Ingersoll-Rand ML100K, ML50K, ML25K User Manual

03529245

Form P6432
Edition 2

May, 1981

OPERATOR AND MAINTENANCE MANUAL

MODEL ML25K

MODEL ML50K

MODEL ML100K

1 - Ton Air Chain Hoist

i

WARNING

DO NOT USE THIS HOIST FOR
LIFTING CR LOWERING PEOPLE.

ALWAYS OPERATE, INSPECT AND MAINTAIN
THIS HOIST IN ACCORDANCE WITH AMERICAN
NATIONAL STANDARDS INSTITUTE
STANDARDS 830.16 .

READ ALL THE ENCLOSED INSTRUCTIONS BEFORE
INSTALLING, OPERATING OR REPAIRING THIS
HOIST.

SAFETY

Refer All Communications to the Nearest
Ingersoll-Rand Office or Distributor.

Printed in U.S.A.

AIR HOISTS

HOW TO ORDER REPAIR PARTS FOR YOUR HOIST

Your Hoist is designed and constructed to give you long, trouble-free service. In time it may become necessary to order
and install new parts to replace those that have been subjected to wear. For prompt service and genuine Ingersoll-Rand parts,
place orders with your nearest Ingersoll-Rand Distributor. The use of other than genuine Ingersoll-Rand replacement parts
may result in decreased Hoist performance, and may, at the Company’s option, invalidate all warranties.

When ordering parts, give your Distributor the following data:

1. Complete model number of the Hoist as it appears on the nameplate.

2. Complete part number, part description and quantity needed as shown on the pages of this manual.
If it becomes necessary to return the complete Hoist or certain parts to the factory, contact the Distributor from whom

you purchased the Hoist, or the nearest Ingersoll-Rand Distributor in your locality.

INSTALLING THE HOIST

Make certain your Hoist is properly installed. A little extra time and effort in so doing can contribute a lot toward prevent-

ing accidents and helping you get the best service possible.

Always make certain the supporting member from which the Hoist is suspended is strong enough to support the weight of

the Hoist plus the weight of a maximum rated load plus a generous factor of at least 500% of the combined weights.

When installing a Fabric Chain Container on an MLK Hoist refer to the illustration on Page 30. Note: Make certain to ad-

just the balance chain so that the Container does not contact the load chain.

If the Hoist is suspended by a Top Hook, the supporting member should rest completely within the saddle of the Hook

and be centered directly above the hook shank. Do not use a supporting member that cants the Hoist to one side or the other.

For installing a Trolley on a beam measure the beam flange and temporarily install the Trolley on the Hoist to determine

to 6.35 mm) greater than the width of the beam flange. The number of spacers between the Trolley side plate and the mount­ing lug on the Hoist must be the same in all four locations in order to keep the Hoist centered under the I-beam. The remain­ing spacers must be equally distributed on the outside of the side plate.

When installing the Hoist and Trolley on the beam, make certain the side plates are parallel and vertical. After installation,

operate the Trolley over the entire length of the beam with a capacity load suspended a few inches off the floor.

LUBRICATION SPECIFICATION

Whenever a Series MLK Hoist is disassembled for overhaul or replacement of parts, lubricate as follows:

Coat all motor parts with a light film of Ingersoll-Rand Pneu-Lube@Medium Oil No. 50 or a good quality SAE 20 or

1.
20W motor oil before assembling.
Apply a coating of Ingersoll-Rand No. 11 Grease to the Planet Gear Bearings (83) and the Brake Driver Bearing (87) be-

2.
fore assembly.
Lubricate each link of the load chain weekly using a good quality SAE 50 to 90W EP oil. Lubricate the chain more fre-

3.
quently depending on the severity of service.

OPERATION

Always use an air line filter and lubricator with an MLK Hoist. The diameter of the air passage must be at least 1/2” (13

mm). We recommend using No. NFLRU-8 Filter-Lubricator-Regulator installed as close to the inlet of the Hoist as practical.

If quick disconnect fittings are used at the inlet of the Hoist, they must have at least a

3/8"

(9.5 mm) air passage. Use of

smaller fittings will reduce performance.

OPERATING PRACTICES

The two most important aspects of Hoist operation are: (1) Allow only qualified people to operate a Hoist, and (2) Sub-

ject each Hoist to a regular inspection and maintenance procedure.

A qualified operator must be physically competent. He must have no health condition which might affect his ability to re­act, and he must have good hearing, vision and depth perception. The qualified 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. He must thor­oughly understand proper methods of hitching loads. He should have a good attitude regarding safety and should refuse to
operate under unsafe conditions.

Proper use of a Hoist begins before a load is lifted. Make certain to:
a. Check to see that the Hoist is directly over the load. Do not lift the load at an angle.

b. Check to see that the Hoist is securely connected to the overhead crane, monorail, trolley or supporting member.
c. Check to see that the load is securely inserted in the hook.

Regular inspection procedures should be set up, rigidly adhered to and recorded by or under the direction of a qualified
person. On Hoists in continuous service, inspection should be made at the beginning of each shift. The items to be checked

include, but are not limited to:
a. Lubrication according to the instructions above.

b. Brakes: Lift a capacity or near capacity load a few inches off the floor and check ability of braking system to stop and

hold the load and without excessive drift.

c. Chain and Hooks: Visually inspect the load chain for cleanliness and lubrication as well as wear or other damage. Note:

Excessive wear may not be apparent upon casual observation. The only positive check is to gauge it according to manufac­turer’s instructions. Refer to CHAIN REPLACEMENT on page 7. Never operate a Hoist with dry, dirty, worn, damaged
or kinked chain.

Hooks should be checked for wear. increase in throat opening, and bending.

(Note:

Increased throat opening or a bent
hook indicates overloading or abuse). Replace hooks having a 15% increase in throat opening or 10% bend. 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. See that they swivel easily and smoothly.

(Dwg. TPD450)

Hoist Size

For ML25K and

MLS0K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For ML100K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

in mm

1-1/6
I-1/4

“T” Throat Opening

New Hook Discard Hook

27.0

31.8

in

l-7/32

l-7/16 36.5

mm

31.0

Observe the action of Chain feeding through the Hoist. Do not operate a Hoist unless the Chain feeds through the Hoist
and Hook Block smoothly and without audible clicking or other evidence of binding or malfunctioning.
d. Controls: See that the controls function properly and return to neutral when released, Check the functioning of up and

down stops by running the empty hook slowly to both extremes of travel. If the hook does not stop in its normal position,

do not operate the Hoist until the cause of the trouble is located and corrected.
e. General: Check to see that suspension fastenings are secure, unworn and undamaged. On trolley-mounted Hoists, check

that trolley wheels track the rail properly and that wheels and rail are not excessively worn. Be alert for unusual visual or

audible signs which could indicate a defect. Do not operate the Hoist until the defect has been determined and corrected.

Periodically, depending upon severity of service, the following items should also be inspected. These are in addition to
those previously listed.

a. Check all load-supporting members, including Chain, Pocket Wheel and Chain Guides, for excessive wear or damage.
b. Inspect top and bottom hooks with a magnetic particle or other suitable crack detector.
c. Hook retaining nuts or collars along with their locking members and support bearings should be inspected. Proper inspec-

tion will require disassembly.
d. Check and clean the brake parts each time the Hoist is disassembled. Replace the brake disc if the thickness is less than

.090 in (2.286 mm).
e. At least once yearly disassemble the Hoist and check for worn gearing, bearings and shafts. The parts should be cleaned,

lubricated and reassembled. Replace worn parts.

f. Check all Trolleys for smoothness of operation and for wear on supporting members.

g. Check for excessive wear in the fabric in a Fabric Chain Container. and check for loose mounting bolts and nuts on Fabric

and Metal Chain Containers.

5

OPERATING INSTRUCTIONS

1.

Read the manufacturer’s operating instructions before operating the Hoist.
Never lift a load greater than the rated capacity of the Hoist.

2.
Never use the load chain as a sling.

3.

4.

Never operate the Hoist with twisted, kinked or damaged chain.
Be certain the load is properly seated in the saddle of the hook. Faulty loading leads to spreading of the hook.

5.

6.

Do not use load chains as a ground for welding. Do not attach a welding electrode to a Hoist or sling chain.
Do not use the up and down stops as means of stopping a Hoist-these are emergency devices only. Keep hands and

7.
clothing free from the throttle lever.

8.

Do not leave a load suspended for any extended period.

9.

Always stand clear of the load.
Never use the Hoist for lifting or lowering people, and never stand on a suspended load.

10.

11.

Never carry loads over people.

12.

Before each shift, check the Hoist for wear or damage. Check brakes, limit stops, etc.

13.

Periodically inspect the Hoist thoroughly and replace worn or damaged parts.

14.

Follow the lubrication instructions.

15.

Do not attempt to repair load chain or hooks. Replace them when they become worn or damaged.

16.

Never operate a Hoist when the load chain is not centered under the hook. Do not “side pull” or “yard”.

17.

Always rig the Hoist properly and carefully.

18.

Ease the slack out of the load chain when starting a lift. Do not jerk the Hoist.

19.

Keep the load chain clean and well lubricated. Do not drag the load chain or hook on the floor.

20.

Be certain there are no objects in the way of a load or hook when moving the Hoist.

21.

Be certain the air supply is shut off before performing maintenance work on the Hoist.

22.

Avoid swinging the load when moving the Hoist.

23.

Keep the load block overhead when not in use.

24.

Properly secure an outdoor Hoist before leaving it unattended.

25.

Do not allow unqualified personnel to operate a Hoist.

26.

Avoid collision or bumping of Hoists. Do not swing a suspended load.

27.

Do not operate a Hoist if you are not physically fit to do so.

28.

Do not do anything that you feel may be unsafe.
Pay attention to the load at all times when operating a Hoist.

29.

30.

Never splice a hoist chain by inserting a bolt between links or by any other means.
Do not force a chain or hook into place by hammering, and never insert the point of the hook into a chain link.

31.
Do not allow the chain to be exposed to extremely cold weather. Do not apply sudden loads to a cold chain.

32.

6

CHAINLUBRICATION

The load chain and chain attachment pins must, be kept clean and lubricated at all times. Unlubricated Chain will wear out
in a very few capacity lifts. Failure to maintain clean lubricated Chain will void the Manufacturer’s Warranty and cause chain
wear which will make operation of the Hoist hazardous. Use an open chain lubricant or any good EP gear oil. Several excel­lent types of open chain lubricants are available and can be purchased in convenient aerosol cans.

CHAINREPLACEMENT

Excessive Chain wear cannot be detected by casual observation. The Chain is case hardened to a depth of .0l0” to .012”,
and once this case is worn through, wear will progress rapidly and the strength of the Chain will be considerably reduced. Fur­ther, the Chain will no longer fit the Chain Wheel properly, greatly increasing the chance of malfunction and Chain breakage.

Periodically, as experience dictates, examine the Chain for wear. Be certain to inspect that portion of the Chain which reg-

ularly passes over the Chain Wheel, since this is the portion that suffers the greatest wear. Check the individual links for stria-

tion-that is, minute parallel lines indicating excessive stress or wear.

Suspend a light load (SO to 100 pounds) from the Hoist and measure the Chain over the outside of the specified number

of links.

The Chain must be measured over its entire working length-that is, over that portion of Chain which continuously passes
over the Chain Wheel. When any number of links in the working length reaches or exceeds the discard length, replace the en­tire Chain. Always use a genuine Ingersoll-Rand replacement Chain. Never use any other Chain.

GAUGE LENGTH OVER N LINKS

WITH LIGHT LOAD SUSPENDED

NOMINAL

WIRE DIAMETER

1/4

FROM HOOK

DIMENSIONS OF LINK - INCHES

INSIDE OUTSIDE OF

PITCH

.767 .298 .823

WIDTH WIDTH LINKS

N

NUMBER LENGTH

7

(Dwg. TPD635-1)

DISCARD

OVER N LINKS,

INCHES

5.89

One Chain Wheel will outlast several Chains if the Chain is replaced as recommended, whereas the use of a worn Chain will

cause the Chain Wheel to wear rapidly.

If the Chain is visibly damaged, examine the Chain Wheel and Chain Guard. Install a new Chain Wheel if the old one is

visibly worn; install a new Guard if the old one is broken or distorted.

7

CHAIN REPLACEMENT (Continued)

For Single Line Hoists, Method 1

1. Remove the Brake Spring and Piston Housing, Brake Discs and Brake Plates to expose the Brake Driver.

2. Engage the first link of chain in a pocket of the pocket wheel
face away from the pocket wheel.

FLAT SIDE DOWN.

The weld on the second link must

(Dwg. TPD571)

3. Rotate the Brake Driver by hand to thread the chain through the Hoist.

4. Keep the chain straight and do not twist it. Attach the free end of the chain using the chain anchor bolt, washers and
spacer. Clean the brake parts and inspect them for excessive wear before assembling.

(Dwg. TPD572)

For Double Line Hoists, Method 1

WARNING: THE REPLACEMENT CHAIN FOR A SERIES MLK DOUBLE LINE HOIST MUST HAVE AN EVEN

NUMBER OF LINKS.

1. Install the load chain through the Hoist pocket wheel as in Step 1 of the instructions for single line Hoist and attach the
end of the chain to the Hoist using the anchor bolt and fasteners. Keep the chain straight.

2. Make certain the load chain is straight and feed the end through the bottom hook wheel with the first link ON EDGE.

3. Keep the chain straight and attach the free end to the chain anchor bracket.

WARNING:
Make Certain That The Bottom Hook

Block Has Not Been Flipped Through

The Chain With A Resultant Twist+

Appearance Of
Chain That Has

(Dwg. TPD573)

Appearance Of
Chain That Has
Been Twisted

(Dwg. TPD575)

(Dwg. TPD574)

9

Method 2

On ML25K and MLS0K single line Hoists, disconnect the load end of the Chain from the hook block. On ML100K

1.

double line Hoists, disconnect the load end of the Chain from the chain yoke and withdraw it from the hook sheave
block. Do not remove the Chain from the Hoist.
Using an abrasive wheel, cut a section from the last standing link as shown in the following illustration. Caution: Do

2.
not distort the link in any manner. It must be able to pass over the Pocket Wheel without binding.

CHAIN GUARD

(Dwg. TPD451-2)

Connect the new Chain to the old Chain by hooking the end of the new Chain onto the cutaway link. Make certain the

3.
welds on the standing links-links perpendicular to the Pocket Wheel-face away from the Pocket Wheel.
Carefully energize the Hoist in the raise direction, running off the old Chain and reeving the new Chain over the Pocket

4.
Wheel. The first link of new Chain over the Pocket Wheel must be a flat link.
After the new Chain is installed, secure the dead end of the Chain to the side of the Hoist. Make certain there is no twist

5.
in the dead end of the Chain between the Pocket Wheel and the end link. A twisted Chain can jam as it passes over the
Pocket Wheel, possibly resulting in damage to the Hoist or even breaking the Chain and injuring personnel.
On single line Hoists, install the Stop Ring on the second link from the load end of the Chain, or so a load does not hit

6.
the Chain Container, and then attach the Hook Block Assembly.
On double line Hoists, reeve the load end of the new Chain around the Pocket Wheel in the Sheave Block Assembly,

7.
making certain the Chain is not twisted between the Hoist and Sheave Block.
Keeping the load end of the Chain straight, attach the end link to the Chain Anchor.

8.

9.

Lubricate the Chain as instructed in the section CHAIN LUBRICATION.
Run the hook up and down several times under power with no load to make certain the Chain is running smoothly over

10.
the Pocket Wheel. There must be no apparent binding or evidence of malfunctioning.

I0