Ingersoll-Rand 200A40 Parts, Operation And Maintenance Manual
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Ingersoll-Rand 200A40 Parts, Operation And Maintenance Manual

Electric winch models 200 lbs. to 25,000 lbs. capacity (91 kg to 11,364 kg)
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IMPORTANT INFORMATION:
• A copy of our "Safe Operating Practices" Manuals are always available free of charge either by downloading it from our
Technical Publications website @ www.airwinch.com or by contacting the Factory at (800) 866-5457 for North America and
(206) 624-0466 for International. The Safe Operating Practices manual must be read prior to anyone operating a
Ingersoll-Rand winch or hoist. The manual form numbers are as follows:
"Safe Operating Practices Non-Man Rider™ Winches" Manual, Form No. MHD56250
"Safe Operating Practices for Man Rider™ Winches" Manual, Form No. MHD56251
"Safe Operating Practices for Pneumatic, Hydraulic and Electric Hoists" Manual, Form No. MHD56295
• Available winch options may require additional supplements to the basic winch manual.
• For Man Rider™ winches ensure a copy of the Man Rider™ supplement is made available to the operator prior to winch
operation.
Winch Man Rider
™
Model:
FA2, FA2.5,
FH2, FH2.5
FA5
FA10
FA2.5A
FA2B and
HU40A
FH10MR
Fulcrum Electric
LS500HLP/
LS1000HLP
• We strongly recommend that ALL maintenance on Ingersoll-Rand equipment be carried out by personnel certified by
Ingersoll-Rand, or by Ingersoll-Rand Authorized Service Centers.
• Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions.
• Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist.
• ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested
prior to being placed into service:
*
Winches - ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
*
Hoists - ANSI / ASME B30.16 (OVERHEAD HOISTS - UNDERHUNG) Refer to section 16.2.2 - Testing.
Form MHD56298
Edition 2
November 2004
71441844
© 2004 Ingersoll-Rand Company
Supplements:
Publication No.
MHD56046
MHD56042 and
MHD56220
MHD56252
MHD56236
MHD56207
MHD56212
MHD56277
SAM0004
Model:
Publication No.
LS500RLP
LS1000RLP
LS150RLP
LS150RLP/500/
1000
LS150RLP and
LS150PLP-PH
LS500RLP-E
LS150RLP-
DP5M-F
LS150HLP
Form MHD56298
SAM0011
SAM0012
SAM0082
SAM0115
SAM0120
SAM0122
SAM0184
SAM0222

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Summary of Contents for Ingersoll-Rand 200A40

  • Page 1 • Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions. • Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist. • ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested prior to being placed into service: Winches - ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
  • Page 2 WARNING Do not use this winch for lifting, supporting, or transporting people or lifting or supporting loads over people. Refer all communications to the nearest Ingersoll-Rand Material Handling Office or Distributor. Form MHD56054 Edition 2...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Description Page No. Safety Information Danger, Warning, Caution and Notice ................................ 3 Safety Summary ......................................3 Safe Operating Instructions ..................................4 Warning Labels and Tags .................................... 5 Specifications General Specifications ....................................6 Model Code Explanation .................................... 7 Installation Mounting ........................................

  • Page 4: Safety Information

    York, NY 10018. injury, death, or substantial property damage if the warning is ignored. This manual has been produced by Ingersoll-Rand to provide dealers, mechanics, operators and company personnel with the Caution is used to indicate the presence CAUTION...

  • Page 5: Safe Operating Instructions

    This provides adequate safety in the event of a sudden load shift. Ingersoll-Rand recognizes that most companies who use 10. Never place your hand in the throat area of a hook or in the winches have a safety program in force at their facility. In the vicinity of the wire rope as it spools onto the drum.

  • Page 6: Warning Labels And Tags

    LABELS AND TAGS Each winch is supplied from the factory with the labels and tags shown. If one of the labels or tags is not attached to your winch, order a new one and install it. Refer to the parts list for the part number.

  • Page 7: Specifications

    4. Shipping weights are approximate and are based on winches with standard length drums, without wire rope and without options. Drum Wire Rope Storage Capacity Model Wire Rope Size 2nd Layer Full Drum metre metre 200A40 to 800B40 1300A20/B20 5/16 1400A40/B40 1600B90 to 2000B60 3000B40 7/16 3500B80...

  • Page 8: Model Code Explanation

    P1-XX = Hand Held Pendant Station. Specify length of Control Cord ft. (2 Button). (NEMA 1) P4-XX = Hand Held Pendant Station. Specify length of Control Cord ft. (2 Button). (NEMA 4) ** Options not covered in this manual. For additional information contact your nearest Ingersoll-Rand Material Handling Office or Distributor.

  • Page 9: Installation

    The oil level is correct when the surface of the oil is level with the lowest point of the threaded hole. Mounting Bolt Chart Model Model 200A40 2000A20 200B40 2000B20 18-1/2 12-5/8...

  • Page 10: Wire Rope

    Bolt Pattern Dimensions Recommended Wire Rope Size Wire Rope Size Model 200A40 to 800B20 1300A20 to 1400B40 5/16 1600B90 to 2000B60 3000B40 to 3500B80 7/16 4000A20 to 4500B50 6000B20 to 6000B40 10000B20 to 10000B40 15000B20 25000B25 1-1/4 The maximum wire rope diameter is limited by the size of the wire rope anchor hole.

  • Page 11: Wiring

    Safe Wire Rope Handling Procedures Allow the end of the wire rope (1) to extend about 2 in. (50 mm) through the center hole (5). Pull the smaller loop (6) Always use gloves when handling wire rope. Never use wire rope which is twisted, frayed or kinked. tight.

  • Page 12: Controls

    460V Motor and 230V Brake Electical Connections Controls A momentary contact reversing drum switch is recommended for the winch control unless remote or automatic control of the Br ake winch is required. Refer to parts section for recommended switches. Refer to Drum Switch Connection Diagrams Dwg. MHP0201 for single and three phase motors.
  • Page 13 DRUM SWITCH CONNECTION DIAGRAMS (Dwg. MHP0201)
  • Page 14 WIRING DIAGRAM 230 Volt Single Phase 60 Hz (Dwg. MHP0271)

  • Page 15: Wiring Diagrams

    WIRING DIAGRAMS (Dwg. MHP1086)
  • Page 16 WIRING DIAGRAM 208-575 Volt Three Phase 50 or 60 Hz - 22 Amp and smaller (Dwg. MHP1087)
  • Page 17 WIRING DIAGRAM 208-575 Volt Three Phase 50 or 60 Hz - 22 Amp and larger (Dwg. MHP1088)

  • Page 18: Operation

    OPERATION The four most important aspects of winch operation are: The brake requires a lever to be inserted into the release arm. Follow all safety instructions when operating the winch. Pulling the lever away from the motor will open the brake. Refer Allow only personnel trained in safety and the operation of to Dwg.

  • Page 19: Inspection

    INSPECTION Inspection information is based in part on American National such as kinking, “birdcaging”, core protrusion, main strand Standards Institute Safety Codes (ASME B30.7). displacement, corrosion, broken or cut strands. If damage is evident, do not operate winch until the discrepancies have been reviewed and inspected further by personnel familiar WARNING with wire rope maintenance.

  • Page 20: Winches Not In Regular Use

    SUPPORTING STRUCTURE. Check for distortion, wear and continued ability to support the winch and rated load. LABELS AND TAGS. Check for presence and legibility. Replace if damaged or missing. ELECTRICAL COMPONENTS. Check for loose wires, corrosion or other signs of deterioration. 10.

  • Page 21: Inspection And Maintenance Report

    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.

  • Page 22: Lubrication

    Texaco Meropa 220 bearings and shafts with clean grease. Use sufficient grease to Contact your local distributor or the Ingersoll-Rand office for provide a good protective coat. For temperatures -20° to 50° F information on the use of other oils or temperature ranges.

  • Page 23: Troubleshooting

    TROUBLESHOOTING This section provides basic troubleshooting information. Specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common winch symptoms, probable causes and remedies. SYMPTOM CAUSE REMEDY...

  • Page 24: Maintenance

    MAINTENANCE rubber seal (130) and any accessories mounted on the WARNING motor at the fan end. Insert a feeler gauge between the brake coil body (133) and • Before performing maintenance, disconnect the load from the stationary disc (132), tighten the three brake adjustment the winch.

  • Page 25: Chain Adjustment

    6,000 lb to 2,5000 lb winches Refer to Drawing MHP0583. Tighten the capscrews (113) equally no more than half turn at a time until the winch holds the load required without slipping. Do not overtighten the capscrews or completely flatten the disc springs (110).

  • Page 26: General Disassembly

    General Disassembly Remove capscrews (17), lockwashers (21), washers (12) and nuts (22). Using an overhead hoist with sufficient capacity to The following instructions provide the necessary information to adequately support the weight of the motor and reducer disassemble, inspect, repair, and assemble the winch. An assembly remove the motor and reducer assembly from frame exploded drawing of the winch is provided in the Parts Section (1).

  • Page 27: Winch Assembly

    Repair 14. Using a straight edge, position sprocket (5) so it aligns with Actual repairs are limited to the removal of small burrs and the sprocket on drum (2). Install setscrews (32) with other minor surface imperfections from sprockets and shafts. Loctite 609 or equivalent and tighten.

  • Page 28: Testing

    Limit Switch Assembly (optional feature) Torque Limiter Assembly Refer to Drawings MHP0583 and MHP0854. Refer to Drawings MHP0263 and MHP0579. Limit Switch Assemblies are custom mounted at the factory to Ensure the clutch plate, motor sprocket, driving plate and ensure proper alignment. Contact your local service center, friction plates are free of oil, grease, dirt and rust prior to distributor or the factory before attempting to install a limit assembly.
  • Page 29 Capscrew (Bolt) Torque Chart Grade 5 Tightening Torque Grade 8 Tightening Torque Bolt Diameter Lubricated Lubricated in inches lb. ft lb. ft lb. ft lb. ft No. 10-24 No. 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11...

  • Page 30: Electric Winch Assembly Drawings And Parts Lists

    ELECTRIC WINCH ASSEMBLY PARTS DRAWING 15,000 lb and 25,000 lb winches only Frame (1) shown is for a 25,000 lb winch. (Dwg. MHP0278)
  • Page 31 ELECTRIC WINCH ASSEMBLY PARTS DRAWING 1,300 lb to 10,000 lb winches Note: Appearance of motor and reducer assembly (26) and (27) will (Dwg. MHP0255) vary depending on winch model.
  • Page 32 ELECTRIC WINCH ASSEMBLY PARTS LIST 1,300 lb to 2,000 lb Capacity Winches PART NO. ITEM DESCRIPTION TOTAL OF PART QTY. 1300A20 2000A20 2000A40 1400A40 1400B40 1300B20 2000B20 2000B40 Frame (Parallel Motor) 9491-* 9491-* 3291-* Frame (with Torque Limiter) 9666-* Frame (Right Angle Motor) 3787-* Drum 21624-*...
  • Page 33 ELECTRIC WINCH ASSEMBLY PARTS LIST 3,000 lb to 6,000 lb Capacity Winches PART NO. ITEM DESCRIPTION TOTAL OF PART QTY. 4000A20 3000B40 4500B50 6000B20 6000B40 4000B20 Frame (Parallel Motor) 8491-* 13254-* 7661-* Frame (with Torque Limiter) Frame (Right Angle Motor) 14256-* Drum 949-*...
  • Page 34 ELECTRIC WINCH ASSEMBLY PARTS LIST 10,000 lb to 25,000 lb Capacity Winches PART NO. ITEM DESCRIPTION TOTAL OF PART QTY. 10000B20 10000B40 15000B20 25000B25 Frame 7392-* 7837-* 19437-* Frame (with Torque Limiter) Contact Factory Drum 4015-* 3210-* 3855-* Guard 7567 3198 3852 Guard (with Torque Limiter)

  • Page 35: Direct Drive Electric Winch Assembly Drawings And Parts Lists

    DIRECT DRIVE ELECTRIC WINCH ASSEMBLY PARTS DRAWING Note: Appearance of motor and reducer assembly (27) will vary depending on winch model. (Dwg. MHP0260)
  • Page 36 DIRECT DRIVE ELECTRIC WINCH ASSEMBLY PARTS LIST PART NO. ITEM DESCRIPTION TOTAL 200A40 250A20 500A20 500A40 700A40 800A20 OF PART QTY. 200B40 250B20 500B20 500B40 700B40 800B20 Motor Refer to Motor Chart Nameplate 71106967-R Drive Screw 50915 Warning Label 71060529...

  • Page 37: Limit Switch Assembly Drawings And Parts Lists

    LIMIT SWITCH ASSEMBLY PARTS DRAWING (OPTIONAL FEATURE) 200 lb through 10,000 lb winches (Dwg. MHP0263) 15,000 lb and 25,000 lb winches only (Dwg. MHP0579)
  • Page 38 All Limit Switch Assemblies shown provide a ratio of 120:1. Contact your local distributor or the factory for other ratios. Direct Drive Winches PART NO. ITEM DESCRIPTION TOTAL OF PART QTY. 200A40 250A20 700A40 800A20 1600B90 2000B60 3500B80 200B40 250B20...

  • Page 39: Remote Control Assembly Drawing And Parts List

    REMOTE CONTROL ASSEMBLY PARTS DRAWING AND LIST (OPTIONAL FEATURE) (Dwg. MHP0642) ITEM DESCRIPTION TOTAL PART NO. (All Models) OF PART QTY. Capscrew 52856 Lockwasher 51801 Starter Assembly Refer to "Winch Controls" Section 53039 Remote Control Refer to "Winch Controls" Section Connector 45 71149983 Connector...

  • Page 40: Torque Limiter Assembly Drawings And Parts Lists

    TORQUE LIMITER ASSEMBLY PARTS DRAWING (OPTIONAL FEATURE) 1,300 lb to 4,500 lb winches Refer to page 41 for parts list. (Dwg. MHP0854)
  • Page 41 TORQUE LIMITER ASSEMBLY PARTS DRAWING (OPTIONAL FEATURE) 6,000 lb to 25,000 lb winches (Dwg. MHP0583)
  • Page 42 TORQUE LIMITER ASSEMBLY PARTS LIST (OPTIONAL FEATURE) PART NO. ITEM DESCRIPTION TOTAL 1300A20, 3000B40, 6000B20 10000B20 15000B20 OF PART QTY. 1300B20,1400A40, 4000A20, 1400B40, 2000B20, 4000B20 and 6000B40 10000B40 25000B25 2000A40 and 2000B40 45000B50 Torque Limiter Assembly Contact Contact - - - 50778 25196 52220...

  • Page 43: Motor And Reducer Assembly Chart

    (2) Motor only (Baldor) requires reducer assembly 52764 (3) Motor only (Baldor) requires reducer assembly 71061956 Contact your nearest distributor or Ingersoll-Rand Material Handling Office for part number information. Chain Drive Winches (item 26 - with Torque Limiter Option) Amps at Full...
  • Page 44 71111587 (M) 25000B25 80:1 71054597 Unless otherwise specified motor and reducer assemblies are manufactured for Ingersoll-Rand by Eurodrive (SP) Single Phase Motor P = Motor mounted parallel to drum RA = Motor mounted at right angles to drum (1) Motor only (Baldor) requires reducer assembly 54047...
  • Page 45 22000B30 95:1 26.5 Unless otherwise specified motor and reducer assemblies are manufactured for Ingersoll-Rand by Eurodrive * For 575V (60 cycle) only. Slightly modified ratios are used for 380V (50 cycle) motors P = Motor mounted parallel to drum RA = Motor mounted at right angles to drum...

  • Page 46: Tags And Labels Parts Drawing And List

    Models 1300A20 to 4500B50 Models 6000B20 to 25000B25 Nameplate 71106967-R Drive Screw 50915 Warning Label 71060529 Warning Label 71107130 Caution Tag 71107148 Notice Tag 71107155 Ingersoll-Rand Logo Label 71106272 71109508 Refer to "Labels and Tags" section on page 5 for additional information.

  • Page 47: Winch Controls And Wiring Components

    (Watertight) (M4) 115/230V Single Phase-NEMA 4 1/4 to 3 hp 71063333 Transformer 71262125 * These Furnas components are no longer used in Ingersoll-Rand 1/4 to 3 hp 71029292 winches. They are physically larger and are therefore not 5 hp 71029300 interchangable with the new Allen-Bradley parts.

  • Page 48: Reducer Assemblies

    Reducer assemblies. Check the nameplate attached to the motor for appropriate Reducer assembly type. A typical part number may be similar to R70DT90L4BMHR where the first letter represents the reducer type. For additional information and parts contact your nearest distributor or Ingersoll-Rand Material Handling Office. ‘S’ Type Reducer (Dwg.

  • Page 49: Brake Coil And Brake Disc Parts List

    ‘K’ Type Reducer (Dwg. MHP0308) BRAKE COIL AND BRAKE DISC PARTS LIST Check nameplate attached to motor and reducer assembly for the correct voltage and motor frame size. Select replacement parts from the following chart. Parts are for current production Eurodrive BM series brakes. The last four letters of the motor nameplate for this series are BMHR.
  • Page 50 WIRING INFORMATION Recommended Copper Wire and Transformer Size Single Phase Motors - 230 volts Three Phase Motors - 230 and 460 volts Distance Trans- Distance Transformer Motor to Transformer in feet former Motor to Transformer in feet VOLTS KV A KV A 1-1/2 1-1/2...

  • Page 51: Parts Ordering Information

    The use of replacement parts other than Ingersoll-Rand Return Goods Policy Material Handling may invalidate the Company’s warranty. For Ingersoll-Rand will not accept any returned goods for warranty prompt service and genuine Ingersoll-Rand Material Handling or service work unless prior arrangements have been made and...

  • Page 52: Warranty

    WARRANTY LIMITED WARRANTY IMPORTANT NOTICE Ingersoll-Rand Company (I-R) warrants to the original user its It is our policy to promote safe delivery of all orders. Hoists and Winches (Products) to be free of defects in material This shipment has been thoroughly checked, packed and...
  • Page 53 201-6351 Westminster Hwy Order Status and the world. Contact the nearest Richmond, B. C. Technical Support Chicago, IL 888 Inadustrial Drive Ingersoll-Rand office for the V7C 5C7 Elmhurst, IL 60126 name and address of the Phone: (604) 278-0459 Ingersoll-Rand Phone:...

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