binding
occurs.
31. Do not use the up and down stops as a means of stopping a hoist. The up and down stops are
emergency devices only.
32. Always rig the hoist properly and carefully.
33. Be certain the air supply is shut off before performing maintenance on the hoist.
34. Do not allow the chain to be exposed to extremely cold weather. Do not apply loads to a cold
chain.
WARNING LABEL
Eachhoistissuppliedfromthe factorywith the
warninglabelshown.Ifthelabelisnotattached
to your hoist, order a new label and install it.
WARNING
•Do not use hoist for lifting, supporting or
transporting people.
DESCRIPTION
Hoistsdescribedinthismanualarepoweredbyair,andwiththeuseofapendantcontrol,aredesigned
to lift and lower loads. The hoists can be bolted or hook mounted to a trolley or permanent mounting
structure.
The air hoists are equipped with vane motors which act as the drive for the gear section. The output
from the gear section is transmitted directly to the load chain drive sheave.
Each air hoist contains a brake which is released by air pressure applied to an annular brake piston.
Whenthe“UP”or“DOWN”controlpendantbutton/leverispressedairissenttothebrake.Thebrake
piston compresses the brake springs, releasing the brake. When the pendant “UP” or “DOWN”
button/lever is released the air is exhausted and the brake is applied.
3

ENGLISH
SPECIFICATIONS
Hoist Model
No.
Rated
Capacity
(kg)
No.
Chain
Falls
Air Flow
m³/min
Sound
Pressure
Level
dBA
Sound
Power
Level
dBA
Speed with
Rated Load
m/m
Speed with
No Load
m/m
Hook
Mount
Hoist
Weight
3 m (10 ft)
lift
kg
Overload
nominal
limit
kg
up down up down
ML250KS-E
250 1
1,27
90 100
12,2 27,4 21 16
21,8
- - -
ML250K-E 1,98 30,8 35,7 52 30
ML250KR-E 1,27 7,9 11,6 12,8 9,1
ML500KS-E
500 16,7 20,1 13 10
ML500K-E 1,98 16,8 29,6 32 18
ML500KR-E 2
1,27
4,0 6,1 6,4 4,6
27,7ML1000KS-E 980 23,4 10,0 6,7 4,9
ML1000K-E 8,5 14,9 16 9
HL1000K-E 1000 1
1,98 87 97
7,9 11,3 12,2 7,9 38,1 1250
HL1000KR-E
HL1500K-E 1500 4,9 7,9 8,5 4,9 1875
HL2000K-E 2000 245,5 6,1 456,6 2500
HL3000K-E 3000 2,4 44,3 2,4 58,5 3750
HL4500K-E 4500 31,4 33,2 287,5 5625
HL6000K-E 6000 4 1 2,3 2,6 1,5 112,5 7500
* Sound measurements have been made in accordance with ISO 11201, ISO 3744-3746 and ISO 4871
test specifications for sound from pneumatic equipment. Readings shown are based on the average noise
level of each hoist configuration, proportionate to the utilized time in a regular cycle.
* Lpc (Peak Sound Pressure) does not exceed 130 dB.
* Performance based on 6,3 bar operating pressure.
INSTALLATION
Prior to installing the hoist, carefully inspect it for possible shipping damage.
Hoists are supplied fully lubricated from the factory.
Lubricate load chain before initial hoist operation.
CAUTION
•Owners and users are advised to examine specific, local or other regulations which may
apply to a particular type of use of this product before installing or putting hoist to use.
WARNING
•A falling load can cause injury or death. Before installing, read “SAFE OPERATING
INSTRUCTIONS”.
4

ENGLISH
Hoist
The supporting structures and load-attaching devices used in conjunction with this hoist must
provide adequate support to handle all hoist operations plus the weight of the hoist and attached
equipment.Thisisthecustomer’sresponsibility. Ifindoubt,consultaregisteredstructuralengineer.
On HLK hoists remove the solid plug located on top of the hoist and install the attached vent plug
priorto usingthehoist.Whenthe hoistisin itsnormallevelpositioncheckthatthegear caseoillevel
is at the check plug on the side of the gear box.
Hook Mounted Hoist Installation
Place hook over mounting structure. Make sure hook latch is engaged.
Ensurethesupportingmemberrestscompletelywithinthesaddleofthehookandiscentereddirectly
above the hook shank.
CAUTION
•Do not use a supporting member that tilts the hoist to one side or the other.
Trolley Mounted Hoist Installation
Refer to trolley manufacturers installation information to safely install the trolley and attach the
hoist.
Chain Container
When installing a chain container, refer to the manufacturers installation Instructions for Chain
Containers.
CAUTION
•Makecertaintoadjustthebalancechainsothatthechaincontainerdoesnotcontacttheload
chain.
•Allow chain to pile naturally in the chain container. Piling the chain carelessly into the
container by hand may lead to kinking or twisting that will jam the hoist.
1. Check the chain container size to make sure the length of load chain is within the capacity of
the chain container. Replace with a larger chain container, if required.
2. Attach the chain container to the hoist.
3. Run bottom block to lowest point and run hoist in up direction to feed the chain back into the
container.
Air System
The supply air must be clean, lubricated and free from water or moisture. A minimum of 6.3 bar/
630 kPa (90 psig) at the hoist motor is required, during operation to provide rated hoist performace.
Air Lines
The minimum allowable hose size is 13 mm (1/2 in). Hose size is based on a maximum of 15 m
(50ft)betweentheairsupplyandthehoistmotor.Contactyournearestdistributor forrecommended
air line sizes for distances greater than 15 m (50 ft). Before making final connections to hoist inlet,
all air supply lines should be purged with clean, moisture free air. Supply lines should be as short
and straight as installation conditions will permit.
Long transmission lines and excessive use of fittings, elbows, tees, globe valves etc. cause a
reduction in pressure due to restrictions and surface friction in the lines. If quick-disconnect fittings
are used at the inlet of the hoist, they must have at least a 10 mm (3/8 in) air passage. Use of smaller
fittings will reduce performance.
5

ENGLISH
NOTICE
•Always use an air line filter and lubricator with the hoist.
Air Line Lubricator
Alwaysuse an air line lubricatorwiththese hoists. Use a lubricatorhavingan inlet and outlet at least
as large as the inlet on the hoist motor. Install the air line lubricator as close to the air inlet on the
hoist motor as possible.
NOTICE
•Lubricator must be located no more than 3 m (10 ft) from the hoist motor.
•Shut off air supply before filling air line lubricator.
The air line lubricator should be replenished daily and set to provide lubrication at a minimum rate
of 1 to 3 drops per minute adjusted at maximum hoist speed, of SAE 10W oil or a good grade of
hydraulic oil.
NOTICE
•Do not use automotive type detergent oil. Detergents will delaminate the MLK and HLK
hoist motor vanes and cause premature failure.
Air Line Filter
Itisrecommended that an air line strainer/filter be installed as closeas practicalto themotor air inlet
port to prevent dirt from entering the motor. The strainer/filter should provide 10 micron filtration
and include a moisture trap. Clean the strainer/filter monthly to maintain its operating efficiency.
Moisture in Air Lines
Moisture that reaches the air motor through the supply lines is the chief factor in determining the
length of time between service overhauls. Moisture traps can help to eliminate moisture. Other
methods,suchas an air receiver whichcollectsmoisturebeforeit reaches the motororanaftercooler
at the compressor that cools the air prior to distribution through the supply lines, are also helpful.
Overload Device
Anoverloaddeviceisrequiredonallhoistswitharatedcapacityofover1metricton(2,200lbs)used
for lifting applications.
The overload device is integrated into the hoist air motor and prevents the hoist from lifting a load
greater than the overload value listed in the specifications chart. If an overload is detected, inlet
supply air is stopped and the hoist will not operate.
Iftheoverloaddeviceisactivatedtheloadmustbeloweredandreduced.Alternativemethodsshould
be used to accomplish the task. To lower the load reset the hoist by pressing the “ON” button of the
emergency stop device and press the hoist control lever to lower.
Adjustment of Bleed Screws on MLK and HLK Pendent Control Hoists
The two bleed adjustment screws, located under the valve chest, used on MLK and HLK hoists with
a pendent control are factory adjusted to provide optimum control and performance at 6.3 bar/
630 kPa (90 psig) air pressure. If the hoist is used with other air supply pressures, the bleed
adjustment screws may require readjustment.
For maximum performance and control, adjust the bleed screws as follows:
1. Loosen the adjustment screw locknut.
2. Back out the adjustment screw approximately one third (1/3) of a turn.
6

ENGLISH
3. While fully depressing the pendent throttle lever and holding it in that position, turn in the
adjustmentscrewuntilthepistonrodfullyretracts.Thisadjustmentwillprovideagoodbalance
of spotting control and maximum hoist speed. If better spotting control is desired, slowly back
out the adjustment screw a little at a time until the spotting control is suitable.
4. Tighten the adjustment screw locknut.
Storing the Hoist
1. Always store the hoist in a no load condition.
2. Wipe off all dirt and water.
3. Oil the load chain, hook pins and hook latch.
4. Place in a dry location.
5. Plug hoist air inlet port.
6. Before returning hoist to service follow instructions for Hoists not in Regular Service in the
“INSPECTION” section.
OPERATION
The four most important aspects of hoist operation are:
1. Follow all safety instructions when operating hoist.
2. Allow only people trained in safety and operation on this hoist to operate the hoist.
3. Subject each hoist to a regular inspection and maintenance procedure.
4. Be aware of the hoist capacity and weight of load at all times.
Always operate, inspect and maintain this hoist in accordance with any applicable safety codes and
regulations.
Operators must be physically competent. Operators should have no health condition which might
affect their ability to react, and they must have good hearing, vision and depth perception. The hoist
operator must be carefully instructed in his duties and must understand the operation of the hoist,
including a study of the manufacturer’s literature. The operator must be aware of proper methods of
hitching loads and should have a good attitude regarding safety. It is the operator’s responsibility to
refuse to operate the hoist under unsafe conditions.
Initial Operating Checks
Hoists are tested for proper operation prior to leaving the factory. Before the hoist is placed into
service the following initial operating checks should be performed.
1. After installation of trolley mounted hoists, check to ensure the hoist is centered below the
trolley.
2. Check for air leaks in the supply hose and fittings to pendant, and from pendant to manifold.
3. Whenfirstrunningthehoistortrolleymotors,asmallamount ofnon-detergent, lightoil should
be injected into the inlet connection to allow good lubrication.
4. When first operating the hoist and trolley it is recommended that the motors be driven slowly
in both directions for a few minutes.
5. Operate the trolley along the entire length of the beam.
6. Check operation of limit devices.
7. Check that trolley (if equipped) and hook movement is the same direction as arrows or
information on the pendant control.
8. Check to see that the hoist is securely connected to the overhead crane, monorail, trolley or
supporting member.
9. Check to see that the load is securely inserted in the hook, and that the hook latch is engaged.
10. Raise and lower a light load to check operation of the hoist brake.
7

ENGLISH
11. Check hoist operation by raising and lowering a load equal to the rated capacity of the hoist a
few centimeters off the floor.
12. Check to see that the hoist is directly over the load. Do not lift the load at an angle (side pull
or “yard”).
13. Inspecthoistandtrolleyperformancewhenraising,movingandloweringtestload(s).Hoistand
trolley must operate smoothly and at rated specifications prior to being placed in service.
WARNING
•Only allow personnel instructed in safety and operation of this product to operate the hoist
and trolley.
•The hoist is not designed or suitable for lifting, lowering or moving persons. Never lift loads
over people.
Hoist Controls
Two Lever Pendant
Two lever pendants provide operation of the hoist only. For units with powered trolleys a four lever
pendantis required. Refer to manufacturers informationonPendantThrottle Handle Assemblies for
two and three motor functions.
The pendant control throttle uses two separate levers for hoist operation. Direction of hook travel is
controlled by whichever lever is depressed.
1. To start hoist operation, press the “ON” button.
2. To operate hoist, press the “UP” or “DOWN”
control lever.
3. Intheeventofanemergency,allhoistoperation
can be stopped by pushing the emergency stop
button. This will prevent air from reaching the
hoist motor which will stop any movement.
4. The “OFF” button willalso stop hoist operation
if pressed.
5. The “ON” button must be pushed to restart the
hoist after the “Emergency Stop” or “OFF”
button have been used.
WARNING
•The hook latch is intended to retain loose slings or devices under slack conditions. Caution
must be used to prevent the latch from supporting any of the load.
8
"ON" and "OFF"
Buttons
Hoist
Control
Levers
Pendant
Handle
Emergency
Stop Button
(Dwg. MHTPA0671)

ENGLISH
INSPECTION
WARNING
•All new, altered or modified equipment should be inspected and tested by personnel trained
in safety, operation and maintenance of this equipment to ensure safe operation at rated
specifications before placing equipment in service.
Frequent and periodic inspections should be performed on equipment in regular service. Frequent
inspectionsarevisualexaminationsperformedbyoperatorsorservicepersonnelduringroutinehoist
operation.Periodicinspectionsarethoroughinspectionsperformedbypersonneltrainedininspection
and maintenance of the hoist.
Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the
early stages, allowing corrective action to be taken before the condition becomes dangerous.
Deficiencies revealed through inspection, or noted during operation, must be reported to an
appointed person. A determination must be made as to whether a deficiency constitutes a safety
hazard before resuming operation of the hoist.
Records and Reports
Some form of inspection record should be maintained for each hoist, listing all points requiring
periodic inspection. A written report should be made monthly on the condition of the critical parts
ofeachhoist.Thesereportsshould bedated, signedby thepersonwhoperformedtheinspection,and
kept on file where they are readily available for review.
NOTICE
•Theexternalplacementofcodedmarksonequipmentidentifyingcompletedinspectionsand
operationally certified equipment is an acceptable method of documenting periodic inspec-
tions in place of written records.
Load Chain Reports
Recordsshouldbemaintaineddocumentingtheconditionofloadchainremovedfromserviceaspart
of a long-range load chain inspection program. Accurate records will establish a relationship
between visual observations noted during frequent inspections and the actual condition of the load
chain as determined by periodic inspection methods.
Frequent Inspection
On a hoist in continuous service, frequent inspection should be made at the beginning of each shift.
In addition, visual inspections should be conducted during regular service for any damage or
evidence of malfunction.
1. OPERATION. Check for visual signs or abnormal noises (grinding etc.) which could indicate
a potential problem. Make sure all controls function properly and return to neutral when
released. Check chain feed through the hoist and bottom block. If chain binds, jumps, is
excessively noisy or “clicks”, clean and lubricate the chain. If problem persists, replace the
chain. Do not operate the hoist until all problems have been corrected.
9

ENGLISH
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 shown in Table 1 (ref. Dwg.
MHTPA0040) or exceed a 10° twist (ref. Dwg. MHTPA0111). If the hook latch snaps past the
tip of the hook, the hook is sprung and must be replaced. Check hook support bearings for
lubrication or damage. Make sure they swivel easily and smoothly. Repair or lubricate as
necessary.
3. UPPER AND LOWER LIMIT DEVICE. Test operation with no load slowly to both extremes
oftravel.Upward travelmuststopwhenthebottomblockorstopbufferonchainhitshoistlimit
arm. Downward travel must stop when the loop at the unloaded end of the chain decreases and
activates the limit arm.
4. AIR SYSTEM. Visually inspect all connections, fittings, hoses and components for indication
of air leaks. Repair any leaks found. Check and clean filters if equipped.
5. CONTROLS.Duringoperationofhoist,verifyresponsetopendantisquickandsmooth.Ensure
the controls return to neutral when released. If hoist responds slowly or movement is
unsatisfactory, do not operate hoist until all deficiencies have been corrected.
6. HOOK LATCH. Check operation of the hook latch. Replace if broken or missing.
CAUTION
•Do not use hoist if hook latch is missing or damaged.
Throat Width
(Dwg. MHTPA0040)
Twisted
DO NOT USE
10°
MAX
Normal
Can Be Used
(Dwg. MHTPA0111)
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Table 1
Hoist Model
"T" Throat Opening
New Hook Discard Hook
in mm in mm
ML250K-E,
ML250KS-E,
ML500K-E
and ML500KS-E
1,06 27 1,15 29
ML1000K-E
and ML1000KS-E 1,25 31,8 1,35 34
ML250KR-E,
ML500KR-E,
HL1000K-E
and HL1500K-E
1,22 31 1,32 34
HL2000K-E 1,50 38 1,62 41
HL3000K-E
and HL4500K-E 1,87 48 2,02 51
HL6000K-E 2,25 57 2,43 62
10

ENGLISH
7. CHAIN (ref. Dwg. MHTPA0102). Examine each of the
linksforbending,cracksinweldareasorshoulders,traverse
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 chain lubrication and lubricate if
necessary. See “Load Chain” under “LUBRICATION.”
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.
8. LOADCHAINREEVING.Makesureweldsonstandinglinksareawayfromthepoweredchain
sheave.Reinstallchainif necessary. Make sure chain is not capsized, twisted or kinked.Adjust
as required.
Periodic Inspection
Frequency of periodic inspection primarily depends on the severity of usage:
NORMAL HEAVY SEVERE
yearly semiannually quarterly
Disassembly may be required for HEAVY or SEVERE usage. Keep accumulative written records
ofperiodicinspectionstoprovideabasisforcontinuingevaluation.Inspectalltheitemsin“Frequent
Inspection”. Also inspect the following:
1. FASTENERS. Check rivets, capscrews, nuts, cotter pins and other fasteners on hooks, hoist
body and chain bucket, if used. 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 for additional inspection return hoist to your nearest
Ingersoll-Rand service repair center.
3. HOOKS. Inspect hooks for cracks. Use magnetic particle or dye penetrate to check for cracks.
Inspect hook retaining parts. Tighten or repair, if necessary.
4. LOAD CHAIN WHEELS. Check for damage or excessive wear. Replace damaged parts.
Observetheactionoftheloadchainfeedingthroughthehoist.Donot operate a hoist unless the
load chain feeds through the hoist and hook block smoothly and without audible clicking or
other evidence of binding or malfunctioning.
5. MOTOR. If performance is poor, contact your nearest service repair center for repair
information.
6. BRAKE. Raise a load equal to the rated capacity of the hoist a few cms (inches) off the floor.
Verifyhoistholdstheoadwithoutdrift.Ifdriftoccurs,contactyournearestservicerepaircenter
for repair information.
7. SUPPORTING STRUCTURE.Ifa permanent structure is usedinspectfor continued ability to
support load.
8. TROLLEY (if equipped). Refer to manufacturers instructions for installation and service
information.
9. LABELS AND TAGS. Check for presence and legibility. Replace if necessary.
Welded Area
Diameter
Wear in
these areas
(Dwg. MHTPA0102)
11

ENGLISH
10. LOAD CHAIN END ANCHORS. Ensure both ends of load chain are securely attached.
Secure if loose, repair if damaged, replace if missing.
11. LOAD CHAIN. Measure the chain for stretching by measuring across eleven link sections all
along the chain (ref. Dwg. MHTPA0041) paying particular attention to the most reeved links.
Whenanyeleven links intheworkinglengthreach or exceedthediscardlengthshown in Table
2,replacetheentirechain.AlwaysuseagenuineIngersoll-RandMaterialHandlingreplacement
chain.
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Table 2
Model
No. Chain Wire Size Normal Length Discard Length
in mm in mm in mm
MLK 1/4 6,35 8448 214,6 8,57 218
HLK 3/8 9,52 9108 231,3 9,24 234
Zinc plated load chain is available for standard hoists. Always use
stainless steel load chain on HL1000KR Spark Resistant Hoists.
Gauge Length
(Dwg. MHTPA0041)
12. CHAIN CONTAINER. Check for damage or excessive wear and that chain container is
securely attached to the hoist. Secure or replace if necessary.
13. LIMIT ASSEMBLY. Check throttle lever moves freely. To limit hook downward travel the
loop in the slack chain side must contact the throttle lever. To limit hook upward travel the
bottom hook block must contact the throttle lever.
To test “UP” and “DOWN” travel limits first run hoist slowly with no load to verify proper
function. Repeat test at full speed with no load to verify proper function.
Hoists Not in Regular Service
1. A hoist which has been idle for a period of one month or more, but less than one year, should
begivenaninspectionconformingwiththerequirementsof“FrequentInspection”beforebeing
placed into service.
2. A hoist that has been idle for a period of more than one year should be given a complete
inspection conformingwiththerequirementsof“PeriodicInspection”beforebeingplacedinto
service.
3. Standby hoists should be inspected at least semiannually in accordance with the requirements
of “Frequent Inspection.” In abnormal operating conditions equipment should be inspected at
shorter intervals.
12

ENGLISH
LUBRICATION
To ensure continued satisfactory operation of the hoist, all points requiring lubrication must be
servicedwith the correct lubricantattheproper time intervalasindicatedfor each assembly. Correct
lubrication is one of the most important factors in maintaining efficient operation.
Thelubricationintervalsrecommendedinthismanualarebasedonintermittentoperationofthehoist
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
corrosivefumes.Useonlythoselubricantsrecommended.Otherlubricantsmayaffecttheperformance
ofthe hoist. Failure to observe thisprecaution mayresultindamage to the hoist and/or its associated
components.
General Lubrication Information
Thetopand bottomhooksaresupportedbythrustbearings.Thesebearingsrequiretobepackedwith
a standard No. 2 multipurpose grease at regular intervals. Neglect of proper lubrication will lead to
bearingfailure.ContactyournearestIngersoll-Randservicerepaircenterforaditionalinformation.
CAUTION
•Do not use automotive type detergent oil. Detergents will delaminate the motor vanes in
MLK and HLK hoists and cause premature failure.
Air Line Lubricator
Lubricate the hoist supply air with SAE 30W non-detergent motor oil (minimum viscosity 135 Cst
at 40° C (104° F)) from an in-line lubricator. The use of detergent oil may cause premature failure.
Load Chain
WARNING
•Failure to maintain clean and well lubricated load chain will result in rapid load chain wear
that can lead to chain failure which can cause severe 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 environment, lubricate more frequently than normal.
3. Lubricate hook and hook latch pivot points with the same lubricant used on the load chain.
4. To remove rust or abrasive dust buildup, clean chain with acid free solvent. After cleaning,
lubricate the chain.
5. Use Ingersoll-Rand LUBRI-LINK-GREEN or a SAE 50 to 90 EP oil.
Hook and Suspension Assemblies
1. Lubricate the hook and hook latch pivot points. Hook and latch should swivel/pivot freely.
2. Use Ingersoll-Rand LUBRI-LINK-GREEN or a SAE 50 to 90 EP oil.
3. On HL4500K and HL6000K hoists Lubricate the Idler wheel bearings in the upper suspension
housing and bottom hook assembly with Ingersoll-Rand No. 68 Grease or a good quality No.
2 multipurpose grease.
4. OnHL4500KandHL6000Khoistsaftereach300hoursofoperationormorefrequentlyifhoist
is operating in a contaminated atmosphere, inject 2 or 3 shots of grease from a grease gun into
grease fittings in the end of the idler wheel shafts.
13

ENGLISH
Gear Housing
MLK Hoists
No additional lubrication is required for the gearing.
HLK Hoists
Removetheoil level plug fromthesideofthe housing. If theoillevelisbelow the piped tappedhole,
remove the vent plug and add a sufficient amount of Ingersoll-Rand No. 62 oil (Texaco Meropa
No. 3 or Texaco Meropa No. 220). Replace the oil level plug and vent plug.
PARTS ORDERING INFORMATION
The use of replacement parts other than Ingersoll-Rand Material Handling may invalidate the
Company’s warranty. For prompt service and genuine Ingersoll-Rand Material Handling parts
provide your nearest Distributor with the following:
1. Complete model number as it appears on the nameplate.
2. Part number and part name as shown in parts manual.
3. Quantity required.
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.
Disposal
When the life of the hoist has expired, it is recommended that the hoist be disassembled, degreased
and parts separated by material so that they can be recycled.
SERVICE AND MAINTENANCE
Hoist repair and maintenance should only be carried out by an Authorized Service Repair Center.
Contact your nearest Ingersoll-Rand office for details.
The original language of this manual is English.
Hoist Parts and Maintenance information is available in English by requesting the following
publications:
MLK Hoist Parts, Operation and Maintenance Manual Form Number P6554
HLK Hoist Parts, Operation and Maintenance Manual Form Number P6587
14

INFORMASJON OM SIKKERHET
Dennehåndboken inneholder viktige opplysningerforpersonersom deltar undermonteringogbruk
avdisseproduktene. Selv om du menerduharerfaringmed dette eller lignende utstyr, børdulikevel
lese håndboken før produktet tas i bruk.
Fare, Advarsel, Obs! og Merk
Denne håndboken beskriver framgangsmåter som, hvis de ikke følges, kan resultere i personskader.
Sikkerhetsmerkingen som er beskrevet nedenfor, brukes til å angi hvor stor risiko de ulike
framgangsmåtene innebærer.
Denne advarselen betyr at framgangsmåten vil forårsake alvorlig
personskademedeventuelldødeligutgang,ellerbetydeligmateriell
skade dersom advarselen ignoreres.
Denne advarselen betyr at framgangsmåten kan føre til alvorlig
personskademedeventuelldødeligutgang,ellerbetydeligmateriell
skade dersom advarselen ignoreres.
Denne advarselen betyr at framgangsmåten vileller kanforårsake
mindre personskade eller materiell skade dersom advarselen
ignoreres.
Denne merknaden formidler viktig informasjon om montering,
bruk eller vedlikehold, men er ikke forbundet med fare.
Sammendragavsikkerhetsinformasjon
ADVARSEL
•Trykkluft-taljen eller påmontert tilleggsutstyr skal ikke brukes til å løfte, trekke eller flytte
personer eller til å løfte eller trekke last over personer.
•Bærekonstruksjon og utstyr for festing av last som brukes i forbindelse med løftingen, skal
kunnebærealleløfteoperasjoner,plussvektenavtrykkluft-taljenogpåmonterttilleggsutstyr.
Dette er kundens ansvar. Kontakt en kvalifisert bygningsingeniør hvis du er i tvil.
MERK
•Løfteutstyr er underlagt ulike regler og forskrifter. Disse reglene og forskriftene kan være
utelatt i denne håndboken.
Denne håndboken er utarbeidet av Ingersoll-Rand for å gi forhandlere, mekanikere, operatører og
firmamedarbeideredeninformasjonensomernødvendigforåkunnemontereogbetjeneproduktene
som er beskrevet i håndboken.
N-1
LES DENNE HÅNDBOKEN FØR DISSE PRODUKTENE TAS I
BRUK. Håndboken inneholder viktige opplysninger om
sikkerhet, montering og anvendelse.
FARE
ADVARSEL
OBS!
MERK
NORSK

Det er svært viktig at mekanikere og operatører er kjent med servicerutiner for disse eller lignende
produkter. Likeledes skal mekanikere og operatører være fysisk skikket til å utføre disse
servicerutinene. Personell som betjener utstyret, skal dessuten ha generell kunnskap om følgende:
•Riktig og sikker bruk og betjening av en mekanikers alminnelige håndverktøy i tillegg til
spesialverktøy fra Ingersoll-Rand eller verktøy som anbefales av Ingersoll-Rand.
•Sikkerhetsrutiner,forholdsreglerogarbeidsrutinersomerfastsattigodkjenteindustristandarder.
Ingersoll-Rand kan ikke ha kjennskap til eller gi informasjon om alle framgangsmåtene som kan
brukes ved betjening eller reparasjon av produktet, eller vite eller gi opplysninger om hvilken risiko
hver framgangsmåte innebærer og/eller hvilket resultat framgangsmåtene kan føre til. Dersom man
anvender bruks- eller vedlikeholdsrutiner som ikke er uttrykkelig anbefalt av produsenten, må man
forsikresegomatsikkerheteniforbindelsemedbrukenavproduktetikkereduseresavarbeidsrutinene.
Hvispersonelleterusikkerpåenframgangsmåte eller et trinn i forbindelse med bruk og vedlikehold
av utstyret, skal produktet sikres på forsvarlig måte før de tar kontakt med overordnede og/eller
fabrikken for å få hjelp.
INSTRUKSJONER FOR TRYGG BRUK
Ingersoll-Rand er klar over at de fleste firma som bruker trykkluft-taljer, allerede har fastsatt
sikkerhetsregler for fabrikkanlegget. Hvis det skulle oppstå situasjoner der det er konflikt mellom
en retningslinje i denne håndboken og en lignende regel som er fastsatt av det aktuelle firma, skal
den strengeste av de to retningslinjene ha forrang.
Hensikten med informasjonen i denne delen av håndboken er å gjøre operatøren klar over
framgangsmåter som ikke er trygge, og som bør unngås, men samtlige faremomenter er ikke
nødvendigvistattmedidenneoversikten.Deulikedeleneavdennehåndbokeninneholderytterligere
opplysninger om trygg bruk av produktene.
1. Trykkluft-taljen skal kun betjenes av personer som har gjennomgått trening med hensyn til
sikkerhet og bruk av dette produktet.
2. Trykkluft-taljen skal kun betjenes av personer som er fysisk skikket til det.
3. Når et skilt merket med «SKAL IKKE ANVENDES» er festet til trykkluft-taljen eller
kontrollene, skal ikke utstyret brukes før skiltet er fjernet av kvalifisert personell.
4. Før hvert nytt skift skal operatøren kontrollere at trykkluft-taljen ikke er slitt eller ødelagt.
5. Trykkluft-taljen skal aldri brukes dersom en inspeksjon avdekker tegn som tyder på at
trykkluft-taljen er slitt eller ødelagt.
6. Trykkluft-taljenskalundersøkesnøyemedjevnemellomrom,ogeventuelleslitteellerødelagte
deler skal skiftes ut.
7. Trykkluft-taljen skal smøres med jevne mellomrom.
8. Trykkluft-taljen skal ikke brukes dersom kroklåsen på en krok er sprukket eller ødelagt.
9. Kontroller at kroklåsene er i inngrep før trykkluft-taljen tas i bruk.
10. Kjettingen på en trykkluft-talje skal aldri skjøtes ved å sette inn bolter mellom leddene.
11. Trykkluft-taljen skal kun brukes til å løfte last med en vekt som er mindre enn eller tilsvarer
trykkluft-taljens nominelle løftekapasitet (se under «SPESIFIKASJONER»).
12. Når to trykkluft-taljer brukes til løfting av én last, velges to trykkluft-taljer som hver har en
nominellløftekapasitetsomtilsvarerelleroverstigervektenavlasten.Dermedoppnåstilstrekkelig
sikkerhet i tilfelle lasten plutselig forskyver seg.
13. Stikk aldri hånden inn i halsområdet på en krok.
14. Lastekjettingen på trykkluft-taljen skal aldri brukes som en lastestropp.
15. Trykkluft-taljenskalaldrianvendeshvisikkelastenerplassertdirekteunderkroken.Trykkluft-
taljen skal ikke brukes til å senke eller trekke last sidelengs.
16. Entrykkluft-taljeskalaldrianvendeshvislastekjettingenervridd,floketellerskadet,ellerhvis
leddene har hengt seg opp.
N-2
NORSK

17. Kjetting eller krok skal ikke tvinges på plass med hamring.
18. Tuppen på kroken skal aldri stikkes inn i et kjettingledd.
19. Kontroller at lasten sitter ordentlig i kroksalen og at kroklåsen er i lås.
20. Lasten på kroken skal ikke støttes på noen måte.
21. Lastekjettingen skal aldri føres over en skarp kant. Bruk en blokkskive.
22. Lasten skal hele tiden holdes under nøye oppsyn når trykkluft-taljen er i bruk.
23. Sørg for atdu selvog andrepersoner alltidstår igod avstandfra området somlasten føresover.
Last skal ikke løftes over personer.
24. Trykkluft-taljen skal aldri brukes til å heise personer opp eller ned, og ingen personer skal stå
på en hengende last.
25. Slakk i kjettingen og stroppen skal reduseres litt etter litt idet løftingen tar til. Lasten skal ikke
rykkes opp.
26. Hengende last skal ikke svinges.
27. Hengende last skal alltid holdes under oppsyn.
28. Last som henger fra trykkluft-taljen skal aldri sveises eller skjæres.
29. Kjettingen på trykkluft-taljen skal aldri brukes som en sveiseelektrode.
30. Trykkluft-taljen skal ikke anvendes hviskjettingenhopper,lagerunormaltmyestøy, setter seg
fast, overlastes eller er fastklemt.
31. Opp-ognedsperreneskalikkebrukestilåstansetrykkluft-taljen.Dissesperrenemåkunbrukes
i nødsituasjoner.
32. Trykkluft-taljen skal alltid settes opp på en forsvarlig og omhyggelig måte.
33. Kontroller at lufttilførselen er stengt av før vedlikeholdsarbeid utføres på trykkluft-taljen.
34. Kjettingen skal ikke utsettes for ekstremt lave temperaturer. Når kjettingen er kald, skal den
ikke brukes til løfting av last.
VARSELSMERKING
Advarselsmerket nedenfor er festet til hver
trykkluft-talje ved levering fra fabrikken. Hvis
dette merket ikke er festet til din enhet, skal et
nytt merke bestilles og festes til trykkluft-
taljen.
ADVARSEL
•Trykkluft-taljen skal ikke brukes til å
løfte, trekke eller transportere personer.
N-3
NORSK

PRODUKTBESKRIVELSE
Trykkluft-taljene som er beskrevet i denne håndboken, er drevet av trykkluft og beregnet til å løfte
og senke last ved hjelp av en styringsenhet. Trykkluft-taljene kan monteres til en løpevogn eller en
permanent installasjon ved hjelp av bolter eller krok.
Trykkluft-taljene er utstyrt med lamellmotorer som driver girsystemet. Effekten fra girsystemet blir
direkte overført til lastekjettingens drivskive.
Hver trykkluft-talje er utstyrt med en bremse som utløses ved hjelp av lufttrykk på et ringformet
bremestempel. Når knappen/spaken «UP» eller «DOWN» på styringsenheten trykkes, utløses luft
som sendes til bremsen. Bremsestempelet presser bremsefjærene sammen, slik at bremsen løses ut.
Når knappen/spaken «UP» eller «DOWN» slippes, blir luften blåst ut og bremsen koples inn.
SPESIFIKASJONER
Trykkluft-
talje,
modellnr.
Nom.
løfte-
kapasitet
(kg)
Antall
kjet-
ting-
parter
Luft-
tilførsel
(m³/min)
Lyd-
trykks-
nivå,
dBA
Lyd-
effekt-
nivå,
dBA
Hastighet ved
nom. last
m/m
Hastighet
uten last
m/m
Vekt av
krokopphengt
trykkluft-talje
ved 3 m
(10 fot) løft,
kg
Nominell
grense for
løftesperre
for
overlast,
kg
opp ned opp ned
ML250KS-E
250 1
1,27
90 100
12,2 27,4 21 16
21,8
- - -
ML250K-E 1,98 30,8 35,7 52 30
ML250KR-E 1,27 7,9 11,6 12,8 9,1
ML500KS-E
500 16,7 20,1 13 10 ML500K-E 1,98 16,8 29,6 32 18
ML500KR-E 2
1,27
4,0 6,1 6,4 4,6
27,7ML1000KS-E 980 23,4 10,0 6,7 4,9
ML1000K-E 8,5 14,9 16 9
HL1000K-E 1000 1
1,98 87 97
7,9 11,3 12,2 7,9 38,1 1250
HL1000KR-E
HL1500K-E 1500 4,9 7,9 8,5 4,9 1875
HL2000K-E 2000 245,5 6,1 456,6 2500
HL3000K-E 3000 2,4 44,3 2,4 58,5 3750
HL4500K-E 4500 31,4 33,2 287,5 5625
HL6000K-E 6000 4 1 2,3 2,6 1,5 112,5 7500
* Lydmålingene er foretatt i henhold til testspesifikasjonene ISO 11201, ISO 3744-3746 og ISO 4871
for lyd fra trykkluftsutstyr. Avlesingene ovenfor er basert på det gjennomsnittlige støynivået for hver
taljekonfigurasjon, og er proporsjonale med anvendelsestiden i en regelmessig syklus.
* Lpc (Maksimalt lydtrykk) overstiger ikke 130 dB.
* Ytelsen er basert på et driftstrykk på 6,3 bar.
N-4
NORSK

MONTERING
Før montering skal trykkluft-taljen undersøkes nøye med hensyn til eventuelle transportskader.
Trykkluft-taljene leveres i ferdig smurt stand fra fabrikken.
Lastekjettingen skal smøres før første løfteoperasjon.
OBS!
•Før trykkluft-taljen monteres og tas i bruk, anbefaler vi at eiere og brukere av trykkluft-
taljen undersøker hvilke andre spesifikke, lokale regler eller forskrifter som eventuelt kan
gjelde for anvendelse av dette produkt.
ADVARSEL
•Lastsomfallerned,kanføretilpersonskademedeventuelldødeligutgang.Lesopplysningene
under «INSTRUKSJONER FOR TRYGG BRUK» før produktet monteres.
Trykkluft-talje
Bærekonstruksjon og utstyr for festing av last som brukes i forbindelse med løftingen, skal kunne
bære alle løfteoperasjoner, pluss vekten av trykkluft-taljen og påmontert tilleggsutstyr. Dette er
kundens ansvar. Kontakt en kvalifisert bygningsingeniør hvis du er i tvil.
Nårdetgjeldertrykkluft-taljeravtypenHLK,skaltetningspluggenøverstpåtrykkluft-taljenfjernes,
og den tilhørende luftepluggen skal monteres før trykkluft-taljen tas i bruk. Når trykkluft-taljen
henger i normal loddrett stilling, må det kontrolleres at oljenivået i girkassen når opp til kontroll-
pluggen på siden av girboksen.
Montering av trykkluft-talje etter krok
Heng kroken fra bærekonstruksjonen. Kontroller at kroklåsen er i lås.
Sjekk at den bærende konstruksjonen er godt plassert i kroksalen og direkte over krokskaftet.
OBS!
•Bærekonstruksjoner som vipper trykkluft-taljen mot enten den ene eller andre siden, skal
ikke brukes.
Montering av trykkluft-talje til løpevogn
Slå opp i løpevognprodusentens monteringsveiledning med hensyn til forsvarlig montering av
løpevognen og trykkluft-taljen.
Kjettingbeholder
Slå opp i produsentens monteringsveiledning for kjettingbeholdere med hensyn til montering av
kjettingbeholderen.
OBS!
•Husk å justere balansekjettingen, slik at kjettingbeholderen ikke kommer i kontakt med
lastekjettingen.
•La kjettingen kveile seg naturlig i kjettingbeholderen. Skjødesløs manuell kveiling av
kjettingen i beholderen kan føre til at kjettingledd henger seg opp, eller at kjettingen vris på
en slik måte at trykkluft-taljen kjører seg fast.
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NORSK