Ingersoll-Rand Hercu-Link BHS Series Product information

Ingersoll-Rand
Brand
Ingersoll-Rand
Model
Hercu-Link BHS Series
Type
Product information

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Edition A
May 2018
CCN 47638924
Hercu-Link™ Air B.O.P.
Handling Systems
Models
BHS 50 (50 Metric Tons)
BHS 75 (75 Metric Tons)
BHS 100 (100 Metric Tons)
BHS 150 (150 Metric Tons)
yProduct Information
2
Only allow Ingersoll Rand trained technicians to
perform maintenance on this product. For additional
information contact Ingersoll Rand factory or nearest
Distributor.
For additional supporting documentation refer to
Table 1, p. 2.
Manuals can be downloaded from www.irmhdocs.
skysite.com
The use of other than genuine Ingersoll Rand
replacement parts may result in safety hazards,
decreased performance and increased maintenance
and will invalidate all warranties.
Original instructions are in English. Other languages
are a translation of the original instructions.
Refer all communications to the nearest Ingersoll Rand
Office or Distributor.
Table 1. Product Information Manuals
Publication Part/Document Number (CCN)
Product Safety Information Manual MHD56295 (71441281)
3
Table of Contents
Product Description . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Line Lubricator . . . . . . . . . . . . . . . . . . . . 7
Air Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Pressure Regulator . . . . . . . . . . . . . . . . 7
Moisture in Air Lines . . . . . . . . . . . . . . . . . . 7
Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shut Off Valve . . . . . . . . . . . . . . . . . . . . . . . . 7
Hoist and Trolley Motors . . . . . . . . . . . . . . 8
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing Trolley Over End of Beam . . . . . . . . 8
Installing Trolley from Underneath
Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rack Drive (optional feature). . . . . . . . . . . . . . . 8
Pre-Installation Checks . . . . . . . . . . . . . . . . 8
Installing Rack Segments Onto
Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chain Container . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Attaching Limit Stop . . . . . . . . . . . . . . . . . . 9
Accu-Trol® Pendant . . . . . . . . . . . . . . . . . . . . . . 9
Initial Operating Checks . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hoist Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accu-Trol® Pendant Operation (Push
Button Type). . . . . . . . . . . . . . . . . . . . . . . . . 10
Emergency Stop . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . 11
Daily Inspection. . . . . . . . . . . . . . . . . . . . . . 11
Load Chain Reports . . . . . . . . . . . . . . . . . . . . . . 12
Hoists Not in Regular Use . . . . . . . . . . . . . . . . 12
Storing the Hoist . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pivot Points and Bushings . . . . . . . . . . . . . . . . 13
Hoist Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Piston Trolley Drive Motor. . . . . . . . . . . . . . . . 13
Bottom Hook Block Assembly . . . . . . . . . . . . 13
Load Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Trolley Drive Assembly . . . . . . . . . . . . . . . . . . 14
Reduction Gear Assembly . . . . . . . . . . . . . . . . 14
Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Seals and Bearings . . . . . . . . . . . . . . . . . . . . . . 14
Product Information Graphics . . . . . . . . . . . . . 15
Hercu-Link™ and B.O.P. Hoist
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . 19
4
Product Description
The Hercu-Link™ air-powered hoist consists primarily
of a power head assembly that acts as control for lower
hook block movement. The power head assembly is
made up of three main sections: gear reducer section,
brake/motor section and sheave section.
The output shaft from piston motor is connected to
brake shaft. The brake shaft is connected to drive shaft
by way of a coupling that passes through center of
brake and sheave section and acts as sun gear for first
stage planetary reducer. The gear reducer section
consists of three planetary assemblies with each
planetary assembly being driven by sun gear from
previous planetary assembly. Output from planetary
reduction section is transmitted directly to load chain
sheave(s).
The motor-driven brake shaft is connected to brake
through a sprag clutch. In hoist “UP” direction, clutch
allows shaft to rotate without releasing brake. No air
pressure is applied to brake piston in “UP” direction.
The brake shaft cannot rotate in hoist “DOWN”
direction until brake has been released. Brake is
released by air pressure applied to annular brake
piston and piston compresses brake springs, releasing
brake discs. There are four sintered, bronze-type brake
friction discs and five stationary brake discs.
The brake piston is actuated by air from main control
valve. When control pendant “DOWN” button is
pushed, it moves main control valve spool. The spool is
designed to send air to brake in “DOWN” direction
only. When pendant “DOWN” button is released,
exhaust valves allow brake to set quickly and avoid
downward load drift.
Contact your Ingersoll Rand authorized service
provider for any parts/service/ inspection/support
related needs.
5
Model Driver
Standard equipment includes the following:
Hercu-Link
TM
Air B.O.P. Handling Systems
Piston Motor Drive - 50 to 150 metric ton Capacity
Piston motor driven hoist and trolley
Marine 812 paint system
30 feet of lift
Corrosion resistant load chain
Accu-Trol® pendant with on-off buttons
30 feet of pendant control drop
Upper and lower limit switch
Galvanized steel chain container
Trolley rail sweeps with bumpers
Trolley guide rollers
Air preparation package (filter and lubricator)
Mufflers
50 110000 2 x 25 tons=
=
75 165000 2 x 37.5 tons=
100 220000
standard
2” extension
2 x 50 tons=
150 330000 2 x 75 tons=
Lifting Lugs
All non-oil bath bearings are regreasable
BHS50MA6-30-30-KR
Series
BHS
BHS = Blowout Preventer
Handling System
M
RT
tons lbs # of hoists x cap.
RF
A
=B
Notes:
M1 - Material traceability certificates according to EN 10204 (Ex DIN 50049) 2.2 on load bearing parts. This
conformity document affirms (by the manufacturer) that parts are in compliance with the requirements of the
order based on non-specific inspection and testing (i.e. results are typical material properties for these parts).
M2 - Material traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on load bearing parts. These
documents affirm (by a department independent of the manufacturing department) that the actual parts used in
the product are in compliance with the order based on specific inspection and testing (i.e. results are as-
purchased material propertied for those parts).
M3 - Material traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on load bearing parts. These
documents affirm (by a department independent of the manufacturing department) that the actual parts used in
the product are in compliance with the order based on specific inspection and testing (i.e. results are actual
material properties for those parts in a finished as delivered condition).
2 Mtr. Pendent
(4 button w/on-off)
=6
3 Mtr. Pendent
(6 button w/on-off)
=7
Length of lift
in feet
=XX
Pendent hose
drop and/or hand
chain drop in feet
Clevis (in place of bottom hook)
only used with BHS150
6 falls, 22x66 chain size
=XX
=K
Per DIN 50049/EN10204 Para 2.2 “Typicals”=
M1
ABS witness test=W1
DNV witness test=W2
Customer witness test=W4
Compliance with European Machinery Directive=-CE
Per DIN 50049/EN10204 Para 3.1b actual per product as
purchased
=M2
Per DIN 50049/EN10204 Para 3.1b actual per product as
delivered in final condition
=M3
American Bureau of Shipping “Certification of Drilling
Systems”
=N4
Copper plated (S COR E package)
The product will be equipped with copper plated load
hook(s) and trolley wheels
=R1
Det Norske Veritas “DNV-OS-E101 Drilling Plant”=N5
Marine 812-X Paint System=P1
4” extension=C
6” extension=D
= Piston Motor Trolley
= Rack and Pinion Trolley
Drive for Tapered Beam
Flange
= Rack and Pinion Trolley
Drive for Flat Beam
Flange
50 M A 622 30 30
KR1
System
Cap.
Suspension Trolley flange
adjustment
Control Lift
(in feet)
-
-
-
-
Control Drop
(in feet)
Options
PPrroodduucctt DDeessccrriippttiioonn
6
Specifications
Table 2. General Specifications
Hoist Model
Rated
Capacity
metric tons
Load Chain
Falls /
Each Hoist
HP
Air Consumption @
Rated Load
Chain
Size
Standard Lift
scfm
m³/min
mm
ft
m
BHS50 50 2
9.4 280 8 22 30 9
BHS75 75 3
BHS100 100 4
BHS150 150 6
Hoist Model
Speed at 105 psi
(700 kPa / 7 bar)
Speed at 60 psi
(400 kPa / 4 bar)
Lift
Lower
Lift
Lower
fpm
m/min
fpm
m/min
fpm
m/min
fpm
m/min
BHS50 8 2.4 12 3.7 3.4 1.04 4.6 1.4
BHS75 4 1.2 6 1.8 1.7 0.5 2.3 0.7
BHS100 2.5 0.76 3.75 1.1 1.1 0.3 1.5 0.5
BHS150 2 0.61 3 0.9 0.8 0.2 1.1 0.3
Traceability
Load bearing parts are documented to provide
traceability. Documentation includes chemical and
physical properties of raw material, heat treating,
hardening, tensile and charpy tests as required for the
part.
Units with M1, M2 or M3 in the model code have
traceable load bearing components.
M1 – Material Traceability certificates according to EN
10204 (Ex DIN 50049) 2.2 on load bearing parts.
Conformity documents affirm (by the manufacturer)
that parts are in compliance with requirements of the
order, based on non-specific inspection and testing (i.e.
results are typical material properties for these parts).
M2 – Material Traceability certificates according to EN
10204 (Ex DIN 50049) 3.1b on load bearing parts.
Conformity documents affirm (by a department
independent of the manufacturing department) that
actual parts are in compliance with requirements of the
order, based on specific inspection and testing (i.e.
results are actual material properties for these parts).
M3 – Material Traceability certificates according to EN
10204 (Ex DIN 50049) 3.1b on load bearing parts.
Conformity documents affirm (by a department
independent of the manufacturing department) that the
actual parts used in the product are in compliance with
the order, based on specific inspection and testing (i.e.
results are actual material properties for these parts in
a finished, as delivered condition).
7
Installation
Prior to installing the product, carefully inspect it for
possible shipping damage. Products are supplied fully
lubricated from the factory. Check oil levels and adjust
as necessary before operating product. Refer to
“LUBRICATION,” p. 13 section for recommended oils
and lubrication intervals. Lubricate load chain before
operating hoist.
WWAARRNNIINNGG
• Product not installed properly may fall or
cause a load to fall resulting in severe
injury or death. Before installation refer
to Product Safety Manual and all safety
warnings pertaining to this product.
CCAAUUTTIIOONN
• Owners and users are advised to
examine specific, local or other
regulations, including American Society
of Mechanical Engineers (ASME) and/or
OSHA Regulations which may apply to a
particular type of use of this product
before installing or putting product to
use.
Remove cover from shipping crate. Carefully remove
packing straps. Attach wire rope sling to lifting lugs on
trolley side plates and slowly lift into position.
Attach chain container to hoist with chain container
hardware, bolt chain to bracket under trolley
suspension yoke.
Air Supply
The air supply must be clean, free from moisture and
lubricated to ensure optimum motor performance.
Foreign particles, moisture and lack of lubrication are
the primary causes of premature motor wear and
breakdown. Using an air filter, lubricator and moisture
separator will improve overall product performance
and reduce unscheduled downtime. Refer to Figure 4,
p. 16.
Refer to Table 2, p. 6 for motor air consumption and
rated operating pressure. If air supply varies from what
is recommended, product performance be diminished.
A lockable shut off valve and a pressure relief valve set
to 125 psi should be installed in the air supply line.
Air Lines
Inside diameter of air supply lines must not be less
than 1-1/2 inch. Before making final connections, all air
supply lines should be purged with clean, moisture free
air or nitrogen before connecting to main air inlet.
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 lines.
Air Line Lubricator
Always use an air line lubricator with these motors. The
lubricator must have an inlet and outlet at least as large
as inlet on motor manifold.
CCAAUUTTIIOONN
• Lubricator must be located no more than
10 ft. (3 m) from motor.
• Shut off air supply before filling air line
lubricator.
The air line lubricator should be replenished daily and
set to provide 3 to 9 drops. Refer to Table 4, p. 13. A
fine mist will be exhausted from control valve when air
line lubricator is functioning properly.
Air Line Filter
It is recommended that an air line strainer/filter be
installed before the lubricator to prevent dirt from
entering the motor. The strainer/filter should provide
20 micron filtration and include a moisture trap. Clean
the strainer/filter periodically to maintain its operating
efficiency.
NNOOTTIICCEE
• When air filter is used ensure it allows air
to pass through at products rated scfm.
Refer to Table 2, General Specifications.
Air Pressure Regulator
If an air pressure regulator is used, install between
lubricator and filter.
Moisture in Air Lines
Moisture that reaches the air motor through air supply
lines is a primary factor in determining the length of
time between service overhauls. Moisture traps can
help to eliminate moisture. Other methods, such as an
air receiver which collects moisture before it reaches
motor, or an after-cooler at compressor that cools air to
condense and collect moisture prior to distribution
through supply lines, are also helpful.
Mufflers
Ensure mufflers are installed in hoist and trolley and
control valve exhaust port. Check mufflers periodically
to ensure they are functioning correctly.
Shut Off Valve
Refer to the Product Safety Information Manual for
information.
8
Hoist and Trolley Motors
For optimum performance and maximum durability of
parts, provide an air supply to operate hoist and trolley
motors with 105 psi at 280 scfm (700 kPa/7 bar at 8 cu.
m/m).
Note: Contact Technical Support Department for
operating requirements with optional 60 psi (400
kPa/4 bar system).
Mounting
Make certain your hoist is properly installed. A little
extra time and effort in doing so can contribute a lot
toward preventing 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 the
maximum rated load plus a generous factor of at least
500% of the combined weights.
WWAARRNNIINNGG
• Ensure mounting structure is adequate
to hold the hoist and rated load, refer to
Table 2, General Specifications.
Installing Trolley Over End of
Beam
Pre-adjust trolley width for beam flange measurement.
Refer to “Installing from Underneath Beam,” p. 8.
Remove rail stop and slide trolley on end of beam.
Reinstall rail stop. If this procedure cannot be used due
to insufficient space or fixed limit stops the trolley must
be installed from underneath beam using the
procedure which follows.
Installing Trolley from
Underneath Beam
Refer to Figure 3, p. 16 and Figure 5, p. 17.
1. Measure beam flange width ‘Y’ and compare with
measurement between trolley wheel flanges ‘X’.
The correct total clearance (X-Y) between beam and
trolley wheel flanges is 1/16 to 3/16 in. (1.6 to 4.7
mm).
2. To adjust trolley wheel spacing remove eight cotter
pins (173) and four pins (174) at each side plate
(150) or (184). Remove adjusting spacers (156) and
side plates and add or subtract an equal number of
adjusting spacers (156) between suspension yokes
(170) and side plates.
3. When desired trolley wheel spacing measurement
is achieved, install remaining adjusting spacers
(156) on outside of one pair of side plates. Install
suspension yoke pins (174) and cotter pins (173) on
ends of suspension yokes (170) bend ends apart to
secure. Use lifting lugs on trolley side plates to
adequately support hoist and side plates and raise
into place on beam flange.
CCAAUUTTIIOONN
• To avoid an unbalanced load which may
damage trolley, hoist must be centered
under trolley using spacers (156).
4. Using lifting lugs on second pair of trolley side
plates raise into place beneath beam flange. Slide
side plates onto suspension yokes and push side
plates together.
5. Slide extra spacers (156) over free end of
suspension yoke (170). Insert suspension yoke pin
(174) into hole in suspension yoke (170). Secure by
installing cotter pins (173) and bending ends apart.
NNOOTTIICCEE
• Trolley wheels ride on top of lower flange
of beam.
6. The pin (174) and outside spacers (156) must hold
trolley to adjustment in step 1. If side plates can be
spread farther apart, install more outside spacers
(156) between side plate (150) and pin (174).
7. Measure beam flange width ‘Y’ and compare with
measurement between rollers ‘Z’. Side roller
spacing measurement should be 1/16 to 3/16 in. (1.6
to 4.7 mm) greater than beam flange width.
8. Prior to using, test trolley. Check that trolley side
plates are vertical. Raise a load equal to rated
capacity of hoist 6 to 7 in. (130 to 180 mm) off floor
and operate trolley along entire length of beam.
9. Remove connecting plates (159) by removing
capscrews (157) and lockwashers (158) after
installation is complete. Ensure beam stops are
installed.
NNOOTTIICCEE
• Refer to Product Parts Information
Manual for other parts not listed.
Rack Drive (optional feature)
Pre-Installation Checks
Refer to Figure 6, p. 17.
Before welding rack segments onto trolley beam,
install rack segments on the bottom of the beam lower
flange and clamp in place. Mount trolley on the lower
beam flange.
Measure gap between outside diameter of drive pinion
and root of rack segment teeth. Trolley drive pinion and
rack teeth must have a 0.06 to 0.10 inch (1.5 to 2.5 mm)
clearance.
IInnssttaallllaattiioonn
9
Adjust Clearance
Refer to Figure 9, p. 17.
There is an adjustment screw located below reducer
adapter.
1. Loosen capscrews attaching trolley drive to
sideplate.
2. Loosen jam nut and rotate adjustment screw to
achieve clearance.
3. Tighten jam nut and mounting screws.
If a larger adjustment is required.
1. Add shims between rack segment and beam to
decrease distance.
Installing Rack Segments Onto Beam
Refer to Figure 7, p. 17 and Figure 8, p. 17.
Rack segments should be installed on the outside edge
of the lower flange of the trolley beam. Allow 1/4 inch
(6.5 mm) clearance between the edge of the lower
flange and rack segment for fillet weld. The rack
segments should be clamped tight against the lower
flange so that there is no sagging. Sagging of the rack
could cause the drive pinion to bind as it traverses
along the runway beam.
Racks are provided in segments. These segments
should be jack welded (refer to Figure 8, p. 17) in place
and the trolley traversed the entire length. During this
movement observe for any high or low spots and
correct. Also check each segment connection for drive
tooth contact and correct as necessary. When all
clearances are achieved, weld both sides of the rack to
the beam flange to prevent corrosion between the rack
segment and beam.
Chain Container
When a chain bucket is used, always connect the free
end of the chain to the hoist. Attach the chain container
to the hoist. Run bottom block to the lowest point and
run hoist in the ‘UP‘ direction to feed the chain back
into the container.
WWAARRNNIINNGG
• Allow chain to pile naturally in the chain
container. Load chain that does not pile
naturally can chafe excessively, leading
to sparks.
NNOOTTIICCEE
• Make certain to adjust the balance chain
so that the chain container does not
contact the load chain.
Attaching Limit Stop
1. Install limit stop as described under ‘Load Chain
Replacement‘.
2. Run hoist slowly in the both directions to verify
limit stops activate and hoist ceases to operate.
Accu-Trol® Pendant
Refer to Figure 10, p. 18.
Check that all hose connections are tight and that hoses
are not twisted or crimped. Refer to Product Manual
MHD56014 for hose connections and all other
operation information.
Pendant lengths up to 66 ft (20 m) are available.
Contact factory for pendant lengths greater than 66 ft
(20 m).
CCAAUUTTIIOONN
• To avoid damaging pendant hose, make
sure strain relief cable, not pendant
hose, is supporting weight of pendant.
Initial Operating Checks
Hoists are tested for proper operation prior to leaving
factory. Before hoist is placed into service the following
initial operating checks should be performed.
1. After installation of trolley mounted hoists, check to
ensure hoist is centered below trolley.
2. Remove side plate connecting plates.
3. Check for air leaks in supply hose and fittings to
pendant, and from pendant to manifold.
4. When first running hoist or trolley motors a small
amount of light oil should be injected into inlet
connection to allow good lubrication.
5. When first operating hoist and trolley it is
recommended that motors be driven slowly in both
directions for a few minutes.
6. Operate trolley along entire length of beam.
7. Inspect 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.
8. Check that trolley (if equipped) and hook movement
is in same direction as arrows or information on
pendant control.
9. Raise and lower a light load to check operation of
hoist brake.
10. Check hoist operation by raising and lowering a
load equal to rated capacity of hoist 4 to 6 inches
(100 to 150 mm) off floor.
11. Check operation of limit devices.
12. On trolley units, check ‘O’ ring (360) on breather
plug (362) in trolley drive piston motor has been
removed.
IInnssttaallllaattiioonn
10
Operation
The four most important aspects of hoist operation are:
1. Follow all safety instructions when operating hoist
and trolley.
2. Allow only people trained in safety and operation of
this product to operate hoist and trolley.
3. Subject each hoist to a regular inspection and
maintenance procedure.
4. Be aware of hoist capacity and weight of load at all
times.
WWAARRNNIINNGG
• Only allow personnel trained in safety
and operation of this product to
operate hoist and trolley.
• Do not use this hoist for lifting,
supporting or transporting people or
lifting or supporting loads over
people.
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 operation of hoist, including a study of the
manufacturer’s literature. The operator must be aware
of proper methods of rigging loads and should have a
good attitude regarding safety. It is the operator’s
responsibility to refuse to operate hoist under unsafe
conditions.
Hoist Controls
Accu-Trol®® Pendant Operation (Push
Button Type)
The pendant is a remote control that allows the
operator to control the positioning of a load. The Accu-
Trol® Pendant is available with 4 or 6 buttons. Refer to
Accu-Trol® Pendant manual form number MHD56014
for additional information. A four-function pendant will
control trolley movement along the support beam and
hoist operation. A six function pendant would include
the above movements plus control a bridge assembly
allowing hoist movement in four directions. Always
apply smooth even pressure during operation, avoid
quick starts and abrupt stops. This will allow smoother
control of suspended loads and reduce undue stress on
components.
Emergency Stop
The Emergency Stop button, when activated, will
immediately stop all operations of the trolley and hoist.
The Emergency Stop button will remain depressed
after activation. To reset Emergency Stop button, twist
(rotate) Emergency Stop button clockwise until button
releases and spring returns to its original position.
Depress “ON” button.
11
Inspection
1. Check hoist for oil leaks daily. Immediately repair
any leaks.
2. At the beginning of each shift operate the hoist in
both directions without a load. Ensure the motor
runs free, and that the brake(s) do not drag.
3. Keep hoist housings clean of dust and dirt build up
which may cause heat build up and sparks.
Inspection information is based in part on American
Standards of Mechanical Engineers Safety Codes
B30.16.
WWAARRNNIINNGG
• 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.
Frequent Inspection
On equipment in continuous service, a “Daily
Inspection,” p. 11 shall 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.
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. Lubricator: Adjust air line lubricator drops during
hoist operation, refer to “LUBRICATION,” p. 13
section for requirements.
2. 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.
3. Hoses and Fittings: Visually inspect for damage, air
leaks, and loose connections. Repair all leaks or
damage and tighten loose connections prior to
starting daily tasks.
4. 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.
5. Upper and Lower Limit Device: Test operation with
no load slowly in both extremes of travel. Upward
travel must stop when chain stop on the bottom
block hits hoist limit switch. Downward travel must
stop when the chain stop attached to the end of the
unloaded load chain activates limit switch.
6. Controls: During operation of the hoist, verify that
response to pendant 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.
7. Brake: During operation test brake. Brake must be
capable of supporting load without slipping. Brake
must stop the load when control returns to neutral.
If brake does not hold load or does not stop the load
properly, brake must be further inspected.
WWAARRNNIINNGG
• Worn or improperly functioning
brakes may cause excessive heat
build up and sparks.
8. 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 Figure 12, p. 18. Replace
hooks which exceed a 10° twist. Refer to Figure 13,
p. 18. 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.
9. Hook Latch: Make sure hook latch is present and
not damaged. Replace if necessary.
12
CCAAUUTTIIOONN
• Do not use hoist if hook latch is
missing or damaged.
10. 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
Figure 14, p. 18. 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.
NNOOTTIICCEE
• 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.
11. 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 MHP0043 in Product Safety Information
Manual.
12. Label and Tags: Check for presence and legibility.
Replace if necessary.
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 Inspection,” p. 11 and actual
condition of load chain as determined by ‘Periodic
Inspections‘. Refer to Product Maintenance Information
Manual for chain specifications.
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,” p. 11
section 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‘ (refer to Product Maintenance
Information Manual) before being placed in service.
Refer to authorized Ingersoll Rand service center.
3. Standby equipment shall be inspected at least
semiannually in accordance with requirements of
“Frequent Inspection,” p. 11.
Storing the Hoist
1. Always store the hoist in a no load condition.
2. Wipe off all dirt and water.
3. Oil the chain, hook pins and hook latch.
4. Plug hoist air inlet port.
5. Place in a dry location.
6. Replace breather with plug on hoist reducer trolley
gearbox.
7. Before returning hoist to service, follow instructions
for “Hoists Not In Regular Use,” p. 12. Refer to the
“INSPECTION,” p. 11 section.
IInnssppeeccttiioonn
13
Lubrication
To ensure continued satisfactory operation of hoist, all
points requiring lubrication must be serviced with
correct lubricant at proper time interval as indicated for
each assembly.
Refer to chart below for recommended lubrication
intervals. Use only those lubricants recommended.
Other lubricants may affect product performance.
Approval for use of other lubricants must be obtained
from your Ingersoll Rand distributor. Failure to observe
this precaution may result in damage to hoist and/ or
its associated components.
Interval Lubrication Checks
Start of each
shift
Check flow and level of air line lubricator
(approximately 3 to 9 drops per minute
required at maximum motor speed).
Check oil levels in hoist and trolley piston
motors.
Monthly
Inspect and clean or replace air line filter.
Lubricate all grease fittings.
Check oil level in brake and reduction gear
assembly.
Quarterly
Drain and replace oil in trolley and hoist
piston drive motors.
Yearly
Drain and refill oil in hoist trolley and
reduction gear assembly.
Pivot Points and Bushings
Lubricate grease fittings monthly with 2 or 3 pumps
from a grease gun or more frequently, depending on
severity of service.
Table 3. Recommended Lubricants
Ambient Temperature
Recommended Grease
Type
-20° to 50° F (-30° to 10° C)
EP 1 multipurpose lithium-
based
30° to 120° F (-1° to 49° C)
EP 2 multipurpose lithium-
based
Hoist Motor
The motor is splash lubricated by oil in motor housing
and has no other means of lubrication. It is therefore
important to use only high quality, rust- and oxidation-
non-detergent inhibiting lubricant to ensure maximum
performance and minimum downtime for repairs.
Refer to Table 4, p. 13 for recommended oil type. Allow
oil to settle prior to topping off. Oil capacity for HA2
hoist motor is 0.2 gals (0.76 ltr). Do not use synthetics
or detergents.
Table 4. Hoist Motor Recommended Oil
Ambient Temperature Recommended Oil Type
Below 32° F (0° C) ISO VG 32 (10W SAE)
30° to 80° F (0° to 26° C) ISO VG 68 (20W SAE)
(a)
Above 80° F (26° C) ISO VG 100 (30W SAE)
Table 4. Hoist Motor Recommended Oil (continued)
(a)
Hoists are shipped from factory with ISO VG 68 (20W SAE) oil.
Piston Trolley Drive Motor
The motor is splash lubricated by oil in motor housing
and has no other means of lubrication. It is therefore
important to use only high quality, rust and oxidation-
inhibiting lubricant to insure maximum performance
and minimum down time for repairs. Allow oil to settle
prior to topping off. Oil capacity for HA2 trolley drive
motor is 0.1 pints (65 ml). Refer to Table 5, p. 13 for
recommended oil.
Table 5. Piston Trolley Motor Recommended Oil
Ambient Temperature Recommended Oil Type
Below 32° F (0° C) ISO VG 68 (20W SAE)
30° to 80° F (0° to 26° C) ISO VG 100 (30W SAE)
(a)
Above 80° F (26° C) ISO VG 150 (40W SAE)
(a)
Trolley Motors are shipped from factory with ISO VG 100 (30W SAE)
oil.
Bottom Hook Block Assembly
Refer to Dwgs. MHP0314, MHP0315, MHP0316 and
MHP0317 in the Product Parts Information Manual.
To prevent moisture entering bottom block assemblies
they should periodically be repacked with grease.
Apply grease to grease fitting until grease escapes
through breather (421). Refer to Table 3, p. 13 for
recommended grease types at specific temperature
ranges.
Load Chain
WWAARRNNIINNGG
• 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 load chain weekly, or more frequently,
depending on severity of service.
2. In a corrosive environment, lubricate more
frequently than normal.
3. Lubricate each link of load chain and apply new
lubricant over existing layer.
4. Lubricate hook and hook latch pivot points.
5. If required, clean chain with acid free solvent to
remove rust or abrasive dust build-up and lubricate
chain.
14
Trolley Drive Assembly
Refer to MHP0306 in the Product Parts Information
Manual.
The gear housing is filled at the factory and shipped
with oil, a non-toxic, high quality, Extreme Pressure
(EP), rust- and oxidation-inhibiting worm gear AGMA
#7 lubricant that is suitable for an ambient temperature
of 50° F to 125° F (10° C to 52° C).
Fill gear housing (212) through vented fill plug (210)
hole to height of level plug (201) hole located in cover
(202). The gear housing oil capacity is approximately
0.3 gals (1.5 ltr).
After first 50 hours of operation oil should be changed.
Thereafter it should be changed every 100 hours of
service or every 6 months, whichever occurs first.
The oil is drained by removing pipe plug (213) located
underneath gear housing (212). If oil drains too slowly,
removing vented fill plug (210) may speed up draining.
The oil should be replaced using one of the
recommended lubricants or its equivalent.
Table 6. Synthetic Lubricants Recommended for the
Reduction Gear and Disc Brake
Ambient
Temperature
0° C/+20° C
+20° C+40° C
SHELL TIVELA S150 TIVELA S220
AGIP BLASIA S150 BLASIA S220
ESSO GLYCOLUBE 150 GLYCOLUBE 220
IP PONTIAX HDS PONTIAX HDS
KLUBER
SYNTHESO D150
EP
SYNTHESO D220
EP
MOBIL SHC 629 SHC 630
BP-MACH ERNESYN HTX 220
Table 7. Trolley Drive Recommended Lubricants
Ambient Temperature
Recommended Lubricant
-10° to 50° F (-23° to 10° C) AGMA #5 (EP 5)
50° to 125° F (10° to 52° C) AGMA #7 (EP 7)
Reduction Gear Assembly
Refer to Figure 11, p. 18.
The reduction gear assembly is shipped with oil from
the factory. Check oil level before initial hoist
operation. If hoist is used at a normal frequency replace
oil in reduction housing once every year.
To ensure correct performance, highest efficiency and
long life, it is essential that lubricating oil be
maintained at correct level. Oil capacity for reduction
gear assembly is 1.1 gals (4.2 ltr).
CCAAUUTTIIOONN
• Do not over fill. Excess oil will reduce
operating efficiency and increase oil
temperature.
Use only high quality lubricants in reduction gear
assembly such as synthetic gear oil or high grade EP4
gear oil.
The recommended grade of oil must be used at all
times since use of unsuitable oil may result in
excessive temperature rise, loss of efficiency and
possible damage to gears. Check vented fill plug is
unrestricted.
Disc Brake
Refer to MHP0353 in the Product Parts Information
Manual.
The disc brake housing is filled and shipped with oil
from the factory. Check oil level before initial hoist
operation. If hoist is used at a normal frequency replace
oil in disc brake housing six months.
To ensure correct performance, highest efficiency and
long life, it is essential that lubricating oil be
maintained at correct level. Oil capacity for disc brake
housing is 0.2 gals (0.76 ltr).
CCAAUUTTIIOONN
• Do not over fill. Excess oil will reduce
operating efficiency and increase oil
temperature.
Use only high quality lubricants in disc brake housing
assembly same as reducer oil.
The recommended grade of oil must be used at all
times since use of unsuitable oil may result in
excessive temperature rise, loss of efficiency and
possible damage to brake discs and sprig clutch. Fill
brake housing (27) to height of level plug (28).
Seals and Bearings
Refer to Figure 2, p. 16.
Lubricate grease fittings monthly with 2 or 3 pumps of
a grease gun. For correct grease type, refer to Table 3,
p. 13.
LLuubbrriiccaattiioonn
15
Product Information Graphics
Figure 1. MHP4244
Air Supply
Filter/
Separator
Lubricator
1"
1"
Accu-Trol
Off
On
Hoist
Up
Trolley
Right
Trolley
Left
Hoist
Down
5 3
2
1
4
6
Brake
Hoist Mot
or
Trolley Motor
Spring
Set
Release
(down only)
Brake
Exhaust
Limit Paddle
16
Figure 2. MHP0338
Trolle
y
Gearbox
Oil Drain
Plug
Bottom Block
Grease Fittings
Suspension Yoke
Grease Fitting
(2 Locations)
Air Filter
Air Lubricator
Trolley Wheel
Grease Fittings
Troll
ey Motor
Oil Level Plug
Trolley Gearbox
Vented Oil
Fill Plug
Trolley
Gearbox
Oil Level
Plug
Trolley Motor
Vented Oil
Fill Plug
Hook
Latch
Pivot
Hoist Motor
Oil Level Plug
Hoist Motor Level
Plug Located
Below Manifold
Load
Chain
Hoist Motor
Oil Fill Plug
A
B
C
R
N
P
M
D
E
F
G
H
J
K
L
Figure 3. MHP0340
A
B
C
D
E
Trolley
Wheel
Flange
Side
Roller
Beam
Spacers
Ensure Hoist
is Centered
Beneath Trolley
Figure 4. MHP0191
Air Out
Regulator
Lubricator
Air In
Filter
A
B
C
D
E
PPrroodduucctt IInnffoorrmmaattiioonn GGrraapphhiiccss
17
Figure 5. MHP0352
159
170
158
156
150
165
173
174
157
170
Figure 6. MHP1177
Maintain clearance between rack and
pinion teeth of 0.06 inch (minimum) to
0.10 inch (maximum) [1.5 to 2.5 mm] to
prevent pinion binding during operation.
Measure gap between outside
diameter of drive pinion and root of
rack segment.
Note: 0.08 inch feeler gauge use is
recommended.
Rack
Pinion
0.06 to 0.10 inch
(1.5 to 2.5 mm)
A
B
C
D
Figure 7. MHP1178
Rack
Segment
Lower Beam
Flange
A
Hoist Trolley
Drive Assembly
Mounted This Side.
Fillet Weld:
• Allow 1/4 inch (6.5 mm)
clearance between edge
of lower flange and rack
segment.
• Apply weld to both sides
of rack segment.
B
C
D
Figure 8. MHP3016
Figure 9. MHP1605
A
Normal trolley drive mounded
above supported bean between
trolley wheels
Located behind
motor housing
Reducer
Adapter
Mounting
Capscrew
Jam Nut
Side Plate
Adjustment
Capscrew
Trolley rack drive
mounted below
support beam
B
G
H
D
C
E
F
PPrroodduucctt IInnffoorrmmaattiioonn GGrraapphhiiccss
18
Figure 10. MHP0434
Power ON
Power OFF
Hoist RAISE
Hoist LOWER
Trolley RIGHT
Trolley LEFT
A
B
C
D
E
F
Figure 11. MHP0343
Vented
Fill Plug
Oil
Level
Plug
Disc Brake
Level Plug
Drain Plugs
Located at
Bottom
A
C
B
D
Figure 12. MHP0040
A
Throat Width
Figure 13. MHP0111
max.
Twisted
DO NOT USE
Normal
Can be Used
Figure 14. MHP0102
A
B
C
Diameter
Welded
Area
Wear in
These Area
PPrroodduucctt IInnffoorrmmaattiioonn GGrraapphhiiccss
19
Hercu-Link™™ and B.O.P. Hoist Maintenance Intervals
Table 8. Hercu-Link™™ and B.O.P. Hoist Maintenance Interval Chart
The following work can be completed by owner maintenance personnel.
System Air Filter Inspect system air filter every 30 days. Drain if necessary.
System Lubricator Inspect system lubricator every 30 days. Refill as necessary.
System Regulator Inspect system regulator. Verify 105 psi. Adjust if necessary.
Hoist Gearbox Oil Level
Check oil level every 90 days. Replace oil yearly.
Trolley Gearbox Oil Level Check oil level every 90 days. Replace oil yearly.
Hoist Motor Oil
Check motor oil level daily. Replace oil every 3 months.
Trolley Motor Oil Check motor oil level daily. Replace oil every 3 months.
Disc Brake
Check oil level every 90 days. Replace oil every 6 months.
Grease Fittings Lubricate grease fittings every 90 days.
Chain
Lubricate chain every 7 days.
The following work shall be completed by an Ingersoll Rand trained service technician or a Qualified Person.
(a)
Components 1 year 2 years 3 years 4 years 5 years
Inspect Hoist Motor
X
Inspect Hoist Gearbox
X
Inspect Hoist Control Valve
X
Inspect Disc Brake
X
Inspect Chain
X X X X X
Inspect Chain Stopper
X X X X X
Inspect Shut-Off Valve
X X X X X
Inspect Hook or Clevis
X X X X X
Inspect Hoist Frame
X
Inspect Hoist Limit Switch
X X X X X
Inspect Limit Paddle
X
Inspect Trolley Motor
X
Inspect Trolley Gearbox
X
Inspect Trolley Control Valve
X
Inspect Trolley Bracket
X
Inspect Suspension Yokes
X
Inspect Trolley Sideplates
X
Inspect Trolley Limit Switch
X X X X X
Inspect Trolley Wheels
X
Inspect Pendant
X X X X X
Inspect Chain Bucket
X
Inspect all Hoses/Fittings
X X X X X
Test Emergency Lowering System
X X X X X
Perform Load Test X X X X X
(a)
Qualified Person (as defined by ANSiB30.7): A person who is having a recognized Degree or certificate of professional training, extensive knowledge,
experience, and problem solving skills relate to the subject matter.
Recommend complete general overhaul.
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08 May 2018
Supersedes (New) ©2018 Ingersoll Rand
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Ingersoll-Rand Hercu-Link BHS Series Product information

Ingersoll-Rand
Brand
Ingersoll-Rand
Model
Hercu-Link BHS Series
Type
Product information
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