1.
Oil Temperature.
The presence of hot fluid in a hydraulic system is a primary
cause of poor operation, component failure and system downtime. The fluid used
in any hydraulic system is formulated for operation within a temperature range
of 0° to 60° C (32° to 140° F). If the temperature is frequently exceeded
component and system operation will be degraded. Under continuous operating
conditions the temperature of the oil at any given point in the hydraulic system
should not be allowed to exceed 82° C (180° F).
2.
Oil Cleanliness.
Hydraulic system cleanliness is extremely important to ensure
safe, continued operation of components. Dirty or contaminated hydraulic fluid
may cause components to break down, operate erratically or damage valuable
equipment.
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Hoist Controls
Hoist controls are customer supplied.
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Initial Hoist 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, ensure the clevis or hook is centered below the beam.
2. Make sure the hydraulic motor and case drain line is filled with the recommended
hydraulic fluid. Internal motor leakage at low operating pressures may not be
sufficient to provide start-up lubrication.
3. Verify oil levels are in accordance with recommendations in “LUBRICATION”
4. When first operating the hoist it is recommended that the hoist be driven slowly
in both directions for a few minutes.
5. Check for oil leaks in the supply hose and fittings to controls, and from controls
to hoist.
6. Check that trolley and clevis or hook movement is the same direction as arrows
or information on the controls.
7. If hoist is trolley mounted operate the trolley along the entire length of the beam.
8. Using a light load on the hoist check operation of hoist and trolley brakes. Refer
to Product Maintenance Information manual for brake adjustment or repair.
9. Check 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.
10. Check operation of limit switches, emergency stops and all safety devices when
equipped.
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Storing the Hoist
1. Always store hoist in a no load condition.
2. Wipe off all dirt and water.
3. Oil the 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
Use”. Refer to the “INSPECTION” section on page 6.
INSPECTION
Inspection information is based in part on American Society of Mechanical Engineers
Safety Codes (ASME B30.16).
WARNING
• All new or repaired equipment should be inspected and tested by
Ingersoll Rand trained technicians to ensure safe operation at rated
specifications before placing equipment in service.
• Never use a hoist that inspection indicates is damaged.
Frequent and periodic inspections should be performed on equipment in regular
service. Frequent inspections are visual examinations performed by operators or
Ingersoll Rand
trained inspectors and include observations made during routine
equipment operation. Periodic inspections are thorough inspections conducted by
Ingersoll Rand
trained technicians. ASME B30.16 states inspection intervals depend
upon the nature of the critical components of the equipment and the severity of
usage. Refer to ‘Inspection Classifications’ chart and ‘Maintenance Intervals’ chart in
Product Maintenance Information Manual for recommended maintenance intervals.
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 to ensure corrective action is taken. A determination as to
whether a condition constitutes a safety hazard(s) must be decided, and the
correction of noted safety hazard(s) accomplished and documented by written report
before placing the equipment in service.
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Frequent Inspection
On equipment in continuous service, a ‘Daily Inspection’ should be made by the
operator at the beginning of each shift and a ‘Quarterly Inspection’ (90 days) should
be conducted during regular service for any damage or evidence of malfunction.
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Daily Inspection
Complete inspections prior to start of daily tasks. Conduct visual inspections during
regular operation for indications of damage or evidence of malfunction (such as
abnormal noises).
1.
Surrounding Area.
Visually check hoist for oil leaks. Do not operate hoist if
leaking oil is found. Ensure surrounding area has no slippery surfaces and is
obstruction free.
2.
Hoses and Fittings.
Visually inspect for damage, leaks, and loose connections.
Repair all leaks or damage and tighten loose connections prior to starting daily
tasks.
3.
Hoist.
Check for visual signs or abnormal noises (grinding, etc.) which could
indicate a potential problem. Make sure all controls function properly. Check
chain feed through hoist and bottom block. If chain binds, jumps, is excessively
noisy or “clicks,” clean and lubricate chain. If problem persists, replace chain. Do
not operate hoist until all problems have been corrected.
4.
Hydraulic System.
Check hydraulic lines, fittings, valves and other components
for deterioration, leakage or wear. Tighten, repair or replace as necessary. Check
reservoir sight gauge for proper hydraulic oil level. Check dirt alarms at both
pressure and return line filters for visual indication of dirty filter.
5.
Controls.
Controls are customer supplied, however, during operation of the hoist,
verify that response of controls is quick and smooth. Ensure controls return to
neutral when released. If hoist responds slowly or movement is unsatisfactory,
do not operate the hoist under load conditions until all problems have been
corrected.
6.
Brake.
During operation test brake. Brake must be capable of supporting load
without slipping. Brake must release when control returns to neutral. If brake
does not hold load or does not release properly when pendant is not being used,
brake must be further inspected. Refer to Product Maintenance Information
Manual.
WARNING
• Worn or improperly functioning brakes may cause excessive heat build up
and sparks.
7.
Hooks.
Check for wear or damage, increased throat width, bent shank or twisting
of the hook. Replace if hook latch snaps past tip of hook. Check hooks swivel
freely. Replace hooks which exceed the throat opening. Refer to Dwg. MHP0040
A.
Throat Width. Replace hooks which exceed a 10° twist. Refer to
A.
Twisted DO NOT USE;
B.
Normal Can Be Used. If
hook latch snaps past tip of hook, the hook is sprung and must be replaced. Refer
to the latest edition of ASME B30.10 ‘HOOKS‘ for additional information. Check
hook support bearings for lubrication or damage. Ensure that they swivel easily
and smoothly. Refer to Product Maintenance Information Manual.
8.
Hook Latch.
Make sure hook latch is present and not damaged. Replace if
necessary.
CAUTION
• Do not use hoist if hook latch is missing or damaged.
9.
Load 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. Refer to Dwg. MHP0102 on page 9,
A.
Diameter;
B.
Welded Area;
C.
Wear
in these areas. Visually inspect as much of the chain as is possible. Inspect for
wear, damage and corrosion. If damage is evident, do not operate hoist until the
damage has been reviewed and inspected further by an
Ingersoll Rand
trained
inspector. Refer to Product Maintenance Information Manual.
NOTICE
• The full extent of chain wear cannot be determined by visual inspection. At
any indication of wear inspect chain in accordance with instructions in
‘Periodic Inspection‘. Refer to Product Maintenance Information Manual.
10.
Load Chain Reeving.
Ensure welds on standing links are away from load sheave.
Reinstall chain if necessary. Refer to Product Maintenance Information Manual.
Make sure chain is not capsized, twisted or kinked. Adjust as required. Refer to
Dwg. MHP0043 in Product Safety Information Manual.
11.
Lubrication.
Refer to “LUBRICATION” on page 7 for recommended procedures
and lubricants.
12.
Labels and Tags:
check for presence and legibility of labels. Refer to Product
Parts Information Manual for correct labels and placement. Replace if damaged
or missing.
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Load Chain Reports
Records should be maintained documenting condition of load chain removed from
service as part of a long-range chain inspection program. Accurate records will
establish a relationship between visual observations noted during ‘Frequent
Inspections‘ and actual condition of load chain as determined by ‘Periodic
Inspections‘. Refer to Product Maintenance Information Manual for chain
specifications.
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Hoists Not in Regular Use
1. Equipment which has been idle for a period of one month or more, but less than
six months, shall be given an inspection conforming to the requirements of
‘Frequent Inspection’ on page 6 before being placed in service.
2. Equipment which has been idle for a period of over six months shall be given a
complete inspection conforming with requirements of ‘Periodic Inspection‘ before
being placed in service. Refer to Product Maintenance Information Manual.
3. Standby equipment shall be inspected at least semiannually in accordance with
requirements of ‘Frequent Inspection‘.
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Form MHD56465 Edition 3
