Ingersoll-Rand VL2-030, VL2-005, VL2-010, VL2-015, VL2-150 User Manual
...
Form MHD56012
PARTS, OPERATION AND MAINTENANCE MANUAL
for
MANUAL CHAIN HOIST MODELS
VL2-005 VL2-010 VL2-015 VL2-020 VL2-030
1/2 ton 1 ton 1-1/2 ton 2 ton 3 ton
VL2-050 VL2-080 VL2-100 VL2-150 VL2-200
5 ton 8 ton 10 ton 15 ton 20 ton
Including S•COR•E (Spark and Corrosion Resistant) Features
Unless otherwise noted, tons in this manual are metric tons (2,200 lbs.)
(Dwg. MHP0037)
1/2, 1, 1-1/2 and 2 ton
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
installation, operation and maintenance of these products.
Do not use this hoist for lifting, supporting, or transporting people or lifting or
supporting loads over people.
Always operate, inspect and maintain this hoist in accordance with American National
Standards Institute Safety Code (ASME B30.16) and any other applicable safety codes
and regulations.
Form MHD56012
Edition 8
July 2004
71116107
© 2004 Ingersoll-Rand Company
(Dwg. MHP0038)
3 and 5 ton
(Dwg. MHP0039)
15 ton
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.
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 a 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.
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.
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.
Safety Summary
• Do not use this hoist for lifting, supporting, or transporting
people or lifting or supporting loads over people.
• Hoists are designed to provide a 4 to 1 safety factor.
Supporting structures and load-attaching devices used in
conjunction with this hoist must provide an adequate safety
factor to handle the rated load, plus the weight of the hoist and
attached equipment. This is the customer’s responsibility. If in
doubt, consult a registered structural engineer.
Ingersoll-Rand hoists are manufactured in accordance with the
latest ASME B30.16 standards.
2 MHD56012 - Edition 8
WARNING TAG
Each hoist is supplied from the factory with the warning tag
shown. If 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.
SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions have been
adapted in part from American National Standard ASME B30.16
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 plants. 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 dangerous practices to avoid and are not necessarily
limited to the following list. Refer to specific sections in the
manual for additional safety information.
1. Only allow personnel trained in safety and operation to
operate hoist.
2. Only operate a hoist if you are physically fit to do so.
3. When a “DO NOT OPERATE” sign is placed on hoist, do
not operate hoist until sign has been removed by designated
personnel.
4. Before each shift, the operator should inspect hoist for wear
or damage.
5. Never use a hoist which inspection indicates is worn or
damaged.
6. Periodically, inspect hoist thoroughly and replace worn or
damaged parts. Refer to “INSPECTION” section.
7. Lubricate hoist regularly. Refer to “LUBRICATION”
section.
8. Do not use hoist if hook latch has been sprung or broken.
9. Check that 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 rated capacity of hoist.
Refer to “SPECIFICATIONS” section.
12. Never use the hoist chain as a sling.
13. Never operate a hoist when load is not centered under top
hook. Do not “side pull” or “yard.”
14. Never operate a hoist with twisted, kinked, “capsized” or
damaged load chain.
15. Do not force a chain or hook into place by hammering.
16. Never insert point of hook into a chain link.
17. Be certain load is properly seated in saddle of hook, and hook
latch is engaged.
18. Do not support load on tip of hook.
19. Never run load chain over a sharp edge. Use a sheave.
20. 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.
21. Pay attention to the load at all times when operating hoist.
22. Always ensure that you, and all other people, are clear of load
path. Do not lift a load over people.
23. Never use hoist for lifting or lowering people, and never
allow anyone to stand on a suspended load.
24. Ease slack out of chain and sling when starting a lift. Do not
jerk load.
25. Do not swing a suspended load.
26. Do not leave a load suspended when hoist is unattended or
not in use.
27. Never weld or cut a load suspended by the hoist.
28. Never use hoist chain as a welding electrode.
29. Do not operate hoist if chain jumping, excessive noise,
jamming, overloading or binding occurs.
30. Keep load from hitting load chain.
31. Only operate the hoist with manual power.
32. After use, or when in a non-operational mode, hoist should be
secured against unauthorized and unwarranted use.
MHD56012 - Edition 8 3
SPECIFICATIONS
General
The VL2 Manual Chain Hoist 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
effort.
To determine your hoist configuration refer to the capacity and
serial number nameplate for serial and model number information.
Model Code Explanation
Model Code Example: VL2-050-10-8V VL2 - 050 - 10 - 8 V
Series
Hoist Capacity
S•COR•E
Lift
Hand Chain Drop
Options
Series
VL2 = 005, 010,
Model No.
VL2-005 1/2 55
VL2-010 1 73
VL2-015 1-1/2 74
VL2-020 2
VL2-030 3 7.1 x 21.2 112
VL2-050 5 85
VL2-080 8
VL2-100 10 362
VL2-150 15
VL2-200 20 2 x 362
* One metric ton equals 2200 lbs.
Hoist
Capacity
015, 020,
030, 050,
080, 100,
150 and 200
Rated
Capacity
metric
tons*
S•COR•E
- = Standard
CP = Copper Plated
SB = Solid Bronze
Pull to lift rated load Load
lb
76 34.5
90 40.9
2 x 90 2 x 41
(Hoist load chain/hook
10 = Hook travel, 10
XX = Specify length
kg ft mlbkg
25.0 5.0 x 15 25 7.6
33.2 6.3 x 19.2 28 8.5 36 16.4
33.6 7.1 x 21.2 57 17.4 45 20.4
38.6
Lift:
travel)
std, 15 and 20 ft.
Hand Chain O’Hauled
Chain size
(mm)
8.0 x 24.2 73
9.0 x 27.2
to lift load 1 ft (0.3 m) No. of
2 x 272
181 55.2 94 42.6
272
Hand Chain Drop:
(Hand chain is 2 ft. (0.6 m)
less than lift)
8 = Lift 10 ft. chain drop
8 ft. (standard)
13 = Lift 15 ft. chain drop
13 ft.
18 = Lift 20 ft. chain drop
18 ft.
XX = Specify drop
chain falls
1
22.3 50 22.7
34.1
82.9 3 150 68.2
110.3 4 188 85.5
2 x 82.9 6 395 179.5
2 x 110 8 485 220.4
2
Options
V = Overload Clutch
(standard)
H = Zinc Plated hand chain
S•COR•E
N = Nickel plated load
chain S•COR•E
Z = Sand blast/carbozinc
P=Marine Grade
corrosion preventative
finish
S = Chain Container
(fabric)
-E = Meets European
Machinery Directives
H o i st N e t We i g h t
(std. 10 ft. lift)
20 9.0
52 23.6
4 MHD56012 - Edition 8
INSTALLATION
Prior to installing 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.
• Depending on model selected, hoist may weigh up to 485 lbs.
(220 kg). If parts of the hoist are dropped, they can cause
injury, death or property damage. Adequately support hoist
during installation.
• Owners and users are advised to examine specific, local or
other regulations, including ASME standards and/or OSHA
Regulations which may apply to a particular type of use of this
product before installing or putting hoist to use.
The VL2 manual chain hoist must be used in a vertical position to
provide a straight line pull from top 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 hoist body and hand
chain from being obstructed.
Initial Operating Checks
Operate hoist with a test load (10% of rated capacity) by raising
and lowering this load several times. Verify brake operation with
this light load prior to applying heavier loads.
Familiarize operators and personnel responsible for hoist
installation and service with ASME B30.16 specifications and this
manual prior to placing unit into service. All requirements of this
specification, including testing should be met before approving
hoist for operation.
(Dwg. MHP0436)
Installing Chain Container
Refer to Dwg. MHP0321 on page 19. Position chain container to
ensure minimum contact with handchain. On larger CC-8 and CC9 style chain containers which use S-Hooks to support chain
container, ensure hook ends are bent closed.
• Each time a load is lifted, the operation of the brake should
be checked by raising load slightly and stopping to ensure
brake will hold load before continuing to lift.
OPERATION
The four most important aspects of hoist operation are:
1. Follow all safety instructions when operating 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 the hoist capacity and weight of load at all times.
• Hoist is not designed or suitable for lifting, lowering or
moving persons. Never lift loads over people.
Hoist Operation
When facing hand chain side of hoist:
Pull down on right hand chain (clockwise) to raise load.
Pull down on left hand chain (counterclockwise) to lower load.
On 15 and 20 ton hoists, use two operators, one on each of the two
hand chains. To keep the load chain centered in the block
assemblies, operate hoist units simultaneously and at the same
speed. An equal amount of unloaded chain must be maintained
under each hoist body.
• Do not allow load chain, on 15 and 20 ton hoists, to
accumulate on one side (under one hoist body). Excessive
loading to load chain anchor may occur resulting in a falling
load which can cause death, injury or property damage.
MHD56012 - Edition 8 5
Storing the Hoist
• The clicking sound of the pawl on the ratchet gear is normal
when a load is being raised.
INSPECTION
• All new, altered or modified equipment should be inspected
and tested by personnel trained in safety, operation and
maintenance of this equipment to ensure safe operation at
rated specifications before placing equipment in service.
Frequent and periodic inspections should be performed on
equipment in regular service. Frequent inspections are visual
examinations performed by operators or service personnel and
include observations made during routine equipment operation.
Periodic inspections are thorough inspections conducted by
personnel trained in the safety, operation and maintenance of this
equipment. ASME B30.16 states inspection intervals depend upon
the nature of the critical components of the equipment and severity
of usage.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages, allowing
corrective action to be taken before the condition becomes
dangerous.
Deficiencies revealed through inspection, or noted during
operation, must be reported to designated personnel trained in
safety, operation and maintenance of this equipment. A
determination as to whether a condition constitutes a safety hazard
must be decided, and the correction of noted safety hazards
accomplished and documented by written report before placing
the equipment in service.
Records and Reports
Inspection records, listing all points requiring periodic inspection
should be maintained for all load bearing equipment. Written
reports, based on severity of service, should be made on the
condition of critical parts as a method of documenting periodic
inspections. These reports should be dated, signed by the person
who performed the inspection, and kept on file where they are
readily available for review.
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 Service in “INSPECTION” section.
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
The Manual Chain Hoist 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 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, replace the chain. Do not operate the hoist until all
problems have been corrected. Check that hand chain moves
freely and without binding or excessive drag. Hook should
stop moving when hand chain stops moving.
2. HOOKS. Check for wear or damage, increased throat width,
bent shank or twisting of hook. Replace hooks that exceed
the throat opening discard width (15%) shown in Table 1
refer to Dwg. MHP0040 on page 6, or exceed a 10º twist
refer to Dwg. MHP0111 on page 7. If hook latch snaps past
tip of hook, hook is sprung and must be replaced. Check hook
support bearings for lubrication and damage. Check hooks
swivel easily and smoothly. Repair or lubricate as necessary.
• The external placement of coded marks on equipment
identifying completed inspections and operationally certified
equipment is an acceptable method of documenting periodic
inspections in place of written records.
6 MHD56012 - Edition 8
(Dwg. MHP0040)
Table 1: Hook Throat Dimension
Model No.
VL2-005 1.22
VL2-010 1.33
VL2-015 1.5
VL2-020 1.61
VL2-030 1.85
VL2-050 2.01
VL2-080
VL2-100
VL2-150
VL2-200
Throat Width Discard Width
in.
2.8 71 3.21 81.6
3.54
mm in. mm
31 1.4 35.6
34 1.54 39.1
38 1.72 43.7
41 1.86 47.2
47 2.12 54
51 2.31 58.6
90 4.07 103.5
• 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 load sheave. Inspect
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. 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:
3. HOOK LATCHES. Check operation of hook latches. Replace
if broken or missing.
4. CHAIN. Refer to Dwg. MHP0102 on page 7. 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” section.
(Dwg. MHP0111)
(Dwg. MHP0102)
NORMAL HEAVY SEVERE
yearly semiannually quarterly
Disassembly may be required for HEAVY or SEVERE usage.
Keep accumulative records of periodic inspections to provide a
basis for continuing evaluation. Inspect all items in “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, disassemble. Check gears, shafts, bearings, sheaves,
chain guides, springs and covers. Replace worn or damaged
parts. Clean, lubricate and reassemble.
3. HOOKS. Inspect hooks for cracks. Use magnetic particle or
dye penetrant to check for cracks. Inspect hook retaining
parts. Tighten, repair or replace if necessary. Refer to the
latest edition of ASME B30.10 (Hooks) for additional hook
inspection information.
4. CHAIN SHEAVES. Check for excessive wear or damage.
Replace if necessary.
5. BRAKES. Ensure proper operation. Brake must hold hoist
rated capacity. If load test indicates the need, disassemble.
Brake discs must be free of excess oil, any grease, unglazed,
uniform in thickness and at least 5/64 in. (2 mm) thick. Check
all other brake surfaces for wear, deformation or foreign
deposits. Inspect pawl brake. Teeth of ratchet gear should be
undamaged, and should stop gear rotation in the
counterclockwise direction. Check pawl spring for damage.
Clean and replace components as necessary.
6. SUPPORTING STRUCTURE. If a permanent structure is
used, inspect for continued ability to support load.
7. LABELS AND TAGS. Check for presence and legibility.
Replace if necessary.
8. END ANCHOR. Ensure end anchor on chain hoist is
engaged and unbent. Repair if damaged, replace if missing.
Refer to “Attaching End of Load Chain” in
“MAINTENANCE” section.
9. LOAD CHAIN. Measure chain for stretching by measuring
across five link sections all along chain. Refer to Dwg.
MHP0041on page 8 and Table 2. When any five links in the
working length reach or exceed discard length shown in
Table 2, replace entire chain. Always use a genuine
Ingersoll-Rand replacement chain.
MHD56012 - Edition 8 7
(Dwg. MHP0041)
Table 2: Load Chain Length Inspection
Model
No.
VL2-005 LCCF005
VL2-010 LCCF010
VL2-015 LCCF015
VL2-020 LCCV020
VL2-030 LCCF015
VL2-050
VL2-080
VL2-100
VL2-150
VL2-200
Note: Nickel Plated load chain for the VL2 is designated by “ND”
at the end of the part number.
Part No.
LCCF025 9.0 x 27.2 5.35 136.0 5.47 139.0
Chain
Size
mm in. mm in. mm
5.0 x 15 2.95 75.0 3.03 77.0
6.3 x 19.2 3.76 95.5 3.85 97.9
7.1 x 21.2 4.17 106.0 4.28 108.7
8.0 x 24.2 4.72 120.0 4.84 123.0
7.1 x 21.2 4.17 106.0 4.28 108.7
Normal
Length
Discard
Length
Hoists not in Regular Service
1. A hoist that has been idle for a period of one month or more,
but less than one year should be given an inspection
conforming with requirements of “Frequent Inspection”
before being placed in service.
2. A hoist that has been idle for a period of more than one year
should be given a complete inspection conforming with
requirements of “Periodic Inspection” before being placed in
service.
3. Standby hoists should be inspected at least semiannually in
accordance with requirements of “Frequent Inspection.” In
abnormal operating conditions equipment should be
inspected at shorter intervals.
TROUBLESHOOTING
This section provides basic troubleshooting information. Specific causes to problems are best identified by thorough inspections performed
by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common hoist
symptoms, probable causes and remedies.
Symptom Cause Remedy
Hoist will not lift load. Hoist is overloaded. Reduce load to within hoist rated capacity.
Hoist will not hold load. Brake may be slipping. Inspect brake. Replace brake discs or repair brake as described in
the “MAINTENANCE” section.
Hoist is overloaded. Reduce load to within hoist rated capacity.
Load Chain Binds. Damaged load chain, pinion shaft, gears or
sheaves.
Load chain not installed properly (twisted,
kinked or “capsized”).
Hand Chain Binds. Damaged hand chain, hand chain wheel,
pinion shaft, gears, load chain, sheaves.
Hand chain not installed properly (twisted or
kinked).
Load Hook Latch does
not work.
Latch broken. Replace hook latch.
Load hook bent or twisted. Inspect load hook as described in “INSPECTION” section.
Disassemble hoist, inspect and repair or replace damaged
components.
Remove load chain and re-install.
Disassemble hoist, inspect and repair or replace damaged
components.
Remove load chain and re-install.
Replace if necessary.
LUBRICATION
General
Thread lubricant or an anti-seize compound use is recommended
for threaded shafts, capscrews and nuts. Unless otherwise stated,
remove old lubricant, clean part with an acid free solvent and
apply a new coating of lubricant to part before assembly.
8 MHD56012 - Edition 8
Gears (11 and 14)
Remove U-nuts (40), on opposite side of hoist as the hand chain,
and remove gear cover (17) and support plate (16). Remove old
grease and replace with new. For temperatures -20° to 50° F (-29°
to 10° C) use EP 1 grease or equivalent. For temperatures 30° to
120° F (-1° to 49° C) use EP 2 grease or equivalent.
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