Ingersoll-Rand LCA015, Parts, Operation And Maintenance Manual

Page 1: ...ried out by personnel certified by Ingersoll Rand or by Ingersoll Rand Authorized Service Centers Contact the Factory if in doubt about installation operation inspection and maintenance instructions Use only Genuine Ingersoll Rand parts when maintaining or repairing a winch hoist or any component of a winch or hoist ANSI ASME recommends that a winch or hoist or any components of a winch or hoist t...

Page 2: ...orthe operation installation 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 Refer all communications to the nearest Inge...

Page 3: ...tion 10 Periodic Inspection 11 Hoists Not in Regular Use 12 Inspection and Maintenance Report Form 13 Lubrication Frequency Chart 14 Brake and Gear Assemblies 14 Hook Assemblies 15 Trolley 15 Load Chain 15 Troubleshooting Chart 16 Maintenance Brake Adjustment 17 Overload Device Adjustment 18 General Disassembly Instructions 18 Load Chain Replacement 18 Accessing the Brake 19 Motor Disassembly 20 C...

Page 4: ...re no personnel would be injured This means keep out from under a raised load and keep out of the intended path of any load Ingersoll Rand Material Handling 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...

Page 5: ...arts 7 Never place your hand in the throat area of a hook 8 Always rig loads properly and carefully 9 Never use the load chain as a sling 10 Be certain the load is properly seated in the saddle of the hook Do not tipload the hook as this leads to spreading and eventual failure of the hook 11 Do not side pull or yard 12 Make sure everyone is clear of the load path and there are no objects in the wa...

Page 6: ...ntrol P Pendant Control Type 2 1 motor Suspension A Fixed lug C Swivel top hook Load Chain Lift 3M 3 metres standard 10 ft X Specify length Pendant Control 2 2 metres standard 6 ft XX Specify length Options A Standard chain bucket B Large chain bucket C Extra large chain bucket R Zinc plated S COR E Package T Bronze copper plated S COR E Package Options for Non E Models U Emergency stop SU Overloa...

Page 7: ...a lube free gear motor which is connected to a pinion shaft which in turn drives the planetary reduction gear The output from the planetary reduction gear drives the load chain sprocket The pinion shaft from the planetary reduction is also coupled to the brake discs The brake is engaged at all times until the hoist is powered in either the raise or lower direction System pressure acts on the brake...

Page 8: ... moisture A minimum of 58 psi 4 bar 400 kPa at the hoist motor is required to provide rated hoist capacity Air inlet port size for LCA015S and LCA030D units is 1 2 in BSP On all other units the inlet port size is 3 4 in BSP Air Lines The inside diameter of the hoist air supply lines must not be smaller than 3 4 in 19 mm Before making final connections all air supply lines should be purged before c...

Page 9: ...ndex value established by spring adjustment A difference in pressure greater than the index value causes the emergency stop to be activated This then exhausts the air and hoist operation stops Overload protection is adjusted at the factory to 120 of the safe working load SWL It is also able to operate on both sides for mining versions with two bottom hooks Refer to the MAINTENANCE section for adju...

Page 10: ...g test loads Hoist must operate smoothly and at rated specifications prior to being placed in service 5 Check that hook movement is in the same direction as arrows and pendant control labels 6 Raise and lower a light load to check operation of the hoist brake 7 Check hoist operation by raising and lowering a load equal to the rated capacity of the hoist a few inches cm off the floor 8 Check to see...

Page 11: ...ed 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 Load Chain Reports Records should be maintained documenting the condition of load ...

Page 12: ...RE 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 the items in Frequent Inspection Also inspect the following 1 FASTENERS Check all rivets split pins capscrews and nuts Replace if missing or tighten if loose 2 ALL COMPONENTS Inspect for wear damage...

Page 13: ...a m r o N h t g n e L d r a c s i D m m n i m m n i m m S 5 1 0 A C L 4 2 x 8 2 7 4 0 2 1 8 4 2 2 1 D 0 3 0 A C L S 0 3 0 A C L 6 3 x 3 1 9 0 7 0 8 1 2 7 3 8 1 D 0 6 0 A C L S 0 6 0 A C L 5 4 x 6 1 5 8 8 5 2 2 9 9 8 8 2 2 D 0 2 1 A C L Dwg MHP0041 11 CHAIN CONTAINER Check for damage or excessive wear and that chain container is securely attached to the hoist Secure or replace if necessary Hoists N...

Page 14: ...L s e d i u G n i a h C s g n i r p S s g n i s u o H s r e v o C s k o o H p o T s h t d i w e l b a t p e c c a m u m i x a m m u m i n i m r o f 4 e l b a T o t r e f e R m m _ _ _ _ _ _ _ _ _ _ _ s e h c n i _ _ _ _ _ _ _ _ _ _ h t d i W t a o r h T k o o H l a u t c A t s i w T k o o H 0 1 m u m i x a m _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ r e h t O _ _ _ _ _ _ e l c i t r a P c i t e n g a M ...

Page 15: ...oval for the use of other lubricants must be obtained from your Ingersoll Rand Technical Support Department or distributor Failure to observe this precaution may result in damage to the hoist and or its associated components Whenever a hoist is disassembled for overhaul or replacement of parts lubricate as follows Brake and Gear Assemblies The gear and brake assemblies share a common oil bath On l...

Page 16: ...must be packed with Ingersoll Rand No 68 Grease or a standard No 2 multi purpose grease at regular intervals Neglect of proper lubrication can lead to excessive wear 1 Lubricate the hook and latch pivot points Refer to Dwg MHP1300 Hook and latch should swivel pivot freely 2 Use Ingersoll Rand LUBRI LINK GREEN or ISO VG 220 50W lubricant 3 To lubricate hooks separate hook halves and pack with greas...

Page 17: ...g n i r p s e k a r b k c e h C n o i t c e s E C N A N E T N I A M d e t a r t f i l t o n l l i w t s i o H y t i c a p a c d e d a o l r e v o s i t s i o H y t i c a p a c d e t a r n i h t i w o t d a o l e c u d e R e l t t i l o o t r o t s i o h o t y l p p u s r i a o N I S P r o M F C n o i t c e s S N O I T A C I F I C E P S o t r e f e R t e l n i t s i o h t a r a b I S P k c e h C r ...

Page 18: ...s a day or is operated in severe applications or environments more frequent maintenance should be performed L A V R E T N I K C E H C E C N A N E T N I A M t f i h s h c a e f o t r a t S e h t f o n o i t c e p s n i l a u s i v h g u o r o h t a e k a M t s i o h e h t e t a r e p o t o n o D e g a m a d r o f t s i o h d n u o f s i e g a m a d f i t s u m t s i o H s n o i t c e r i d h t o b ...

Page 19: ...ng bearings during hoist assembly or disassembly always tap or press on the bearing inner race for shaft fit bearings or the outer race for bore fit bearings 9 For assembly work above body height suitable working platforms or ladders should be made available 10 Do not attempt to wash sealed bearings If hoists are to be completely disassembled it is recommended that the motor assembly and brake gea...

Page 20: ...t or even breaking the chain and causing injury Chain Reeving Dwg MHP1301 Accessing the Brake LCA015S and LCA030D Hoists Refer to Dwg MHP1462 1 It is recommended that carry handle 25 on the brake end be removed prior to brake disassembly 2 Carefully remove the four brake cover screws 27 one half turn at a time each until spring compression is relaxed Remove brake cover 34 brake support plate 64 an...

Page 21: ... Remove ring gear 18 and planetary support assembly 8 Remove bearings 17 and 40 from planetary support 19 9 Slide out satellite axles 47 bearings 46 spacers 45 and planetary gears 44 10 Remove ring gear 20 LCA030S and LCA060D Hoists Refer to Dwg MHP1464 1 Remove the three nuts 13 lockwashers 12 and capscrews 11 which secure the motor assembly and gear housing assembly to the chain guide housing 52...

Page 22: ...ts on the gears and frames If bushings have been removed it maybe necessary to carefully scrape old Loctite from the bushing bores Dry each part using low pressure filtered compressed air Inspection All disassembled parts should be inspected to determine their fitness for continued use Pay particular attention to the following 1 Inspect all gears for worn cracked or broken teeth 2 Inspect all bush...

Page 23: ...Nm 2HP with Emergency Stop and Overload Refer to Dwg MHP1467 Follow steps 1 through 11 immediately above for initial motor assembly Assembly of Emergency Stop and Overload options 1 Ensure dowels 12 are installed in motor cover 22 2 Lubricate and position O rings 13 and stops 18 on motor cover 3 Assemble items 31 32 33 and 37 on screw 30 Install screw with parts into motor cover Screw 32 33 and 35...

Page 24: ...nst bearing 39 10 Install ring gear 18 11 Lubricate and install O ring 43 in gear cover 48 Install oil seal 13 with lip toward planetary support 12 Install gear cover 48 Attempt to locate the puller holes at the top and bottom just off vertical This may aid disassembly at some later date Install pinion 11 13 Refer to Brake Assembly for information on assembling the remaining brake parts LCA030S an...

Page 25: ...5 in ring gear 16 Install ring gear in gear housing 30 11 Install sun gear 41 and tap into position through bearing 5 until seated 12 Turn gear housing over and support to avoid damaging the sun gear Align tabs on steel discs 44 and install brake sleeve 39 on sun gear spline Secure in position with retainer ring 36 13 Install remaining brake parts as described in Brake Assembly 14 Install oil seal...

Page 26: ...25 SERVICE NOTES ...

Page 27: ...26 SERVICE NOTES ...

Page 28: ...orsepower with emergency stop and overload device Dwg MHP1467 36 4 horsepower without emergency stop or overload device Dwg MHP1457 38 Reversible 4 horsepower without emergency stop or overload device Dwg MHP1456 39 Reversible 4 horsepower with emergency stop and overload device Dwg MHP1455 40 Bottom Hook Assembly Single and Double Fall Hoists Dwgs MHP1426 MHP1427 MHP1454 and MHP1468 42 Accessorie...

Page 29: ...28 LCA015S AND LCA030D HOIST ASSEMBLY PARTS DRAWING 1 5 and 3 ton Hoist Capacities Dwg MHP1462 ...

Page 30: ... 8 2 3 0 4 2 4 9 7 4 e l x A e t i l l e t a S 3 9 3 0 0 9 0 6 9 7 1 g n i r a e B 1 5 0 0 0 0 8 0 5 8 4 r e v o C r a e G 1 3 1 3 0 4 2 4 9 8 1 r a e G g n i R 1 8 0 0 0 8 1 6 9 9 4 g n i R O 1 9 2 5 5 3 2 8 5 9 1 t r o p p u S y r a t e n a l P 1 1 4 0 0 8 1 6 9 0 5 e d i u G n i a h C 1 2 3 0 0 4 2 4 9 0 2 r a e G g n i R 1 8 3 0 0 9 0 6 9 1 5 r e c a p S 2 8 6 1 0 4 2 4 9 1 2 n o i n i P 1 5 1...

Page 31: ...30 LCA030S AND LCA060D HOIST ASSEMBLY PARTS DRAWING 3 and 6 ton Hoist Capacities Dwg MHP1464 ...

Page 32: ...i R O 1 9 2 1 1 3 2 8 5 6 1 g n i R O 1 9 2 8 5 1 2 8 5 8 4 g n i R r e n i a t e R 1 2 3 8 7 4 8 7 4 7 1 n o i n i P e v i r D 1 8 0 4 0 2 1 4 9 9 4 r e l f f u M 2 6 2 4 0 2 1 4 9 8 1 r a e G g n i R 1 1 3 0 0 0 2 6 9 0 5 g n i R r e n i a t e R 1 0 6 0 3 0 7 7 4 9 1 r e h s a W g n i r p S 1 2 3 1 2 7 1 9 6 1 5 g n i R O 2 9 2 7 5 3 2 8 5 0 2 r a e G n u S 1 1 1 4 0 2 1 4 9 2 5 g n i s u o H e ...

Page 33: ...32 LCA060S AND LCA120D HOIST ASSEMBLY PARTS DRAWING 6 and 12 ton Hoist Capacities Dwg MHP1465 ...

Page 34: ...P 1 3 2 0 0 5 1 6 9 6 1 r a e G g n i R 1 1 5 1 0 6 2 5 9 9 4 e l x A t e n a l P 4 9 1 0 0 3 7 5 9 7 1 g n i R O 2 9 2 7 5 3 2 8 5 0 5 w e r c s p a C 3 6 0 6 1 2 3 1 4 8 1 g n i R r e n i a t e R 1 0 6 0 3 0 7 7 4 1 5 r e h s a w k c o L 3 0 2 0 1 0 2 5 4 9 1 r e l f f u M 2 6 2 4 0 2 1 4 9 2 5 t u N 3 1 1 0 4 0 0 3 4 0 2 r e c a p S 4 1 2 0 0 3 7 5 9 3 5 l a e S l i O 1 0 3 6 8 0 0 8 5 1 2 g n ...

Page 35: ...2 2 1 3 1 4 7 r a e G e v i r D 1 9 1 3 0 4 2 4 9 2 2 r e v o C r o t o M 1 8 1 3 0 4 2 4 9 8 w e r c s p a C 4 6 0 8 0 0 3 1 4 3 2 g n i R d a u Q 2 9 2 9 8 2 2 8 5 9 e g n a l F r o t o M 1 8 0 0 0 9 0 6 9 4 2 g n i R d a u Q 2 9 2 2 1 3 2 8 5 0 1 p o t S r a e R 2 0 3 0 0 2 1 4 9 5 2 e v l a V e d i l S 2 2 1 2 0 4 2 4 9 1 1 g n i r p S 2 4 2 2 0 4 2 4 9 6 2 n i P 2 8 1 9 2 0 4 6 4 2 1 n i P 6 ...

Page 36: ...0 9 0 6 9 0 2 e l d n a H 1 5 5 0 0 4 2 4 9 5 r e h s a W 1 2 3 0 0 9 0 6 9 1 2 w e r c s p a C 4 6 0 2 2 2 3 1 4 6 w e r c s p a C 1 6 0 7 6 0 3 1 4 2 2 r e v o C r o t o M 1 2 2 3 0 4 2 4 9 7 r a e G e v i r D 1 9 1 3 0 4 2 4 9 6 2 n i P 2 8 1 9 2 0 4 6 4 8 w e r c s p a C 4 6 0 8 0 0 3 1 4 8 4 g n i R O 2 9 2 3 2 2 2 8 5 9 e g n a l F r o t o M 1 8 0 0 0 9 0 6 9 3 6 g u l P 2 7 3 0 0 8 1 6 9 2 ...

Page 37: ...36 REVERSIBLE 2 HP SU MOTOR ASSEMBLY PARTS DRAWING Dwg MHP1467 Reversible 2 horsepower Motor with Emergency Stop and Overload for LCA015S and LCA030D Hoists ...

Page 38: ... 1 9 1 6 4 6 5 5 4 r e h s a W 1 9 1 0 0 6 3 6 9 5 1 g n i R r e n i a t e R 2 9 3 3 1 0 8 7 4 6 4 m g a r h p a i D 1 0 2 0 0 6 3 6 9 6 1 g n i t t i F 5 2 3 6 2 5 6 1 6 7 4 e n o C e v l a V 1 7 1 0 0 6 3 6 9 7 1 w e r c S 1 7 0 3 7 0 0 2 4 8 4 g n i R O 3 9 2 3 2 2 2 8 5 8 1 p o t S 2 2 4 0 0 9 0 6 9 9 4 r e h s a W l a e S 1 1 2 0 0 6 3 6 9 9 1 g n i R O 2 9 2 0 5 0 2 8 5 0 5 g u l P 1 9 6 2 0...

Page 39: ... 2 6 4 6 5 8 g n i r p S 2 9 2 0 0 2 1 4 9 4 2 g n i R r e n i a t e R 1 2 3 7 6 3 8 7 4 9 t u n k c o L 1 3 0 0 0 0 0 7 5 7 2 g n i R O 2 9 2 0 6 2 2 8 5 0 1 g n i r a e B 1 3 0 0 0 0 6 0 5 8 2 p o t S r a e R 2 9 6 0 0 0 2 6 9 1 1 p o t S e l t t u h S 1 3 2 2 0 9 0 6 9 9 2 g n i R d a u Q 2 9 2 0 9 2 2 8 5 2 1 g n i R O 1 9 2 2 2 1 2 8 5 0 3 g n i r a e B 1 3 1 2 2 9 4 6 5 3 1 l l a B 1 5 2 6 1...

Page 40: ...3 0 0 0 0 0 7 5 2 2 e l d n a H 1 0 8 0 0 2 1 4 9 0 1 g n i r a e B 1 3 0 0 0 0 6 0 5 3 2 g n i r a e B 1 3 1 8 2 6 4 6 5 1 1 p o t S e l t t u h S 1 3 2 2 0 9 0 6 9 4 2 g n i R r e n i a t e R 1 2 3 7 6 3 8 7 4 2 1 g n i R O 1 9 2 2 2 1 2 8 5 8 2 p o t S r a e R 2 9 6 0 0 0 2 6 9 3 1 l l a B 1 5 2 6 1 0 4 9 6 0 3 g n i r a e B 1 3 1 2 2 9 4 6 5 4 1 g n i s u o H r o t o M 1 8 0 0 0 0 2 6 9 2 3 w ...

Page 41: ...40 REVERSIBLE 4 HP SU MOTOR ASSEMBLY PARTS DRAWING Dwg MHP1455 Reversible 4 HP Model SU with Overload and Emergency Stop for use with Hoist Models LCA030S LCA060S LCA060D and LCA120D ...

Page 42: ... 2 6 9 8 4 t u n k c o L 1 1 1 6 7 0 7 3 4 5 1 r a e G e l d I 1 6 2 0 0 0 2 6 9 9 4 r e h s a W l a e S 1 1 3 5 4 0 4 8 5 6 1 e v l a V e d i l S 2 6 0 0 0 0 2 6 9 0 5 l l a B 1 5 2 1 0 0 4 9 6 7 1 w e r c s p a C 4 6 0 2 2 0 3 1 4 1 5 r e v i e c e R g n i r p S 1 3 2 0 0 6 3 6 9 8 1 n i P 2 0 2 4 3 0 5 6 4 2 5 g n i r p S 1 2 3 4 9 5 1 9 6 9 1 n i P 4 6 1 4 0 0 0 6 4 3 5 t u N 3 1 1 1 1 0 0 3 4...

Page 43: ...E AND DOUBLE FALL BOTTOM HOOK ASSEMBLY PARTS DRAWINGS Single Fall 1 5 ton Hoist Dwg MHP1468 Dwg MHP1426 Double Fall 3 6 and 12 ton Hoists Single Fall 3 ton Hoist Single Fall 6 ton Hoist Dwg MHP1454 Dwg MHP1427 ...

Page 44: ... 0 0 0 2 5 4 0 1 0 0 0 2 5 4 8 r e h s a w k c o L 1 2 1 0 0 0 2 5 4 0 2 0 0 0 2 5 4 9 t i K h c t a L k o o H 1 y r o t c a F t c a t n o C y l n o n o t 5 1 r o f d e r i u q e R y t i t n a u Q n o t 2 1 3 s t s i o H l l a F e l b u o D n o t 3 n o t 6 n o t 2 1 1 t u N 3 1 1 1 0 0 0 3 4 1 1 3 0 0 0 3 4 2 r e h s a w k c o L 3 8 0 0 0 0 2 5 4 2 1 0 0 0 2 5 4 3 w e r c s p a C 3 6 0 5 4 0 3 1 4...

Page 45: ...5 9 2 r e h s a W 1 7 7 1 0 4 2 4 9 8 1 1 0 2 1 4 9 0 6 0 0 6 2 5 9 3 n i P 1 0 2 8 2 0 5 6 4 0 2 9 2 0 5 6 4 0 2 0 4 0 5 6 4 4 p o t S t i m i L 1 5 0 1 0 4 2 4 9 0 5 1 0 2 1 4 9 8 3 0 0 6 2 5 9 5 k l u B n i a h C d a o L y f i c e p S h t g n e L 4 2 8 C L P Z 8 G 6 3 3 1 C L P Z 8 G 5 4 6 1 C L P Z 8 G s t s i o H l l a F e l g n i S 1 r e f f u B 1 0 7 0 0 4 2 4 9 1 4 1 0 2 1 4 9 1 4 1 0 2 1 ...

Page 46: ... w k c o L 2 8 0 0 0 0 2 5 4 2 1 0 0 0 2 5 4 4 1 0 0 0 2 5 4 4 t u N 2 1 1 1 0 0 0 3 4 1 1 3 0 0 0 3 4 1 1 9 0 0 0 3 4 5 h c t a C k o o H f l a H 2 1 8 0 0 4 2 4 9 7 2 1 0 2 1 4 9 3 4 0 0 6 2 5 9 6 t u N 2 1 1 1 0 0 0 3 4 1 1 3 0 0 0 3 4 1 1 8 0 0 0 3 4 7 r e h s a w k c o L 2 8 0 0 0 0 2 5 4 2 1 0 0 0 2 5 4 0 2 0 0 0 2 5 4 8 w e r c s p a C 2 6 0 8 1 0 3 1 4 6 0 3 0 1 3 1 4 7 3 0 0 6 2 5 9 9 n i...

Page 47: ...46 PENDANT ASSEMBLY PARTS DRAWINGS Dwg MHP1558 Dwg MHP1544 Pendant without Emergency Stop Pendant with Emergency Stop ...

Page 48: ...V 3 2 4 0 1 0 9 7 5 9 1 1 5 g n i R O 5 2 9 2 2 9 0 2 8 5 2 1 5 g n i R r e n i a t e R 1 0 3 0 3 1 7 7 4 3 1 5 r e h s a W t s u a h x E 1 3 0 3 0 0 6 7 6 4 1 5 e l d n a H t n a d n e P 1 9 2 1 0 9 7 5 9 6 1 1 0 9 7 5 9 9 5 1 5 w e r c S 3 2 7 0 3 8 0 0 2 4 6 1 5 l l a B 5 2 5 2 6 1 0 4 9 6 7 1 5 g n i r p S 4 2 1 4 5 8 2 1 9 6 8 1 5 g u l P 4 2 1 4 7 7 0 1 5 6 9 1 5 g u l P 1 8 0 1 0 9 7 5 9 1 ...

Page 49: ...oad SU ACCESSORIES N O I T P I R C S E D R E B M U N T R A P t n a c i r b u L N E E R G K N I L I R B U L w o l l e y t n i a P p u h c u o T Y 7 3 2 P A F M E T I O N N O I T P I R C S E D T R A P F O Y T Q L A T O T T R A P R E B M U N 1 w e r c S 3 6 0 6 2 2 3 1 4 2 r e h s a w k c o L 3 6 0 0 1 0 2 5 4 3 e s a C 1 5 2 4 0 2 1 4 9 ...

Page 50: ...49 SERVICE NOTES ...

Page 51: ... than Ingersoll Rand Material Handling may result in decreased hoist performance and may at the company s option invalidate the warranty For prompt service and genuine Ingersoll Rand Material Handling parts provide your nearest Distributor with the following 1 Complete hoist model number as it appears on the nameplate 2 Part number and part description as shown in this manual 3 Quantity required T...

Page 52: ...istsandWinches Products tobefreeofdefects in material and workmanship for a period of one year from the date of purchase I R will repair without cost any Product found to be defective including parts and labor charges or at its option will replace such Products or refund the purchase price less a reasonable allowance for depreciation in exchange for the Product Repairs or replacements are warrante...

Page 53: ...Offices Chicago IL 888 Industrial Drive Elmhurst IL 60126 Phone 630 530 3800 Fax 630 530 3891 Detroit MI 23192 Commerce Drive Farmington Hills MI 48335 Phone 248 476 6677 Fax 248 476 6670 Houston TX 450 Gears Road Suite 210 Houston TX 77067 4516 Phone 281 872 6800 Fax 281 872 6807 Los Angeles CA 11909 E Telegraph Road Santa Fe Springs CA 90670 0525 Phone 562 948 4189 Fax 562 948 1828 Philadelphia ...