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paratech MAXIFORCE G2 Operation, Maintenance And Parts Manual

Air lifting bag system
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OPERATION, PREVENTIVE MAINTENANCE
AND PARTS SUPPORT MANUAL
MAXIFORCE
Paratech Incorporated
P.O. Box 1000, Frankfort, IL 60423 USA
Customer Service: 800.435.9358
Phone: 815.469.3911 Fax: 815.469.7748
www.paratech.com E-mail: paratech@paratech.us
FOR
G2 AIR LIFTING
®
BAG SYSTEM
Paratech Europe, Branch of Paratech Inc.
P.O. Box 174, 5260 Odense S, Denmark
www.paratech.com Email: Paratech@paratech.dk
09 NOVEMBER 2020
PN 22-890800G2

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  • Page 1 ® BAG SYSTEM 09 NOVEMBER 2020 PN 22-890800G2 Paratech Incorporated Paratech Europe, Branch of Paratech Inc. P.O. Box 1000, Frankfort, IL 60423 USA P.O. Box 174, 5260 Odense S, Denmark Customer Service: 800.435.9358 www.paratech.com Email: Paratech@paratech.dk Phone: 815.469.3911 Fax: 815.469.7748...

  • Page 3: List Of Effective Pages

    LIST OF EFFECTIVE PAGES Date of original pages is: Original……….0……….31 March 2014 Total number of pages in this publication is 54 consisting of the following: Page *Change Page *Change Title and A…………………… 0 1-1 through 1-9…………….…2 Change Record………………. 0 1-10 blank……..…………….0 Change Record-2 blank………...
  • Page 4 II – EXCEPTIONS EXCEPTIONS AUTHORIZED BY NONE Kenneth Nielsen, Chief Operating Officer Paratech Incorporated 1025 Lambrecht Drive Frankfort, IL 60423 SIGNATURE OF PUBLICATIONS QUALITY ASSURANCE OFFICER DATE SIGNATURE ON FILE QAP20/002/B...
  • Page 5 Change Record Change Signature of Date Title or Brief Description Validating Officer PAGE 1-9; UPDATED TABLE 1-1 MAX AIR CAPACITY SIGNATURE ON FILE 14 JAN 2016 DATA PAGE i; UPDATED CONTROL EQUIPMENT P/N’s PAGES 1-1 → 1-9; UPDATED CONTROL EQUIPMENT DESCRIPTION IN CHAPTER 1 PAGES 2-1 →...
  • Page 7 M-7298 Commercial Equipment Technical Manual and MIL-M-15071 Equipment and Systems Content Requirements for Technical Manuals. The manual contains description, operating instructions, theory of operation, scheduled maintenance recommendations and parts lists for MAXIFORCE® G2 Air Lifting Bag Systems manufactured by Paratech Incorporated, 1025 Lambrecht Road, Frankfort, Illinois 60423-7000.

  • Page 9: Table Of Contents

    TABLE OF CONTENTS LIST OF FIGURES Chapter/Para Title Page Figure Title Page 1 GENERAL INFORMATION AND SAFETY... 1-1 1-1 MAXIFORCE® G2 Air Lifting Bag System….. 1-2 1-2 MAXIFORCE® G2 Lift Bag………………….. 1-3 FIRST PROCEDURES 1-1 Safety Precautions……………………..1-1 1-3 G2 Pressure Regulator…………………………. 1-4 1-2 Scope Of Manual…………………………...

  • Page 10: Safety First

    Although the following safety first list is quite extensive, the majority of the precautions are just good common sense for any personnel qualified in the use of lift bags. However, some of the precautions are not obvious and Paratech strongly recommends that all operating/assisting/maintenance personnel read and understand the complete safety first procedures in order to ensure personnel and equipment safety.
  • Page 11 DURING PRIOR TO INFLATION DURING AFTER SAFETY FIRST PROCEDURE INFLATION AND WHILE DEFLATION REMOVAL INFLATED Always be on the opposite side of any expected movement. Always stand clear of a load that is only supported by lift bag(s). Never be below a lift bag supported load that has no blocking or cribbing for positive support.
  • Page 12 DURING PRIOR TO INFLATION DURING AFTER SAFETY FIRST PROCEDURE INFLATION AND WHILE DEFLATION REMOVAL INFLATED Never work in the dark. Use flash lights or flood lights to provide shadow-free illumination of work area. Inflate only enough to achieve desired lift. If force must be applied to a small diameter or small area object, always use plywood, rubber mud flaps, etc.

  • Page 13: Safety Precautions

    MAXIFORCE® Lifting Systems manufactured by Paratech Incorporated, 1025 Lambrecht b. Lifting or shifting pipelines requiring welding and Rd, Frankfort, Illinois 60423-7000. maintenance. 1-3 ARRANGEMENT c. Breaking out granite and marble blocks and slabs in quarrying operations.
  • Page 14 Figure 1-1. MAXIFORCE® G2 Air Lifting Bag System Chapter 2 “OPERATION” for component connection For further component explanation, see the chapter shown under the component within figure 1-1. See and system operation.

  • Page 15: Equipment Description

    EQUIPMENT DESCRIPTION 1-6.1 G2 LIFT BAG Figure 1-2. MAXIFORCE® G2 Lift Bag MAXIFORCE® G2 Lift Bags (figure 1-2) are composite used to assist in transport and insertion positioning prior items fabricated from neoprene, reinforced with six layers to inflation. (three per side) of Kevlar reinforced fabric for strength Corners and edges has the maximum tonnage molded into and rigidity even at full inflation pressure of 150 psi (10.3 the bag and filled with bright yellow silicone adhesive to...
  • Page 16 1-6. 2 G3 PRESSURE REGULATORS. Figure 1-3 CGA G3 Pressure Regulator Figure 1-4 DIN G3 Pressure Regulator The G3 pressure regulators (figures 1-3 & 1-4) reduces The G3 pressure regulator will operate with any breathing inlet pressure of up to 5,500 psi (379 bar) to 215 psi (14.8 air.
  • Page 17 1-6.3 G3 CONTROLLER Figure 1-5. Dual “Deadman” 150 psi ALB Controller G3 The dual “deadman” 150 psi ALB controller G3 (figure 1- 155 psi (10.7 bar) non-adjustable safety relief valves are 5) is single input/dual output that incorporates locking, installed into the controller to limit the applied air pressure quick connect safety couplings to prevent accidental and prevent over pressurizing.
  • Page 18 Figure 1-8. Hoses 1-6.6 HOSES. Hoses (figure 1-8) are used to convey air from the air supply source to the lift bag(s). All hoses are equipped with locking, quick connect, safety fittings to Figure 1-6. Manual Compressor prevent their accidental disconnection or improper 1-6.4 MANUAL COMPRESSOR.

  • Page 19: Reference Data

    MAXIFORCE® G2 lift bag system. regulators, self-contained compressed air cylinders, etc. Table 1-1. MAXIFORCE G2 Lift Bag Reference Data LIFT BAG CONSTANTS: Base Material………………………………………………………………………………………... Neoprene Reinforcing Material …………………………………………………………………………...…… Kevlar Number of Reinforcing Layers (Each Side)…………………………………………………………...
  • Page 20 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 U.S. TONS U.S. TONS Table 1-1. MAXIFORCE® G2 Lift Bag Reference Data (Continued)
  • Page 21 MAXIFORCE AIR BAGS TECHNICAL DATA DIMENSIONS W/O EYELETS & STORAGE DIMENSIONS MAX LIFT MAX LIFT MAX AIR WEIGHT WORK NIPPLE (W/EYELETS) CAPACITY HEIGHT CAPACITY PRESSURE MODEL METRIC INCH INCH US TONS INCH LITERS 22-888110G2 KPI-1 152 X 152 X 19 6 X 6 X 0.75 178 X 178 X 19 7.0 X 7.0 X 0.75...

  • Page 23: Operation

    CHAPTER 2 OPERATION INTRODUCTION d. As air flows into the lift bag, it increases in height 2-1.1 MAXIFORCE® G2 Lifting Bag Systems are resulting in a corresponding lift/displacement. Maximum multi-application, portable inflation systems used for lift lift/displacement force occurs at insertion height and displacement of heavy rigid objects, up to 178,400 (maximum lift bag surface area).
  • Page 24 components are addressed generally but not specific a. Remove all dust, dirt, oil or grease from the during the interconnection. It is assumed these parts are MAXIFORCE® Lifting System available and will be installed where required in the components. Do not use any system components without system.

  • Page 25: Normal Operating Procedure During

    If a second G2 safety inline relief valve is used, Slowly open (turn counter-clockwise) the G3 attach air hose quick connect nipple to the second G2 pressure regulator shut-off valve. safety inline relief valve delivery safety coupling using the appropriate interconnecting fittings as required. A Open the shut-off valve on the G2 safety inline different colored air hose should be used to permit the relief valve(s).

  • Page 26: Normal Operating Procedure During

    6. Press the inflate (green) button of the dual a. To either partially or fully deflate an inflated lift “deadman” 150 psi ALB controller G3 repeatedly to bag(s) disconnected from a controller, open and close as slowly inflate the lift bag to the required height or 150 required the shut-off valve on the G2 safety inline relief psi (10.3 bar).

  • Page 27: Applications

    2. Once the air supply is turned off and press the deflate (red) button on the dual “deadman” 150 psi ALB If the components are not to be immediately controller G3 to exhaust air from the system. reused, perform the post operation inspection and storage in accordance with Chapter 3.
  • Page 28 Figure 2-2...
  • Page 29 2-8.4 In addition to the SAFETY FIRST Procedures in the front of this publication, the following general application notes and procedures should be followed whenever a MAXIFORCE G2 Air Lifting Bag System is to be employed. All procedures should be used as guidelines, not absolute dictates.

  • Page 30: Lift Bag Chemical Compatibility

    “Chemical Resistance Guide for Elastomers II” published by Compass Publications, copyright 1994. Paratech is unable to guarantee their accuracy and therefore assumes no liability for the use Figure 2-5. Correct Method for Inflating thereof.
  • Page 31 Amyl Borate ........A Benzene ..........U Amyl Chloride........U Benzenesulfonic Acid ......A Acetamide .......... B Amyl Chloranaphthalene ....U Benzine ..........B Acetic Acid 5% ........A Amyl Naphthalene ......U Benzochloride ........U Acetic Acid 30% ........ A Anderol L-774 (diester) ......
  • Page 32 Copper Chloride ......... A Dioctyl Phthalate ......U Copper Cyanide ......... A Dioctyl Sebacate ....... U Carbon Tetrachloride ......U Copper Salts ........A Dioxane ..........U Carbonic Acid ........A Copper Sulfate........A Diozolane .......... U Castor Oil ........... A Copper Sulfate 10% ......
  • Page 33 Freon, 114 .......... A Helium ..........A Ethyl Cellosolve......... U Freon, 114B2 ........A N-Heptane .......... B Ethyl Cellulose ........B Freon, 115 .......... A N-Hexaldehyde ........A Ethyl Chlorocarbonate ....... U Freon, 142b ........A Hexane ..........B Ethyl Chloroformate ......U Freon, 152a ........
  • Page 34 MCS 463 ..........U MIL-L-6082C ........B Isododecane ........B Mercuric Chloride ......A MIL-H-6083C ........B Iso-Octane .......... B Mercury ..........A MIL-L-6085A ........U Isophorone (Ketone) ......U Mercury Vapors ......... A MIL-L-6086B ........A Isopropanol ........A Mesityl Oxide (Ketone) ...... U MIL-A-6091 ........
  • Page 35 Neville Acid ........U Petroleum Oil, Above 250°F(121.1°C) ......... U MIL-L-23699A ........C Nickel Acetate ........B Phenol ..........U MIL-G-23827A........C Nickel Chloride ........B Phenol, 70%/30% H2O ...... U MIL-G-25013D........B Nickel Salts ........B Phenol, 85%/15% H2O ...... U MIL-F-25172 ........
  • Page 36 Spry ............ B Tetrachloroethylene ......U Red Oil (MIL-H-5606) ...... B SR-6 Fuel ........... U Tetraethyl Lead ........C Red Line 100 Oil ....... B SR-10 Fuel ......... U Tetraethyl Lead "Blend ..... "U RJ-1 (MIL-F-25558) ......B Standard Oil Mobilube GX90-EP Tetrahydrofuran .........
  • Page 37 Ucon-Lubricant 50-HB100 ....A Ucon Lubricant 50-HB260 ....A Ucon Lubricant 50-HB660 ....A Ucon Lubricant 50-HB5100 ....A Ucon Oil LB-385 ....... A Ucon Oil LB-400X ......A Ucon 50-HB-280X (Polyacrylon Glycol Deriv.) ........A Univis 40 (Hydr. Fluid) ..... B Univolt #35 (Mineral Oil) ....
  • Page 38 2-15/(2-16 blank)

  • Page 39: Maintenance And Storage

    CHAPTER 3 MAINTENANCE AND STORAGE may result in a component failure when none should be expected or tolerated. 3-1 GENERAL. major components accessories a. Keep the exterior of all components clean of all dirt, MAXIFORCE® G2 Air Lifting Bag System require little grit, oil and grease accumulations.
  • Page 40 release the nipple. Discard the nipple but the ferrule socket located in the air inlet hole of the fitting can be reused if not damaged. and rotating it clockwise. Be sure to hold the air bag over the inlet fitting stationary. 2.

  • Page 41: Storage

    Replacement COMPONENT QUICK CONNECT COUPLING AND NIPPLE REPLACEMENT. The quick connect couplings and nipples assembled into the G2 pressure regulator, 150 psi ALB controllers G3 and the G2 safety inline relief valve are screw-type fittings. When their replacement is required, it is only necessary to unscrew the damaged part (quick connect safety coupling and/or nipple), remove and discard the "O"...
  • Page 42 3-3/(3-4 blank)

  • Page 43: Parts List

    4. The index numbers which identify the supplied. The parts should be ordered by part number individual parts are separated from the figure number by when ordered from Paratech Incorporated, 1025 a hyphen. Index numbers run consecutively. Lambrecht Road, Frankfort, Illinois 60423-7000.

  • Page 44: Air Source

    Table 4-2 MAXIFORCE Lifting Bag System Components Parts List Figure Part Description Quantity CAGE Index Number Number AIR SOURCE AIR CYLINDER, With valve and gauge, 13 cu ft (368 litres)…... 4-2-1 30978 800013 AIR CYLINDER, With valve and gauge, 80 cu ft (2,265 litres)… 30978 800080 MANUAL AIR COMPRESSOR (hand/foot pump)……………...
  • Page 45 Figure Part Description Quantity CAGE Index Number Number G3 CONTROLLERS CONTROLLER, Dual "Deadman" 150 psi ALB Controller G3 30978 890900G3-150 AIR HOSE 4-2-7 AIR HOSE, Black, 3/8 inch (9.5 mm) dia. X 16 ft (4.9 m) long… 30978 890513 AIR HOSE, Blue, 3/8 inch (9.5 mm) dia. X 16 ft (4.9 m) long….. 30978 890514 AIR HOSE, Yellow, 3/8 inch (9.5 mm) dia.
  • Page 46 Figure Part Description Quantity CAGE Index Number Number LIFT BAGS (See Table 1-1 for Physical Characteristics) 4-2-8 LIFT BAG, Model KPI-1, 1.5 ton (1,360 kg) capacity…………... 30978 888110G2 LIFT BAG, Model KPI-3, 3.5 ton (3,175 kg) capacity…………... 30978 888120G2 LIFT BAG, Model KPI-5, 5.4 ton (4,898 kg) capacity…………... 30978 888130G2 LIFT BAG, Model KPI-8, 8.2 ton (7,438 kg) capacity…………...
  • Page 47 Figure Part Description Quantity CAGE Index Number Number LIFT BAG SETS (Continued) LIFT BAG SET, 8 Bag, 218.4 U.S. ton (198.0 metric ton)……… 30978 889117G2 (consists of 1 each of index numbers: 13, 18 and 2 each of index numbers: 14, 15, 17) LIFT BAG SET, 11 Bag, 242.2 U.S.
  • Page 48 Figure Part Description Quantity CAGE Index Number Number ADAPTERS AND AIR FITINGS (Continued) PROTECTOR, Nipple……………………………………………. 30978 890695 PROTECTOR, Nipple G2………………………………………... 30978 890709T COUPLING, 1/4 inch NPTF……………………………………... 30978 890711V COUPLING, 1/4 inch NPTM……………………………………. 30978 890712V COUPLING, 1/4 inch NPSM open………………………………. 30978 890703V COUPLING, 1/4 inch NPTM open……………………………….
  • Page 49 Figure Part Description Quantity CAGE Index Number Number ADAPTERS AND AIR FITINGS (Continued) NIPPLE, Industrial double male with valve…………...………… 30978 890732 NIPPLE, Male and locking tire chuck…………………….……... 30978 890731 NIPPLE AND GLAD HAND……………………………………. 30978 890734 Y, With two 1/4 inch NPTM couplings………………………….. 30978 890735 Y, With two 1/4 inch NPTM couplings and MAXIFORCE nipple...
  • Page 50 Figure Part Description Quantity CAGE Index Number Number MISCELLANEOUS 30978 890466 SHEET, Neoprene, 20 in. (508 cm) x 20in. (50.8 cm)…………….. 4-2-76 x 1/8 in (0.32 cm) STORAGE CASE, 13 x 6 x 4.75 in. (33 x 15.2 x 12.1 cm)……….. 30978 000905 STORAGE CASE, CUSTOM U.S., master control package………...

  • Page 51: Control Packages

    MAXIFORCE® Air Lifting Bag System. They are accompanied by their parts lists for easy identification and individual components. Any repairs of these assemblies should be performed according to the specifications documented in their own Operation and Maintenance Manuals obtained from Paratech Incorporated, 1025 Lambrecht Road, Frankfort Illinois, 60423-7000 U.S.A.

  • Page 52: Dual "Deadman" 150 Psi Alb Controller G3

    DUAL “DEADMAN” 150 PSI ALB CONTROLLER G3 4-5.2 Item Number Description Quantity CAGE Part Number BODY, DUAL DEADMAN ALB G3………..…………… 30978 890890B O-RING, (5/32 X .070) BN70…………………………….. 30978 890488 GAUGE 1.5” 150 PSI 1/8 BACK MT..…………………… 30978 890605 GAUGE BASE FOR G3 CONTROLLERS………………. 30978 890860 BELLEVILLE DISC SPR .406”...

  • Page 53: Cga G3 Pressure Regulator

    4-5.3 CGA G3 PRESSURE REGULATOR Item Number Description Quantity CAGE Part Number BODY, REGULATOR G3, PRESET ALB………………... 30978 895423 CARTRIDGE HOUSING, REG…………………………... 30978 895413 SEAT, MAIN CARTR. REGULATOR.………………….. 30978 895412 O-RING AS-010 (1/4 X .070) BN90..…………………….. 30978 895513 SPACER FOR CARTRIDGE……….…………………….. 30978 895414 FILTER, SINTER, FOR REGULTR……………………….
  • Page 54 4-5.3 CGA G3 PRESSURE REGULATOR (Continued) Figure 4-3 CGA G3 Pressure Regulator 4-12...

  • Page 55: Din G3 Pressure Regulator

    4-5.4 DIN G3 PRESSURE REGULATOR Item Number Description Quantity CAGE Part Number BODY, REGULATOR G3, PRESET ALB………………... 30978 895410 CARTRIDGE HOUSING, REG…………………………... 30978 895413 SEAT, MAIN CARTR. REGULATOR.………………….. 30978 895412 O-RING AS-010 (1/4 X .070) BN90..…………………….. 30978 895513 SPACER FOR CARTRIDGE……….…………………….. 30978 895414 FILTER, SINTER, FOR REGULTR……………………….
  • Page 56 DIN G3 PRESSURE REGULATOR (Continued) Figure 4-4 DIN G3 Pressure Regulator 4-14...

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