Ingersoll-Rand ManRider force5 FA5AMR-SMK1 Parts, Operation And Maintenance Manual
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Ingersoll-Rand ManRider force5 FA5AMR-SMK1 Parts, Operation And Maintenance Manual

Ingersoll-Rand ManRider force5 FA5AMR-SMK1 Parts, Operation And Maintenance Manual

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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 infor-
mation. Make this manual available to all persons responsible for the
operation, installation and maintenance of these products.
These instructions apply only to 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 MHD56115
Edition 1
October 1997
71300248
© 1997 Ingersoll-Rand Company
MODEL FA5A-MR
ManRider
1
Form MHD56115
®

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Summary of Contents for Ingersoll-Rand ManRider force5 FA5AMR-SMK1

  • Page 1 Make this manual available to all persons responsible for the operation, installation and maintenance of these products. These instructions apply only to winches designed by Ingersoll-Rand that are identified for personnel lifting by a permanent nameplate attached to the winch at the factory.

  • Page 2: Table Of Contents

    CONTENTS Page Safety Information Danger, Warning, Caution and Notice ................................3 General Information ......................................4 Safe Winch Operating Instructions ................................... 5 Standards ..........................................6 Warning Labels and Tag ....................................7 Specifications Description ......................................... 7 Model Code Explanation ....................................8 General Specifications ....................................... 9 Winch Weight and Wire Rope Capacities .................................

  • 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 Changes in any of the standards or regulations after number of models referred to as Man-Riders which are designed Ingersoll-Rand’s initial shipment of the product. and manufactured to standards and specifications established by More than one winch is used to attach to a common load.

  • Page 5: Safe Winch Operating Instructions

    • Failure to follow these instructions may result in termination of all applicable warranties. Ingersoll-Rand Ingersoll-Rand recognizes that most companies who use assumes no liability for any loss or damage resulting from winches have a safety program in force at their facility. In the...

  • Page 6: Standards

    STANDARDS The standards and/or requirements referred to by Ingersoll-Rand to design or manufacture Man-Rider winches are as follows: ® STANDARD SPECIFICATION Wire rope to drum ratio 18:1 Wire rope design factor at “Man-Rider” rating Minimum of 8:1 Winch design factor at “Man-Rider” rating...

  • Page 7: Warning Labels And Tag

    WARNING LABELS AND TAG Each unit is shipped from the factory with the warning labels and tag shown. If the labels or tag are not attached to your unit, order new labels and tag and install. See the parts list for the part numbers.

  • Page 8: Model Code Explanation

    * Remote throttles are provided with 6 feet (1.8 metres) of hose. Specify hose lengths greater than 6 feet. If in doubt, contact Notes: your Ingersoll-Rand distributor or the factory for control acceptability. Metric lengths are provided for reference only, order lengths in feet.

  • Page 9: General Specifications

    General Specifications Utility Rating Man-Rider Rating Rated Operating Pressure 90 psig (6.3 bar/630 kPa) Air System Air Consumption 600 scfm 17 cu.m/min Refer to Performance Curve (at rated pressure and load) Mid Drum Line Pull 10,000 lbs 4,536 kg 6,250 lbs 2,835 kg Rated Performance (at rated pressure / volume)

  • Page 10: 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 11 Forming a large loop with the wire rope, insert the end back Wire Rope Selection into the top of the anchor hole. Consult a reputable wire rope manufacturer or distributor for Place the wire rope wedge into the wire rope anchor pocket assistance in selecting the appropriate type and size of wire rope in the drum.

  • Page 12: 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 13: Motor

    Lifting and lowering speeds are operator controlled and and applicable regulations before placing this product into use. should be as slow as practical. Ingersoll-Rand recommends that you do not exceed 100 feet (30 m) per The four most important aspects of winch operation are: minute.

  • Page 14: Winch Controls

    * To ensure accurate winch control when remotely operating the thereafter for any new employees assigned to the operation. winch at distances greater than 60 feet (18 metres) contact Ingersoll-Rand Technical Sales for control suitability. Winch Controls A spring loaded, motor mounted, manual throttle control valve is supplied as a standard feature on these winches.
  • Page 15 Remote Full Flow Throttle Optional feature. Refer to Dwg. MHP0161. Provides for the remote mounting of the winch control at a fixed location at up to 20 feet (6 metres) away from the winch motor. Air hoses connect the throttle to the winch motor to provide winch operation.

  • Page 16: Brakes

    Overload Device Manual Drum Brake Optional feature. An overload device is available on winches Refer to Dwg. MHP1449. provided with the emergency shut-off valve. Overload device The manual drum brake may be applied by pushing down on the operation is based on the differential pressure between the motor handle (135) and released by pulling up.

  • Page 17: 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 18: Periodic Inspection

    MOTOR. Check oil level. Place a suitable container below ALL COMPONENTS. Inspect for wear, damage, the motor and carefully open drain plug to remove any distortion, deformation and cleanliness. If external evidence accumulated water. Check oil level in motor and add oil as indicates damage, disassemble as required to conduct a necessary to maintain correct level.

  • Page 19: Inspection 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 20: 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 21: Lubrication

    Approval for the use of other lubricants must be the winch drum must be rotated to align the plugs for either obtained from your Ingersoll-Rand distributor. Failure to the fill or drain operation. observe this precaution may result in damage to the winch and/ or its associated components.
  • Page 22 The motor should be level-checked daily or at the start of each shift after any accumulated water has been drained off. When Apply a wire rope lubricant, Ingersoll-Rand LUBRI- motors are operated in temperatures below freezing, wait long LINK-GREEN or ISO VG 100 (30W) lubricant.

  • Page 23: Maintenance

    450º F (232º C). Optimum temperature is 300º F directions. Winch must operate smoothly (149º C) for best results. A small propane torch (Ingersoll-Rand without sticking, binding or abnormal noises. Part No. 71308886) or heat gun (Ingersoll-Rand Part No.

  • Page 24: Adjustments

    1/16 inch (1.6 mm) heat the area clockwise direction. and then apply thermoplastic coating powder, Ingersoll-Rand Part No. 71308902 [2 oz. (56.7 g)], to fill NOTICE the area. Continue heating until coating liquefies and flows together with the existing coating.
  • Page 25 When grasping a part in a vise, always use leather-covered WARNING or copper-covered vise jaws to protect the surface of the part and help prevent distortion. This is particularly true of • Shut off, bleed down and disconnect the air supply line threaded members, machined surfaces and housings.
  • Page 26 11. Using a hoist to support the drum, remove sideframes (65), one at a time, by removing four capscrews (66) and washers (74) attaching each sideframe to uprights (26) and (68). 12. Remove the inboard (motor end) upright (68) by pulling straight away from drum (62) in a horizontal direction.
  • Page 27 Remove retainer ring (432) and separate valve piston Step 7a. does not apply to the Pendant Operated Pilot (431) and poppet seat (428). Control Valve. Skip this step and proceed to step 7b. Remove and discard ‘O’ rings (426), (427) and (430). Push shaft (401) to the front of valve body to cause pin Live Air Throttle Valve Disassembly (405) to push seat restrictor (403) out of valve body.
  • Page 28 Disconnect air line from brake cylinder (121). With the aid Crankshaft Disassembly of a strap wrench, remove brake cylinder (121) and Remove cotter pin (236) and the pin nut (237). components as an assembly by turning brake cylinder Remove lock pin (235) by carefully driving it out of its counterclockwise until disconnected from brake bracket location.

  • Page 29: Cleaning, Inspection And Repair

    Note the position and quantity of the washers (84), Reduction Gear (85) and (86) in each gear assembly. Keeping the Refer to Dwg. MHP1410. washers separated, by assembly, will assist in Place the reduction gear assembly on a clean work bench reinstallation.

  • Page 30: Assembly

    Inspect all remaining parts for evidence of damage. Place crank assembly (231) on a work bench with the oil Replace or repair any part which is in questionable slinger (230) down and slide the sleeve (232), with tang up, condition. The cost of the part is often minor in comparison on the crankpin.
  • Page 31 24. Install motor on winch at motor adapter (71) using Valve Body Assembly capscrews (197), lockwashers (196) and washers (198). Refer to Dwg. MHP1408 (Pendant Pilot Operated Valve) and 25. Ensure oil drain (225) and level plug (225) are installed. MHP1407 (Lever Operated Valve) Facing the flats of the valve shaft (401), slide sleeve (408) Control Valve Assembly...
  • Page 32 Brake Release Valve Installation and Adjustment Refer to Dwgs. MHP1408 (Pendant Pilot Operated Valve) or MHP1407 (Lever Operated Valve) and MHP1411. NOTICE • Valve assembly (413) shaft body is longer on one side of middle groove than the other. Correct placement of valve assembly is with the longer shaft section located towards the bottom of the valve body (410).
  • Page 33 Brake Valve and Dowel Pin Positions (Dwg. MHP1026) (Dwg. MHP1411) Valve Cap Assembly (Handle End) Refer to Dwg. MHP1407. To adjust the brake valve (413) conduct the following: The following describes the assembly of the valve cap assembly Ensure long section of sleeve (408) is positioned at the on the lever control handle end of valve.
  • Page 34 Coat external mating sleeve surface of cylinder (451) with NOTICE Loctite 609 and press into valve cap (438). ® • The slotted pin grooves in the clevis (where clevis and shaft CAUTION (401) are joined) make alignment of the cross shaft and clevis difficult.
  • Page 35 Check throttle handle moves fully left and right without Cover the reduction gear to prevent dirt and contaminants sticking or binding. Throttle handle should center, by from entering assembly and place in a safe place until ready spring force, automatically when released. for assembly to winch uprights.
  • Page 36 Install pivot bar (119) and capscrew (120) through lower NOTICE flange of brake band assembly (104). At lowest point of threads, place a bead of Loctite 680 and install jam nut ® • Refer to ‘ADJUSTMENT’ section for adjusting brake. (117) fully.

  • Page 37: Testing

    Install twelve springs (17) in holes on inside of support Testing plate (19). Install gasket (18) and pressure plate (15). Operational Test Determine correct alignment of cover (2), housing (6) and Prior to initial use, all new, altered or repaired winches shall be support plate (19) by checking matchmarks placed during tested to ensure proper operation.

  • Page 38: Winch Parts Drawings And Parts Lists Table Of Contents

    WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS Page Winch Cross Section Drawing (MHP1459) ..............................39 Winch Assembly Parts Drawing (MHP1410) ..............................40 Winch Assembly Parts List ....................................41 Motor Assembly Parts Drawing (MHP0690) ..............................42 Motor Assembly Parts List ....................................43 Disc Brake Assembly Parts Drawing (MHP1230) ............................

  • Page 39: Winch Cross Section Drawing

    WINCH CROSS SECTION DRAWING...

  • Page 40: Winch Parts Drawings And Parts Lists

    WINCH ASSEMBLY PARTS DRAWING...

  • Page 41: Winch Assembly Parts List

    WINCH ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Capscrew (1) 71266613 Spacer 20389 End Cover (1) 24381 Input Sun Gear 23896 • Gasket (1) 71262257 Thrust Washer 71113203 Dowel Pin 71126759 Thrust Bearing 71113195...

  • Page 42: Motor Assembly Parts Drawing (Mhp0690)

    MOTOR ASSEMBLY PARTS DRAWING...

  • Page 43: Motor Assembly Parts List

    MOTOR ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Lockwasher 71268213 Crank Bearing 51066 Capscrew 71268205 Button Head Screw * Washer 71274815 Oil Slinger * Motor Assembly ** K5B-546LP Crank Assembly K5B-A516 Capscrew 52317...

  • Page 44: Disc Brake Assembly Parts Drawing (Mhp1230)

    DISC BRAKE ASSEMBLY PARTS DRAWING...

  • Page 45: 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 * 24140 Pressure Plate 24137 • Capscrew 71264717 Sprag Clutch *** 71044853 • End Cover ** 23605 Spring 71053730 •...

  • 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 (Mhp1448) And Parts List

    MANUAL DRUM BAND BRAKE ASSEMBLY DRAWING AND PARTS LIST PART NUMBER ITEM DESCRIPTION OF PART TOTAL Standard Charpy Drum (with Band Brake) 23750 23750CH Short Drum (12 inch) Drum (with Band Brake) 21729 21729CH Long Drum (24 inch) Upright, Motor End 25567 25567CH Capscrew...

  • Page 48: Lever Operated Control Valve Assembly Parts Drawing (Mhp1407)

    LEVER OPERATED CONTROL VALVE ASSEMBLY PARTS DRAWING...

  • Page 49: Lever Operated Control Valve Assembly Parts List

    LEVER OPERATED CONTROL VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER - - - • Valve Assembly * ‘O’ Ring 52573 Single Air Brake 24801 Valve Piston 23519 Single Air Brake -E * 25451 Retainer Ring 71138010...

  • Page 50: Pendant Operated Pilot Control Valve Assembly Parts Drawing (Mhp1408)

    PENDANT OPERATED PILOT CONTROL VALVE ASSEMBLY PARTS DRAWING...

  • Page 51: Pendant Operated Pilot Control Valve Assembly Parts List

    PENDANT OPERATED PILOT CONTROL VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER • Valve Assembly: * - - - ‘O’ Ring 52573 Single Air Brake 25440 Valve Piston 23519 Single Air Brake -E * 25439 Retainer Ring 71138010...

  • Page 52: Remote Pendant Assembly Parts Drawing (Mhp0934)

    REMOTE PENDANT ASSEMBLY PARTS DRAWING...

  • Page 53: Remote Pendant Assembly Parts List

    * Pendant Assembly includes items 620 through 645. Pendant Extension Assembly (item 646) must be ordered in feet. Example: 15 feet = Part Number 24259-15. Lengths available up to 54 feet. Contact your distributor or the nearest Ingersoll-Rand office for assistance on lengths greater than 54 feet.

  • Page 54: Shuttle Valve Assembly Parts Drawing (Mhp1409)

    SHUTTLE VALVE ASSEMBLY PARTS DRAWING...

  • Page 55: Shuttle Valve Assembly Parts List

    SHUTTLE VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Pendant Operated Pilot Air Valve: Tubing (Hose) * As required 71261374 Nipple Fitting 24242 Tubing Fitting 71262083 Plug 71262141 Fitting 71268536 Short Tubing 24241-1 Hose...

  • Page 56: Emergency Stop And Overload Assembly Parts Drawing (Mhp1188)

    EMERGENCY STOP AND OVERLOAD ASSEMBLY PARTS DRAWING...

  • Page 57: Emergency Stop And Overload Assembly Parts List

    EMERGENCY STOP AND OVERLOAD ASSEMBLY PARTS LIST PART NUMBER ITEM DESCRIPTION Pendant with Manual Lever with Pendant with NUMBER OF PART TOTAL Emergency Stop and Overload Device Emergency Stop Overload Device Spring 71053730 Setscrew 71266589 Plug 23745 - - - - - - Label, E-Stop Instructions 71320279...

  • Page 58: Control Valve Assembly Drawing (Mhp1380) And Parts List

    CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Valve Assembly * K5B-REMOTEP Roll Pin 71326102 Handle K5B-556P Grease Fitting 53095 Roll Pin K5B-1115 Valve Bushing ** K5B-1101P •...

  • Page 59: Remote Full Flow Control Valve Assembly Drawing (Mhp0161) And Parts List

    Exhaust Cover 251P2559A Lockwasher 50181 Add hose length (feet/metres). Maximum length = 20 feet (6 metres). Contact Ingersoll-Rand for information on control suitability for lengths greater than 20 feet (6 metres). Metres are for reference only; order quantities in feet.

  • Page 60: Muffler Assembly Parts Drawing (Mhp1189) And Parts List

    MUFFLER ASSEMBLY PARTS DRAWING AND PARTS LIST ITEM DESCRIPTION QUANTITY PART OF PART TOTAL NUMBER Motor Muffler and Fittings: Muffler 50594 Elbow Fitting 71106439 Reducer 71057459 Control Valve Muffler and Fittings: Nipple Fitting 71311260 Elbow Fitting 54299 Muffler 71264360...

  • Page 61: Drum Guard Assembly Parts Drawing (Mhp1450) And Parts List

    DRUM GUARD ASSEMBLY PARTS DRAWING AND PARTS LIST PART NUMBER ITEM DESCRIPTION OF PART TOTAL Manual Band Brake Automatic Band Brake Washer 71274807 - - - Drum Guard - Short Drum (12 in) 23836-1P 23836 Drum Guard - Long Drum (24 in) 23506-1P 23506 Bracket...

  • Page 62: Air Preparation Assembly Parts Drawing (Mhp0233) And Parts List

    AIR PREPARATION ASSEMBLY PARTS DRAWING AND PARTS LIST ITEM DESCRIPTION QUANTITY PART NUMBER OF PART TOTAL NUMBER Filter F42-0B-000 Pipe Nipple 51670 Regulator R30-0B-G00 Pipe Nipple 51704 Pipe Bushing Contact factory Lubricator L40-0B-G00 Air preparation components for 1-1/2 inch NPT system. Items 578 and 579 depend on required size for customer application. ACCESSORIES AND KITS DESCRIPTION PART...

  • Page 63: Winch Label/Tag Location Drawing (Mhp1460) And Parts List

    WINCH LABEL/TAG LOCATION AND PART NUMBER REFERENCE DRAWING ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER ManRider Label 71108856 Drum Direction Label 71126585 Check Oil Level Notice 71107148 Nameplate 71108849 Warning Label 71124887 Drive Screws 50915 Air Supply Label Do Not Weld Label...
  • Page 64 SERVICE NOTES...
  • Page 65 SERVICE NOTES...

  • Page 66: 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 67: 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 68: Office Locations

    (562) 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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