Ingersoll-Rand Force 5 MANRIDER FA2MRA, Installation And Operation Manual

Page 1: ...ied out by personnel certified by Ingersoll Rand or by Ingersoll Rand Authorized Service Centers Contact the Factory if in doubt about installation operation inspection and maintenance instructions Us...

Page 2: ...responsible for the operation installation and maintenance of these products The winch is only part of the Personnel Lifting System For information defining the Personnel Lifting System requirements r...

Page 3: ...eddrum hoistsas definedby ASME B30 7 and for thepurposeof personnel handling asdefined by ANSI A 10 22 1990 In furnishing customersMan Rider winches Ingersoll Rand doesnot warrant the suitability of t...

Page 4: ...er capacityratings 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Prior to use inspect andtestthe personnellifting systemto the requirementsof ANSI Al 0 22 Section 13 Inspection andTests The winch operat...

Page 5: ...orage r Capacity feet metres Drum Length inches 24 Wire Rope Diameter 808ft FA2 Utility rating of 3 500lbs 1 558kg is basedon requirementsof ASME B30 7 5 1designfactor with 7 l6 inch 11 mm wire rope F...

Page 6: ...th muffler and 10 feet 3 meters of exhaust hose 4 Copy of Operation and Maintenance Manual and ANSI A10 22 Standard supplied in container attached to winch Model Code Explanation Example FA2MRA24MAlG...

Page 7: ...he drum for overwind operation ONLY Failure to correctly spool the wire rope will result in falling load which can causesevereinjury death and property damage Refer to Dwg MHTPA0661 1 2 Ensurethe winc...

Page 8: ...imes Ensure wire rope top layer is a minimum of 2 inches 50 mm below drum flange edge Refer to Dwg MHTPA0498 l To prevent wire rope line run ensure a weight greater than the total weight of the longes...

Page 9: ...d of the wire rope to eliminate line slack This helps achieve level winding andtight spooling l Wire rope must be spooled at least2 inches 51 mm below the outer diameter of the drum flange Refer to Dw...

Page 10: ...m 6 2 bar 620kpa at 10cum m for FA2 winches The air motor should be installed asnear aspossibleto the compressoror air receiver Recommendedpressuresandvolumes are measuredatthe point of entry to the a...

Page 11: ...onnelbeing lifted should checkthat winch wire rope working platform lifelines safetybelts harnesses etc arepresentand functional prior to authorizing personnellifting 2 Personnelbeing transportedmustb...

Page 12: ...sand operator sresponsibility to adjustwinch operating limits prior to using the winch to transport personnel To adjust the limit switch setpoints refer to Winch Adjustments in the WINCH MAINTENANCE...

Page 13: ...INTERVAL Startof eachshift Monthly LUBRICATION CHECKS Checkflow andlevel of air line lubricator approximately6 to 9 dropsper minuterequiredat maximum motor speed Checkwinch motoroil level Lubricate c...

Page 14: ...erformance highest efficiency and long life it is essentialthat the lubricating oil be maintained atthe correctlevel Rotatethe drum until the fill plug is locatedattop deadcenterthen addoil up to the...

Page 15: ...eenvisual observationsnotedduring frequentinspectionsandthe actual condition of wire ropeasdeterminedby periodic inspections PersonnelLifting Systemwire roperecordsshouldbe maintained andmadeavailable...

Page 16: ...mbination of weekly inspection requirementsandthe performanceof a static drop teston guided cagesystemsonly to verify operation of the cage ssafetyclamp Winch Daily Checks and Weekly Inspections On eq...

Page 17: ...ductadetailedinspection Inspect gears shafts bearings springsandcovers Replace worn or damagedparts Clean lubricate and reassemble 8 9 10 11 12 SUPPORTING STRUCTURE WEEKLY Checkfor distortion wear and...

Page 18: ...ctthe nearestIngersoll RandDistributor or the factoryfor technicalassistance CONDITION CORRECTIVE COMPONENT ACTION NOTES Pass Fail Repair Replace SideRails andEnd uprights Manual Drum Band Brake 150 L...

Page 19: ...ottle valve Remove and disassemble motor Examine all parts and replace any that are worn or damaged Insufficient air supply Verify air supply pressureandvolumeat winch inlet meets the requirements lis...

Page 20: ...whencontrolvalvehandleisin neutral If noair escapes replace dumpvalve Limit Switch Winchdoesnotoperate in one Limit switchengaged direction Line Speed Monitor andOverspeed Alarm Operatewinch in oppos...

Page 21: ...ustment 1 Releasewire ropetensionon the drum 2 Raisehandle to freebrakebands 3 Removecotterpin andpin 4 Rotatelink studclockwise to increasebraketorque 5 Install pin andcheckadjustment 6 Brake should...

Page 22: ...erating the winch through three completecyclesto ensureconsistantlimit switch operation within 2 feet 2 3 m feet of setpoints 7 Install accesscover when final adjustmentsare complete Wire Rope Line Sp...

Page 23: ...outboardend oppositethe motor end mustbe elevatedto prevent draining oil from contaminating the drum brakebandlining l The FA2MR4 air motor weighs approximately 117 lbs 53 kg Adequately support the ai...

Page 24: ...motor housing 463 then pushout the wrist pin 457 andremovepiston 455 Plugs 456 pressedinto endsof wrist pins 457 shouldnot beremoved To avoid breakageuse extremecarewhen removing compressionrings 454...

Page 25: ...ng 463 shifting it asnecessarysoeachconnectingrod 459 endwill project through acylinder hole Align bearing 465 in theboreof the motor housing 463 andtap crankshaftassemblyin place until bearing 465 bo...

Page 26: ...Tap dowels 52 through ring gear 53 input housing 59 andgearcarrier 47 until they arejust below the flange surfaceof the gearcarrier 47 Manual and Automatic Drum Brake Assembly Ref Dwg MHTPB0636 1 Inst...

Page 27: ...imately 117 lbs 53 kg Adequately support the air motor while installing the motor mounting capscrews 20 21 Mount motor assemblyto motor adapter 6 with capscrews 97 andlockwashers 96 Torque capscrews 9...

Page 28: ...m brakebandlinings require a run in period Operatethe winch without load in the payout direction while gradually applying the brake Allow the braketo slip for approximately oneminute Winch motor may s...

Page 29: ......

Page 30: ...er Assembly Drawing MHTPAxxx andPartsList 45 Disc Brake optional Assembly Drawing MHTPA0628 andPartsList 46 Air PreparationAssembly Drawing MHTPA0223 andPartsList 47 Winch AccessoriesPartsList 47 ITEM...

Page 31: ...Dwg MHTPC0635 30...

Page 32: ...10498 71 Spacer 1 71068522 72 Ring Gear 1 71107437 73 Cover 1 71107486 81 82 83 Wire RopeAnchor SideRail 8 in drum SideRail 12 in drum SideRail 16 in drum SideRail 24 in drum SideRail 30 in drum SideR...

Page 33: ......

Page 34: ...Wrist Pin Assembly Incl s item 456 5 94 011 1A l 458 oil Ring 5 OrderKit 94 RS 459 ConnectingRod 5 94 009 l 460 Gasket 1 Set 94 025 5 462 Vent CapAssembly 1 94 018 463 Motor Housing 1 94 014 464 PipeP...

Page 35: ...Dwg MHTPB0636 34...

Page 36: ...t I 1 50159 I 109 Breather 1 I 52384 110 Cylinder 1 4575 l 111 Fitting 1 52006 l 112 Dump Valve 1 51954 113 Fitting 2 52385 114 Elbow 1 52330 115 Hose 1 50923 116 Capscrew 3 I 50873 I 117 Lockwasher 6...

Page 37: ...Dwg MHTPB0633 36...

Page 38: ...er 1 19232 502 Seal 1 71054688 503 Spacer 3 14998 7 504 Bracket Limit Switch 1 11501 505 Lo washer 4 52909 506 Nut 4 54142 507 Coupling Assembly 1 52381 508 Limit Switch Assembly 1 19578 1 509 Capscre...

Page 39: ...rew 151 Clamp 152 Support Drum Guard 8 inch long drum Drum Guard 12 inch long drum 153 Drum Guard 16 inch long drum Drum Guard 24 inch long drum 154 Lo washer QUANTITY TOTAL 1 4 4 2 1 4 PART NUMBER 11...

Page 40: ...268 End Cap Inlet Side 1 11778 269 Capscrew 8 52234 270 Adjusting Screw 1 71083968 271 Nut 1 52265 272 ShoulderScrew 1 817 002 273 Guide 1 52233 274 Spring 1 52240 I 275 Washer 1 52239 52238 280 stop...

Page 41: ...Dwg MHTPB0632 40...

Page 42: ...Elbow 1 71034714 343 Valve 1 50277 344 Fitting Plug 2 50822 345 Fitting Tee 1 71063374 346 Fitting Elbow 1 52182 347 Capscrew 3 71053763 348 Fitting 3 52092 349 Bracket 1 20231 355 Valve Assembly 1 3...

Page 43: ...614 Dwg IMHTPAO643...

Page 44: ...5 Valve Assembly 1 20991 710 Muffler 1 50594 711 Fitting Pipe 1 71144976 712 Fitting 2 52076 713 HoseAssembly 10feet Contactfactory 714 Fitting Pipe 1 71144984 715 Fitting Pipe 1 71068860 716 Fitting...

Page 45: ...PART NUMBER 5 51448 21 BrakeHousing 1 11324 6 Motor Adapter 1 10361 24 PipePlug 1 50801 7 ShaftExtender 1 11104 25 Fitting 1 52182 10 BrakePiston 1 15453 26 27 1 52181 TeeFitting Tubing 1 52520 2 Nut...

Page 46: ...Regulator 1 578 PipeNipple 3 579 PipeBushing 2 580 Lubricator 1 PART NUMBER F42 OA 000 R30 OA GO0 51704 51706 L4O OA GO0 Air preparationcomponentsfor l 1 4 inch NPT system DESCRIPTION OF ACCESSORY AC...

Page 47: ...an genuine Ingersoll Rand Material Handling parts may adversely affect the safeoperation of this product Return Goods Policy Ingersoll Rand will not acceptany returned goodsfor warranty or servicework...

Page 48: ...uctswhich I R hasdeterminedto havebeenmisusedor abused improperly maintainedby the user or wherethe malfunction or defectcanbe attributed to the useof non genuine I R parts This warranty gives you spe...

Page 49: ...erial Handling P O Box 24046 2724 Sixth Avenue South Seattle WA 98124 0046 USA Phone 206 624 0466 Telex 786573 Fax 206 624 6265 Canada National SalesOffice Regional Warehouse Toronto Ontario 51Worcest...