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PARTS, OPERATION AND MAINTENANCE MANUAL
THIRD GENERATION
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
operation, installation and maintenance of these products.
This manual applies only to FA2A-GMR winches designed by Ingersoll-Rand 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
Edition 2
September 1997
71328041
© 1997 Ingersoll-Rand Company
MODEL FA2A-GMR
GULF MAN-RIDER
1
Form MHD56136
®
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Summary of Contents for Ingersoll-Rand force5 GULF MAN-RIDER FA2A-GMR
- Page 1 Make this manual available to all persons responsible for the operation, installation and maintenance of these products. This manual applies only to FA2A-GMR winches designed by Ingersoll-Rand that are identified for personnel lifting by a permanent nameplate attached to the winch at the factory.
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Page 2: Table Of Contents
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 ...................................... -
Page 3: Safety Information
10018. hazard-related. This manual has been produced by Ingersoll-Rand to provide dealers, mechanics, operators and company personnel with the Safety Summary information required to install, operate, maintain and repair the products described herein. -
Page 4: General Information
GENERAL INFORMATION Ingersoll-Rand offers in its air winch product line, a limited Operating Limitations number of models referred to as Gulf Man-Riders which are Gulf Man-Rider winches manufactured by Ingersoll-Rand are designed and manufactured for the purpose of lifting and furnished with limitations;... -
Page 5: Warning Labels
When a “DO NOT OPERATE” sign is placed on the 10. Do not “side pull” or “yard”. winch, or controls, do not operate the winch until the sign 11. Always ensure that you, and all other people, are clear of has been removed by designated personnel. -
Page 6: Specifications
SPECIFICATIONS winch is in the neutral or operated in the haul-in positions; Description disengaged when the winch is operated in the payout direction. FA2A-GMR winches are air powered, planetary geared units During winch operation a sprag type clutch in the disc brake designed for transporting personnel. -
Page 7: General Specifications
Winch Model FA2A-GMR General Specifications Rated Operating Pressure 90 psig (6.3 bar/630 kPa) Air System Air Consumption 380 scfm 10.8 cu.m/min (at rated pressure and load) Rated Performance Mid Drum Line Pull 2,500 lbs 1,134 kg with 2,500 lb load (at rated Mid Drum Line Speed * 165 fpm 50 mpm... -
Page 9: Installation
INSTALLATION Prior to installing the winch, carefully inspect it for possible Tighten mounting bolts evenly and torque to 380 ft lbs (515 shipping damage. Nm) for dry thread fasteners. If the fasteners are plated, Winches are supplied fully lubricated from the factory. Check lubricated or a thread locking compound is used, torque to oil levels and adjust as necessary before operating winch. - Page 10 Wire Rope Selection CAUTION Consult a reputable wire rope manufacturer or distributor for assistance in selecting the appropriate type and size of wire rope • Make sure the first wrap of wire rope is tight and lays flush and, where necessary, a protective coating. Use a wire rope against the drum flange.
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Page 11: Air Supply
Wire Rope and Fleet Angle Installation Drawing Air Supply The air supply must be clean, free from moisture and lubricated to ensure optimum motor performance. Foreign particles, moisture and lack of lubrication are the primary causes of premature motor wear and breakdown. Using an air filter, lubricator and moisture separator will improve overall winch performance and reduce unscheduled down time. -
Page 12: Motor
Lifting and lowering speeds are operator controlled and and applicable regulations regarding the lifting or handling of should be as slow as practical. Ingersoll-Rand people with this winch before putting it into use. recommends that you do not exceed 100 feet (30 m) per minute. -
Page 13: Emergency Lowering
When personnel are suspended, a signalman must be Operate winch throttle control using smooth, even movements. provided unless voice communication equipment is Do not slam or jerk throttle controls during operation. utilized. Signals must be visible or audible to the operator at all times. -
Page 14: Brakes
Drum Brake Handle Operation * To ensure accurate winch control when remotely operating the winch at distances greater than 60 feet (18 metres) contact Ingersoll-Rand Technical Sales for control suitability. Pendant Operation (Dwg. MHP1375) (Dwg. MHP1311) -
Page 15: Inspection
INSPECTION Inspection information is based in part on American National Wire Rope Reports Standards Institute Safety Codes (ASME B30.7). Records should be maintained as part of a long-range wire rope inspection program. Records should include the condition of WARNING wire rope removed from service. Accurate records will establish a relationship between visual observations noted during frequent •... -
Page 16: Periodic Inspection
MOTOR. During operation check motor housing for excess ALL COMPONENTS. Inspect for wear, damage, heat build up. Housing should not be hot to the touch. distortion, deformation and cleanliness. If external evidence Listen for grinding or knocking noises in the motor. There indicates damage, disassemble as required to conduct a should be no grinding or knocking noises. -
Page 17: Inspection And Maintenance Report Form
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 18: Troubleshooting
TROUBLESHOOTING This section provides basic troubleshooting information. Determination of 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 19: Lubrication
Other lubricants may affect the performance of (1.9 litres). the winch. Approval for the use of other lubricants must be obtained from your Ingersoll-Rand distributor. Failure to observe this precaution may result in damage to the winch and/ Recommended Grease or its associated components. - Page 20 Use only high quality rust and oxidation inhibiting lubricant. Apply a wire rope lubricant, Ingersoll-Rand LUBRI- LINK-GREEN or ISO VG 100 (30W) lubricant. To Drain: Brush, drip or spray lubricant weekly, or more frequently, Rotate the winch drum to align one of the reduction gear depending on severity of service.
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Page 21: Maintenance
450º F (232º C). Optimum temperature is 300º F (Operator or winch for damage. Do not operate the winch (149º C) for best results. A small propane torch (Ingersoll-Rand Maintenance if damaged. Part No. 71308886) or heat gun (Ingersoll-Rand Part No. -
Page 22: Adjustments
Contact [located closest to the head of capscrew (120)] may be used to Ingersoll-Rand Technical Assistance for more information. adjust the band brake. Ensure capscrew turns with nut. For specific disassembly and assembly information refer to When adjustments are complete tighten jam nut (117) ‘Assembly’... - Page 23 When removing ball bearings from shafts, it is best to use a Remove the fasteners securing winch to its foundation and bearing puller. When removing bearings from housings, move the winch to a suitable work area before beginning drive out the bearing with a sleeve slightly smaller than the disassembly.
- Page 24 Remote Control Valve and Inlet Manifold Removal CAUTION Optional feature. Refer to Dwg. MHP1304. Disconnect main air supply line at the winch. • Ensure the reduction gear oil is drained before disassembly Disconnect disc brake air line from connector fitting (621) and that the drain and fill plugs are removed.
- Page 25 Piston Disassembly Automatic Drum Band Brake: Remove piston sleeve (243) and ‘O’ ring (242) from the Optional feature. Refer to Dwg. MHP1281. piston and discard. Loosen jam nut (117) closest to plunger (114). Turn Press out pin (246) and remove washers (248). capscrew (120) counterclockwise until disconnected from Pull link rod (244) apart from piston rod (241).
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Page 26: Cleaning, Inspection And Repair
Reduction Gear Disassembly Cleaning, Inspection and Repair Refer to Dwg. MHP1313. Cleaning Place the reduction gear assembly on a clean work bench Clean all winch component parts in solvent (except the drum such that reducer housing (59) with oil seal (58) is down. brake bands and disc brake friction plates). - Page 27 Tighten locknut (202) to 60 in lb. (22 Nm). Use a wooden Thermoplastic Coated Parts Assembly (or fiberglass) tool handle to lock the crankshaft. Place it through two of the cylinder ports in the motor housing and CAUTION 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 one of the slots in the •...
- Page 28 The flats on counterweight must align within 1/16 in (2 Cylinder Cap Sealant Placement mm) of the flats on the crankshaft. Use a small metal flat edge to check. Refer to Dwg. MHP1307. Counterweight Alignment Check (Dwg. MHP1297) Place cylinder assembly over piston, push and twist into position on motor housing.
- Page 29 Align bolt holes, with air inlet on motor housing facing up. Connect air supply line to control valve. Apply Loctite 242 to capscrews (221) and insert through ® motor flange into adapter (71) and tighten to 33-36 ft lb. Reduction Gear Assembly (45-49 Nm).
- Page 30 To install planet gear assemblies on the input carrier (47) Align holes in motor adapter (71) and install on upright. conduct the following: Secure with six washers (74) and capscrews (73). Torque Ensure pin (49) is securely attached to input carrier capscrews to 125 ft lbs (170 Nm) for dry threads, or 95 ft (47).
- Page 31 Place brake link stud (141) into pivot nut (134) and rotate WARNING clockwise until approximately 1 in. (25 mm) of threads are exposed. • Failure to correctly arrange friction and separator plates will result in irratic brake operation. Sudden brake NOTICE applications may cause winch and/or wire rope damage resulting in a falling load.
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Page 32: Testing
Place spacer (105) between upper brake band flange and Drum Guard Assembly bracket. Attach band assembly (104) to bracket (106) using Refer to Dwg. MHP0658. three capscrews (101), spacers (102) and spacer tubes Place drum guard (590) on rear (drum brake side) (103). -
Page 33: Winch Parts Drawings And Parts Lists Table Of Contents
WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS Page Winch Cross Section Drawing (MHP1312) ..............................33 Winch Assembly Parts Drawing (MHP1313) ..............................34 Winch Assembly Parts List ....................................35 Motor Assembly Parts Drawing (MHP1310) ..............................36 Motor Assembly Parts List ....................................37 Disc Brake Assembly Parts Drawing (MHP0947) ............................ -
Page 34: Winch Parts Drawings And Parts Lists
WINCH ASSEMBLY PARTS DRAWING... -
Page 35: Winch Assembly Parts List
WINCH ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Pin, Dowel 71126759 Shaft Coupling 25482 Brake Shaft 25109 Drive Shaft Upright, Outboard End 24871 Short Drum (7 in) 25292 Output Shaft 24817 Medium Drum (13-1/2 in) 25291... -
Page 36: Motor Assembly Parts Drawing (Mhp1310)
MOTOR ASSEMBLY PARTS DRAWING... -
Page 37: Motor Assembly Parts List
MOTOR ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Motor Assembly ATPM15 26135 Capscrew 71307292 Motor Adapter 25445 Inboard Cap 24971 Capscrew 71311674 Outboard Cap 24972 Washer 71304844 Cylinder 24970 Locknut 71293104 Capscrew 71307284... -
Page 38: Disc Brake Assembly Parts Drawing (Mhp0947)
DISC 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: Disc Brake Assembly Parts List
DISC BRAKE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Disc Brake Assembly * 25426 Pressure Plate 24137 • Capscrew 71264717 Sprag Clutch *** 71044853 • End Cover ** 23605 Spring 71053730 •... -
Page 40: Control Valve Assembly Parts Drawing (Mhp1314)
CONTROL VALVE ASSEMBLY PARTS DRAWING... -
Page 41: Control Valve Assembly Parts List
CONTROL VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER • Valve Assembly * 26126 Seal Ring K5B-606 Handle K5B-556P Valve Body 26125 • Roll Pin K5B-1115 Gasket K5B-275 Capscrew 71292064 Flange KK5B-276SP •... -
Page 42: Remote Pendant And Control Valve Assembly Parts Drawing (Mhp1304)
REMOTE PENDANT AND CONTROL VALVE ASSEMBLY PARTS DRAWING... -
Page 43: Remote Pendant And Control Valve Assembly Parts List
REMOTE PENDANT AND CONTROL VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION QTY. PART ITEM DESCRIPTION QTY. PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Valve Assembly 26170 Clamping Sleeve MLK-521 (see note 3) Manifold 26168 Cover, Manifold 26169 Clamping Thimble MLK-602 Capscrew 71311674... -
Page 44: Pilot Air Valve Assembly Parts Drawing (Mhp1305) And Parts List
CONTROL AIR VALVE ASSEMBLY DRAWING AND PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Valve Assembly * 26170 Spring 52240 End Cap 52241 Washer 52239 • Gasket 52457 Spacer 52238 • Valve Body ‘O’... -
Page 45: Drum Guard Assembly Parts Drawing (Mhp0658) And Parts List
DRUM GUARD ASSEMBLY DRAWING AND PARTS LIST PART NUMBER ITEM DESCRIPTION OF PART TOTAL Manual Drum Brake Automatic Drum Brake Short Drum (7 in) 25298 25299 Medium Drum (13-1/2 in) 25255 25300 Long Drum (20 in) 25301 25302 Extra Long Drum (24 in) 26257 26258 Bracket *... -
Page 46: Automatic Drum Band Brake Assembly Drawing (Mhp1281) And Parts List
AUTOMATIC DRUM BAND BRAKE ASSEMBLY DRAWING AND PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Hose Assembly 24403-39 Plunger 23886 Valve, Exhaust 71047898 Pin, Dowel 71144968 Brake Assembly * 25155 Roller 23883 Capscrew 71264808 Jam Nut... -
Page 47: Manual Drum Band Brake Assembly Drawing (Mhp1372) And Parts List
MANUAL DRUM BAND BRAKE ASSEMBLY DRAWING AND PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Upright, Motor End 24893-1 Front Brake Pad * 26305 Capscrew 71331847 4303-S Capscrew 71331839 Cotter Pin 51937 Washer 71274807 Brake Link Stud... -
Page 48: Air Preparation Assembly Parts Drawing (Mhp0233) And Parts List
AIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST ITEM DESCRIPTION QUANTITY PART OF PART TOTAL NUMBER Filter 71323935 Regulator R40-0B-G00 Pipe Nipple 51704 Pipe Bushing Contact factory Lubricator 71323927 Liquidator 1-1/2 inch NPT (not shown on drawing) 8834-WI-000 Pipeline Strainer (not shown on drawing) K4U-A267AT Air preparation components for 1-1/4 inch NPT system unless noted otherwise. -
Page 49: Winch Label/Tag Location Drawing (Mhp1315) And Parts List
WINCH LABEL/TAG LOCATION AND PART NUMBER REFERENCE DRAWING ITEM DESCRIPTION PART OF PART TOTAL NUMBER Label and Tag Assembly Short Drum (7 in) 26202-1 Medium Drum (13-1/2 in) 26202-2 Long Drum (20 in) 26202-3 Extra Long Drum (24 in) Label Sheet 71295240 Warning Label 71124895... -
Page 50: Parts Ordering Information
For your convenience and future reference it is recommended Return Goods Policy that the following information be recorded. Ingersoll-Rand will not accept any returned goods for warranty or service work unless prior arrangements have been made and Model Number written authorization has been provided from the location where the goods were purchased. -
Page 51: Warranty
WARRANTY HOIST AND WINCH LIMITED WARRANTY Ingersoll-Rand Company (I-R) warrants to the I-R makes no other warranty, and all implied original user its Hoists and Winches (Products) to be warranties including any warranty of free of defects in material and workmanship for a merchantability or fitness for a particular purpose period of one year from the date of purchase. -
Page 52: Office Locations
(310) 948-1828 Fax: (416) 213-4510 Order Desk Asia Pacific Operations Philadelphia, PA Fax: (416) 213-4605 Ingersoll-Rand (Japan) Ltd. P.O. Box 425 Shin-Yokohama Square Bldg. 900 E. 8th Ave., Suite 103 Regional Sales Offices Floor) King of Prussia, PA 19406 2-3-12 Shin-Yokohama,...
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