Ingersoll-Rand SMB015, SMB030, SMB005, SMB020, SMB010 User Manual

...

Form MHD56391

PARTS, OPERATION AND MAINTENANCE MANUAL

for

MANUAL CHAIN HOIST MODELS

SMB005 SMB010 SMB015 SMB020

1/2 ton 1 ton 1-1/2 ton 2 ton

SMB030 SMB050

3 ton 5 ton

(Dwg. MHP0831)

Unless otherwise noted, tons in

this manual are metric tons.

1 metric ton = 2,200 lb.

READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual contains important safety, installation, operation and maintenance information. Make this manual available to all persons responsible for the operation, installation and maintenance of these products.

WARNING

Do not use this hoist for lifting, supporting, or transporting people or lifting or supporting loads over people.

Always operate, inspect and maintain this hoist in accordance with American Society of Mechanical Engineers Safety Code (ASME B30.16) and any other applicable safety codes and regulations.

Refer all communications to the nearest Ingersoll Rand Office or Distributor.

Form MHD56391 Edition 2 October 2008 45518578

SAFETY INFORMATION

This manual provides important information for all personnel involved with the safe installation, operation and proper maintenance of this product. Even if you feel you are familiar with this or similar equipment, you should read this manual before operating the product.

Danger, Warning, Caution and Notice

Throughout this manual there are steps and procedures which, if not followed, may result in a hazard. The following signal words are used to identify the level of potential hazard.

DANGER

WARNING

CAUTION

NOTICE

The words shall and should are used throughout this manual in accordance withdefinitions in the ASME B30 standards as follows:

Shall - this word indicates that the requirement is mandatory and

must be followed.

Should - this word indicates that the requirement is a

recommendation. The advisability of the recommendation depends on the facts in each situation.

Also used in this manual and other manuals are the following words with definitions: Owners/users - these words also refer to winch operators.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which if not avoided, could result in death or serious injury.

Indicates potentially hazardous situation which if not avoided, may result in minor or moderate injury or property damage.

Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property.

Signal-person - person who observes load and relays directions to winch operator. Operation Manuals - documentation that is provided with the winch that contains installation, parts information, maintenance, lubrication and related service instructions.

Safety Summary

WARNING

• Do not use this hoist for lifting, supporting, or transporting people or lifting or supporting loads over people.

The National Safety Council, Accident Prevention Manual for Industrial Operations, Eighth Edition and other recognized safety sources make a common point: Employees who work near cranes or assist in hooking on or arranging a load should be instructed to keep out from under the load. From a safety standpoint, one factor is paramount: conduct all lifting operations in such a manner that if there were an equipment failure, no personnel would be injured. This means keep out from under a raised load and keep out of the line of force of any load.

Ingersoll Rand hoists are manufactured in accordance with the latest ASME B30.16 standards.

The Occupational Safety and Health Act of 1970, generally places the burden of compliance with the user, not the manufacturer. Many OSHA requirements are not concerned or connected with the manufactured product but are, rather, connected with the final installation. It is the owner's and user's responsibility to determine the suitability of a product for any particular use. It is recommended that all applicable industry, trade association, federal, state and local regulations be checked. Read all operating instructions and warnings before operation.

Rigging: It is the responsibility of the operator to exercise caution, use common sense and be familiar with proper rigging techniques. Refer to ASME B30.9 for rigging information, American Society of Mechanical Engineers, Three Park Avenue, New York, NY

10016.

SAFE OPERATING INSTRUCTIONS

The following warnings and operating instructions have been adapted in part from American Society of Mechanical Engineers ASME B30.16 (Overhead Hoists) and are intended to avoid unsafe operating practices which might lead to injury or property damage.

Ingersoll Rand recognizes that most companies who use hoists have a safety program in force in their facilities. In the event that some conflict exists between a rule set forth in this publication and a similar rule already set by an individual company, the more stringent of the two should take precedence.

Safe Operating Instructions are provided to make an operator aware of unsafe practices to avoid and are not necessarily limited to the following list. Refer to specific sections in the manual for additional safety information.

1. Only allow people, trained in safety and operation of this product, to operate the hoist.

2 MHD56391 - Edition 2

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, do not operate the hoist until the sign has been removed by designated personnel.

4. Before each shift, the operator should inspect the hoist for wear or damage.

5. Never use a hoist which inspection indicates is worn or damaged.

6. Periodically, inspect the hoist thoroughly and replace worn or damaged parts. Refer to the “INSPECTION” section on page

7. Lubricate the hoist regularly. Refer to the “LUBRICATION” section on page 7.

8. Do not use hoist if hook latch has been sprung or broken.

9. Check that the hook latches are engaged before using.

10. Never splice a hoist chain by inserting a bolt between links.

11. Only lift loads less than or equal to the rated capacity of the hoist. Refer to the “SPECIFICATIONS” section on page 3.

12. 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.

13. Never place your hand inside the throat area of a hook.

14. Never use the hoist load chain as a sling.

15. Never operate a hoist when the load is not centered under the hook. Do not “side pull” 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.

WARNING TAG

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 weld or cut on 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. Only operate the hoist with manual power.

31. After use, or when in a non-operational mode, the chain hoist should be secured against unauthorized and unwarranted use.

32. Do not leave a load suspended when the hoist is unattended or not in use.

Each hoist is supplied from the factory with a multi-language warning tag. If the tag is not attached to your unit, order a new tag and install it. Refer to the parts list for the part number. Read and obey all warnings and other safety information attached to this hoist. Tag may be shown smaller than actual size.

SPECIFICATIONS

General

Manual Chain Hoists can be mounted to the suspension shaft of a trolley or a permanent mounting structure. The hoist is designed to lift and lower loads up to rated capacity with minimal hand chain effort.

WARNING

Failure to follow these warnings may result in death, severe injury or property damage:

• Read manual before using this product.

• Do not lift, lower or pull more than rated load.

• Do not lift people or loads over people.

• Do not operate with twisted or damaged chain or kinked, frayed or cut rope or strap.

• Do not operate lever hoist or puller with handle extension (cheaters).

• Do not operate if damaged or malfunctioning.

• Do not operate when chain, rope or strap cannot form straight line with load.

• Do not operate with other than manual power.

• Do not operate with open latch, twisted hook or without a latch.

• Always keep minimum of 3 wraps of wire rope or 2 wraps of strap on drum.

• Do not remove or obscure warning labels.

Model Code Explanation

Example: SMB - 005 - 10 - 8 V

Series

To determine your basic hoist configuration, refer to capacity and

Capacity

lot number label located on gear end cover for model number information.

Lift

Hand Chain

Slip Clutch

MHD56391 - Edition 2 3

Series

SMB= Silver Series

Manual Chain Hoist

General Specifications

Model No.

SMB005 1/2 55.5

SMB010 1 64

SMB015 1-1/2 69

SMB020 2 77

SMB030 3 100

SMB050 5 83.5

* One metric ton = 2,200 lbs.

Capacity

005 = 1/2 metric ton / 500 kg 010 = 1 metric ton / 1,000 kg 015 = 1-1/2 metric ton /

1,500 kg 020 = 2 metric ton / 2,000 kg 030 = 3 metric ton / 3,000 kg 050 = 5 metric ton / 5,000 kg

Rated

(metric

tons)*

Pull to Lift Rated Load

Hoist

Capacity

Lift

(Hoist load chain/

hook travel)

10 = 10 ft (3 m)

(standard) 15 = 15 ft (5 m) 20 = 20 ft (6 m) XX = Specify length F = Hoist without

load chain

Load

Chain Size

kg ft mlbkg

25 5 x 15 31.5 9.6

29 6 x 18 53.1 16 26.8 12.2

31 7 x 21 71.6 22 38.5 17.5

35 8 x 24 84.6 26

45 10 x 30 99.4 30 70.4 32

38 9 x 27 213.2 65 2 90.2 41

(mm)

Overhauled to Lift

Load 1 ft (0.3 m)

8 = 8 feet (standard)

13 = 13 feet

18 = 18 feet

XX = Specify length

Hand Chain

(Hand chain is 2 ft

less than lift)

(10 foot lift minus 2 ft)

(15 foot lift minus 2 ft)

(20 foot lift minus 2 ft)

No. of Chain

Falls

Slip

Clutch

V = Slip Clutch

(standard)

Hoist Net Weight with

Standard 10 ft (3 m)

Lift

23.5 10.7

42.4 19.3

INSTALLATION

Prior to installing the hoist, carefully inspect it for possible shipping damage.

Hoists are supplied fully lubricated from the factory. Lubrication of the load chain is recommended before initial hoist operation.

(Dwg. MHP0832)

WARNING

• A falling load can cause injury or death. Before installing, read “SAFETY INFORMATION”.

CAUTION

• Owners and users are advised to examine specific, local or other regulations, including American Society of Mechanical Engineers and/or OSHA Regulations which may apply to a particular type of use of this product, before installing or putting hoist to use.

Hoists are designed to provide a 4:1 safety factor. The supporting structures and load-attaching 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. If in doubt, consult a registered structural engineer.

The SMB manual chain hoist must be used in a vertical position to provide a straight line pull from top hook to bottom hook. The hoist must be positioned so that it does not contact the support members when in use. When operating in limited areas suitable lifting attachments or slings must be used to prevent the hoist body and hand chain from being obstructed.

4 MHD56391 - Edition 2

Initial Operating Checks

NOTICE

CAUTION

• Ensure the hoist top hook is properly installed on the support member and the hook latch is engaged.

Operate the hoist with a test load (10% of rated capacity) by raising and lowering this load several times. Verify the brake operation by lowering the same load to check load does not slip when lowering stops.

OPERATION

The four most important aspects of hoist operation are:

1. Follow all safety instructions when operating the hoist.

2. Allow only personnel trained in safety and operation of this hoist to operate hoist.

3. Subject each hoist to a regular inspection and maintenance procedure.

4. Be aware of hoist capacity and weight of load at all times.

WARNING

• Hoist is not designed or suitable for lifting, lowering or

moving persons. Never lift loads over people.

Hoist Operation

• Each time a load is lifted, the operation of the load brake should be checked by raising the load slightly and stopping to ensure the brake will hold the load before proceeding to lift the load.

Familiarize operators and people responsible for hoist installation and service with ASME B30.16 specifications prior to placing the unit into service. All the requirements of this specification, including testing should be met before approving the hoist for operation.

NOTICE

• The clicking sound of the pawl on the ratchet gear is normal when a load is being raised.

Slip Clutch Operation

Hoists are equipped with a slip clutch. When trying to lift a load that exceeds capacity of hoist the hand chain will rotate in the hoist body but the load will not be lifted.

It is important to keep the slip clutch properly adjusted. Refer to the “MAINTENANCE” section on page 8 for the proper procedure.

When facing hand chain side of hoist:

1. Pull down on the right hand chain (clockwise) to raise load.

2. Pull down on the left hand chain (counterclockwise) to lower load.

INSPECTION

WARNING

• All new, altered or modified hoists should be inspected and

tested by personnel trained in safety, operation and maintenance of this hoist to ensure safe operation at rated specifications before placing hoist in service.

Frequent and periodic inspections should be performed on hoists in regular service. Frequent inspections are visual examinations performed by operators or service personnel and include observations made during routine hoist operation. Periodic inspections are thorough inspections conducted by personnel trained in the safety, operation and maintenance of this hoist. ASME B30.16 states inspection intervals depend upon the nature of the critical components of the hoist and the severity of usage.

Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the early stages, allowing

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 pins.

4. Hang in a dry place.

5. Before returning hoist to service follow instructions for “Hoists Not in Regular Use” in the “INSPECTION” section on page 5.

corrective action to be taken before the condition becomes dangerous.

Deficiencies revealed through inspection, or noted during operation, must be reported to designated personnel trained in safety, operation and maintenance of this hoist. A determination as to whether a condition constitutes a safety hazard must be decided, and the correction of noted safety hazards accomplished and documented by written report before placing the hoist in service.

Records and Reports

Inspection records, listing all points requiring periodic inspection should be maintained for all load bearing equipment. Written reports, based on severity of service, should be made on the condition of critical parts as a method of documenting periodic inspections. These reports should be dated, signed by the person who performed the inspection, and kept on file where they are readily available for review.

MHD56391 - Edition 2 5

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

Manual Chain Hoists should be inspected at the beginning of each shift. Visual inspections should also be conducted during regular service for any damage or evidence of malfunction which appears between regular inspections.

1. Operation. Check for visual signs or abnormal noises which could indicate a potential problem. Do not operate a hoist unless the load chain feeds through the hoist and hook block smoothly. Listen for “clicking”, binding or malfunctioning. The clicking sound of the pawl on the ratchet gear is normal when a load is being raised. If chain binds, jumps, or is excessively noisy, clean and lubricate the chain. If problem persists, the chain and load sheave may have to be replaced. Do not operate the hoist until all problems have been corrected. Check that hand chain moves freely without binding or excessive drag. Load chain travel should stop when hand chain stops moving.

2. Hooks. Check for wear or damage, increased throat width, bent shank or twisting of hook. Replace hooks which exceed the throat opening discard width (15%) shown in Table 1 (refer to Dwg. MHP0040 on page 6) or exceed a 10° twist (refer to Dwg. MHP0111 on page 6). If the hook latch snaps past the tip of the hook, the hook is sprung and must be replaced. Check hooks swivel easily and smoothly. Repair or lubricate as necessary.

Table 1: Hook Throat Opening

Model No.

SMB005 0.94

SMB010 1.00

SMB015

SMB020

SMB030 1.50 39 1.76 44.8

SMB050 1.89

3. Hook Latches. Check operation of the hook latches. Replace if broken or missing.

4. Chain. Refer to Dwg. MHP0102 on page 6. Examine each link for bending, cracks in weld areas or shoulders, transverse nicks and gouges, weld splatter, corrosion pits, striation (minute parallel lines) and chain wear, including bearing surfaces between chain links. Replace a chain that fails any of the inspections. Check lubrication and lubricate if necessary. Refer to “Load Chain” in “LUBRICATION”

on page 7.

section

Normal Discard

1.10 33 1.50 38

mm in mm

24 1.09 27.6

26 1.18 30

48 2.17 55.2

(Dwg. MHP0111)

(Dwg. MHP0040)

(Dwg. MHP0102)

CAUTION

• The full extent of chain wear cannot be determined by visual

inspection. At any indication of chain wear, inspect chain and load sheave in accordance with instructions in “Periodic Inspection.”

• A worn load chain may cause damage to the load sheave.

Inspect the load sheave and replace if damaged or worn.

5. Load Chain Reeving. Refer to Dwg. MHP0042 on page 9. Make sure welds on standing links are away from load sheave. Reinstall chain if necessary. Check that the last link of the load chain is securely connected. On 2, 3 and 5 ton hoists, make sure chain is not capsized, twisted or kinked. Adjust as required.

Periodic Inspection

According to ASME B30.16, frequency of periodic inspection depends on the severity of usage:

NORMAL HEAVY SEVERE

yearly semiannually quarterly

Disassembly may be required for HEAVY or SEVERE usage. Keep accumulative written records of periodic inspections to provide a basis for continuing evaluation. Inspect all items in “Frequent Inspection”. Also inspect the following:

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