Falltech 022420 Operator's manual

MCS13 Rev B 022420
Conned Space Personnel Winch
User Instrucon Manual
This manual is intended to meet the Manufacturer’s Instrucons as required by the American Naonal Standards
Instute (ANSI) Z359 and should be used as part of an employee training program as required by the Occupaonal
Safety and Health Administraon (OSHA).
1306 S. Alameda Street, Compton, CA 90221, USA Tel: [phone] Fax: [phone]

Table of Contents
1.0 Warnings and Important Informaon ..................................................................................
2.0 Descripon ..........................................................................................................................
3.0 Applicaon ...........................................................................................................................
4.0 System Requirements ..........................................................................................................
5.0 Installaon and Use .............................................................................................................
6.0 Maintenance, Service, and Storage .....................................................................................
7.0 Inspecon ............................................................................................................................
8.0 Labels ...................................................................................................................................
9.0 Denions ...........................................................................................................................
Appendix A .........................................................................................................................
Appendix C .........................................................................................................................
3
4
4
5
6
10
10
13
14
16
17
For purposes of this manual, the FallTech® Conned Space Personnel Winch, in all iteraons, may be referred to collecvely as the personnel winch,
the equipment, the product, or the unit.
Throughout this manual, ANSI Z359.0-2012 fall protecon words, phases and terms are used. These terms are all formally dened in Secon 9 of
this manual.
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1.0 Warnings and Important Informaon
This product is part of a personal fall arrest, restraint, work posioning, suspension, or rescue system. A Personal Fall Arrest System (PFAS) is
typically composed of an anchorage and a Full Body Harness (FBH), with a connecng device, i.e., a Energy Absorbing Lanyard (EAL), or a
Self-Retracng Device (SRD), aached to the dorsal D-ring of the FBH.
These instrucons must be provided to the worker using this equipment. The worker must read and understand the manufacturer’s instrucons for
each component or part of the complete system. Manufacturer’s instrucons must be followed for proper use, care, and maintenance of this
product. These instrucons must be retained and be kept available for the worker’s reference at all mes. Alteraons or misuse of this product, or
failure to follow instrucons, may result in serious injury or death.
A Fall Protecon Plan must be on le and available for review by all workers. It is the responsibility of the worker and the purchaser of this
equipment to assure that users of this equipment are properly trained in its use, maintenance, and storage. Training must be repeated at regular
intervals. Training must not subject the trainee to fall hazards.
Consult a doctor if there is reason to doubt your tness to safely absorb the shock of a fall event. Age and tness seriously aect a worker’s ability
to withstand falls. Pregnant women or minors must not use this equipment.
ANSI limits the weight of fall protecon equipment users to a maximum of 310 lbs. Products in this manual may have a rated capacity exceeding
ANSI capacity limits. Heavy users experience more risk of serious injury or death due to falls because of increased fall arrest forces placed on the
user’s body. In addion, the onset of suspension trauma aer a fall even may be accelerated for heavy users.
The user of the equipment discussed in this manual must read and understand the enre manual before beginning work.
NOTE: For more informaon consult the ANSI Z359 body of standards.
• Avoid moving machinery, thermal, electrical, and/or chemical hazards as contact may cause serious injury or death.
• Avoid swing falls.
• Follow the weight restricons and recommendaons in this manual.
• Remove from service any equipment subjected to fall arrest forces.
• Remove from service any equipment that fails inspecon.
• Do not alter or intenonally misuse this equipment.
• Consult FallTech when using this equipment in combinaon with components or subsystems other than those described in this manual.
• Do not connect rebar hooks, large carabiners, or large snap hooks to the FBH dorsal D-rings as this may cause a roll-out condion and/or
unintenonal disengagement.
• Avoid sharp and/or abrasive surfaces and edges.
• Use cauon when performing arc welding. Arc ash from arc welding operaons, including accidental arcs from electrical equipment, can
damage equipment and are potenally fatal.
• Examine the work area. Be aware of the surroundings and workplace hazards that may impact safety, security, and the funconing of fall arrest
systems and components.
• Hazards may include but not be limited to cable or debris tripping hazards, equipment failures, personnel mistakes, moving equipment such as
carts, barrows, fork lis, cranes, or dollies. Do not allow materials, tools or equipment in transit to contact any part of the fall arrest system.
• Do not work under suspended loads.
WARNING
IMPORTANT
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The FallTech® Conned Space Personnel Winch is primarily for those entering and working in conned spaces, both permit and non-permit, and is
to be used as part of a restraint, work posioning, suspension, or rescue system in a complete conned space system. See Secon 3 and Appendix
C of this manual.
The Personnel Winch is composed of a steel frame, gears, sha and winch handle, with stainless steel or galvanized wire rope cable or Technora®
rope. The frame is bolted to a mang bracket to facilitate installaon onto an anchorage structure such as a tripod or davit, see Figure 1.
2.0 Descripon
2.1 American Naonal Standards Instute (ANSI) and Occupaonal Safety and Health Administraon (OSHA): The winch discussed in this
manual, including all devices aached to it, meets the standards of ANSI Z359.4-2013, Z117.1-2009, A10.32-2012, and Occupaonal
Safety and Health Administraon (OSHA) regulaons for general industry 1926.502, 1910.146, and 1926.1200 for construcon. OSHA
requires all employees working in a conned space applicaon be trained regarding the nature of hazards involved, the necessary
precauons to be taken, and in the use of protecve and emergency equipment.
Figure 1 - About FallTech® Personnel Winch
A
D
B
C
G
E
F
H
A Winch Arm and Handle
BSwivel Snap Hook
CLine Constuent
D Drum Gear Cover
E Drum Gear
F Drive/Pinion Gear
G Integral Bracket
H Bracket Mang Slots for Tripod/
Davit
3.0 Applicaon
3.1 Purpose: A typical conned space applicaon is a support structure set up over an entry point, equipped with a conned space access
system. The winch discussed in this manual is part of a system to help facilitate non-entry rescue and entry rescue from conned spaces,
including work posioning and personnel riding. See Appendix C of this manual.
The winch operator directs the cable and maintains constant contact with the entrant, either visually or by other means.
The entrant is in the conned space is equipped with an approved full body harness and remains aached to a lifeline.
3.2 Applicaon Limits: Take acon to avoid sharp edges, rough, abrasive or corroded surfaces and edges, and thermal, electrical and
chemical hazards. Ensure the winch is properly aached to a support structure as specied in this manual.
When used with a FallTech anchorage structure, the winch is rated for one worker weighing a minimum of 130 lbs to a maximum of 310
lbs (including all clothing, tools, and equipment).
NOTE: The winch discussed in this manual is not intended for material handling applicaons. The material handling winch is discussed in
FallTech User Instrucon Manual MCS09.
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4.1 Capacity: The capacity of the winch is one worker between 130 lbs to 310 lbs. (140 kg) including tools, clothing, etc.
4.2 Compability Of Connectors: Connectors are considered compable with connecng elements when they have been designed to work
together in such a way that their sizes and shapes do not cause their gate mechanisms to open inadvertently, regardless of how they
become oriented. Contact FallTech if you have any quesons about compability. Connectors must be compable with the anchorage or
other system components. Do not use equipment that is not compable. Non-compable connectors may unintenonally disengage.
Connectors must be compable in size, shape, and strength. Self-closing, self-locking snap hooks and carabiners are required by OSHA.
4.0 System Requirements
4.3 Compability Of Components: Equipment is designed for use with approved components and subsystems only. Substuons or
replacements made with non-approved components or subsystems may jeopardize compability of equipment and may aect the safety
and reliability of the complete system.
4.4 Making Connecons: Only use self-locking connectors with this equipment. Only use connectors that are suitable to each applicaon.
Ensure all connecons are compable in size, shape, and strength. Do not use equipment that is not compable. Visually ensure all
connectors are fully closed and locked. Connectors are designed to be used only as specied in each product’s user’s instrucons.
4.5 Personal Fall Arrest System: A PFAS is an assembly of components and subsystems used to arrest a person during a fall event. A PFAS
is typically composed of an anchorage and a FBH, with an energy absorbing connecng device, i.e., an SAL, an SRD, or a Fall Arrester
Connecng Subsystem (FACSS), connected to the dorsal D-ring of the FBH. PFAS components used in conjuncon with this SRD should
comply with ANSI Z359 requirements and applicable OSHA regulaons.
4.5.1 PFAS Anchorage Strength: The winch shown in Table 1 is listed as having a minimum tensile strength of 5,000 lbs. To maintain
OSHA compliance, the structure where the unit is installed must be capable of supporng at least 5,000 lbs, or be designed, installed and
used as part of a PFAS, which maintains a safety factor of at least 2:1, under the supervision of a qualied person.
4.5.2 Work Posioning: Work posioning requires an anchorage capable of supporng 5,000 lbs applied in the direcon permied by the
system.
4.5.3 Personnel Riding: A structure used for personnel riding, lowering and hoisng must be able to support a stac load of 2,500 lbs
applied in the direcon permied by the system.
4.5.4 Rescue: A structure used for rescue must be able to support a stac load of 2,500 lbs applied in the direcon permied by the
system.
ANever connect two acve components (snap hooks or carabiners) to each other.
BNever connect two acve components (snap hooks or carabiners) to a single D-ring at the same me.
CNever connect in a way that would produce a condion of loading on the gate.
DNever aach to a object in a manner whereby the gate (of the snap hook or carabiner) would be
prevented from fully closing and locking. Always guard against false connecons by visually inspecng for closure and lock.
ENever aach explicitly to a constuent subcomponent (webbing, cable or rope) unless specically provided for by the manufacturer’s instrucons for both
subcomponents (snap hook or carabiner and webbing, cable or rope).
FNever aach in a manner where an element of the connector (gate or release lever) may become caught on the anchor thereby producing addional risk of
false engagement.
GNever aach a spreader snap hook to two side/posioning D-rings in a manner whereby the D-rings will engage the gates; the gates on a spreader must
always be facing away from the D-rings during work posioning.
Figure 2 - Non-Compable Connecons
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5.0 Installaon and Use
5.1 General Installaon Requirements: The winch is designed as a part of a conned space system. The user must perform specic job hazard
analysis in accordance with OSHA regulaons. Migate hazards in accordance with OSHA guidelines.
5.2 Install the Winch Onto the Anchorage Structure: The winch is equipped with an integral bracket to aach it to the leg bracket on the
anchorage structure. See FallTech manual number MCS07 for Tripods and MCS30 for Davit installaon instrucons regarding that poron
of the bracket installed on the anchorage structure.
Place the winch bracket mang slots onto the mang rod on the structure leg bracket, align the top holes, and insert the detent pin, as
shown in Figure 3A for an 8’ tripod, Figure 3B for an 11’ tripod and Figure 3C for a conned space davit.
Figure 3A - Aach Personnel Winch to 8 Tripod Leg Bracket
A Winch with Integral Mounng Bracket
BBracket Mang Slots for Tripod/Davit
CIntegral Device Securing Detent Pin
D Align Mang Slots to Engage Leg Bracket Rod
E Leg Bracket Rod
F Insert Detent Pin through Winch and Leg Brackets
G Personnel Winch Secured to Leg Bracket
#7291B Leg Bracket shown in Figure 3A
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FSCSWP2B.1
060915
C
D
A
B
E
F
G
Figure 3B - Aach Personnel Winch to 11 Tripod Leg Bracket
A Winch with Integral Mounng Bracket
BBracket Mang Slots for Tripod/Davit
CIntegral Device Securing Detent Pin
D Align Mang Slots to Engage Leg Bracket Rod
E Leg Bracket Rod
F Insert Detent Pin through Winch and Leg Brackets
G Personnel Winch Secured to Leg Bracket
#7291A Leg Bracket shown in Figure 3B
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FSCSWP2B.1
060915
C
D
A
B
E
F
G
Figure 3C - Aach Personnel Winch to Davit
A Winch with Integral Mounng Bracket
BBracket Mang Slots for Davit Bracket Aachment
CIntegral Device Securing Detent Pin
D Align Mang Slots to Engage Davit Bracket
E Davit Bracket Rod
F Insert Detent Pin through Winch and Davit Brackets
G Personnel Winch Secured to Davit
#65101DU Leg Bracket shown in Figure 3C
E
D
F
G
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5.3 Use of the Winch: Inspect the winch and line constuent before each use in accordance with the procedures in Secon 7 of this
manual. Ensure the cable or rope are in proper working order, with no damage or deformies. See Secon 7 for inspecon criteria.
Ensure the support structure is congured for maximum eciency, and correctly oriented. The device should be at a comfortable height
for use. Adjust device bracket if necessary. For more informaon see instrucon manuals MCS07 for tripods or MCS30 for the davit.
Aach the winch leg end connector to the entrant’s dorsal D-ring of the full body harness.
To raise a load, rotate the winch handle in the clockwise direcon.
To suspend a load, release the handle and the brake will suspend the load unl further acon is needed. Do not exceed the rated capacity
of 310lbs.
To lower a load, rotate the crank handle counterclockwise to lower the entrant into a conned space. The handle will rotate
approximately one revoluon before the load starts to lower. If the secondary brake is engaged, raise the load approximately one turn of
the drum before aempng to lower the load.
NOTE: Maintain 15 lbs of tension in both direcons on the cable at all mes to ensure proper funconing and to prevent bird nesng of
the cable on the drum. See Figure 4. The entrant must ascend and descend from the conned space at a consistent, even pace. The
aendant must remain in visual or voice contact with the entrant at all mes.
When the crank handle stops turning, the internal fricon brake will hold the load without crank rotaon. If the winch exhibits signs of
load slip or errac funconing due to wear or overheang of the brake, remove the winch from service. When hoisng, the winch will
make a clicking sound. Ensure the cable lies evenly on the drum, with no over-lay. With a gear rao of 5:1, 15 lbs of force on the winch
handle, at a cranking rate of one revoluon per second, will yield a hoist rate of 12 /min. Ensure working lines are free of entanglement
and contact with sharp edges. The winch is not a fall protecon device and must not be subjected to fall arrest forces.
Use of the winch for suspension or personnel riding requires a back-up fall protecon system, see Appendix C.
For addional informaon on conned space, see Appendix C of this manual.
CORRECTINCORRECT
Figure 4 - Correct and Incorrect Cable Placement
Incorrect- Avoid Bird’s Nesting of Cable Correct- Even Cable Placement
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6.0 Maintenance, Service, and Storage
6.1 Maintenance: Ensure the winch is kept free of excess paint, grease, dirt, or other contaminants. Clean the exterior of the unit as required
with a detergent/water soluon. Do not allow water other corrosion causing elements to enter the gears. Aer cleaning, pull the
lifeline all the way out, allow the unit to air dry, then rewind the lifeline into the unit.
Apply a thin coat of number 2 lithium grease to the winch gears occasionally.
DO NOT use heat to dry.
DO NOT aempt to disassemble the winch.
6.2 Service: If service is required for any reason; inspecon failure, or any type of malfuncon, tag the unit as “UNUSABLE”, store separately,
and contact FallTech at 323-752-0066 to receive a Return Authorizaon number or to locate the nearest FallTech Service Center. The
winch is not user repairable. Only the manufacturer, or a repair facility authorized in wring, may make repairs to the winch.
6.3 Storage: Store the winch in a cool, dry, clean environment out of direct sunlight. Avoid exposure to chemical or causc vapors. Thoroughly
inspect the winch aer any period of extended storage.
7.0 Inspecon
7.1 Pre-Use User Inspecon Wire Rope: Prior to each use, inspect the enre unit, including the leg end connector, for signs of corrosion,
cracks, deformies, and broken, or missing parts. Inspect the wire rope for cuts, abrasions, weld spaer, arc damage, shhooks, broken
strands, kinks, bird caging, any type of debris.
A thorough inspecon of the wire rope should be made at least once a month. This is performed by unreeling of all the wire rope from
the winch. Using gloves, extract all of the cable and check the enre working length for damage caused by chemical corrupon or
excessive heat as evident by discoloraon (A), bird caging (B), broken wire strands (C), kinks and bent strands (D), see Figure 5. Rewind the
cable onto the drum, in accordance with the procedures in this manual. If the cable bird nests or over rides onto itself, crank the cable
out, remedy the cause, and rewind the cable.
Figure 5: Inspecon of Cable
Rewind the cable onto the drum, in accordance with the procedures in this manual. If the cable bird nests or over rides onto itself, unwind
the cable out, remedy the cause, and rewind the cable.
Inspect the labels to be sure they are present and legible.
An inspecon by a competent person other than the user is required every six months in accordance with the procedures in this manual.
If roune inspecon reveals an unsafe condion, remove it from service.
Record the results of each inspecon on the Inspecon Log provided or in another suitable place.
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