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Ingersoll-Rand force5 GULF MAN-RIDER FA2A-GMR, Parts, Operation And Maintenance Manual

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Ingersoll-Rand force5 GULF MAN-RIDER FA2A-GMR Parts, Operation And Maintenance Manual Download Page 2

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CONTENTS

Page

Safety Information
Danger, Warning, Caution and Notice .............................................................................................................................................................. 3
General Information ........................................................................................................................................................................................... 4
Safe Winch Operating Instructions ................................................................................................................................................................... 4
Warning Labels .................................................................................................................................................................................................. 5

Specifications
Description ......................................................................................................................................................................................................... 6
Model Code Explanation ................................................................................................................................................................................... 6
General Specifications ....................................................................................................................................................................................... 7
Winch Weight and Wire Rope Capacities ......................................................................................................................................................... 7
Performance Graph ............................................................................................................................................................................................ 8

Installation
Mounting ............................................................................................................................................................................................................ 9
Wire Rope ........................................................................................................................................................................................................... 9
Air Supply ........................................................................................................................................................................................................ 11
Motor ................................................................................................................................................................................................................ 12
Initial Operating Checks .................................................................................................................................................................................. 12

Operation
Emergency Lowering ....................................................................................................................................................................................... 13
Training ............................................................................................................................................................................................................ 13
Winch Controls ................................................................................................................................................................................................ 13
Brakes ............................................................................................................................................................................................................... 14

Inspection
Records and Reports ........................................................................................................................................................................................ 15
Wire Rope Reports ........................................................................................................................................................................................... 15
Frequent Inspection ......................................................................................................................................................................................... 15
Periodic Inspection .......................................................................................................................................................................................... 16
Winches Not in Regular Use ........................................................................................................................................................................... 16
Inspection and Maintenance Report Form ...................................................................................................................................................... 17

Troubleshooting .............................................................................................................................................................................................. 18

Lubrication ...................................................................................................................................................................................................... 19

Maintenance
Thermoplastic Coating ..................................................................................................................................................................................... 21
Adjustments ...................................................................................................................................................................................................... 22
Disassembly ..................................................................................................................................................................................................... 22
Cleaning, Inspection and Repair ..................................................................................................................................................................... 26
Assembly .......................................................................................................................................................................................................... 26
Testing .............................................................................................................................................................................................................. 32
Load Testing ..................................................................................................................................................................................................... 32

Parts Section
Winch Parts Drawings and Parts Lists Table of Contents .............................................................................................................................. 33
Winch Cross Section Drawing ......................................................................................................................................................................... 33
Winch Parts Drawings and Parts Lists .................................................................................................................................................... 34 - 49

Parts Ordering Information .......................................................................................................................................................................... 50

Warranty ......................................................................................................................................................................................................... 51

Office Locations .............................................................................................................................................................................................. 52

Summary of Contents for force5 GULF MAN-RIDER FA2A-GMR

Page 1: ... that are identified for personnel lifting by a permanent nameplate attached to the winch at the factory Always operate inspect and maintain this winch in accordance with American National Standards Institute Safety Code ASME B30 7 and any other applicable safety codes and regulations Refer all communications to the nearest Ingersoll Rand Material Handling Office or Distributor Form MHD56136 Editi...

Page 2: ...ng 13 Training 13 Winch Controls 13 Brakes 14 Inspection Records and Reports 15 Wire Rope Reports 15 Frequent Inspection 15 Periodic Inspection 16 Winches Not in Regular Use 16 Inspection and Maintenance Report Form 17 Troubleshooting 18 Lubrication 19 Maintenance Thermoplastic Coating 21 Adjustments 22 Disassembly 22 Cleaning Inspection and Repair 26 Assembly 26 Testing 32 Load Testing 32 Parts S...

Page 3: ... 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 co...

Page 4: ... standards Operating Limitations Gulf Man Rider winches manufactured by Ingersoll Rand are furnished with limitations approval for use in Gulf Man Riding applications automatically terminates for any of the following reasons 1 Winch does not meet other applicable codes or standards 2 Winch is not part of an approved system 3 Winch is not properly maintained in a new condition with all parts intact...

Page 5: ... refer to SPECIFICATIONS section 6 Keep hands clothing etc clear of moving parts 7 Never place your hand in the throat area of a hook or near wire rope spooling onto or off of the winch drum 8 Always rig loads properly and carefully 9 Be certain the load is properly seated in the saddle of the hook Do not support the load on the tip of the hook 10 Do not side pull or yard 11 Always ensure that you...

Page 6: ...to the disc brake diaphragm to overcome spring tension and release the brake When the payout operation is complete the air is vented and the brake is automatically applied The drum band brake operates by applying a friction force between the drum band and the winch drum The manual brake requires an operator to engage and disengage the brake using a handle located on the brake band The automatic dr...

Page 7: ...m flange per ASME B30 7 feet metres 7 178 300 91 13 1 2 343 600 183 20 508 900 274 24 610 1 085 330 Winch Model FA2A GMR General Specifications Air System Rated Operating Pressure 90 psig 6 3 bar 630 kPa Air Consumption at rated pressure and load 380 scfm 10 8 cu m min Rated Performance with 2 500 lb load at rated pressure volume Mid Drum Line Pull 2 500 lbs 1 134 kg Mid Drum Line Speed 165 fpm 50...

Page 8: ...8 ...

Page 9: ...lting to a suitable foundation Do not attempt to mount the winch by welding to a foundation structure 1 The winch mounting surface must be flat and of sufficient strength to handle the rated load plus the weight of the winch and attached equipment An inadequate foundation may cause distortion or twisting of the winch uprights and side rails resulting in winch damage 2 Make sure the mounting surfac...

Page 10: ... and pull through approximately three feet 1 metre of wire rope 3 Forming a large loop with the wire rope insert the end back into the top of the anchor hole 4 Place the wire rope wedge into the wire rope anchor pocket in the drum Install the wedge such that the wire rope will wrap around the wedge as shown in Dwg MHP1317 5 Pull the wire rope into position in the drum anchor pocket Ensure the wire...

Page 11: ...ir supply before filling air line lubricator The air line lubricator should be replenished daily and set to provide 3 drops per minute of ISO VG 32 10W oil Air Line Filter Refer to Dwg MHP0191 Place the strainer filter as close as practical to the motor air inlet port but upstream from the lubricator to prevent dirt from entering the motor The filter strainer should provide 20 micron filtration an...

Page 12: ... to assure that it is secure and properly balanced before personnel are allowed to occupy the platform Before elevating or lowering personnel the following conditions shall exist a Hoist wire rope shall be free of kinks b Multiple part lines shall not be twisted around each other c The primary point of wire rope attachment shall be centered over the platform so that the platform will not oscillate...

Page 13: ...ints at which employees will enter and leave the platform the use of safety equipment signals and the lift chart information NOTICE This meeting shall be held prior to the beginning of personnel hoisting operations at each new work location and thereafter for any new employees assigned to the operation General Winch Operation Winch Controls A spring loaded motor mounted manual throttle control val...

Page 14: ... brake does not operate properly it must be disassembled inspected and repaired WARNING If the brake is disassembled the friction and separator plates must be correctly installed as shown in the MAINTENANCE section of this manual Failure to correctly install the friction and separator plates can cause injury and or property damage Manual Drum Brake Refer to Dwg MHP1375 The manual drum brake may be...

Page 15: ...nnel if the test results in instability or causes permanent deformation of any component 4 A visual inspection of the winch personnel platform and rigging shall be conducted immediately after the test lift Wire Rope Reports Records should be maintained as part of a long range wire rope inspection program Records should include the condition of wire rope removed from service Accurate records will e...

Page 16: ...tion of the wire rope should be conducted by an experienced inspector to determine the suitability of the wire rope to remain in service Refer to Dwg MHP0056 Dwg MHP0056 5 ALL COMPONENTS Inspect for wear damage distortion deformation and cleanliness If external evidence indicates damage disassemble as required to conduct a detailed inspection Inspect gears shafts bearings sheaves springs and cover...

Page 17: ...ppropriate 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 COMPONENT CONDITION CORRECTIVE ACTION NOTES Pass Fail Repair Replace Uprights and Sideframes Disc Brake 125 Load Test Disc Brake Visual Inspection Drum Band Brake 125 Load Test Drum Band Brake Visual Inspection Motor Cont...

Page 18: ...re the air pressure at the winch inlet is at least 90 psig 6 3 bar 630 kPa at rated volume Clean air line filter Air leak Check hose and fitting connections Check hose s for breaks Motor runs hot or makes excessive noise during operation Improper lubrication Set lubricator to provide a minimum of 3 drops per minute Damaged or broken motor internal parts Disassemble and repair motor Winch runs slow...

Page 19: ...ce oil according to the intervals recommended 2 Always inspect removed oil for evidence of internal damage or contamination metal shavings dirt water etc If indications of damage are noted investigate and correct before returning winch to service 3 After winch operation allow oil to settle before topping off 4 Always collect lubricants in suitable containers and dispose of in an environmentally sa...

Page 20: ...able container and inspect drained oil for evidence of damage metal shavings dirt water etc Dispose of oil in an environmentally safe manner 3 Collect the drained oil and dispose of properly If replacing oil refer to To Fill instructions Re install the reduction gear and disc brake plugs Motor Assembly Lubrication for the motor is provided by the air line lubricator An air line lubricator must be ...

Page 21: ...nts of lubricants water or any other fluids Remove or open all vents and drains Components will be hot and may discharge hot fluids or gases Allow sufficient time for components to cool or cool off components prior to handling Gaskets O rings and any components that may be damaged should be removed prior to applying coating Thermoplastic coating is heat applied The surface of the component to whic...

Page 22: ...rew 120 is not accessible the jam nut 117 located closest to the head of capscrew 120 may be used to adjust the band brake Ensure capscrew turns with nut 3 When adjustments are complete tighten jam nut 117 closest to plunger 114 Remote Pendant Control Valve Adjustment Optional feature Refer to Dwg MHP1305 If winch operating speeds differ from performance specifications the pilot air control valve ...

Page 23: ...tion 5 Remove the fasteners securing winch to its foundation and move the winch to a suitable work area before beginning disassembly WARNING The air motor weighs approximately 100 lbs 45 3 kg Adequately support the air motor before removing the motor mounting capscrews 6 Remove the four capscrews 221 securing the motor assembly to the motor adapter 71 Using a hoist to support the motor pull the mo...

Page 24: ...valve bushing 314 while disconnecting the spring 303 5 Remove seal rings 315 from valve body 316 6 Check parts for score marks or wear 7 Measure clearance between the valve bushing 314 and valve body 316 Clearance between valve bushing and valve body should not exceed 0 002 inch 0 05 mm or excessive air leakage will occur Remote Control Valve and Inlet Manifold Removal Optional feature Refer to Dw...

Page 25: ...he sprag clutch 16 The sprag clutch can be further disassembled into two wearing plates and the sprag cage Automatic Drum Band Brake Optional feature Refer to Dwg MHP1281 1 Loosen jam nut 117 closest to plunger 114 Turn capscrew 120 counterclockwise until disconnected from plunger 2 Disconnect air line from brake cylinder 121 With the aid of a strap wrench remove brake cylinder 121 and components ...

Page 26: ...lacing To remove press bearing out of housing Cleaning Inspection and Repair Cleaning Clean all winch component parts in solvent except the drum brake bands and disc brake friction plates The use of a stiff bristle brush will facilitate the removal of accumulated dirt and sediments on the housings frame and drum If bushings have been removed it may be necessary to carefully remove old Loctite from...

Page 27: ...t 202 should be facing out and the curve of the locknut and tab washer should match 8 Tighten locknut 202 to 60 in lb 22 Nm Use a wooden or fiberglass tool handle to lock the crankshaft Place it through two of the cylinder ports in the motor housing and let the crankshaft pin 213 come to rest on it Loosen locknut just enough to allow one of the locking tabs from the tab washer 203 to be bent into ...

Page 28: ...linders and pistons 2 Apply a 1 16 in 2 mm bead of Loctite 515 around the inboard cap 226 and outboard cap 227 Refer to Dwg MHP1297 Cylinder Cap Sealant Placement Dwg MHP1297 3 Place cylinder assembly over piston push and twist into position on motor housing CAUTION Ensure that the inboard and outboard cylinder assemblies are in the correct position This is noted by the offset position of the air ...

Page 29: ...rque to 21 ft lb 28 Nm 4 Connect brake line to connector fitting 621 5 Connect pendant hoses to valve fittings 6 Connect air supply line to control valve Reduction Gear Assembly Refer to Dwg MHP1313 1 Press caged needle bearings 57 into reducer housing 59 With oil seal 58 lip facing towards reducer housing install oil seal in reducer housing 2 Install thrust washer 44 in groove in output planet ca...

Page 30: ...mbly splines 4 If equipped with an automatic band brake install the drum band brake bracket and piston assemblies Do not attach the brake band assembly 104 Refer to the Drum Band Brake section for instructions 5 Install coupling 60 on drive shaft 61 and install on end of the input sun gear 54 located in the reduction gear assembly 6 If equipped with an automatic band brake place brake band assembl...

Page 31: ...adjusting brake 9 Lift up brake handle 135 until hole in brake link stud 141 and bracket in brake band 137 are aligned Insert pin 138 and secure with cotter pin 139 10 Push brake handle 135 down to the lock position 11 Tighten capscrews 112 12 Adjust cam stop 132 Refer to ADJUSTMENT section for adjusting brake Automatic Drum Band Brake Assembly Optional feature Refer to Dwg MHP1281 For ease of ass...

Page 32: ...p 1 until the nut stops at approximately 9 16 inch 14 mm from the cover 125 4 Refer to further adjusting in Automatic Drum Brake Adjustment Drum Guard Assembly Refer to Dwg MHP0658 1 Place drum guard 590 on rear drum brake side sideframe 64 with the longer inside tab located under the sideframe edge and the smaller outside tabs located on top of the sideframe edge 2 Place washers 593 on brackets 5...

Page 33: ...alve Assembly Parts List 41 Remote Pendant and Control Valve Assembly Parts Drawing MHP1304 42 Remote Pendant and Control Valve Assembly Parts List 43 Pilot Air Valve Assembly Parts Drawing MHP1305 and Parts List 44 Drum Guard Assembly Parts Drawing MHP0658 and Parts List 45 Automatic Drum Band Brake Assembly Drawing MHP1281 and Parts List 46 Manual Drum Band Brake Assembly Drawing MHP1372 and Par...

Page 34: ...34 WINCH ASSEMBLY PARTS DRAWING ...

Page 35: ... Brake 41 Bearings Roller 108 71113252 Short Drum 7 in 1 24901 6 42 Spacer 3 20389 Medium Drum 13 1 2 in 24901 4 43 Gear Planet 3 23899 Long Drum 20 in 24901 3 44 Thrust Washer 1 25153 Extra Long Drum 24 in 24901 8 69 Input Carrier Assembly 1 1 25151 66 Capscrew 8 71264683 45 Intermediate Sun Gear 1 25146 68 Upright Motor End 1 24893 46 Retainer Ring 2 71303309 71 Motor Adapter 1 25445 47 Input Ca...

Page 36: ...36 MOTOR ASSEMBLY PARTS DRAWING ...

Page 37: ...ut 2 50852 213 Pin Crankshaft 1 24978 240 Piston Assembly 2 25726 214 Counterweight 1 24968 241 Piston Rod 2 24962 2 215 Washer 1 71300347 242 O Ring 4 71311773 216 Capscrew 1 71316764 243 Piston Sleeve 4 24964 1 217 Locknut 1 71316756 244 Link Rod 2 24966 218 Setscrew 1 71300719 245 Bearing 2 71287130 220 Motor Housing 1 23305 246 Pin 2 24965 221 Capscrew 4 71306443 247 Bearing 2 71287122 223 Mot...

Page 38: ...SC BRAKE ASSEMBLY PARTS DRAWING Note Winches may be provided with the brake cover release port located at either the 9 o clock left or the 6 o clock bottom position as viewed from the brake end of the winch ...

Page 39: ...r 2 71046981 11 Spacer 2 19007 77 Capscrew 2 71146617 12 Outer Race 1 22032 78 Clamp 2 71300131 13 Friction Plate 5 71126874 79 Valve Exhaust 1 71047898 14 Separator Plate 6 22033 80 Elbow Fitting 1 24141 Sideframe Brake Hose 65 Short Drum 7 in 1 24901 6 75 Short Drum 7 in 1 25403 39 Medium Drum 13 1 2 in 24901 4 Medium Drum 13 1 2 in 25403 45 5 Long Drum 20 in 24901 3 Long Drum 20 in 25403 52 Ext...

Page 40: ...40 CONTROL VALVE ASSEMBLY PARTS DRAWING ...

Page 41: ...ing Retaining Stud 1 K5B 553 523 Fitting Elbow 1 71273676 307 Latch 1 K5B 869AP 524 Fitting Nipple 1 71057483 308 Roll Pin 1 HLK 20 525 Muffler 1 52472 309 Pipe Plug 2 71263297 606 Manifold 1 26128 310 Fitting Bushing 1 51814 607 Cover Manifold 1 26130 311 Valve Housing 1 26062 611 Gasket 1 26129 312 Roll Pin 1 71326102 612 Pipe Plug 2 54246 313 Grease Fitting 1 53095 613 Dowel Pin 1 71326508 314 ...

Page 42: ...42 REMOTE PENDANT AND CONTROL VALVE ASSEMBLY PARTS DRAWING ...

Page 43: ...4679 639 Pendant Kit 1 MLK K269C 618 Valve 1 54672 640 Pendant Assembly 1 MLK A269C 619 Fitting Elbow 2 52182 641 Throttle Lever 2 MLK 273 620 Fitting Elbow 1 71063473 642 Throttle Lever Pin 1 DLC 120A 621 Fitting Connector 1 71110894 643 Plug 1 502 95 622 Fitting Nipple 1 52092 644 Pendant Throttle Valve 2 MLK K264B 623 Fitting Elbow 1 71034714 645 Valve Seal 2 R000BR1C 283 624 Fitting Tee 1 5218...

Page 44: ... 277 O Ring 6 52456 268 End Cap Inlet Side 1 11778 278 Valve Sleeve 1 269 Capscrew 8 71327738 279 Valve Spool 1 270 Adjusting Screw 1 71327720 280 Nut 1 50176 271 Nut 1 71069132 524 Fitting Nipple 1 71057483 272 Shoulder Screw 1 54710 525 Muffler 1 52472 273 Guide 1 52233 544 Fitting Elbow 1 71330112 Recommended spare Valve Assembly 355 includes items 265 through 280 Valve Body 267 Valve Sleeve 27...

Page 45: ...3608 2 592 Capscrew 4 71261739 593 Washer As Req d 71296800 594 Capscrew 1 71328389 595 Bracket 1 26311 596 Extension 1 26312 Drum Guard Assembly with Automatic Drum Brake Includes Items 590 through 593 Short Drum 7 in 1 25294 Long Drum 20 in 1 25297 Medium Drum 13 1 2 in 25295 Extra Long Drum 24 in 25738 Drum Guard Assembly with Manual Drum Brake includes Items 590 through 596 Short Drum 7 in 1 2...

Page 46: ... Pivot Bar 1 23755 103 Spacer Tube 3 21891 120 Capscrew 1 71267405 104 Band Assembly 1 25144 121 Cylinder 1 26138 105 Spacer 1 23029 122 O Ring 1 52536 106 Brake Bracket 1 22984 123 Piston 1 25534 107 Capscrew 2 71298921 124 Spring 1 71299721 108 Cylinder Rod 1 23885 125 Cover 1 25392 109 O Ring 1 71049423 126 Retainer Ring 1 71126668 110 O Ring 1 52662 127 Spring 1 71299713 111 Retainer Ring 1 54...

Page 47: ...937 131 Washer 5 71274807 141 Brake Link Stud 1 2448 132 Cam Stop 1 26304 142 Washer 1 71331771 134 Pivot Nut 1 2445 143 Bushing 2 71331730 135 Brake Handle 1 2329 144 Cotter Pin 1 51021 136 Rear Brake Pad 1 26306 145 Adapter Plate 1 26136 Drum with Drum Band Brake 62 Short Drum 7 in 1 25316 62 Long Drum 20 in 1 25351 Medium Drum 13 1 2 in 25353 Extra Long Drum 24 in 25751 Items 136 and 137 must b...

Page 48: ...at Gun 1 each 71308894 Lubricant 16 fl oz LUBRI LINK GREEN ITEM NO DESCRIPTION OF PART QUANTITY TOTAL PART NUMBER 575 Filter 1 71323935 577 Regulator 1 R40 0B G00 578 Pipe Nipple 3 51704 579 Pipe Bushing 2 Contact factory 580 Lubricator 1 71323927 581 Liquidator 1 1 2 inch NPT not shown on drawing 1 8834 WI 000 582 Pipeline Strainer not shown on drawing 1 K4U A267AT Air preparation components for ...

Page 49: ...1 71295240 653 Warning Label 1 71124895 654 Warning Do Not Weld 3 71270813 655 Rivet Drive 4 50915 656 IR Logo Label Short Drum 7 in 1 71106249 Medium Drum 13 1 2 in 71106256 Long Drum 20 in 71106272 Extra Long Drum 24 in 657 Label Throttle Direction 1 71297816 658 Label IR Monogram 1 71137780 659 Force 5 ManRider Logo Short Drum 7 in 1 71328538 Medium Drum 13 1 2 in 71111793 Long Drum 20 in 71111...

Page 50: ... 206 624 0466 Fax 206 624 6265 or Ingersoll Rand Material Handling Douai Operations 111 avenue Roger Salengro 59450 Sin Le Noble France Phone 33 3 27 93 08 08 Fax 33 3 27 93 08 00 PARTS ORDERING INFORMATION The use of other than Ingersoll Rand Material Handling replacement parts may adversely affect the safe operation and performance of this product For your convenience and future reference it is ...

Page 51: ...original user its Hoists and Winches 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...

Page 52: ...14 695 0963 British Columbia 201 6351 Westminster Hwy Richmond B C V7C 5C7 Phone 604 278 0459 Fax 604 278 1254 Latin America Operations Ingersoll Rand Production Equipment Group 730 N W 107 Avenue Suite 300 Miami FL 33172 3107 Phone 305 559 0500 Fax 305 559 7505 Europe Middle East and Africa Ingersoll Rand Material Handling Douai Operations 111 avenue Roger Salengro 59450 Sin Le Noble France Phone...

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