BUNDLE HANDLER - Ingersoll Rand
Contents
1. Replace air cylinder Lack of guide bar lubrication Clean and lubricate guide bars Guide bar bushings worn Replace guide bar bushings Improper chain tension Adjust chain tension Broken chain Debris in air lines or fittings Loose or broken air lines or fittings Replace chain Remove debris Flush air lines Tighten connections or replace air lines or fittings Faulty rotate lever valve Replace lever valve Faulty air cylinder Replace air cylinder Improper chain tension Adjust chain tension Broken chain Replace chain Interlock does not prevent clamp from opening with a load Debris in air lines or fittings Remove debris Flush air lines Loose or broken air lines or fittings Tighten connections or replace air lines or fittings Improper interlock adjustment Refer to Adjustment Procedures Faulty Interlock valve Replace Interlock valve Load shifts or slips with clamp engaged Deteriorated loose or damaged clamp pads Tighten or replace clamp pads Insufficient air supply pressure Adjust air supply to the highest maintainable pressure Bundle strap loose Check strapper equipment 14 MHD56227 Edition 3 MAINTENANCE Turn off air supply to system and be sure wire rope is slack before attempting any disassembly operations Never perform maintenance on the unit while it is2. Locknut 8 75503 21 Washer 6 74529 60 Screw 12 70112 22 Locknut 2 75517 63 End Plate RH 1 95483015 23 Chain Bracket 2 95483013 64 Side Guide RH 1 95483018 24 Lockwasher 4 16099 65 Bearing 8 65042 25 Capscrew 4 70437 66 Bearing Tube 4 95483009 26 Chain As Req d 99005 67 RH 1 95508 27 Chain Connecting Link 4 99006 68 Arm RH 1 95483014 28 Guide Bar 1 67 in dia 4 96138 69 Capscrew 1 10019 29 Arm LH 1 95483011 70 Handle 1 95483022 30 Pin 2 77005 71 Capscrew 2 70430 31 Arm Bracket 2 95483032 73 Handle Clamp 2 95483024 32 Cylinder Rod Extension 2 95483041 74 Control Handle Mount RH 1 95483023 33 Spherical Washer 2 99011 75 Capscrew 4 34 Capscrew 16 71473 76 Control Handle Mount LH 1 95483038 35 Side Guide 4 95483017 7 Control Handle Mount 2 95483034 36 Plunger 2 99012 End Paddle 37 Platform Bracket 2 95483035 Contact factory 20 to 50 inch 508 to 1270 mm with Standard Length Paddles Item Description Qty Part Item Description Qty Part No of Part Total Number No of Part Total Number 6 Lift Bale 1 95537002 55 Cover Far Side 1 95537009 28 Guide Bar 1 5 in dia 4 96128 56 Cover Near Side 1 95537003 29 Arm LH 1 95537011 57 Platform 1 95537001 32 Rod Extension 2 Not required 65 Bearing 8 65048 50 Bearing 4 65047 66 Bearing Tube 3 95537005 35 52 Cylinder 4 x 15 in 2 60605 66 Bearing Tube 1 95537005 40 53 Cover Far Side 1 95537004 68 Arm RH 1 95537011 54 Cover Near
3. Typical Bundler Handler Circuit Supply Balancer 1 EEE Interlock 6 Check Valve Eu BE 4 Way Valves la 9 rr Balancer FI 4 Controls E ERA io H Clamp Unclamp Y ru _ Unclamp Tr CNN REN Clamp Dwg MHP2218 OPERATION Description Of Operation Bundle Handler The bundle handler is an integrated group of components designed to maximize the interaction of man and machine These components can be mounted to an overhead rail system on which the Ingersoll Rand Balancer travels The balancer has a wire rope with load hook attached to the bundle handler The operator controls the system by use of the Ingersoll Rand ZA Zim Air up and down control to lift a bundle of signatures onto a stream feeder or directly to a gather in feed shelf The clamp is actuated by push button or lever valves The system renders the bundles virtually weightless through the balancer s compressed air operation The rail system or Manipulator Arm provides for ease of horizontal movement This combination requires little physical strength to operate and reduces operator fatigue The bundle handler should not be left suspended when not in use
4. Lower device to the floor or a suitable location out of the work area Always use good posture when operating the Bundler Handler The suspended bundle must have a clear passage from a pick up point to a set down point The suspended bundle can be raised or lowered approximately twelve inches from which it has been raised by gently nudging the load up or down This is known as floating Use of the controls is not required for this operation just pressure applied to the load by the operator in the desired direction Balancer Energy used to power the balancer is compressed air a minimum of 70 psig 4 8 bar 480 kPa is required Air is controlled by an external control package Compressed air pushes against the piston causing it to move laterally The piston pushes the reel assembly causing the reel to move laterally as well as rotate which winds the wire rope into the balancer raising the bundle handler Compressed air is released through the controls to atmosphere and the reel rotates in the opposite direction lowering the bundle handler The balancer reaches maximum capacity when 100 psig 6 9 bar 690 kPa is applied As air pressure decreases the unit capacity decreases proportionally If 80 psig 5 5 bar 552 kPa is applied to the balancer maximum balancer operational capacity is 8096 of rated capacity For additional information refer to the Balancer Parts Operation and Maintenance manual form number MHD56151 Control T
5. 9 bar is applied as air pressure decreases the unit capacity decreases proportionally If 80 psi 5 5 bar is applied to the balancer you will obtain 80 of rated capacity For a more detailed principle of operation refer to the Ingersoll Rand Balancer Service Manual Form No MHD56151 Do not exceed 100 psig 6 9 bar 690 kPa inlet pressure Do not use a lubricator of any kind Oil will damage internal components The air supply must be clean and free from water and water vapor MHD56227 Edition 3 Air Lines The inside diameter of unit air supply lines must not be smaller than 3 8 inch 10 mm based on a maximum of 100 feet 30 m of air line between air supply and unit Contact factory for recommended air line sizes for distances greater than 100 feet 30 m Before making final connections all air supply lines should be purged 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 the lines If quick disconnect fittings are used at the inlet of the unit they must have at least a 3 16 inch 10 mm air passage Use of smaller fittings will reduce performance Connection of Air Lines ZA Control Refer to Dwg 2405 on page 7 The control tube is pre assembled tubing connected to the bundle handler Control tubes are black yellow and
6. Capscrew 8 71473 80 EndPlate LH 1 98038002 36 Plunger 2 81 End Plate RH 1 98038001 38 Side Guide LH 1 54034947 82 Fitting Connector 4 93970 40 Locknut 4 75511 83 Cylinder 2 12475DP 4l Screw 8 70219 84 Threaded Rod 2 42 Block Bracket 4 95483031 85 Cylinder Mount Bracket 2 66447030D01 43 Screw 2 72006 86 Capscrew 8 44 Tension Block 2 95483012 87 Platform Bracket 2 66447030D02 45 Retainer Ring 2 65050 88 JamNut 2 75553 46 2 65012 89 Nut 2 D 3556 47 Spacer 2 95483019 90 Side Guide 4 61871020 57 Platform 1 95483036 92 Locknut 6 75558 58 Screw 8 70446 93 Edge Locator 2 66447030D03 59 Nut 8 75503 94 Screw 4 70423 64 Side Guide RH 1 54035746 Contact factory MHD56227 Edition 3 29 SCHEMATIC PARTS DRAWING Single Cylinder Bundle Handler With Balancer BALANCER SUPPLY PILOT 5 32 WHITE HVAT 8 6 NC SIDE COVER REF 5 32 WHITE P 5 5 32 WHITE A E TOP SWIVEL HANDLE 69 RA SINGLE CONTROL 50 REF 74 CLAMP UNCLAMP O VA DN UP aE 5 32 BLACK FT 5 32 8 Or 3 8 RED TT 3 8 YELLOW Om S 5 32 YELLOW cone 5 32
7. Distance from hook throat to bottom of load bundle Dimension 2 Refer to Dwg MHP2394 on page 6 Obstruction Dwg MHP2393 Dwg MHP2394 3 Add dimension 1 to dimension 2 then add 3 1 2 inches 89 mm 4 Measuring from the floor with the wire rope fully retracted install hook using the dimension established in step 3 Refer to Balancer Parts Operation and Maintenance Manual Form No MHD56151 for hook installation information Mounting The Unit Insert load hook through lifting eye in bundle handler Ensure bundle handler lifting eye is fully seated in load hook and that hook latch is resting on hook tip Ensure bundle handler hangs freely in a horizontal position and does not tilt to one side or the other Remove the ZA control manifold from the packaging Ensure there is an ring on the back of the manifold at the balancer port Install manifold using 4 mounting screws and lock washers The white hose will be installed in the port to the left of the manifold Air System The air supply system should be purged for a minimum of 30 seconds prior to the connection of the balancer and bundle handler This will remove any debris from the air lines and help prevent damage to the controls at start up Zim Air Balancers require 1 8 of a cubic ft of air per cycle A minimum of 70 psi 4 8 bar is recommended The balancer reaches maximum capacity when 100 psi 6
8. Paddles N WES KR Y amp Y 2 N 9 VO Y N Dwg MHP2210 20 MHD56227 Edition 3 BUNDLE HANDLER ASSEMBLY PARTS LIST 34 to 50 inch 864 to 1270 mm with Standard Length Paddles Item Description Qty Part Item Description Qty Part No ofPart Total Number No ofPart Total Number 1 1 ZHS99147 38 Side Guide LH 1 95483018 2 Pin 1 77027 39 EndPlate LH 1 95483016 3 Nut 1 75516 40 Locknut 4 75511 4 Capscrew 4 72047 41 Screw 8 70219 5 Lockwasher 4 74513 42 Tension Block Bracket 4 95483031 6 Lift Bale 1 95483037 43 Shoulder Screw 2 72005 7 Sleeve 1 96944 44 Tension Block 2 95483012 8 Bearing 1 65118 45 Ring 2 65050 9 Shoulder Screw 1 73132 46 Bearing 2 65012 10 Riser RH 1 95483027 47 Spacer 2 95483019 11 Riser LH 1 95483028 48 Washer 2 74508 12 Capscrew 1 73143 49 Sprocket 2 95483020 13 Washer 2 74516 52 Cylinder 4 x 8 in 2 60600 14 Paddle LH 1 95508 53 Cover Far Side 1 95483025 15 Pin 4 77048 54 Cover Near Side 1 95483029 16 Pin 2 T1054 55 Cover Far Side 1 95483030 17 Rigid Bumper Mount 2 95536094 56 Near Side 1 95483010 18 Capscrew 4 15782 57 Platform 1 95483036 19 6 93096 58 Screw 8 70446 20 Capscrew 6 70919 59
9. Req d 93960 BK 56 Fitting Tee 1 10718 84 Tube White 5 32 in As Reqd 93960 W 57 Fitting Connector 7 93977 85 Fitting Tee 1 10708 58 Fitting Elbow 9 93969 86 Fitting Adapter 5 10703 59 Interlock Valve 1 99064 87 Quad Coil 1 93950 A 60 Fitting Elbow 4 93970 88 Fitting Connector 1 93964 61 Fitting Elbow 6 10375 89 Fitting Adapter 1 10376 62 Fitting Nipple 1 10731 90 Vent 2 90334 63 Fitting Tee 3 01964 91 4 Way Lever Valve 1 99092 e 64 Pilot Valve 4 Way 1 99099 92 Union 2 99159 65 Muffler 2 90333 93 Precoil Hose 5 32 in Orange 1 93945 66 Fitting Elbow 6 93978 94 Precoil Hose 3 8 Yellow 1 93951 Y 67 Fitting Elbow 2 01973 Precoil Hose 3 8 in Black 1 93951 B 68 Fitting Branch Y 2 93982 95 EZ Grip Control 2 18621 e 69 Pilot Valve 4 Way 1 93851 96 Shuttle Valve 3 90397 73 Fitting Swivel Elbow 2 93979 97 Bushing 2 13501 75 Quad Coil Hose Assembly 1 93950 98 Y 2 93992 76 Tube Black 3 8 in As Req d 93980 B 99 Fitting Elbow 2 10354 TI Tube Yellow 3 8 in As Req d 93980 Y 100 Tube Blue 5 32 in 1 93960 B 78 Tube Clear 3 8 in As Req d 93980 C Recommended Spare 33 PARTS ORDERING INFORMATION Bundle handlers are designed and constructed to provide long trouble free service In time it may become necessary to order and install new parts to replace those that have been subjected to wear The use of replacement parts other than Ingersoll Rand may re
10. chain on sprocket Repeat steps 1 5 7 If chain chatters or slack is detected Repeat steps 1 5 8 Thechain will be properly adjusted when clamp paddles move simultaneously with no slack on either chain or bending of tension rod Power Rotate Air Cylinder Removal Replacement Refer to Dwg MHP2242 on page 24 1 Complete General Disassembly Procedures steps 1 10 2 Remove paddle end cover 111 3 Labeland disconnect air lines from air cylinders 97 to be removed 4 Loosen locknuts 96 Slide sprocket assembly to loosen chain 5 Remove socket head capscrews 106 attaching chain to tension block 105 on cylinder rod end e 7 Remove cylinder mount clevis dowel pin 100 16 Remove roll pin from paddle end of guide bar being replaced Remove cotter pin 99 from cylinder mount dowel pin 100 8 Remove air cylinder 97 9 Remove chain tension block from air cylinder rod end 10 Assemble in reverse order 11 Perform Power Rotate Chain Tension Adjustments Power Rotate Chain Removal Replacement Complete General Disassembly Procedures steps 1 10 Remove paddle end cover 111 Loosen tension locknut 96 until chain is slack Identify and remove master links 108 of chain Remove chain 89 Assemble in reverse order Perform chain tension adjustments IONA oS Power Rotate Chain Tension Adjustment Tighten tension locknut 96 until chain has no slack Cycle power rotate Check for chain
11. cylinder clamp mount socket head screws from end cover Remove end cover as Slide guide bar assembly out of opposite end cover Assemble in reverse order Lightly lubricate guide bar assembly CO EE Clamp Chain Removal Replacement Refer to Dwg MHP2210 on page 20 NOTICE When replacing chain ensure the new chain has the same number of links as the chain not being replaced This will make adjustment of the new chain less difficult 1 Complete the General Disassembly Procedures 1 10 Remove 4 socket head capscrews 60 from side cover of chain being replaced 3 Loosen tension nut 40 of chain being replaced Slide sprocket assembly to loosen chain 5 Identify and remove the chain master links 27 One master link is located at the sprocket assembly The second master link is located on the paddle at the chain attaching bracket 23 Remove chain 26 Assemble in reverse order 8 Perform chain tension adjustments IA Chain Tension Adjustments Refer to Dwg MHP2210 on page 20 1 Open bundle handler clamp paddles 2 Tighten tension nut 40 until chain has no noticeable slack 3 Check tension rod 68 for bending 4 If tension rod is bending loosen tension nut until tension rod becomes straight 5 Cycle clamp unclamp circuit Ensure chain does not jump sprocket Check for chain chatter and slack when in clamp cycle 6 If chain jumps sprocket loosen tension nut and install
12. each shift check the system for wear and damage Never use a bundle handler that inspection indicates is worn or damaged Never lift a load greater than the rated capacity of the bundle handler Refer to SPECIFICATIONS section When bundle handler is suspended from a wire rope ensure load is centered Do not side pull or yard Never operate a bundle handler which is suspended from twisted kinked or damaged wire rope Pay attention to the load at all times when operating the bundle handler Make sure everyone is clear of the load path Do not lift a load over people Never use the bundle handler for lifting or lowering people and never allow anyone to stand on a suspended load Never weld or cut a load suspended by the bundle handler Remove load and shut off air supply before performing any maintenance Do use good posture when operating the bundle handler Check interlock for proper operation at first operation of bundle handler Do check air connections for leakage Check clamp for smooth operation WARNING LABELS Each bundle handler is shipped from the factory with the warning label shown If the label is not attached to the bundle handler order new label and install it Label is shown actual size Ingersoll Rand PN 10290 WARNING To Avoid Injury DO NOT LEAVE BUNDLE HANDLER SUSPENDED WHEN NOT IN USE DO NOT ATTEMPT TO MOVE A LOAD GREATER THAN THE BUNDLER HANDLER S CAPAC
13. 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 instructed 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 authorized review Frequent Inspections For equipment in continuous service frequent inspections should be made by operators at the beginning of each shift 1 OPERATION Check for visual signs or poor movement which could indicate a potential problem Make sure all controls function properly Check bundle handler swivels freely through 90 degrees 2 INTERLOCK Safety Circuit ZA Controls only Test operation wi
14. or 180 degrees 4 4 inch 102 mm extended paddles __ Location of controls ZA S Side E End T Top swivel B Side and end dual only Description Signature Bundle Handler SBH Dual Cylinder 2 WT z Weightless Top Swivel Handle 2P Safety Interlock INSTALLATION Prior to installing unit carefully inspect it for possible shipping damage CAUTION Owners and users are advised to examine specific local or other regulations including American National Standards Institute and or OSHA Regulations which may apply to a particular type of use of this product before installing or putting the unit into use A falling load can cause injury or death Before installing read SAFETY INFORMATION Ensure unit is properly installed A little extra time and effort in doing so can contribute a lot toward preventing accidents injuries and will help achieve the best service possible Always make certain the supporting member from which the unit is suspended is strong enough to support the weight of the unit plus the weight of a maximum rated load plus a generous factor of at least 30096 of the combined weights If in doubt contact a registered structural engineer Positioning the Load Hook To correctly install and position load hook to wire rope you must determine the following 1 Highest point which load bundle must clear from floor Dimension 1 Refer to Dwg MHP2393 on page 6 2
15. setting did not change when the jam nut was tightened Platform Adjustment If the platform is set too low the bundle may split out toward the platform If the platform is set too high the bundle will split out toward the floor Manual Platform Refer to Dwg MHP2210 on page 20 Platform 57 position is fixed located by a plunger 36 at each end A limited amount of adjustment is available in either direction The platform is factory set so that the gripper pads on the paddles align with the base of the bundle to prevent the log from splitting out No adjustment should be necessary unless the log height changes If adjustment is required pull both plungers 36 out while pushing up or down on the platform 57 Release the plungers and continue to move the platform until plungers fully engage the next hole position Typically holes are spaced at 2 in 51 mm intervals MHD56227 Edition 3 Power Platform Refer to Dwg MHP2285 on page 28 The power platform is adjusted by the threaded rod 84 The jam nuts 88 that thread onto the rods 84 act as stops for the air cylinders 83 The platform is factory set so that the gripper pads on the paddles align with the centerline of the bundle to prevent the log from splitting out No adjustment should be necessary unless the log height changes Minor adjustment can be made by changing the position of the jam nuts 88 on threaded rods 84 to shorten the stroke of t
16. supporting a load Before performing maintenance tag controls WARNING DO NOT OPERATE EQUIPMENT BEING REPAIRED Only allow personnel trained in safety and maintenance on this unit to perform service Use of replacement parts other than Ingersoll Rand original parts could result in damage to the unit and void the warranty Maintenance Intervals The Maintenance Interval chart is based on intermittent operation of the bundle handler eight hours each day five days per week If bundle handler operation is more than eight hours per day or in HEAVY or SEVERE environments more frequent maintenance should be performed Refer to Periodic Inspection in the INSPECTION section for additional information INTERVAL MAINTENANCE CHECK Start of each shift Make a thorough visual inspection of the bundle handler for damage Do not operate Operator or if damaged Maintenance Operate the system through the normal Personnel range of movements System must operate smoothly without sticking binding or abnormal noises 3 Months Inspect interlock Clean or replace parts as required Maintenance Check pivot assembly and guide bars Personnel Yearly Check all the supporting members including the balancer fasteners nuts etc Maintenance for indications of damage or wear Repair Personnel or replace as required Adjustments Refer to OPERATION section for all adjustme
17. 1 95483010 18 Capscrew 4 15782 57 Platform 1 95483036 19 Bumper 6 93096 58 Screw 8 70446 20 Capscrew 6 70919 59 Locknut 8 75503 21 Washer 6 74529 60 Screw 12 70112 22 Locknut 2 75517 63 EndPlate RH 1 95483015 23 Chain Bracket 2 95483013 64 Side Guide RH 1 95483040 24 Lockwasher 4 74506 65 Bearing 8 65042 25 Capscrew 4 70437 66 Bearing Tube 4 95483009 26 Chain As Req d 99005 67 Paddle RH 1 95508 27 Chain Connecting Link 4 99006 68 Arm RH 1 95483014 28 Guide Bar 4 96138 69 Capscrew 1 10019 29 Arm LH 1 95483011 70 End Handle 1 95483022 30 Pin 2 77005 71 Capscrew 2 70430 31 Arm Bracket 2 95483032 73 Handle Clamp 2 95483024 32 Cylinder Rod Extension 2 95483041 74 Control Handle Mount RH 1 95483023 33 Spherical Washer Set 2 99011 75 Capscrew 4 34 Capscrew 16 71473 76 Handle Mount LH 1 95483038 35 Side Guide 4 95483017 77 Control Handle Mount 2 95483034 36 Plunger 2 99012 End Paddle 37 Platform Bracket 2 95483035 23 POWER ROTATE PADDLE ASSEMBLY PARTS DRAWING Standard Length Paddles Dwg MHP2242 MHD56227 Edition 3 24 POWER ROTATE PADDLE ASSEMBLY PARTS LIST Item Description Qty Part Item Description Qty Part No ofPart Total Number Total Number 14 Paddle LH 1 95508 94 1 65012 17 Bumper Mount 1 95483026 95 Washer 1 74508 19 Bumper 6 93096
18. 1 x 318 mm Extended paddles designed to clamp on end boards and handle cross sections up to 14 5 in x 17 5 in 368 x 445 mm Maximum bundle length of 48 in 1219 mm unit allows for 12 in 305 mm to 26 in 660 mm of variance between min max bundle length based on cylinder length Note Although the bundle handler opens 16 in 406 mm or 30 in 762 mm it is recommended to allow 2 in 51 mm of variance to clear the bundle when fully opened and to allow for compression of the bundle when clamped Signature Bundle Handler Dual Cylinder 16 in Stroke Unit No SBH22248 Description Lift bundles from 22 in 559 mm to 38 in 965 mm SBH22436 SBH22638 Lift bundles from 24 in 610 mm to 40 in 1016 mm Lift bundles from 26 in 660 mm to 42 in 1067 mm SBH23042 SBH23244 Lift bundles from 28 in 711 mm to 44 in 1118 mm Lift bundles from 30 in 762 mm to 46 in 1168 mm SBH23246 SBH23450 Lift bundles from 32 in 813 mm to 48 in 1219 mm Lift bundles from 34 in 864 mm to 50 in 1270 mm Note All units come equipped with hose fittings and controls Signature Bundle Handler Dual Cylinder 30 in Stroke Unit No Description SBH22050 MHD56227 Lift bundles from 20 in 508 mm to 50 in 1270 mm Edition 3 Model Code Explanation Dual Cylinder SBH22248 S D R 4 Options D Dual controls R Power rotate 90
19. 27 93 08 08 Fax 33 3 27 93 08 08 For additional information on the following products order the publication by the referenced Part Document Number listed 34 Publication Part Document Number Publication Part Document Number Z Balancer MHD56151 Z Rail System MHD56159 Manipulator Arm MHD56162 Valu Trak Rail System MHD56161 MHD56227 Edition 3 LIMITED WARRANTY Ingersoll Rand Company I R warrants to the original user its Products to be free of defects 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 warranted for the remainder of the original warranty period If any Product proves defective within its original one year warranty period it should be returned to any Authorized I R Material Handling Service Distributor transportation prepaid with proof of purchase or warranty card This warranty does not apply to Products which I R has determined to have been misused or abused improperly maintained by the user or where the malfunction or defect can be attributed to the use of non genuine I R parts I R makes no other warranty and all implied warranties including any warranty of merchantability or fitnes
20. 32 Clamp Pad 2 96952 5 Pin 2 77058 33 Capscrew 8 ZHS71508 6 Pivot 1 96959 34 Lockwasher 8 74530 7 Shoulder Screw 1 72006 35 Rest Pad 2 96954 8 Eye Nut 1 ZHS99147 36 Cylinder Mount 1 96949 9 Pin 1 77027 37 Retainer Ring 4 99145 10 Bearing 2 ZHS65117 38 Cylinder 1 7 560604 12 Locknut 1 75511 39 Bottom Cover 1 96951 13 Handle Mount 1 96958 40 Sleeve 2 65117 14 Nut without Swivel Handle 1 75516 41 Bearing 4 65042 Nut with Swivel Handle 1 75534 Support Tube 24 32 2 16010779 15 Handle Stop 1 96957 42 Support Tube 32 40 2 87306650 16 Capscrew 4 ZHS72024 Support Tube 40 48 2 96941 17 Lockwasher 4 74532 43 Guide Bar 2 97081 18 Bar 2 97370 75 Cylinder Rod Extension 24 32 1 87306643 19 Lift Bale 1 96943 44 Cylinder Rod Extension 32 40 1 87306635 20 Bushing 1 65119 Cylinder Rod Extension 40 48 1 22 Sleeve 1 96944 45 Screw 6 77045 23 Bearing 1 65118 46 Washer Set 1 99011 Shoulder Screw without 73132 47 Clamp Paddle 1 96946 34 Swivel Handle 48 Washer 1 74516 Shoulder Screw with Swivel 1 73133 49 Capscrew 1 ZHS10013 Handle 50 D Handle optional 2 97077 25 Cover 1 96950 51 Capscrew 4 70512 26 Cover air supply side 1 97074 52 Nut 4 75528 27 Capscrew 20 70221 114 Control Mounting Bracket 1 97500 28 Grommet 1 99146 MHD56227 Edition 3 19 BUNDLE HANDLER ASSEMBLY PARTS DRAWING Dual Cylinder 34 to 50 inch 864 to 1270 mm with Standard Length
21. 7 Edition 3 31 SCHEMATIC PARTS DRAWING Dual Controls Power Rotate Bundle Handler With Balancer Supply Y 174 Black c 8 MN Ee pee Clamp Unclamp 54 66 86 r 1 3 8 Yellow CA 2 3 8 X po Down Up 90 7 LA 3 N 1 A nm Up Down 94 Dwg MHP2217 32 MHD56227 Edition 3 SCHEMATIC PARTS DRAWING AND LIST MHD56227 Edition 3 Item Description Qty Part Item Description Qty Part No ofPart Total Number No ofPart Total Number 1 Control Handle 2 18600 79 Tube Red 3 8 in As Req d 93980 R 51 Bulkhead Union 7 93956 80 Tube Green 1 4 in As Req d 93961 G 53 Fitting Connector 2 93966 81 Tube Green 5 32 in As Req d 93960 G 54 Coupling 7 10466 82 Yellow 5 32 in As Req d 93960 Y 55 Check Valve 1 13270 83 Black 5 32 in As
22. 96 Locknut 2 75542 20 Capscrew 6 70919 97 Cylinder 2 x 3 75 in 2 60750 21 Washer 6 74529 98 Fitting Elbow 4 93970 80 Counterweight 1 95872 99 Cotter Pin 2 81 Capscrew 4 15782 100 Pin 2 95483006 82 Retainer Ring 1 65053 101 Sprocket 1 95483008 83 Bearing 2 65043 103 Retainer Ring 1 65052 84 Retainer Ring 2 65051 104 Locknut 2 75558 85 Bumper Mount Power Rotate 1 95483003 105 Chain Tension Block 2 95483005 86 Key 1 3 16 sq x 1 106 Capscrew 8 70011 87 Bushing 2 65046 107 Link Attachment 2 99003 88 Spacer 1 95483004 108 Master Link 3 99006 89 Chain 1 99005 109 Capscrew 7 70423 90 Sprocket 1 99002 110 Detent Pin 1 99010 91 Tension Plate 1 95483007 111 1 95509 92 Spacer 1 95483002 112 Paddle Power Rotate RH 1 95506 93 Retainer Ring 1 65050 Contact factory MHD56227 Edition 3 25 POWER ROTATE PADDLE ASSEMBLY PARTS DRAWING 4 inch 102 mm Extended Paddles nu Dm TRE Ka p gt GE e GE Dwg MHP2404 MHD56227 Edition 3 26 POWER ROTATE PADDLE ASSEMBLY PARTS LIST Item Description Qty Part Item Description Qty Part No of Part Total Number No Total Number 14 Paddle LH 1 97523 94 1 65012 17 Bumper Mount 1 95483 94 95 Washer 1 74508 19 Bumper 6 93096 96 Locknut 2 75542 20 Capscrew 6 70919 97 Cy
23. BLACK 83 Dwg MHP2183 30 MHD56227 Edition 3 SCHEMATIC PARTS LIST Item Description Qty Part Item Description Qty Part No jof Part Total Number No of Part Total Number 1 Control Handle 1 18600 66 Fitting Elbow 2 93978 3 Pressure Gauge 1 99152 67 Fitting Elbow 1 01973 38 Cylinder 1 60604 68 Fitting Branch Y 1 ZHS93982 50 Valve 2 93849 69 Pilot Valve 4 Way 1 93851 51 Bulkhead Union 1 93956 70 Fitting Nipple 1 10370 52 Bulkhead Connection 1 ZHS93955 71 Fitting Connector 1 93963 53 Fitting Connector 1 ZHS93966 72 Coupling 1 10465 54 Coupling 1 10466 73 Fitting Elbow 2 93979 55 Check Valve 1 13270 74 Button Brass 2 93850 56 Fitting Tee 1 10718 75 Quad Coil Hose Assembly 1 ZHS93949 57 Fitting Connector 2 93977 76 Tube Black 3 8 in As Req d 93980 B 58 Fitting Elbow 5 ZHS93969 77 Tube Yellow 3 8 in As Req d 93980 Y 59 Interlock Valve 1 99064 78 Tube Clear 3 8 in As Req d 93980 C 60 Fitting Elbow 5 93970 79 Tube Red 3 8 in As Req d 93980 R 61 Fitting Elbow 3 10375 80 Tube Green 1 4 in As Req d 93961 G 62 Fitting Nipple 1 10731 81 Tube Green 5 32 in As Req d 93960 G 63 Fitting Tee 3 01964 82 Tube Yellow 5 32 in As Req d 93960 Y 64 Pilot Valve 4 Way 1 99099 83 Tube Black 5 32 in As Req d 93960 B 65 Muffler 2 90333 84 Tube White 5 32 in As Req d 93960 W MHD5622
24. Form MHD56227 PARTS OPERATION AND MAINTENANCE MANUAL for BUNDLE HANDLER Dwg MHP2184 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 This equipment is intended for industrial use only and should not be used for lifting supporting or transporting people or lifting or supporting loads over people Always operate inspect and maintain this unit in accordance with applicable safety codes and regulations Form MHD56227 Edition 3 October 2013 I 71374391 dR Ingersoll Rand 2013 Ingersoll Rand Company 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 A DANG ER hazardous situation which if not avoided will result in death or serious injury Indicates a potentially WARNIN G hazardous situation which if no
25. ITY DO NOT TURN BUNDLE HANDLER CONTINUOUSLY IN ONE DIRECTION DO NOT ATTEMPT TO MOVE A LOOSELY CLAMPED LOAD DO NOT PUT PERSONS OR BODY PARTS IN CLAMP PATH DO USE GOOD POSTURE WHEN OPERATING BUNDLE HANDLER DO CHECK INTERLOCK CIRCUIT AT FIRST OPERATION OF THE DAY DO CHECK AIR CONNECTIONS FOR LEAKAGE DO CHECK CLAMP FOR SMOOTH OPERATION DO USE 70 P S I MIN 100 P S I MHD56227 Edition 3 SPECIFICATIONS Features Single Cylinder Dual Cylinder Bundle Lengths 24 48 in 610 1219 mm 34 50 in 864 1270 mm 20 50 in 508 1270 mm Maximum Load 250 Ibs 114 kg Minimum Bundle Length 24 in 610 mm 36 in 915 mm 22 in 559 mm Maximum Bundle Length 48 in 1219 mm Clamp Force 90 psi 6 3 bar 900 Ibs 409 kg 942 bs 428 kg Weight varies with options 100 Ibs 45 5 kg 180 Ibs 82 kg Operating Pressure Range 70 psi 4 8 bar Minimum 100 psi 6 9 bar Maximum Description The bundle handler is an ergonomic handling device designed to move Signature Bundles The bundler handler incorporates either a single or dual air cylinder system to open and close clamping plates paddles Bundle handlers are supplied with an interlock system to prevent accidental release of the bundle The bundle handler is designed to be supported by an Air Balancer and operated with an integral control system A signature bundle or Log is a horizontal or vertica
26. Side 1 95537008 MHD56227 Edition 3 21 BUNDLE HANDLER ASSEMBLY PARTS DRAWING Dual Cylinder 34 to 50 in 864 to 1270 mm with 4 inch Extended Length Paddles Dwg MHP2401 22 MHD56227 Edition 3 BUNDLE HANDLER ASSEMBLY PARTS LIST Contact factory Refer to Dwg MHP2210 on page 20 for parts listed on this page that are not shown on Dwg MHP2401 MHD56227 Edition 3 Item Description Qty Part Item Description Qty Part No jof Part Total Number No of Part Total Number 1 Eye Nut 1 ZHS99147 38 Side Guide LH 1 95483039 2 Pin 1 77027 39 End Plate LH 1 95483016 3 Nut 1 75516 40 Locknut 4 75511 4 Capscrew 4 72047 41 Screw 8 70219 5 Lockwasher 4 74513 42 Tension Block Bracket 4 95483031 6 Lift Bale 1 95483037 43 Shoulder Screw 2 72005 7 Sleeve 1 96944 44 Tension Block 2 95483012 8 Bearing 1 65118 45 Retainer Ring 2 65050 9 Shoulder Screw 1 73132 46 2 65012 10 Riser RH 1 95483027 47 Spacer 2 95483019 11 Riser LH 1 95483028 48 Washer 2 74508 12 Capscrew 1 73143 49 Sprocket 2 95483020 13 Washer 4 74516 52 Cylinder 4 x 15 in 2 60605 14 Paddle LH 1 97523 53 Cover Far Side 1 95483025 15 Pin 4 77048 54 Near Side 1 95483029 16 Pin 2 77054 55 Cover Far Side 1 95483030 17 Rigid Bumper Mount 2 95536094 56 Near Side
27. clamp circuit is disabled to prevent accidental unclamping of a suspended load and air passes directly to the clamp side of the cylinder When the load is set down the pilot pressure from the balancer is reduced The valve will shift to its original state allowing the unclamp circuit to function and the load to be released MHD56227 Edition 3 Bundle Handler Operation If bundle is not held securely by Signature Bundle Handler and slips out of clamp the empty handler will rise rapidly with the approximate force of the load If system air pressure is lost lower load immediately The operator must stay out of the vertical path of the bundle handler and load Clamp may lose force required to hold load which can cause severe injury or property damage The UP and DN levers allow adjustable speed control As the lever is depressed further the operational speed increases Use the lever to throttle the speed to ensure controlled movement of the bundle handler Dwg MHP2406 Do not wrap control hoses around wire rope Damage to hoses and failure of bundle handler may result Proper turning of the bundle handler prevents twisting and wear of the balancer wire rope and air control lines Do not attempt to continuously turn in one direction rather reverse direction with each cycle Raising and lowering of the bundle handler is dependent on the type of control circuit on the handling de
28. clatter and slack during cycle Repeat steps 1 3 until rotating paddle moves smoothly PSI ES Cleaning Inspection and Repair Examine disassembled components and fasteners for wear or damage If worn or damaged do not reuse During reassembly all damaged and worn components should be replaced to prevent component failure which may result in injury or property damage It is recommended that locknuts be discarded and replaced with new ones after each use Use the following procedures to clean inspect and repair the bundle handler and associated components Cleaning Thoroughly clean all bundle handler components in solvent The use of a stiff bristle brush will facilitate the removal of accumulated dirt and sediments on the housings Wipe off each part after cleaning Remove all old Loctite residue Inspection All disassembled parts should be inspected to determine their fitness for continued use Pay particular attention to the following 1 Inspect all threaded items and replace those having damaged threads 2 Inspect pivot handle Replace if bent distorted or worn 3 Inspect air lines for cracks cuts and leakage Ensure there are no pinched air hoses Inspect air fittings for cracks leakage and security Inspect maneuvering handles for wear and damage Ensure clamp valve functions Ensure bundle handler support swivel assembly rotates freely ON Repair Actual repairs are limited to the rem
29. clear 3 8 inch 4 5 mm and white 5 32 inch 3 9 mm precoiled assemblies The yellow tube must be connected to the down port of the ZA manifold on the balancer The black tube must be attached to the up port of the ZA manifold The white tube must be installed in the pilot port of the balancer White Black Yellow Clear Control Hose a Dwg MHP2405 coo o 5 lt Air Line Filter It is recommended that an air line strainer filter be installed as close as practical to the unit air inlet port The strainer filter should provide 5 micron filtration and include a moisture trap Clean the strainer filter monthly to maintain its operating efficiency MHD56227 Edition 3 To maintain dry air the frequency for draining the filter should also be based on the condition of the air supply We suggest the filter be drained weekly at first Depending on air supply condition a proper filter drain schedule should be established Moisture in Air Lines Moisture that reaches the unit through supply lines is the chief 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 the unit controls or an aftercooler at the compressor that cools the air prior to distribution through the supply lines are also helpful
30. erial Number Inspected By Reason for Inspection Check Applicable Box 1 Scheduled Periodic Inspection Quarterly Semiannually Yearly Operating Environment 2 Discrepancies noted during Frequent Inspection 3 Discrepancies noted during Maintenance P g Normal Heavy Severe 4 Other Refer to the Parts Operation and Maintenance Manual INSPECTION section for general inspection criteria Also refer to appropriate National Standards and codes of practice If in doubt about an existing condition contact the nearest Ingersoll Rand Distributor or the factory for technical assistance CONDITION CORRECTIVE ACTION NOTES COMPONENT Pass Fail Repair Replace Fasteners Fittings 5 Lifting Eye Assembly e Air Cylinder s Guide Bars Covers Housings Controls Switches Lu Refer to Balancer Parts Operation and Balancer Maintenance Manual MHD56151 Clamp Pads Handles Labels and Tags Other Components list in NOTES section This page may be photocopied and used as an Inspection Maintenance record MHD56227 Edition 3 13 TROUBLESHOOTING Refer to the Balancer Parts Operation and Maintenance Manual Form No MHD56151 for Balancer Control specific problems The following table is for bundle handler specific problems This section provides basic troubleshooting information Specific causes to problems are best identified by thoro
31. ft suspended when not in use Lower the Signature Bundle Handler to the floor or pallet out of the work area 3 Raise bundle handler to clear the pick up point and maneuver to the set down point 4 At the set down point depress the down lever and lower the bundle completely 5 Actuate the clamp open button or lever while continuing to depress the down lever to unclamp and disengage the bundle Maneuver the bundle handler back to the pick up point and repeat steps Power Rotate Paddle optional feature Refer to Dwgs MHP2242 on page 24 and MHP2407 on page 9 The power rotate optional feature allows the bundle to be rotated a maximum of 180 Install the detent pin 110 in the paddle cover upper hole when not required or when using the full 180 rotate Install the detent pin 110 in the paddle cover lower hole to stop rotation at 90 Ensure detent pin is pushed all the way in to engage detents Stow pin Install detent in upper pin in lower hole when hole to stop not in use rotation at 90 Dwg MHP2407 Operation Adjustments Air supply pressure must be a minimum of 70 psig 4 8 bar 480 kPa and a maximum of 100 psig 6 9 bar 690 kPa Excessive air pressure may damage the balancer or controls Prior to adjustment of controls ensure air is off and wire rope is slack The interlock should not be adjusted until all control adjustments have been completed The interlock may not function properl
32. he air cylinders 83 The gripper pads on the paddles must align with the centerline of the bundle When correct adjustment is achieved tighten jam nuts Ensure platform is adjusted equally at both ends Yarding Do not operate bundle handler if load is not centered under Balancer wire rope Yarding of the wire rope will cause premature wear to wire rope and Balancer wire rope guides Wire rope should not be yarded more than 10 degrees from vertical Excessive yarding may create unsafe operation cause increased wear on balancer and decrease working life of related components MHD56227 Edition 3 11 INSPECTION All new or repaired equipment should be inspected and tested by personnel instructed in safety operation and maintenance of this equipment to ensure safe operation at rated specifications before placing equipment is service Never use a unit 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 personnel trained in safety and operation of this equipment 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 Inspection intervals will depend upon the nature of the critical components of the equipment and the severity
33. hile in transit notify the carrier s agent immediately MHD56227 Edition 3 Damage Claims You must file claims for damage with the carrier It is the transportation company s responsibility to reimburse you for repair or replacement of goods damaged in shipment Claims for loss or damage in shipment must not be deducted from the Ingersoll Rand invoice nor should payment of Ingersoll Rand invoice be withheld awaiting adjustment of such claims as the carrier guarantees safe delivery You may return products damaged in shipment to us for repair which services will be for your account and form your basis for claim against the carrier 35 www ingersollrandproducts com ner soll Rand
34. l stack of paper usually from 24 in 610 mm to 48 in 1219 mm wide The bundle is held together with a strap around the length and has wood boards at each end The stapled side of a signature is referred to as a spine Single Cylinder Max Opening 53 3 8 Dwg 2648 e Standard paddles designed to clamp on end boards and handle cross sections from 6 in x 9 in 152 x 229 mm to 12 in x 12 in 305 x 305 mm Minimum bundle length of 24 in 610 mm maximum bundle length of 48 in 1219 mm unit allows for 6 in 152 mm of variance between min max bundle length Note Although the bundle handler opens 10 in 254 mm it is recommended to allow 2 in 51 mm of variance to clear the bundle when fully opened and to allow for compression of the bundle when clamped Model Code Explanation Single Cylinder SBH1 O STYLE Signature Bundle Handler Series I 87306428 CONTROLS 1 Single Side Control 87306536 2 Dual Side Control 87306544 3 End Control 87306551 4 Side amp End Control 87306569 5 Top Swivel Handle Control 87306577 BUNDLE SIZES 1 24 32 610 mm 813 mm 87306585 2 32 40 813 mm 1016 mm 87306593 3 40 48 1016 mm 1219 mm 87306601 FUTURE OPTIONS MHD56227 Edition 3 Dual Cylinder Dwg MHP2211 e Designed to clamp on end boards and handle cross sections of up to 9 5 in x 12 5 in 24
35. levers correct before placing bundle handler in service 2 Actuate clamp control 3 Actuate rotate control if equipped With Load 1 Place a test load equal to 100 of capacity 2 Actuate UP lever bundle handler should rise smoothly Actuate DOWN lever Bundle handler should lower smoothly If movement direction does not match levers correct before placing bundle handler in service 3 Actuate clamp control Interlock Valve NOTICE Interlock valve will not allow clamp control to release while bundle handler is supporting a load 1 test engage nose assembly in a load and lift 2 3 inches 51 76 mm off the floor Actuate clamp control to the unclamp position Load should remain secured to bundle handler For adjustments refer to Operation Adjustments on page 10 17 BUNDLE HANDLER ASSEMBLY PARTS DRAWING Single Cylinder 24 to 48 inch 610 to 1219 mm bundles Without Swivel Handle Dwg MHP2181 18 Optional Control Mount MHD56227 Edition 3 BUNDLE HANDLER ASSEMBLY PARTS LIST Item Description Qty Part Item Description Qty Part No of Part Total Number No of Part Total Number 1 Control Handle Assembly 1 18600 29 Fixed Paddle 1 96947 2 Screw 3 70424 30 Pin 6 77048 3 Pressure Gauge 1 99152 31 Bracket 1 97501 4 Handle 1 97370 15
36. linder 2 x 3 75 2 60750 21 Washer 6 74529 98 Fitting Elbow 4 93970 80 Counterweight 1 95872 99 Cotter Pin 2 81 Capscrew 4 15782 100 Pin 2 95483 8 82 Retainer Ring 1 65053 101 Sprocket 1 99001 83 Bearing 2 65043 102 Clevis 2 96168 84 Retainer Ring 2 65051 103 Retainer Ring 1 65052 85 Bumper Mount Power Rotate 1 95483 4 104 Locknut 2 60751 86 Key 1 3l6sqxlin 105 Tension Block 2 95483 5 87 Bushing 2 65046 106 Capscrew 8 70011 88 Spacer 1 95483 6 107 Link Attachment 2 99003 89 Chain 1 99005 108 Master Link 3 99006 90 Sprocket 1 99002 109 Capscrew 2 70402 91 Tension Plate 1 95483 7 111 1 97524 92 Spacer 1 95483 3 112 Power Rotate RH 1 97521 93 Retainer Ring 1 65050 113 Capscrew 2 71445 Contact factory MHD56227 Edition 3 27 2 Z em z A un 24 lt 5 p 2 N an lt lt 5 2 Z gt E 2 Z Q lt e E on 480 PI 79 5 Sener NS LY MHD56227 Edition 3 RH gj TNE OY For 34 to 50 inch 864 to 1270 mm bundles Dwg MHP2285 28 SELF RETRACTING LEVELING PAD ASSEMBLY PARTS LIST Item Description Qty Part Item Description Qty Part No ofPart Total Number No ofPart Total Number 34
37. nts Disassembly Refer to Dwgs MHP2181 on page 18 and MHP2210 on page 20 Labeling all air lines with valve port number or location prior to disconnection will ease reassembly of the bundle handler 1 Lower bundle handler to the floor or a suitable work surface 2 Turn off and lock out the system air supply 3 Depress the down lever until all the air has been exhausted from the balancer and the load cable is slack 4 Remove the load hook from the bundle handler lifting eye 5 Label and disconnect the air lines at the top of the bundle handler 6 Remove 4 socket head capscrews and lockwashers from top of bundle handler MHD56227 Edition 3 7 Remove bundle handler top cover 8 Remove socket head capscrews from the top front and back side covers Remove top front and back side covers 10 Ensure all cable ties are removed prior to any component removal and replaced upon completion of tasks Interlock Valve Removal Replacement Refer to Dwg MHP2183 on page 30 1 Complete the General Disassembly Procedures 1 10 2 Label and disconnect air lines to the valve package 3 Carefully remove the valve package from bundle handler 4 Label and disconnect air fittings connected to the interlock valve 59 Remove interlock valve 59 Assemble in reverse order 7 Adjust and test interlock valve Refer to OPERATION section The interlock valve must be adjusted and tested prior to putting the b
38. of an operation or maintenance procedure or step personnel should place the product in a safe condition and contact supervisors and or the factory for technical assistance MHD56227 Edition 3 SAFE OPERATING INSTRUCTIONS The following warnings and operating instructions are intended to avoid unsafe operating practices which might lead to injury or property damage Ingersoll Rand recognizes that most companies who use material handling equipment have a safety program in force at their facility If you are aware 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 The manual supports a fully installed system Operators should be familiar with the operation of the controls before using the system 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 on this product to operate and maintain the system 2 Only operate bundle handler if you are physically fit to do so 3 When a NOT OPERATE sign is placed on the system do not operate the bundle handler until the sign has been removed by designated personnel 4 10 11 12 13 14 15 16 Before
39. ould be injured This means keep out from under a raised load and keep out of the line of force of any load 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 This manual has been produced by Ingersoll Rand to provide dealers mechanics operators and company personnel with the information required to install operate maintain and repair the products described herein It is extremely important that mechanics and operators be familiar with the servicing procedures of these products or like or similar products and are physically capable of conducting the procedures These personnel shall have a general working knowledge that includes 1 Proper and safe use and application of mechanics common hand tools as well as special Ingersoll Rand or recommended tools 2 Safety procedures precautions and work habits established by accepted industry standards Ingersoll Rand cannot know of or provide all the procedures by which product operations or repairs may be conducted and the hazards and or results of each method If operation or maintenance procedures not specifically recommended by the manufacturer are conducted it must be ensured that product safety is not endangered by the actions taken If unsure
40. oval of small burrs and other minor surface imperfections Use a fine stone or emery cloth for this work 1 Worn or damaged parts must be replaced Refer to parts section for specific replacement parts information MHD56227 Edition 3 2 Inspect all remaining parts for evidence of wear or damage Replace or repair any parts which are in questionable condition The cost of the part is often minor in comparison with the cost of redoing the job Assembly Bundle Handler Refer to Dwgs MHP2181 on page 18 and MHP2210 on page 20 1 Gather air lines together and install cable ties to ensure lines do not rub bind or get pinched during bundle handler operation 2 Install top front and back side covers with capscrews 3 Install bundle handler top cover with lockwashers and capscrews 4 Connect air lines to the top of the bundle handler as labeled during disassembly 5 Attach the Balancer load hook to the bundle handler lifting eye 6 Turn on the system air supply 7 Check all bundle handler functions to ensure correct operation Testing Prior to testing bundle handlers various control valves must be adjusted Refer to Operation Adjustments on page 10 for these adjustments MHD56227 Edition 3 Bundle Handler With NO load 1 Actuate UP lever bundle handler should rise smoothly Actuate DOWN lever bundle handler should lower smoothly If movement direction does not match
41. s bearings springs clamp pads and covers Replace worn or damaged parts Clean lubricate and reassemble 3 SUPPORTING STRUCTURE Check for distortion wear and continued ability to support load 4 LABELS AND TAGS Check for presence and legibility of labels Replace if damaged or missing 5 BALANCER Follow inspection recommendations in Balancer Parts Operation and Maintenance Manual form MHD56151 6 POWER ROTATE optional feature Inspect for proper operation and leakage 7 COVERS Check covers are installed and secure Replace if damaged or missing 8 ZA CONTROL HANDLE Check for tubing leaks and security of connections Ensure levers operate freely Units Not in Regular Use 1 Units which have been idle for a period of one month or more but less than one year should be given an inspection conforming with the requirements of Frequent Inspection prior to being placed into service 2 Units which have been idle for a period of more than one year should be given an inspection conforming with the requirements of Periodic Inspection prior to being placed into service 3 Standby units should be inspected at least semiannually in accordance with the requirements of Frequent Inspection In abnormal operating conditions units should be inspected at shorter intervals MHD56227 Edition 3 INSPECTION AND MAINTENANCE REPORT Ingersoll Rand End Effectors Bundle Handler Model Number Date S
42. s for a particular purpose are limited to the duration of the expressed warranty period as set forth above I R s maximum liability is limited to the purchase price of the Product and in no event shall I R be liable for any consequential indirect incidental or special damages of any nature rising from the sale or use of the Product whether based on contract tort or otherwise Note Some states do not allow limitations on incidental or consequential damages or how long an implied warranty lasts so that the above limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state IMPORTANT NOTICE It is our policy to promote safe delivery of all orders This shipment has been thoroughly checked packed and inspected before leaving our plant and receipt for it in good condition has been received from the carrier Any loss or damage which occurs to this shipment while en route is not due to any action or conduct of the manufacturer Visible Loss or Damage If any of the goods called for on the bill of lading or express receipt are damaged or the quantity is short do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt Concealed Loss or Damage When a shipment has been delivered to you in apparent good condition but upon opening the crate or container loss or damage has taken place w
43. ss UP lever on the ZA control block Adjust UP control screw by turning counterclockwise until desired speed is achieved Interlock Clamp Adjustment The interlock should not be adjusted until all control adjustments have been completed NOTICE It may be necessary to actuate clamp and unclamp button lever several times to obtain the correct interlock setting Interlock is only present on ZA controlled bundle handlers 1 With empty bundle handler device suspended by the balancer adjust interlock adjustment screw by turning counterclockwise until 3 4 inch 19 mm of thread is visible 2 While cycling clamp and unclamp functions turn interlock adjustment screw clockwise until both clamp and unclamp circuits function 3 Cycle clamp unclamp switch several times to ensure smooth operation and that the interlock valve is shifting completely 4 Raise empty bundle handler to its up stop Depress UP lever for 3 to 4 seconds to simulate a load on the balancer 5 Actuate clamp and unclamp circuits Clamp should not open Air may be heard discharging to the atmosphere 6 If clamp does open repeat this adjustment procedure until clamp does not open with bundle handler at the up stop 7 interlock valve is adjusted correctly hold interlock stem with a suitable pair of pliers and tighten 3 8 inch jam nut on interlock adjustment screw to prevent setting from changing Repeat the interlock test to ensure the
44. sult in decreased performance and may at the company s option invalidate the warranty For prompt service and genuine Ingersoll Rand parts provide your nearest Distributor with the following 1 Complete Model description 2 Part number and part description as shown in this manual 3 Quantity required For your convenience and future reference it is recommended that the following information be recorded Model Description Date Purchased Serial Number Return Goods Policy Ingersoll Rand will not accept any returned goods for warranty or service work unless prior arrangements have been made and written authorization has been provided from the location where the goods were purchased NOTICE Continuing improvement and advancement of design may produce changes to this unit which are not included in this manual Manuals are periodically revised to incorporate changes Always check the manual edition number on the front cover for the latest issue Disposal When the life of the unit has expired it is recommended that the air motor be disassembled degreased and parts separated as to materials so that they may be recycled For additional information contact Ingersoll Rand Handling Systems 1872 Enterprise Drive Rochester Hills MI 48309 Phone 248 293 5700 248 293 5800 or Ingersoll Rand Douai Operations 529 Avenue Roger Salengro 59450 Sin Le Noble France Phone 33 3
45. t avoided could result in death or serious injury Indicates a potentially A CAUTION hazardous situation which if not avoided may result in minor or moderate injury or property damage Indicates information or a NOTICE company policy that relates directly or indirectly to the safety of personnel or protection of property Safety Summary Personal protective and safety equipment should be used and maintained in accordance with the manufacturer s instructions Do not use this unit or attached equipment for lifting supporting or transporting people or lifting or supporting loads over people The supporting structures and load attaching devices used in conjunction with these units must provide a safety factor of at least three times the rated capacity of the unit This is the customer s responsibility If in doubt consult a registered structural engineer If system air pressure is lost lower the load immediately The operator must stay out of the vertical path of the load NOTICE Lifting equipment is subject to different regulations in each country These regulations may not be specified in this manual N Employees who work near suspended loads or assist in positioning 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 w
46. th no load Raise empty bundle handler to the UP stop With UP lever depressed for 3 to 4 seconds to simulate load actuate clamp and unclamp circuit Clamp should not open Refer to OPERATION section Interlock for correction instructions 3 AIR SYSTEM Visually inspect all connections fitting hoses and components for indication of air leaks Repair any leaks or damage tighten any loose connections 4 BALANCER Follow inspection recommendations in Balancer Parts Operation and Maintenance Manual form MHD56151 12 5 GUIDE BARS Ensure guide bars are clean and lubricated Clean guide bars when dirty or binding occurs Use a multipurpose synthetic lubricant to lubricate guide bars 6 WIRE ROPE Inspect for wear and lubrication Replace kinked frayed or twisted wire rope Periodic Inspection Frequency of periodic inspection depends on the severity of usage NORMAL HEAVY SEVERE Yearly Semiannually Quarterly Disassembly may be required for HEAV Y 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 1 FASTENERS Check all rivets split pins capscrews and nuts Replace if missing or tighten if loose 2 ALL COMPONENTS Inspect for wear damage deterioration deformation and cleanliness If external evidence indicates the need disassemble Check handles housing
47. ugh inspections performed by personnel instructed in safety operation and maintenance of this equipment The chart below provides a brief guide to common symptoms possible causes and remedies Symptom Possible Cause Remedy Clamp does not close when clamp button or lever is actuated Air supply on bundle handler is off Interlock valve is not set correctly Turn on air supply at bundle handler Refer to Interlock safety circuit in the OPERATION section Clamp switch incorrectly connected Refer to PARTS section for schematic drawings Clamp does not open when clamp button or lever is actuated The weight of the bundle has not been completely removed from the bundle handler Refer to Interlock safety circuit in the OPERATION section Clamp switch incorrectly connected Refer to PARTS section for schematic drawings The Interlock valve is not set correctly Refer to OPERATION section Clamp does not operate smoothly or does not function at all Power rotate of bundle does not operate smoothly or is inoperative Debris in air lines or fittings Remove debris Flush air lines Loose or broken air lines or fittings Tighten connections or replace air lines or fittings Improper interlock adjustment Refer to Adjustment Procedures Faulty clamp button Faulty clamp valve Faulty air cylinder Replace clamp button Replace clamp valve
48. undle handler into production An Clamp and Power Rotate Button Valve Removal Replacement Complete the General Disassembly Procedures 1 10 Label air lines and disconnect from push button valve Remove the setscrew from push button Label and disconnect fittings from push button Remove push button valve Assemble in reverse order Cylinder Clamp Unclamp Valve Removal Replacement 1 Complete the General Disassembly Procedures 1 10 2 Label air lines and disconnect from cylinder clamp unclamp valves 3 Carefully remove the valve package 4 Label and disconnect air fittings from cylinder clamp unclamp valves 5 Remove cylinder clamp valve 6 Assemble in reverse order NOTICE If removing lower air cylinder the bundle handler may be rotated to one side for ease of maintenance Air Cylinder Clamp Removal Replacement Refer to Dwgs MHP2210 on page 20 and MHP2181 on page 18 Complete the General Disassembly Procedures 1 10 Label all air lines to be disconnected Carefully remove valve package Hold air cylinder rod end with proper size wrench Remove rod end bolt and washer from outside of paddle Remove 4 socket head capscrews and lockwashers from air cylinder rod end and piston end Remove air cylinder s 8 Assemble in reverse order DN e eh n 15 Guide Bar Assembly Removal Replacement Complete General Disassembly Procedures 1 10 Remove bottom support plate Remove air
49. vice The Zim Air ZA type control requires manual lever operation to raise and lower the bundle handler 1 Move bundle handler to the pick up point and position it over the bundle for pick up Actuate clamp open button or lever on control pendant To prevent uncontrolled movement use both hands on the bundle handler when activating the clamp and rotate functions Never attempt to lift a loosely clamped bundle Rapid acceleration of the Signature Bundle Handler may cause the bundle to drop Persons and body parts should never be in the path of the clamp paddles during operation The clamp closes with extreme force and could result in injury MHD56227 Edition 3 2 Slowly lower bundle handler and engage the bundle Center the clamp paddles on the end boards of the bundle Actuate the clamp close button or lever and ensure bundle is securely clamped If this is the first use of the SBH for the day the safety interlock circuit should be tested Depress the up lever to raise the bundle approximately 6 inches 152 mm above the pick up point Then actuate the cylinder clamp open button or lever The clamp should not open and air should be heard exhausting from the clamp valve If the clamp opens notify maintenance personnel immediately The suspended load may be raised or lowered approximately 12 inches 305 mm by pushing or pulling the bundle in the desired direction The empty Signature Bundle Handler should not be le
50. y if it is set before the controls NOTICE When wire rope is winding into the balancer air is passing through both up and down flow controls If the up speed is too fast you may rotate the down control clockwise to decrease the up speed ZA Control Refer to Dwg MHP1819 on page 10 1 top of the ZA manifold are three screw type adjustable controls Turn the UP and DOWN control screws clockwise until fully closed Then turn each control screw counterclockwise one full turn Flow Control Hook Valve Balanes Flow Control DOWN Air Line Connection V UP Air Line Connection Dwg MHP1819 2 center control screw is for hook balance adjustment The screw head should be flush with the top of the manifold body The screw type control and hook balance adjustment screws on the ZA manifold should never extend above the manifold body Thread engagement will be minimal and could result in the screw being discharged from the manifold 3 Turn air supply Adjust supply pressure to highest maintainable do not exceed 100 psig 6 9 bar 690 kPa 4 set hook balance adjust hook balance screw by turning clockwise until empty handling device begins to rise Slowly adjust screw by turning counterclockwise until device stops moving 10 5 Depress DOWN lever on the ZA control block Adjust DOWN control screw by turning counterclockwise until desired down speed is reached 6 Depre
51. ypes The bundle handler uses the Ingersoll Rand ZA Zim Air control package Controls are designed to provide flexible mounting options to suit operator preference and convenience Refer to Dwg MHP2396 on page 8 for a typical dual cylinder bundle handler Dwg MHP2396 ZA Control Refer to Dwgs MHP1819 on page 10 and MHP2405 on page 7 The Zim Air control package utilizes an up down control block connected to the manifold mounted to the balancer The top of the manifold has two flow control valves The two flow control valves labeled UP and DN control the speed with which a load will raise and lower The center screw control is for hook balance adjustment to maintain the bundle handler in a floating condition when it does not have a load on it Air is supplied through the manifold to the control block When the UP lever is depressed air passes through a passage in the block and into the balancer piston chamber resulting in the balancer raising the load Lowering the load is accomplished by depressing the DN lever which releases air in the balancer to atmosphere through the block and lowers the load Extreme care must be used until all control adjustments are complete Clamp Interlock System s interlock is a pilot operated valve Pilot pressure from the balancer shifts the valve when a load greater than that of the empty SBH is lifted When the interlock valve is shifted the un
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