Ingersoll-Rand BU7A User manual

Product Information
BU7A AIR WINCH
(Dwg. MHP1233)
Save These Instructions
Form MHD56381
Edition 2
October 2010
43809417
©2010 Ingersoll-Rand Company

Only allow Ingersoll Rand trained technicians to perform maintenance on this product. For additional information contact Ingersoll Rand factory or nearest
Distributor.
For additional supporting documentation refer to Table 1 ‘Product Information Manuals’ on page 2.
Manuals can be downloaded from www.ingersollrandproducts.com.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate all warranties.
Original instructions are in English. Other languages are a translation of the original instructions.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
Table 1: Product Information Manuals
Publication Part/Document Number Publication Part/Document Number
Product Safety Information Manual MHD56250 Product Maintenance Information Manual MHD56461
Product Parts Information Manual MHD56382
PRODUCT DESCRIPTION
The BU7A winch is powered by a radial piston air motor. The output from the motor
is transferred through the drum by the drive shaft. The drive shaft rotates a series of
connected spur gears which form a reduction assembly. Output from the reduction
assembly drives the wire rope drum. Spur gears are not inherently self-locking as other
types of gears are, therefore the brake must be applied whenever there is a load
attached to the load line. The winch is also equipped with a free spool feature.
CAUTION
• The free spool feature must only be used with a manual brake. Use of a
manual brake is the only way to maintain control of the load line.
The free spool feature consists of a spring detented clutch jaw connecting the final
drive shaft and final spur gear in the reduction assembly. When the clutch jaw is
disconnected, the drum becomes disconnected from the reduction gear assembly and
motor and is free to rotate in either direction.
2 Form MHD56381 Edition 2

SPECIFICATIONS
Model Code Explanation
Example: BU7APTAB BU7A PTAB
Model:
BU7A =1000 lbs (454 kg) Air Winch
AB = Automatic Drum Band Brake
RC = Remote Full Flow Control
RCAB =Remote Full Flow Control and Automatic Brake
PTAB =Remote Full Flow Pendant Control and Automatic Brake
AB/PT = Remote Pilot Pendant and Automatic Band Brake
AB/PLT = Remote Pilot Lever Throttle and Automatic Band Brake
E = Construction Cage
G = Drum Guard
J = Air Line Accessories
L = Extended Warranty
P = Marine 812 Finish
P1 = Marine 812–X Paint System
R = Natural Gas Operation
W = Client Witness of Load Test
X = Special Testing
Z = Sandblast and Carbozinc Primer
Notes:
(1) Remote full flow throttles are provided with 6 feet (2 metres) of hose. Specify hose lengths greater than 6 feet. For lengths greater than 20 feet (6 metres) with the
Remote Full Flow Throttle, or 66 feet (20 metres) with the Remote Pilot Lever and Remote Pilot Pendant Throttles contact your Ingersoll Rand distributor or the
factory for control acceptability. Metric lengths are provided for reference only, order lengths in feet. (Used with Auto Band Brake only.)
(2) RC without AB is for pulling applications only. Do not use for lifting or lowering, as the operator may be too far away to operate a manual brake.
(3) Free spool clutches are standard on BU7A winches. A disengaging clutch, however, will not be supplied on units ordered with automatic brakes (AB).
Form MHD56381 Edition 2 3

Table 2: Specifications
General Specifications Model
BU7A BU7APTAB
Air System Rated Operating Pressure 90 psig (6.3 bar)
Consumption Volume (at rated pressure) 50 scfm 1.4 cu. m/min 50 scfm 1.4 cu. m/min
Rated Performance (at rated pressure/
volume)
Mid Drum Line Pull 1,000 lbs 454 kgs 1,000 lbs 454 kgs
Mid Drum Line Speed 43 fpm 13 m/min 37 fpm 11 m/min
Max Stall Pull - 1st Layer 1,950 lbs 886 kgs 1,950 lbs 886 kgs
Net Weight 75 lbs 34 kgs 108 lbs 49 kgs
Air Motor Pipe Inlet Size 1/2 inch 13 mm 1/2 inch 13 mm
Air System Hose Size (inside diameter) 3/4 inch 19 mm 3/4 inch 19 mm
Wire Rope Anchor Hole Diameter 11/32 inch 8.7 mm 11/32 inch 8.7 mm
Drum Flange Diameter 8-1/2 inch (216 mm)
Drum Length (between flanges) 4-1/2 inch (114 mm)
Motor HP 1.6
Drum Wire Rope Storage Capacity * (feet/metres)
Wire Rope Diameter
1/4 inch ** 6 mm 5/16 inch 8 mm
158 ft * 48 m * 105 ft * 32 m *
Factors for determining STALL and LINE PULL at various air pressure.
To obtain performances at operating pressures other than 90 psi, select
the load or speed rating required from the applicable performance graph
and multiply that value by the factor corresponding to the operating
pressure from the table.
Example: Model BU7A at 750 lbs with 70 psi and drum half full.
To determine speed from curve:
50 fpm x 0.72 = 36 fpm.
Air Pressure (psi) Stall Factor Wire Rope Speed Factor
60 0.67 0.58
70 0.78 0.72
80 0.89 0.86
90 1.00 1.00
100 1.11 1.14
* Based on ASME B30.7 standards which require top layer to be at least 1/2 in. (13 mm) below drum flange diameter.
Recommended drum working storage capacity is 80% of values shown.
** Recommended wire rope size.
INSTALLATION
Prior to installing the product, carefully inspect it for possible shipping damage.
Products are supplied fully lubricated from the factory. Check oil levels and adjust as
necessary before operating product. Refer to “LUBRICATION” section on page 8
for recommended oils and lubrication intervals.
CAUTION
•Owners and users are advised to examine specific, local or other regulations,
including American Society of Mechanical Engineers (ASME) and/or OSHA
Regulations which may apply to a particular type of use of this product before
installing or putting product to use.
NOTICE
• Prior to installation refer to Product Safety Information Manual for all
sections of installation.
nMounting
Mount winch with longitudinal center line horizontal and vent cap at top vertical
center. The winch will not function properly if the longitudinal center line is tilted
more than 10˚ or if winch is rotated so that vent cap is more than 20˚ off top vertical
center.
For mounting on a vertical surface or for inverted mounting, the motor case can be
rotated on the motor mounting bracket to any one of four different positions. This
feature allows the motor assembly to be positioned with the vent cap on top. To
change the position of the motor assembly, drain the oil from the motor case, unscrew
the eight motor case capscrews and rotate the motor assembly to suit the mounting.
Ensure clear unrestricted access is always available to control and brake levers.
1. Do not weld to any part of winch.
2. The winch mounting surface must be flat and of sufficient strength to handle the
rated load plus the weight of the winch and attached equipment. An inadequate
foundation may cause distortion or twisting of the winch resulting in winch
damage.
3. Make sure mounting surface is flat to within 1/16 inch (2.0 mm). Shim if
necessary.
4. Mounting bolts must be Grade 8 or better. Use self-locking nuts or nuts with
lockwashers. Refer to Table 3 ‘Mounting Bolts’ on page 4.
5. Tighten mounting bolts evenly and torque to specification in torque chart. Refer
to ‘Torque Chart’ in Product Maintenance Manual.
6. Maintain a fleet angle between sheave and winch of no more than 1-1/2°. The
lead sheave must be on a center line with drum and, for every inch (25 mm) of
drum length, be at least 1.6 feet (0.5 metre) from the drum. Refer to Product
Safety Information Manual.
Table 3: Mounting Bolts
Model Mounting Bolts
inch mm
BU7A 1/2 13
Refer to Dwg. MHP0548 on page 9, A. Center Line; B. Brake Cylinder BU7APTAB
Only.
nWire Rope
CAUTION
• Maintain at least 3 tight wraps of wire rope on the drum at all times.
•Do not use wire rope as a ground (earth) for welding.
• Do not attach a welding electrode to winch or wire rope.
• Install wire rope to come off drum for overwind operation (normal
application).
nWire Rope Selection
Consult a reputable wire rope manufacturer or distributor for assistance in selecting
the appropriate type and size of wire rope and, where necessary, a protective coating.
Use a wire rope which provides an adequate safety factor to handle the actual working
load and meets all applicable industry, trade association, federal, state and local
regulations.
When considering wire rope requirements the actual working load must include not
only the static or dead load but also loads resulting from acceleration, retardation
and shock load. Consideration must also be given to the size of the winch wire rope
drum, sheaves and method of reeving. Maximum wire rope diameter is limited by the
wire rope anchor. It is recommended that wire rope construction be 6 X 19 or 6 X 37
IWRC right lay. Refer to Table 4 ‘Minimum and Maximum Wire Rope Size’
on page 4 for recommended size.
Table 4: Minimum and Maximum Wire Rope Size
Model Minimum Maximum
inch mm inch mm
BU7A 1/4 6 5/16 8
Note: Maximum wire rope diameter is limited by size of wire rope anchor hole.
4 Form MHD56381 Edition 2

Table 5: Breaking Strength*
Rope Size
(in.) lbs kgs Weight per ft (lbs) Weight per metre (kgs)
1/4 (0.25) 6,800 3084 0.11 0.15
5/16 (0.31) 10,540 4781 0.18 0.25
* Based on extra improved plow steel wire rope with independent wire rope core.
ASME B30.7 requires a minimum of 3.5:1 design factor with 15:1 wire rope diameter
to drum diameter for most applications (e.g. pulling/hauling and anchor handling).
For lifting and lowering, a 5:1 design factor with an 18:1 wire rope diameter to
drum diameter is required.
For winches used in lifting applications, ensure that the top layer of the wire rope
is a distance from the top of the drum flange that is equal to at least twice the
diameter of the wire rope. For example: the top layer of a 8 mm wire rope must be at
least 16 mm below the drum flange edge.
As a general rule for lifting applications, a minimum of 5:1 wire rope design factor
is required with an 18:1 wire rope to drum diameter ratio. For pulling applications,
a 3:1 wire rope design factor is required with a 15:1 wire rope to drum diameter ratio.
nInstalling Wire Rope
Refer to Dwg. MHP1288 on page 9, A. Anchor Setscrew; B. Wire Rope End; C. Winch
Base.
1. Cut wire rope to length and fuse end to prevent fraying of strands in accordance
with the wire rope manufacturer’s instructions.
2. Feed the fused end of the wire rope into the wire rope anchor hole, past the two
anchor screws, and position the end just beneath the drum surface.
3. Apply the wire rope so that it winds over the top when the drum is rotated in a
direction that is clockwise when facing the gear end of the winch. This is
indicated by an arrow on the gear case.
4. Secure by tightening both anchor screws. Make sure the anchor screws are below
the surface of the drum when tightened.
CAUTION
• Make sure first wrap of wire rope is tight and lies flush against the drum
flange.
•The wire rope should be applied to the drum so that it overwinds when the
drum rotates in a clockwise direction when facing the gear end of the winch.
This is indicated by an arrow on the gear case.
nSafe Wire Rope Handling Procedure
- Always use gloves when handling wire rope.
- Never use wire rope that is frayed or kinked.
- Never use wire rope as a sling.
-Always ensure wire rope is correctly spooled and the first layer is tight against
drum.
- Always follow wire rope manufacturer’s recommendation on use and
maintenance of wire rope.
nWire Rope Spooling
To compensate for uneven spooling and the decrease in line pull capacity as the drum
fills up, use as short a wire rope as practical. When rewinding apply tension to the
end of the wire rope to eliminate line slack. This helps achieve level winding and
tight spooling.
nRigging
Make sure all wire rope blocks, tackle and fasteners have a sufficient safety margin
to handle required load under all conditions. Do not allow wire rope to contact sharp
edges or make sharp bends which will cause damage to wire rope, use a sheave. Refer
to wire rope manufacturer’s instructions for proper sizing, use and care of wire rope.
nSafe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not attach a welding electrode to winch or wire rope.
3. Never run wire rope over a sharp edge. Use a correctly sized sheave.
4. When a lead sheave is used, it must be aligned with center of drum. The diameter
of lead sheave must be at least 18 times the diameter of wire rope. Refer to Dwg.
MHP2449 in Product Safety Information Manual.
5. Always maintain at least three full, tight wraps of wire rope on drum.
nDrum Guard
Use of a drum guard is recommended on all winches. Refer to the Product Parts
Information Manual.
Install drum guard and remove the minimum amount of mesh from the guard to
provide clearance for wire rope travel.
WARNING
• Do not allow wire rope to come into contact with drum guard during winch
operation. Wire rope could become worn and damaged. Adjust opening in
guard to clear wire rope travel angle.
nAir 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 product performance and reduce unscheduled
downtime. Refer to Dwg. MHP0191 on page 9, A. Air Out; B. Lubricator; C.
Regulator; D. Air In; E. Filter.
Refer to Table 2 ‘Specifications’ on page 4 for motor air consumption and rated
operating pressure. If air supply varies from what is recommended, product
performance will change.
Install air line lubricator, filter and regulator as close as possible to air inlet on motor.
Lubricator must be located no more than 10 ft (3 m) from motor.
nAir Lines
Inside diameter of air supply lines must not be less than size specified in Table 2
‘Specifications’ on page 4. Before making final connections, all air supply lines should
be purged with clean, moisture free air or nitrogen before connecting to main air
inlet. Supply lines should be as short and straight as installation conditions will
permit. Long transmission lines and excessive use of fittings, elbows, tees, globe
valves, etc. cause a reduction in pressure due to restrictions and surface friction in
lines.
nAir Line Lubricator
Always use an air line lubricator with these motors. The lubricator must have an inlet
and outlet at least as large as inlet on motor.
CAUTION
• Lubricator must be located no more than 10 ft (3 m) from motor.
•Shut off air supply before filling air line lubricator.
The air line lubricator should be replenished daily and set to provide 6 to 9 drops per
minute of ISO VG 32 (SAE 10W) oil. A fine mist will be exhausted from control valve
when air line lubricator is functioning properly.
nAir Line Filter
It is recommended that an air line strainer/filter be installed before the lubricator to
prevent dirt from entering the motor. The strainer/filter should provide 20 micron
filtration and include a moisture trap. Clean the strainer/filter periodically to
maintain its operating efficiency.
NOTICE
•When air filter is used ensure it allows air to pass through at products rated
scfm. Refer to “SPECIFICATIONS” on page 3.
nAir Pressure Regulator
If an air pressure regulator is used, install between lubricator and filter.
nMoisture in Air Lines
Moisture that reaches the air motor through air supply lines is a primary factor in
determining the length of time between service overhauls. Moisture traps can help
to eliminate moisture. Other methods, such as an air receiver which collects moisture
before it reaches motor, or an aftercooler at compressor that cools air to condense
and collect moisture prior to distribution through supply lines, are also helpful.
nMufflers
Ensure mufflers are installed in winch exhaust manifold and control valve exhaust
port. Check mufflers periodically to ensure they are functioning correctly.
nShut Off Valve
Refer to the Product Safety Information Manual for information.
nAir Systems Connections
nRemote Full Flow Pendant Throttle (optional feature)
Refer to Dwg. MHP1241 on page 9 for hose connection positions. A. Payout Yellow;
B. Haul-in Green; C. Supply Red; D. Winch Air Supply.
nMotor
For optimum performance and maximum durability of parts, provide recommended air
supply as measured at motor inlet. Refer to Table 2 ‘Specifications’ on page 4. The air
motor should be installed as near as possible to compressor or air receiver.
Form MHD56381 Edition 2 5

nNatural Gas Operation (optional feature)
WARNING
•Ensure all fittings and connections are tight. Inspect all connections with
suitable leak detection equipment.
•At first notice of any unusual odors or noticeable leaks, cease winch
operation until source is identified and corrected.
•Natural gas exhaust must be piped away from the winch.
The winch may be run using natural gas. However, motor and valve modifications are
required for this usage. Refer to Product Parts Information manual for additional
information. Use of natural gas will reduce motor life. Natural gas exhausting from
the winch must be piped away.
nInitial Winch Operating Checks
Winches are tested for proper operation prior to leaving the factory. Before the winch
is placed into service the following initial operating checks should be performed.
1. When first running the motor inject a small amount of light oil into the inlet
connection to provide initial lubrication.
2. Check oil level in motor and gear case grease are correct. Top off levels as required
before operation as described in “LUBRICATION” section on page 8.
3. Operate winch in both directions with no load for one to two minutes.
4. New brake band Lining Run-in Procedure: All new brake band linings require a
‘run-in’ period. Operate the winch without load in the payout direction while
gradually applying the brake. Allow the brake to slip for approximately one
minute. Winch motor may stall as drum brake band lining fully engages. Do not
allow brake to overheat.
5. Check operation of brakes. Adjust if necessary as described in “MAINTENANCE”
section in the Product Maintenance Information Manual.
6. Check operation of limit switches, locking mechanisms and all safety devices
when equipped.
7. Check foundation mounting fasteners are secure.
8. Install drum guard when provided.
For winches that have been in storage, the following start-up procedures are required:
1. Give the winch an inspection conforming to requirements of
‘Winches Not in Regular Use’ on page 7.
2. Pour a small amount of ISO VG 32 (SAE 10W) oil in motor inlet port.
3. Operate motor for 15 seconds in both directions to flush out any impurities.
4. The winch is now ready for normal use.
OPERATION
It is recommended that the user and owner check all appropriate and applicable
regulations before placing this product into use. Refer to Product Safety Information
Manual before operating product.
The four most important aspects of product operation are:
1. Follow all safety instructions when operating the product.
2. Allow only people trained in safety and operation of this winch to operate this
equipment.
3. Subject each product to a regular inspection and maintenance procedure.
4. Be aware of product capacity and weight of load at all times.
WARNING
• Do not lift loads over people.
NOTICE
• Refer to Product Parts Information Manual for drawings unless specified
elsewhere.
nWinch Controls
The spring loaded, motor mounted, live air manual throttle control valve is supplied
as a standard feature on this winch. Optional remote throttle controls are available.
Reference model code on the winch data (name) plate and compare it to
“SPECIFICATIONS” on page 3, to determine your configuration. The throttle controls
provide operator control of motor speed and direction of drum rotation.
nWinch Mounted Air Throttle (standard feature)
Refer to Dwg. MHP1239 on page 10, A. Haul-in; B. Payout.
The winch control throttle valve is spring loaded, full flow air and mounts to the
motor rotary housing.
To operate control valve, place palm of hand on control knob and wrap fingers around
flange of sliding handle. Squeeze fingers, lifting sliding handle up to unlock control
handle. Shift control handle in desired direction to payout or haul-in wire rope. As
viewed from air motor end, move control throttle handle to the right (clockwise) to
payout wire rope and to the left (counterclockwise) to haul-in wire rope. Avoid sudden
movements of handle to ensure smooth operation of winch. When released, handle
will return to neutral or center position, sliding handle will drop down to engage and
lock control handle in place.
nRemote Full Flow Air Pendant Throttle (optional feature)
Refer to Dwg. MHP1319 on page 10, A. Haul-in; B. Payout.
Provides for remote winch control at distances of up to 20 feet* (6 metres) away from
the winch. The pendant control throttle is a two lever movable control station for
winch operation. The winch control valve, located on the winch motor, controls the
motor speed and direction of drum rotation. Direction of rotation is determined by
the pendant lever depressed.
* For distances greater than 20 feet (6 metres) contact Technical Sales for control
acceptability.
nRemote Pilot Pendant Throttle (optional feature)
Refer to Dwg. MHP1546 on page 10.
Provides for remote winch control at distances of up to 66 feet* (20 metres) away
from winch. The pilot pendant control throttle is a two function movable control
station for winch operation. Pilot pressure from pendant control activates winch
control valve. The winch control valve, located on winch motor, controls motor speed
and direction of drum rotation. Direction of drum rotation is determined by the
pendant lever/button depressed.
* For distances greater than 66 feet (20 metres) contact Technical Sales for control
acceptability.
nWinch Brakes
nManual Drum Brake (standard)
The manual drum band brake may be applied by pushing down on handle and released
by pulling up. If handle is pushed down fully, it should lock in that position and
prevent drum rotation, until released by operator. The brake must be kept properly
adjusted to hold required load. Refer to ‘Adjustments’ in “MAINTENANCE” section in
Product Maintenance Information Manual for instructions.
nAutomatic Drum Band Brake (optional feature)
The automatic drum band brake is a spring applied, air released brake which utilizes
an air actuated, spring loaded cylinder, that automatically disengages brake when
motor is operated. Air pressure in cylinder overcomes spring pressure to release brake.
When control valve is placed in neutral position, air in cylinder is vented and spring
automatically engages brake to prevent drum rotation.
The cylinder clevis must be kept properly adjusted to hold required load.
NOTICE
•Extended exposure to corrosive atmospheres can cause the band brake lining
to adhere to the drum. It is recommended when winch is not in operation
and in a no load condition that the band brake be left in a released position.
For winches equipped with an automatic brake, always ensure that clutch jaw spacers
are installed.
nFree Spool Clutch
WARNING
• Do not engage clutch when motor is running or drum is spinning, as this
produces a severe strain on parts.
•Do not disengage clutch when winch is loaded. Be sure clutch is fully engaged
before operating winch.
A jaw type clutch connects the gearing and drum. The function of the clutch is to
disengage the wire rope drum from the motor so that the wire rope can be unwound
from the drum by hand without working against the gearing and the compression of
the motor. The clutch is engaged or disengaged by the clutch lever which is located
on the top of the gear case cover. When clutch is engaged the lever is locked by a
detent to prevent disengagement. Detent is released by pressing down (toward base)
on lever, after which the end can be swung outward from the winch, disengaging the
clutch jaws. When clutch is in disengaged position it can be engaged by moving end
of lever toward winch. It may be necessary to open the throttle a slight amount to
position the jaws for engagement.
WARNING
• Do not use free spool clutch feature in combination with automatic brake.
Use of winches with free spool clutch and automatic brake can result in
severe injury, death or property damage.
6 Form MHD56381 Edition 2

INSPECTION
Inspection information is based in part on American Society of Mechanical Engineers
Safety Codes (ASME B30.7).
WARNING
• All new or repaired equipment should be inspected and tested by
Ingersoll Rand trained Technicians to ensure safe operation at rated
specifications before placing equipment in service.
•Never use a winch that inspection indicates is damaged.
Frequent and periodic inspections should be performed on equipment in regular
service. Frequent inspections are visual examinations performed by operators or
Ingersoll Rand trained Inspectors and include observations made during routine
equipment operation. Periodic inspections are thorough inspections conducted by
Ingersoll Rand trained Technicians. ASME B30.7 states inspection intervals depend
upon the nature of the critical components of the equipment and the severity of
usage. Refer to “Inspection Classifications” chart and “Maintenance Intervals” chart
in Product Maintenance Information Manual for recommended maintenance intervals.
Careful inspection on a regular basis will reveal potentially dangerous conditions
while still in the early stages, allowing corrective action to be taken before the
condition becomes dangerous.
Deficiencies revealed through inspection, or noted during operation, must be reported
to designated personnel to ensure corrective action is taken.
A determination as to whether a condition constitutes a safety hazard(s) must be
decided, and the correction of noted safety hazard(s) accomplished and documented
by written report before placing the equipment in service.
nWire Rope Reports
Records should be maintained as part of a long-term wire rope inspection program.
Records should include the condition of wire rope removed from service. Accurate
records will establish a relationship between visual observations noted during
frequent inspections and the actual condition of wire rope as determined by periodic
inspections.
nFrequent Inspection
On equipment in regular service, frequent inspections should be made by operators
at the beginning of each shift. In addition, visual and audible inspections should be
conducted during regular operation for indications of damage or evidence of
malfunction (such as abnormal noises).
Disassembly may be required as a result of frequent inspection findings or in order
to properly inspect the individual components. Disassembly steps are described in the
Product Maintenance Information Manual.
1. Surrounding Area. Visually check for winch oil leaks. Do not operate winch if
leaking oil is found. Ensure surrounding area has no slippery surfaces and is
obstruction free.
2. Hoses and Fittings. Visually inspect for damage, air leaks and loose connections.
Repair all leaks or damage and tighten loose connections prior to starting daily
tasks.
3. Muffler. Visually check for restrictions or external damage. Clear restrictions or
replace if damaged.
4. Manual Shut-Off Valve. Test shut-off valve to ensure proper operation and free
movement.
5. Guards. Verify wire rope does not contact guard during winch operation and that
guards are secure and undamaged.
6. Winch. Visually inspect winch housings, control(s), external brake, siderails and
drum for damage. Check that all external bolts are in place and secure. Report
damage to supervisor and request additional inspection by an Ingersoll Rand
trained Technician.
7. Winch Operation. Power winch in both directions. Winch must operate smoothly
without sticking, binding or abnormal noises and have minimal vibration.
NOTICE
•The full extent of wire rope wear cannot be determined by visual inspection.
At any indication of wear inspect wire rope in accordance with instructions
in “Periodic Inspection.” Refer to Product Maintenance Information Manual.
8. Pendant (optional feature). Ensure operation of pendant levers is smooth and
winch is responsive to pendant control. Pendant levers must spring return to the
neutral position when released.
9. Manual Throttle Lever. Ensure operation of manual throttle lever is smooth and
winch is responsive to lever movement. Lever must return to neutral and lock in
place when released. If winch responds slowly or controls stick, do not operate
winch until all problems have been corrected.
10. Wire Rope. Visually inspect all wire rope expected to be in use during the day’s
operations. Inspect for wear and damage indicated by distortion of wire rope such
as kinking, “birdcaging,” core protrusion, main strand 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
knowledgeable on wire rope safety and maintenance procedures.
11. Wire Rope Spooling. Visually check reeving and ensure wire rope feeds on and
off the drum smoothly. Verify spooling direction (overwind or underwind) is
correct for winch and application.
12. Brake(s). Lift and lower the load a short distance to test brake(s). Brake(s) must
hold load without slipping. Automatic brake must release when winch control
throttle is operated. If brake(s) do not hold load or do not release properly, they
must be adjusted or repaired.
WARNING
•Worn or improperly functioning brakes may cause excessive heat buildup and
sparks.
13. Lubrication. Refer to “LUBRICATION” on page 8 for recommended procedures
and lubricants.
14. Labels and Tags: Check for presence and legibility of labels. Refer to Product
Parts Information Manual for correct labels and placement. Replace if damaged
or missing.
nWinches Not in Regular Use
1. Equipment which has been idle for a period of one month or more, but less than
six months, shall be given an inspection conforming to the requirements of
‘Frequent Inspection’ on page 7 before being placed in service.
2. Equipment which has been idle for a period of over six months shall be given a
complete inspection conforming with the requirements of ‘Periodic Inspection’
before being placed in service. Refer to Product Maintenance Information Manual.
3. Standby equipment shall be inspected at least semi-annually in accordance with
the requirements of ‘Frequent Inspection’ on page 7.
4. All oils must be drained and replaced with new, and all grease cavities shall be
packed to the prescribed limit. Refer to “LUBRICATION” section on page 8.
Product must be operated for at least 15 seconds in both directions with well
lubricated, dry air.
nStoring the Winch
1. Always store the winch in a no load condition.
2. Wipe off all dirt and water.
3. To prevent rust buildup from internal condensation, open lubricator to allow more
oil into winch and operate with no load. If winch is being stored from air source
place small amount of 20 weight oil at air inlet port.
4. Oil the wire rope.
5. Place in a dry location.
6. Before returning winch to service, follow instructions for ‘Winches Not in Regular
Use’ in the “INSPECTION” section on page 7.
7. Mufflers and Breathers. All mufflers and breathers must be removed and replaced
with threaded plugs to prevent dust and moisture from entering motor and valve
assemblies.
8. Drum Brake. Product equipped with a manual band brake must be stored with
the brake in its disengaged position.
Form MHD56381 Edition 2 7

LUBRICATION
To ensure continued satisfactory operation of the winch, all points requiring
lubrication must be serviced with the correct lubricant at the proper time interval as
indicated for each assembly.
Refer to ‘Maintenance Interval’ chart in Product Maintenance Information Manual for
recommended lubrication intervals. Use only those lubricants recommended. Other
lubricants may affect product performance. Approval for use of other lubricants must
be obtained from your Ingersoll Rand distributor. Failure to observe this precaution
may result in damage to winch and/or its associated components.
Table 6: Lubrication Intervals
Component Interval
Check Air Line Lubricator Daily
Check Motor Oil Level
Check Gear Case Grease Weekly
Change Motor Oil 1 year or 1000 hours of winch operation
Change Gearbox Grease
nGeneral Lubrication
Correct lubrication is one of the most important factors in maintaining efficient
product operation.
1. The recommended grade of oil must be used at all times. Use of unsuitable oil
may result in excessive temperature rise, loss of efficiency and possible damage
to lubricated components. Refer to ‘Recommended Lubricants’ section
on page 8.
2. It is recommend that the first oil change be done after approximately 50 hours
of initial operation. Thereafter, drain and replace oil according to Table 6
‘Lubrication Intervals’ on page 8.
3. Always inspect removed oil for evidence of internal damage or contamination
(metal shavings, dirt, water, etc.). If indications of damage are noted, investigate
and correct before returning winch to service.
4. After product operation, allow oil to settle before topping off.
5. Always collect lubricants in suitable containers and dispose of in an
environmentally safe manner.
WARNING
•Pneumatic products use oil to prevent excessive heat buildup and to prevent
wear that could cause sparks. Oil levels must be properly maintained.
nRecommended Lubricants
Table 7: Ingersoll Rand Lubricants
Where Used Size Part Number
Wire Rope 16 oz Lubri-Link-Green®
Bearings and Gear Case 1 lb 70 1 LB
Air Line Lubricator 1 Qt 29665
Table 8: Air Motor Recommended Lubricant Grade
Temperature Grade Type
Below 32°F (0°C) ISO VG 32 (SAE 10W)
32°to 80°F (0°to 27°C) ISO VG 68 (SAE 20W) *
Above 80°F (27°C) ISO VG 100 (SAE 30W)
* Units shipped from factory with this lubricant.
Table 9: Recommended Grease Grade
Temperature Grade Type
-20°to 50°F (-30°to 10°C) EP 1 multipurpose lithium based grease
30°to 120°F (-1°to 49°C) EP 2 multipurpose lithium based grease
Note: Units are shipped from factory with EP 2 grease.
nMotor
CAUTION
•Do not use synthetic or detergent lubricants in air motor. Synthetic lubricants
will result in oil blowing by piston rings.
The motor is splash lubricated by oil in motor housing and has no other means of
lubrication. It is therefore important to use only good quality, non-detergent motor
oil to ensure maximum performance and minimum downtime for repairs. Refer to
‘Recommended Lubricants’ on page 8.
Add oil through filler opening until oil flows from level plug hole. Add oil slowly to
prevent spilling. Refer to Table 10 ‘Motor Oil Capacity’ on page 8.
The motor should be level-checked daily or at the start of each shift after any
accumulated water has been drained off. When motors are operated in temperatures
below freezing, wait long enough at the end of shift for water to separate from oil
but not long enough for it to freeze. Drain water then refill to level plug, located on
side of motor housing. If desired, all oil may be drained at end of shift and motor
refilled with new oil.
Table 10: Motor Oil Capacity
Capacity
pints litres
0.5 0.24
nGear Case
Check grease in gear chamber weekly by removing lower grease plug in gear case
cover. If grease is below this opening, remove grease plug from top of gear case cover
and add a sufficient quantity to bring grease level in chamber up to the side opening.
nSeals and Bearings
If product is disassembled, clean all parts thoroughly and coat bearings and seals
with clean grease. Refer to ‘Recommended Lubricants’ section on page 8. Use
sufficient grease to provide a good protective coat. Lubricate grease fittings monthly
with 2 or 3 pumps of a grease gun.
nWire Rope
Follow the wire rope manufacturer’s instructions. At a minimum, observe the following
guidelines.
1. Clean with a brush or steam to remove dirt, rock dust or other foreign material
on the surface of the wire rope.
CAUTION
• Do NOT use an acid-based solvent. Only use cleaning fluids specified by the
wire rope manufacturer.
2. Apply a wire rope lubricant, Ingersoll Rand LUBRI-LINK-GREEN® or ISO VG 100
(SAE 30W) grade oil.
3. Brush, drip or spray lubricant weekly, or more frequently, depending on severity
of service.
nNatural Gas Lubrication
CAUTION
•Use of other than PAG Synthetic oils can cause premature seal failure, which
could cause damage to the motor. Refer to caution label part number
71470744.
8 Form MHD56381 Edition 2

PRODUCT INFORMATION GRAPHICS
Bolt Hole Dimensions
A
B
(Dwg. MHP0548)
A
B
C
(Dwg. MHP1288)
Haul-in
Green
Payout
Yellow
Supply
Red
Winch
Air Supply
Haul-in
Green
Supply
Red Payout
Yellow
A
B
C
C
A
B
D
(Dwg. MHP1241)
Air Out
Regulator
Lubricator
Air In
Filter
A
B
C
D
E
(Dwg. MHP0191)
Form MHD56381 Edition 2 9

PRODUCT INFORMATION GRAPHICS (CONTINUED)
Haul-in
Payout
A
B
(Dwg. MHP1239)
AB
PayoutHaul-in
(Dwg. MHP1319)
(Dwg. MHP1546)
10 Form MHD56381 Edition 2

WARRANTY
Ingersoll Rand Limited Warranty
Ingersoll Rand Company (“IR”) warrants to the original user its material handling
products (“Products”) to be free of defects in material and workmanship for a period
of one year from the date of purchase. IR will, at its option either (1) repair, without
cost, any Product found to be defective, including parts and labor charges, or (2)
replace such Products or refund the purchase price, less a reasonable allowance for
depreciation, in exchange for the Product. Repairs or replacements are warranted for
the remainder of the original warranty.
If any Product proves defective within its original one-year warranty period, it should
be returned to any Authorized Product Service Distributor, transportation prepaid with
proof of purchase or warranty card. This warranty does not apply to Products which
IR has determined to have been misused or abused, improperly maintained by the
user, or where the malfunction or defect can be attributed to the use of non-genuine
IR repair parts.
IR MAKES NO OTHER WARRANTY, CONDITION OR REPRESENTATION OF ANY KIND
WHATSOEVER, EXPRESSED OR IMPLIED, STATUTORY OR OTHERWISE, AND ALL
IMPLIED WARRANTIES AND CONDITIONS RELATING TO MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
IR's maximum liability is limited to the purchase price of the Product and in no event
shall IR be liable for any consequential, indirect incidental or special damages of any
nature arising from the sale or use of the Product, whether in contract, tort or
otherwise.
Note: Some states do not allow limitations on incidental or consequential damages,
so that the above limitations may not apply to you. This warranty gives you specific
legal rights and you may also have other rights which may vary from state to state.
Fulcrum series electric winch, product code 405-002: 2 year warranty.
Winch and Hoist Solutions Extended Warranty This option provides a price for
extending the Ingersoll Rand Winch and Hoist Solutions Warranty from the standard
one (1) year to two (2) years from the date of purchase. All other provisions of the
standard warranty to remain in effect.
For additional information or quotations for warranties falling outside of these
parameters, please contact your Client Services Representative with your
requirements.
Form MHD56381 Edition 2 11

www.ingersollrandproducts.com