Ingersoll-Rand FA Series User manual

Form MHD56298
• A copy of our “Safe Operating Practices” Manuals are always available free of charge either by downloading it from our
Technical Publications website @ www.airwinch.com or by contacting the Factory at [phone] for North America and
[phone] for International. The Safe Operating Practices manual must be read prior to anyone operating a
Ingersoll-Rand winch or hoist. The manual form numbers are as follows:
“Safe Operating Practices Non-Man Rider™ Winches” Manual, Form No. MHD56250
“Safe Operating Practices for Man Rider™ Winches” Manual, Form No. MHD56251
“Safe Operating Practices for Pneumatic, Hydraulic and Electric Hoists” Manual, Form No. MHD56295
• Available winch options may require additional supplements to the basic winch manual.
• For Man Rider™ winches ensure a copy of the Man Rider™ supplement is made available to the operator prior to winch
operation.
• We strongly recommend that ALL maintenance on Ingersoll-Rand equipment be carried out by personnel certified by
Ingersoll-Rand, or by Ingersoll-Rand Authorized Service Centers.
• Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions.
• Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist.
• ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested
prior to being placed into service:
Winch Man Rider™Supplements:
Model: Publication No. Model: Publication No.
FA2, FA2.5,
FH2, FH2.5 MHD56046 LS500RLP SAM0011
LS1000RLP SAM0012
FA5 MHD56042 and
MHD56220
LS150RLP SAM0082
LS150RLP/500/
1000 SAM0115
FA10 MHD56252
FA2.5A MHD56236 LS150RLP and
LS150PLP-PH SAM0120
FA2B and
HU40A MHD56207 LS500RLP-E SAM0122
FH10MR MHD56212 LS150RLP-
DP5M-F SAM0184
Fulcrum Electric MHD56277
LS500HLP/
LS1000HLP SAM0004 LS150HLP SAM0222
*Winches-ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
*Hoists - ANSI / ASME B30.16 (OVERHEAD HOISTS - UNDERHUNG) Refer to section 16.2.2 - Testing.
Form MHD56298
Edition 2
November 2004
71441844
© 2004 Ingersoll-Rand Company
IMPORTANT INFORMATION:

INSTALLATION AND OPERATION MANUAL
FOR BU7A AND FA SERIES
AIR WINCHES
MHD56094
Edition 2
11/96
71157200 MATERIAL HANDLING

READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual contains important
safety, installation and operation information.
This manual provides important information for all personnel involved with the safe installation and operation of this product. Even if you feel you
are familiar with this or similar equipment, you should read this manual before operating the product.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures which, if not followed, may result in an injury. The following signal words are used to identify
the level of potential hazard.
Danger is used to indicate the presence of a hazard which will cause severe injury, death, or substantial property
damage if the warning is ignored.
Warning is used to indicate the presence of a hazard which can cause severe injury, death, or substantial property
damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will orcan cause injury or property damage if the warning
is ignored.
Notice is used to notify people of installation, operation, or maintenance information which is important but not
hazard-related.
Safety Summary
l Do not use these winches for lifting, supporting, or transporting people or lifting or supporting loads over people.
l The supporting structures and load-attaching devices used in conjunction with these winches must provide an adequate safety factor to
handle the rated load, plus the weight of the winch and attached equipment. This is the customer’s responsibility. If in doubt, consult a
registered structural engineer.
Ingersoll-Rand Material Handling winches are manufactured in accordance with the latest F.E.M. 9.511 standards.
Rigging: It is the responsibility of the operator to exercise caution, use common sense and be familiar with proper rigging techniques
This manual has been produced by Ingersoll-Rand to provide dealers, mechanics, operators and company personnel with the information required
to install and operate the products described herein.
It is extremely important that mechanics and operators be familiar with the servicing procedures of these products, or like or similar products, and
are physically capable of conducting the procedures. These personnel shall have a general working knowledge that includes:
1 Proper and safe use and application of mechanics common hand tools as well as special Ingersoll-Rand or recommended tools.
2. Safety procedures, precautions and work habits established by accepted industry standards.
Ingersoll-Rand can not know of, nor provide all the procedures by which product operations or repairs may be conducted and the hazards and/or results
of each method. If operation or maintenance procedures not specifically recommended by the manufacturer are conducted, it must be ensured that
product safety is not endangered by the actions taken. If unsure of an operation or maintenance procedure or step, personnel should place the product
in a safe condition and contact supervisors and/or the factory for technical assistance.

The following warnings and operating instructions are intended to avoid unsafe operating practices which might lead to injury or property damage.
Ingersoll-Rand recognizes that most companies who use winches have a safety program in force at their facility. In the event that some conflict exists ::
between arule set forth in this publication and asimilar rule already set by an individual company, the more stringent of the two should take precedence. 3
Safe Operating Instructions are provided to make an operator aware of dangerous practices to avoid and are not necessarily limited to the following d
list. Refer to specific sections in the manual for additional safety information,
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Only allow people, trained in safety and operation of this product, to operate the winch.
Only operate a winch if you are physically fit to do so.
When a “DO NOT OPERATE’ sign is placed on the winch, or controls, do not operate the winch until the sign has been removed by designated
personnel.
Before each shift, the operator should inspect the winch for wear or damage. Never use a winch which inspection indicates is worn or damaged.
Never lift or pull a load greater than the rated capacity of the winch. See “SPECIFICATIONS” section.
Keep hands, clothing, etc., clear of moving parts,
Never place your hand inside the throat area of a hook or near wire rope spooling onto or off of the winch drum.
Always rig loads properly and carefully.
Be certain the load is properly seated in the saddle of the hook and the hook latch is engaged. Do not support the load on the tip of the hook.
Do not “side pull” or “yard”.
Always ensure that you, and all other people, are clear of the path of the load. Do not lift a load over people.
Never use the winch for lifting or lowering people, and never allow anyone to stand on a suspended load.
Ease the slack out of the wire rope when starting a lift or pull. Do not jerk the load.
Do not swing a suspended load.
Never leave a suspended load unattended.
Never operate a winch with twisted, kinked or damaged wire rope.
Pay attention to the load at all times when operating the winch.
Never use the winch wire rope as a sling.
Never use a winch equipped with a disengaging clutch for lifting applications,
Never exceed 6.3 bad630 kPa (90 psig) air pressure at the winch air inlet.
Each winch is supplied from the factory with the required warning labels. All winches are supplied with the “Do Not Lift Personnel” label, and winches
with disengaging clutches are supplied with the “Do Not Use For Lifting” label. Samples of additional labels required are shown elsewhere in this
manual. If the labels are not attached to your unit, order new labels and install.
l Do not use a winch equipped with a disengaging clutch for
lifting applications.
l Do not use winch for lifting, supporting or transporting
people.

mended Wire Maximum Wire
FA2.5 2268 44 4536 16
FA5 20
6.3 4490 20
FA5T 3810 10886
24 22
FA7 6985 14 38 20
21.3
FA7T 5715 16330
15 25
FA10 22.6 I0000 9 17237 28 28
I I “----~1 I I I I rn-..-- Winch Maximum
Overload Foundation Anchor
Setting Shear Force at
One Capscrew
Model
No.
munu YrUm
Pressure Sound Motor Port
Power Level Drum Barrel Diameter Flange
Level Inlet Size Diameter
BU7A
dBA dBA
92 102
inch
l/2 NPT
mm
114
mm
216 kg
___ N
376
Notes:
1. Sound measurements have been made in accordance with IS0 11201, IS0 3744-3746 and IS0 4871 test specifications for sound
from pneumatic equipment. Readings shown are based on the average noise level of each winch configuration, proportionate to the
utilized time in a regular cycle.
2. Lpc (Peak Sound Pressure) does not exceed 130 dB.
3. Performance based on 6.3 bar/630 kPa (90 psig) operating pressure.
4. Maximum Foundation Anchor Shear Force at One Capscrew value based on use of recommended fastener grade and size.
FA Series winches are air powered, planetary geared units designed for lifting and pulling applications. FA Series winches can be supplied with either
an internal disc brake, an external mounted band type brake or both. The output from the externally mounted piston motor is transmitted through a
coupling and shaft to the planetary reduction gear assembly. The output from the planetary reduction gear assembly is connected to the wire rope drum
through the output shaft. The internal disc brake, if equipped, is connected to the output shaft from the piston motor and is automatically applied if
there is a lack of air pressure. The disc brake is spring applied and released by air pressure when the winch is operated. In the event of a loss of air
pressure the brake automatically applies.
BU7A winches are air powered, spur gear units designed for pulling applications only. The winches utilize an external band brake which can be
manually applied to hold the load. The output from the externally mounted piston motor is transmitted through crank assembly to the spur gear reduction
assembly. The output from the reduction assembly drives a ring gear which is machined in the wire rope drum. BU7A winches are equipped with a
manually operated disengaging clutch. The disengaging clutch permits unloaded wire rope to be pulled from the drum by hand.
Prior to installing the winch, carefully inspect it for possible shipping damage.
BU7A winches are supplied drained of oil, when received from the factory.
FA Series winches are supplied fully lubricated from the factory.
Check oil levels and adjust as necessary before operating winch. Refer to “LUBRICATION” section for recommended oils.
3

l Owners and users are advised to examine specific, local or other regulations which may apply to a particular type of use of this product
before installing or putting winch to use.
Mounting 5
Mount the winch so the axis of the drum is horizontal and the motor vent cap is no more than 15° off top vertical center. If the winch is to mounted 2
in an inverted position or if the winch axis will be tilted more than 10” from horizontal, contact your distributor or the nearest service repair center E
for additional installation information.
1. 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 end covers and spacers resulting in winch damage.
2. Make sure the mounting surface is flat to within 0.8 mm (l/32 inch). Shim if necessary.
3. Mounting bolts must be Grade 8 or better. Use self-locking nuts or nuts with lockwashers.
4. Refer to Table 1and Dwg. MHTPA0684 for winch mounting dimensions and mounting bolt hole sizes.
5. Maintain a fleet angle between the sheave and winch of no more than l-1/2 degrees. The lead sheave must be on a center line with the drum and,
for every 25 mm (1 inch) of drum length, be a least 0.5 metre (1.6 feet) from the drum.
6. Do not weld to any part of the winch.
Wire Rope BU7A Mounting Dimensions
l Maintain at least 3 wraps of wire rope on the drum at all times.
Wire Rope Selection
Consult areputable 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 regulations.
When considering wire rope requirements the actual working load must include not only the static FA Series Mounting Dimensions
or dead load but also loads resulting from acceleration, retardation and shock load. Consideration C
must also be given to the size of the winch wire rope drum, sheaves and method of reeving. Refer
to “SPECIFICATIONS” section for recommended wire rope size. Wire rope construction must be
6 x 19 or 3 x 37 IWRC right lay to permit correct installation of wire rope anchor.
For winches used in lifting applications ensure that the wire rope top layer is at least a distance
from the top of the drum flange equal to two (2) times the diameter of the wire rope. Example: top
layer of a10 mm wire rope must be at least 20 mm below the drum flange edge.
As a general rule for lifting applications a minimum of 5: 1wire 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 15:1wire rope to drum diameter ratio.
Table 1: Foundation Bolting Dimensions
r Dimens
1
ions
(Dwg. MHTPA0684)
(w/o drum
brake) C
Winch
Model
Drum
Length A B
(w/drum
brake)
D
(w/drum D
(w/o drum
mm inches mm inches mm inches
BU7A 112 4.5 216 8.5 232 9.125
203 8 178 7
15
17.5
inches
0.625
0.687
20 0.812
140 I 5.5
FA2and 1 305 1 12 1 _-- 1 - 7.5
FA2.5 pGF--pq 5”x 1 20.00 b
610 24 2:
305 12 190 1 7.5
54 1 10
FA5 and
FAST It++--++ 794 1 31’25 l/++t&
760 30 254 10
FAST 915 36 870 34.25 292 11.5
FA7 and
FA7T mi 870 1 34.25 w
I I
FA7T 1 1065 1 42 I 1
229 9
152 6
159 6.25
229 9
305 12
356 305
203 8
241 9.5
216 8.5
254 IO
1 610 1 24 1 1 152 1 6
FAlO i+i 1055 1 42.25 / 203 1 8 152 6
___
Y-q--T
24 0.937
I
4

Installing Wire Rope
BU7A Winches
(Refer to Dwg. MHTPA0070)
1. Cut wire rope to length and fuse the end to prevent fraying of strands in accordance with the wire
rope manufacturers instructions.
2. Feed the fused end of the wire rope into the wire rope anchor hole, past the anchor screw, and
position the end just beneath the drum surface.
3. The wire rope should be applied to the drum so that it overwinds when facing the gear end of the
winch. Refer to wire rope installation label.
4. Secure wire rope by tightening the anchor screw. Make sure the anchor screw is below the surface
of the drum when tightened.
FA Series Winches (Dwg. MHTPA0070)
Anchor
Setscrew
Wire Rope
F .
tna
Winch
Base
(Refer to Dwg. MHTPA0166)
1.
2.
3.
4.
5.
6.
7.
Wire
Cut wire rope to length in accordance with the wire rope manufacturers instructions,
Feed the end of the wire rope into the wire rope anchor hole in the drum and pull through
approximately 0.3 m (1 foot) of wire rope.
Wrap the wire rope with wire a distance from the end equal to the wedge length plus 25 mm
(1 inch).
Slide the sleeve over the end of the wire rope so the larger diameter of the taper bore is nearest
the end of the wire rope.
Spread the end strands of the wire rope and insert the split wedge until it is below the end of the
wire rope.
Pull the sleeve over the wire rope end until tight. Check that the wire rope strands stay in the slots
located on the split wedge.
Pull the wire rope anchor into position in the drum anchor pocket.
l Make sure the first wrap of wire rope is flush against the drum flange.
l Install the wire rope to come off the drum in an overwind position as indicated on the direction of rotation label.
Wire Rope Spooling
To compensate for uneven spooling and 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.
Safe Wire Rope Handling Procedures
1. Always use gloves when handling wire rope.
2. Never use wire rope which is frayed or kinked.
3. Never use wire rope as a sling.
4. Always ensure wire rope is correctly spooled and first layer is tight against the drum
Rigging
Make sure all wire rope blocks, tackle and fastenings have a sufficient safety margin to handle the 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 manufacturers handbook
for proper sizing, use and care of wire rope.
Safe 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 the wire rope over a sharp edge. Use a correctly sized sheave.
4. When a lead sheave is used, it must be aligned with the center of the drum. The diameter of the lead sheave must be at least 18times the diameter
of the wire rope.
5. Always maintain at least three full tight wraps of wire rope on the drum.
Air System
The air supply must be clean, lubricated and free from moisture. A minimum of 6.3 bar/630 kPa (90 psig) atthe winch motor is required during operation
to provide rated winch performance.
5

Air Lines
The inside diameter of the winch air supply lines must not be smaller than the sizes provided in the “SPECIFICATIONS” section. Before making final
connections to winch inlet all air supply lines should be purged with clean, moisture free air or nitrogen. 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 areduction in pressure
due to restrictions and surface friction in the lines.
Air Line Lubricator
Always use an air line lubricator with these motors. Use a lubricator having an inlet and outlet at least as large as the inlet on the winch motor. Install
the air line lubricator as close to the air inlet on the winch motor as possible.
l Lubricator must be located no more than 3 m (10 ft.) from the winch motor.
l Shut off air supply before filling air line lubricator.
The air line lubricator should be replenished daily.
1. On BU7A and FA2 winches set lubricator to provide 2 to 3 drops per minute of SAE 10W oil (minimum viscosity 135 Cst at 40” C (104” F)).
2. On FA2.5, FA5, FA7 and FA10 winches set lubricator to provide 6 to 8 drops per minute.
Air Line Filter
It is recommended that an air line strainer/filter be installed as close as practical to the motor air inlet port, but before the lubricator, to prevent dirt
from entering the valve and motor. The strainer/filter should provide 20 micron filtration and include a moisture trap. Clean the strainer/filter
periodically to maintain its operating efficiency.
Moisture in Air Lines
Moisture that reaches the air motor through the 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 the motor or an aftercooler at
the compressor that cools the air prior to distribution through the supply lines are also helpful.
Mufflers
Make sure mufflers are installed in winch exhaust ports and are functioning correctly.
Motor
For optimum performance and maximum durability of parts, provide an air supply of 6.3 bar/630 kPa (90 psig) at the flow recommended in the
“SPECIFICATION” section, as measured at the motor inlet. The winch should be installed as near as possible to the compressor or air receiver.
l Do not exceed the maximum specified operating pressure, 6.3 bar/630 kPa (90 psig). The winch overload valve will exhaust air if maximum
pressure is exceeded.
Initial 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.
2. When first running the motor some light oil should be injected into the inlet connection to allow good lubrication.
When first operating the winch it is recommended that the motor be driven slowly in both directions for a few minutes.
For winches that have been in storage the following start-up procedures are required.
1. Give the winch an inspection conforming to the requirements of “Winches Not in Regular Use” in the “INSPECTION” section,
2. Pour a small amount of 10W oil in the motor inlet port.
3. Operate the motor for 10 seconds in both directions to flush out any impurities.
4. The winch is now ready for normal use.
The four most important aspects of winch operation are:
1. Follow all safety instructions when operating winch.
2. Allow only people trained in safety and operation of the winch to operate the winch.
3. Subject each winch to a regular inspection and maintenance procedure.
4. Be aware of the winch capacity and weight of load at all times.
l Winches are not designed or suitable for lifting, lowering or moving persons. Never lift loads over people.
l Winches equipped with a disengaging clutch are designed for pulling applications only. Do not use these winches in lifting applications.
Overload Device
An overload device is required on all winches with a rated capacity of over 1 metric ton (2200 lbs) used for lifting applications.
The overload device is integrated into the winch air motor and prevents the winch from lifting a load greater than the overload value listed in the
specifications chart. If an overload is detected, inlet supply air is stopped and the winch will not operate.
6

If the overload device is activated the load must be lowered and reduced. Alternative methods should be used to accomplish the task. To lower the
load reset the winch by pressing the “ON” button of the emergency stop device and action the winch control for wire rope payout.
Winch Controls
ii The spring loaded, motor mounted, live air manual throttlecontrol valve is supplied as a standard feature on the winch. Optional remote throttle controls
2 may be available on some models. Reference the model code on the winch nameplate and compare it to the sales brochure to determine your
configuration. The throttle controls provide operator control of the motor speed and direction of drum rotation,
Winch Mounted Live Air Throttle (standard feature)
When viewed from the air motor, move the control throttle handle to the right (clockwise) to pay out wire
rope and to the left (counterclockwise) to haul in wire rope. Refer to the attached label. To ensure smooth
operation of the winch avoid sudden movements of the control valve.
Remote Control Pendant (optional feature)
(Refer to Dwg. MHTPA0671)
Provides for remote winch control at distances up to 18metres (60 ft.) away from the winch motor. Pilot
air hoses connect the pendant to the winch motor to provide winch operation. The pendant control throttle
is a two lever movable control station. Direction of winch drum rotation is determined by the pendant
control lever depressed.
Emergency Stop Device
(Refer to Dwg. MHTPA0754)
“ON” and “OFF”
The emergency stop device is located at the air inlet of the winch on local control models, or on the pendant
of remote control models. When activated, winch drum rotation will immediately cease.
1. To start winch operation press the “ON” button.
2. To operate winch, press the “Haul-in” or “Pay-out” control lever.
3. In theevent of an emergency all winch operation can be stopped by pushing the emergency stop button.
This will prevent air from reaching the winch motor which will stop any movement.
4. The “OFF” button will also stop winch operation if pressed.
5. The “ON” button must be pushed to restart the winch after the “Emergency Stop” or “OFF’ button have
been used. Pendant
Winch Brake
Manual Drum Brake
(optional feature on FA Series Winches)
The manual drum brake may be applied by pushing down on the handle and released by pulling up. If the
handle is pushed down fully, it should lock in that position and prevent drum rotation, until released by the
operator. The brake must be kept properly adjusted to hold the required load.
Disengaging Clutch (BU7A Winch only)
(Dwg. MHTPA0671)
“ON” and “OFF”
l Do not engage clutch when motor is running or drum is spinning, as this produces a severe strain
on parts.
l Do not disengage clutch when winch is loaded. Ensure clutch is fully engaged before operating
winch. Engage locking dog before leaving load suspended.
l Do not engage locking dog while drum is spinning.
l Do not use winches equipped with a disengaging clutch for lifting applications.
Emergency
Stop Button
(Dwg. MHTPA0754)
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 top of the gear case cover. When the clutch is engaged the lever is locked by adetent to prevent disengagement.
The 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 the clutch is in the disengaged position it can be engaged by moving the end of the lever toward the winch. It may be necessary to open
the throttle a slight amount to position the jaws for engagement.
l All new, altered or modified equipment should be inspected and tested by personnel instructed in safety, operation and maintenance of
this equipment to ensure safe operation at rated specifications before placing equipment in service.
l 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 service personnel during routine winch operation. Periodic inspections are thorough inspections performed by personnel trained in
inspection of the winch. Inspection intervals depend upon the nature of the critical components of the equipment and the severity of usage.
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 an appointed person. A determination must be made as to
whether a deficiency constitutes a safety hazard before resuming operation of the winch.
Records and Reports
Some form of inspection record should be maintained for each winch, listing all points requiring periodic inspection. A written report should be made
monthly on the condition of the critical parts of each winch. These reports should be dated, signed by the person who performed the inspection, and 5
kept on file where they are readily available for review. 1
lz
Wire Rope Reports w
Records should be maintained as part of a long-range 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.
Frequent Inspection
On equipment in continuous service, frequent inspection should be made by operators at the beginning of each shift. In addition, visual inspections
should be conducted during regular operation for indications of damage or evidence of malfunction (such as abnormal noises),
1. WINCH. Prior to operation, visually inspect winch housings, controls, brakes and drum for indications ofdamage. Do not operate the winch unless
the wire rope feeds onto the drum smoothly. Any discrepancies noted must be reviewed and inspected further by authorized personnel instructed
in the operation, safety and maintenance of this winch.
2. WIRE ROPE. Visually inspect all wire rope which can be 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 instructed in the operation, safety
and maintenance of this winch.
l The full extent of wire rope wear cannot he determined by visual inspection. At any indication of wear inspect the wire rope in accordance
with instructions in “Periodic Inspection.”
3. AIR SYSTEM. Visually inspect all connections, fittings, hoses and components for indication of air leaks. Repair any leaks or damage. Check
and clean filters if equipped.
4. CONTROLS. During operation of winch, verify response to control is quick and smooth. If winch responds slowly or movement is unsatisfactory,
do not operate winch until all problems have been corrected.
5. BRAKES. During winch operation test brakes. Brakes must hold load without slipping. Automatic brakes must release when winch motor throttle
6. is operated. If brakes do not hold load, or do not release properly, the brakes must be adjusted or repaired.
WIRE ROPE REEVING. Check reeving and ensure wire rope is properly secured to the drum.
7. LUBRICATION. Refer to the “LUBRICATION” section for recommended procedures and lubricants,
Periodic Inspection
Frequency of periodic inspection primarily depends on the severity of usage:
NORMAL HEAVY
yearly yearly SEVERE quarterly
Disassembly may be required for HEAVY or SEVERE usage. Keep accumulative written records of periodic inspections to provide a basis for
continuing evaluation. Inspect all items listed in “Frequent Inspection.” Also inspect the following:
1. FRAMES and UPRIGHTS. Check for deformed, cracked or corroded main components. If external evidence indicates the need for additional
inspection return winch to your nearest Ingersoll-Rand service repair center.
2. FASTENERS. Check retainer rings, split pins, capscrews, nuts, and other fasteners on winch, including mounting bolts. Replace if missing or
damaged and tighten if loose.
3.
4. DRUM AND SHEAVES. Check for cracks, wear or damage, Replace if necessary,
WIRE ROPE. In addition to Frequent Inspection requirements, also inspect for the following:
a. Build-up of dirt and corrosion. Clean with steam or a stiff wire brush to remove dirt and corrosion if
necessary.
b. Loose or damaged end connection. Replace if loose or damaged.
C. Check wire rope anchor is secure in drum.
d. Verify wire rope diameter. Measure the diameter of the wire rope from crown-to-crown throughout the life
of the wire rope. Recording of the actual diameter should only be done with the wire rope under equivalent
loading and in the same operating section as accomplished during previous inspections. If the actual
diameter of the wire rope has decreased more than 0.4 mm (1164inch) a thorough examination of the wire
rope should be conducted by an experienced inspector to determine the suitability of the wire rope to remain
in service. (Refer to Dwg. MHTPA0056). (Dwg. MHTPA0056)
5. ALL COMPONENTS. Externally inspect for wear, damage, distortion, deformation and cleanliness, Clean, replace or lubricate components as
required.
6. BRAKE. Test brake to ensure proper operation. Brake must hold a 125% rated load with full drum without slipping. If indicated by poor operation
or visual damage, return winch to a authorized service center for repair. Check all brake surfaces for wear, deformation or foreign deposits. If
brake lining thickness appears to be worn, contaminated or damaged the brake band should be replaced. Clean and replace components as
necessary.
7. FOUNDATION OR SUPPORTING STRUCTURE. Check for distortion, wear and continued ability to support winch and rated load. Ensure
8. winch is firmly mounted and that fasteners are in good condition and tight.
LABELS AND TAGS. Check for presence and legibility of labels. Replace if damaged or missing.
8

Winches 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” before being placed in service.
2. Equipment which has been idle for aperiod of over six months shall be given acomplete inspection conforming with the requirements of “Periodic
3 3. Inspection” before being place in service.
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Standby equipment shall be inspected at least semi-annually in accordance with the requirements of “Frequent Inspection”. In abnormal operating
conditions equipment should be inspected at shorter intervals.
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INTERVAL 1 LUBRICATION CHECKS
To ensure continued satisfactory operation of the winch, all points requiring
lubrication must be serviced with the correct lubricant at the proper time I
interval as indicated for each assembly. Correct lubrication is one of the most Start of each shift Check flow and level of air line lubricator
important factors in maintaining efficient operation.
The lubrication intervals recommended in this manual are based on intermittent when operating winch at maximum motor
operation of the winch eight hours each day, five days per week. If the winch speed.
is operated almost continuously or more than the eight hours each day, more Check oil level in the motor.
frequent lubrication will be required. Also, the lubricant types and change Monthly Inspect and clean or replace air line filter.
intervals are based on operation in an environment relatively free of dust,
moisture, and corrosive fumes. Use only those lubricants recommended. Lubricate components supplied by grease
Other lubricants may affect the performance of the winch. Failure to observe fittings.
this precaution may result in damage to the winch and/or its associated Yearly (Contact your Replace grease in BU7A winch gear case.
components. nearest Ingersoll-Rand
distributor) Drain and refill the oil in the FA Series
General Lubrication winch reduction assembly.
FA winches are supplied from the factory filled with oil.
BU7A winches are supplied from the factory without oil.
Check oil and all lubrication levels prior to operating winch,
Wire 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,
l 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 SAE 30W oil.
3. Brush, drip or spray lubricant weekly, or more frequently, depending on severity of service.
Motor
Correct lubrication is one of the most important factors in maintaining efficient winch operation. The motor is splash lubricated by the oil in the motor
housing and has no other means of lubrication. It is therefore important to use only quality, non-detergent motor oil to ensure maximum performance
and minimum downtime for repairs. Allow oil to settle before topping off. Pour sufficient oil into the vent cap opening to bring the oil in the motor
case to the level of the upper oil plug hole. Add oil slowly to prevent spilling.
Oil capacity for the BU7A winch motor is 0.24 litres (112 pint).
Oil capacity for the FA2 winch motor is 0.35 litres (318quart).
Oil capacity for the FA2.5, FA5, FA7 and FA10 winch motors is 2.8 litres (3 quarts).
Recommended Motor Oil: Temperature
1. Below 0” C (32” F) Type Oil
SAE 10W
2. 0” to 27” C (32” to 80” F) SAE 20W
3. Above 27” C (80” F) SAE 30W
The motor should be level-checked daily or at the start of each shift after accumulated water has been drained off. When motors are operated in
temperatures below freezing, wait long enough at end of shift for water to separate from oil but not long enough for it to freeze. Failure to drain the
water when the winch is to remain idle for a protracted period at low temperatures may result in the oil splasher freezing fast. Drain the water, and
then refill to the level plug. If desired, all the oil may be drained at the end of the shift and the motor refilled with new oil.
BU7A Winch Gear Case Lubrication
Check the grease in the gear chamber weekly by removing the lower grease plug in the gear case cover. If the grease is below this opening, remove
the grease plug from the top of the gear case cover and add a sufficient quantity oflngersoll-Rand Heavy Gear Grease No. 70 to bring the grease level
in the chamber up to the side opening. Ingersoll-Rand Light Grease No. 28 or a soda base or mixed base grease of No. 2 consistency may be used
as a substitute.
FA Series Reduction Gear Assembly
Replace the oil in the reduction housing at least once every year. However, when the winch is used at a high frequency, the oil may need to be changed
on a more frequent basis.
9

Recommended Reduction Gear Oil:
Temperature Type Oil
I. Below 0” C (32” F) SAE 10W
2. 0” to 27” C (32” to 80” F) SAE 20W
3. Above 27” C (80” F) SAE 30W 3
Disc Brake =
Oil from the reduction gear assembly also provides lubrication for the disc brake. After an oil change remove the breather plug and pour a small amount s
of oil, 0.2 litres (6 to 8 fluid ounces), through the breather hole in the brake housing to initially lubricate the brake discs. Reinstall the breather plug UJ
before operation of winch or brakes.
Pivot Points, Bushings, Seals and Bearings
Lubricate grease fittings monthly with 2 or 3 squirts from a grease gun. Use sufficient grease to provide a good protective coat.
Recommended Grease (Pivot Points, Bushings, Seals and Bearings)
Temperature
1. -30” to 10° C (-20° to 50° F)
2. -l”to49° C(30° tol20° F)
Type Grease
EP1 multipurpose lithium-based grease
EP 2 multipurpose lithium-based grease
The use of replacement parts other than Ingersoll-Rand Material Handling may invalidate the Company’s warranty. For prompt service and genuine
Ingersoll-Rand Material Handling parts provide your nearest Distributor with the following:
1. Complete model number as it appears on the nameplate.
2. Part number and part name as shown in parts manual.
3. Quantity required.
Return Goods Policy
Ingersoll-Rand will not accept any returned goods for warranty or service work unless prior arrangements have been made and written authorization
has been provided from the location where the goods were purchased.
Winches that have been modified without Ingersoll-Rand approval, mishandled or overloaded, will not be repaired or replaced under warranty.
Disposal
When the life of the winch has expired, it is recommended that it be disassembled, degreased and parts separated as to materials so that they may be
recycled.
Winch repair and maintenance should only be carried out by an Authorized Service Repair Center. Contact your nearest Ingersoll-Rand office for
details.
The original language of this manual is English.
Winch Parts and Maintenance information is available in English by requesting the following publications:
BU7A Winch: Parts, Operation and Maintenance Manual Form Number P5710
FA2 and FA2.5 Winch: Parts, Operation and Maintenance Manual Form Number MHD56040
FA5 Winch: Parts, Operation and Maintenance Manual Form Number MHD56037
FA7 Winch: Parts, Operation and Maintenance Manual Form Number MHD56076
FA10 Winch: Contact your nearest Ingersoll-Rand office for information.
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