Ingersoll-Rand FA2.5A Series Installation guide

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:

Form MHD56114
PARTS, OPERATION AND MAINTENANCE MANUAL
THIRD GENERATION
MODEL FA2.5A
(Dwg. MHP2415)
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance
information. Make this manual available to all persons responsible for the
installation, operation and maintenance of these products.
WARNING
Do not use this winch for lifting, supporting, or transporting people or lifting or
supporting loads over people.
Always operate, inspect and maintain this winch in accordance with American Society of
Mechanical Engineers (ASME B30.7) and any other applicable safety codes and
regulations.
Form MHD56114
Edition 4
February 2003
71299358
© 2003 Ingersoll-Rand Company

2MHD56114 - Edition 4
CONTENTS
Description Page No.
Safety Information
Danger, Warning, Caution and Notice .................................................................................................................................................................3
Safety Summary...................................................................................................................................................................................................3
Safe Operating Instructions .................................................................................................................................................................................4
Warning Labels and Tag ......................................................................................................................................................................................5
Specifications
Description...........................................................................................................................................................................................................8
Traceability ..........................................................................................................................................................................................................8
Installation
Mounting..............................................................................................................................................................................................................9
Wire Rope ..........................................................................................................................................................................................................10
Air Supply..........................................................................................................................................................................................................12
Motor .................................................................................................................................................................................................................13
Emergency Stop and Overload System..............................................................................................................................................................13
Initial Winch Operating Checks.........................................................................................................................................................................13
Operation
Winch Controls ..................................................................................................................................................................................................14
Winch Brakes.....................................................................................................................................................................................................17
Constant Tension Manifold (Optional Feature) .................................................................................................................................................17
Free Spool (Optional Feature) ...........................................................................................................................................................................18
Inspection
Records and Reports ..........................................................................................................................................................................................19
Frequent Inspection............................................................................................................................................................................................19
Periodic Inspection ............................................................................................................................................................................................20
Winches Not In Regular Use .............................................................................................................................................................................20
Inspection and Maintenance Report ..................................................................................................................................................................21
Troubleshooting................................................................................................................................................................................................22
Lubrication
General Lubrication ...........................................................................................................................................................................................23
Wire Rope ..........................................................................................................................................................................................................24
Maintenance
Adjustments .......................................................................................................................................................................................................25
Disassembly .......................................................................................................................................................................................................26
Cleaning, Inspection and Repair........................................................................................................................................................................30
Assembly ...........................................................................................................................................................................................................30
Testing................................................................................................................................................................................................................36
Parts Section
Winch Cross Section Drawing ..........................................................................................................................................................................38
Winch Parts Drawings and Parts Lists Table of Contents ...............................................................................................................................39
Winch Parts Drawings and Parts Lists........................................................................................................................................................40 - 67
Parts Ordering Information ..........................................................................................................................................................................68
Warranty ..........................................................................................................................................................................................................71
Office Locations ..............................................................................................................................................................................................72

MHD56114 - Edition 4 3
SAFETY INFORMATION
This manual provides important information for all personnel
involved with the safe installation, operation and proper
maintenance of this product. Even if you feel you are familiar
with this or similar equipment, you should read this manual
before operating the winch.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures which, if
not followed, may result in a hazard. The following signal words
Danger is used to indicate the presence of
a hazard which will cause severe injury or
death if the warning is ignored.
Warning is used to indicate the presence
of a hazard which can cause severe injury
or death if the warning is ignored.
Caution is used to indicate the presence o
f
a hazard which will or can 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.
DANGER
W
W
A
A
R
R
N
N
I
I
N
N
G
G
C
C
A
A
U
U
T
T
I
I
O
O
N
N
N
N
O
O
T
T
I
I
C
C
E
E
are used to identify the level of potential hazard.
Safety Summary
WARNING
• Do not use this winch for lifting, supporting, or transporting
people or lifting or supporting loads over people.
• The supporting structures and load-attaching devices used in
conjunction with this winch 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 winches are manufactured in accordance with the
latest ASME B30.7 standards.
The National Safety Council, Accident Prevention Manual for
Industrial Operations, Eighth Edition and other recognized safety
sources make a common point: Employees who work near
suspended loads or assist in hooking on or arranging a load
should be instructed to keep out from under the load. From a
safety standpoint, one factor is paramount: conduct all lifting or
pulling operations in such a manner that if there were an
equipment failure, no personnel would be injured. This means
keep out from under a raised load and keep out of the intended
path of any load.
The Occupational Safety and Health Act of 1970 generally places
the burden of compliance with the user, not the manufacturer.
Many OSHA requirements are not concerned or connected with
the manufactured product but are, rather, associated with the final
installation. It is the owner’s and user’s responsibility to
determine the suitability of a product for any particular use. It is
recommended that all applicable industry, trade association,
federal, state and local regulations be checked. Read all operating
instructions and warnings before operation.
Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper rigging
techniques. Refer to ASME B30.9 for rigging information,
American Society of Mechanical Engineers, Three Park Avenue,
New York, NY 10016.
This manual has been produced by Ingersoll-Rand to provide
dealers, mechanics, operators and company personnel with the
information required to install, operate, maintain and repair 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 cannot know of, or 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.

4MHD56114 - Edition 4
SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions have been
adapted in part from American National (Safety) Standard ASME
B30.7 and 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 a rule set forth in this publication
and a similar rule already set by an individual company, the more
stringent of the two should take precedence.
Safe Operating Instructions are provided to make an operator
aware of dangerous practices to avoid and are not necessarily
limited to the following list. Refer to specific sections in the
manual for additional safety information.
1. Only allow people, trained in safety and operation of this
product, to operate and maintain this winch.
2. Only operate a winch if you are physically fit to do so.
3. 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.
4. Before each shift, the operator should inspect the winch for
wear and damage. Never use a winch that inspection
indicates is worn or damaged.
5. Never lift a load greater than the rated capacity of the winch.
Refer to nameplate attached to winch and to
“SPECIFICATIONS” section.
6. Keep hands, clothing, etc., clear of moving parts.
7. Never place your hand in the throat area of a hook or near
wire rope spooling onto or off of the winch drum.
8. Always rig loads properly and carefully.
9. Be certain the load is properly seated in the saddle of the
hook. Do not support the load on the tip of the hook.
10. Do not “side pull” or “yard”.
11. Always ensure that you, and all other people, are clear of the
path of the load. Do not lift a load over people.
12. Never use the winch for lifting or lowering people, and never
allow anyone to stand on a suspended load.
13. Ease the slack out of the wire rope when starting a lift or
pull. Do not jerk the load.
14. Do not swing a suspended load.
15. Do not leave a suspended load unattended.
16. Never operate a winch with twisted, kinked or damaged wire
rope.
17. Pay attention to the load at all times when operating the
winch.
18. Never use the wire rope as a sling.
19. After use, or when in a non-operational mode, the winch
should be secured against unauthorized and unwarranted use.

MHD56114 - Edition 4 5
WARNING LABELS AND TAG
Each winch is shipped from the factory with the warning labels
and tag shown. If the labels or tag are not attached to your winch,
order new labels and tag and install. Refer to the parts list for the
part numbers. Labels and tag shown smaller than actual size.
WARNING
Welded mountings
can fail.
Can cause severe
injury or death.
Do not weld, braze or
solder to winch. 71270813
WARNING
Handling people with
this equipment.
Can cause severe
injury or death.
Do not use for lifting,
lowering or transporting
people. 04306445
Read the latest edition of
ASME B30.7. Comply with other
federal, state and local rules.
READ ADDITIONAL WARNINGS ON OTHER SIDE. READ ADDITIONAL WARNINGS ON OTHER SIDE.
71060529 (winches)
DO NOT REMOVE
THIS LABEL.
(CONTINUED FROM
OTHER SIDE)
71060529 (winches)
Failure to follow these warnings may result in death,
severe injury or property damage.
• Do not operate before reading manual(s) supplied with
this winch.
• Inspect winch, wire rope and rigging prior to every shift.
• Ensure all winch components and attachments are
functioning and properly adjusted.
• Ensure winch anchors and supporting structure are secure and
in good condition.
• Ensure winch supply cables and hoses are in good condition
and connections are tight.
• Do not operate if malfunctioning or damage is found.
• Use only approved rigging methods.
• Do not make unauthorized modifications.
• Use guards to avoid possible hazards.
• Ensure an accessible shut off valve has been installed in the air
supply line and make others aware of its location.
• Use caution when operating in extremely cold temperatures.
BEFORE OPERATING WINCH:
WHEN OPERATING WINCH:
• Do not lift people or loads over people.
• Keep hands, clothing, jewelry, etc. away from wire rope,
drum and other moving parts.
• Stop winch before touching wire rope.
• Ensure wire rope spools evenly across drum width and each
wrap is tight to drum and previous wrap.
• Ensure tension is applied to wire rope when spooling.
• Be aware of load position at all times to avoid moving load into
hazardous situations.
• Do not lift or pull load into support structure or winch.
• Do not run wire rope over sharp edges, use approved diameter
sheaves.
• Ensure load does not exceed winch, wire rope & rigging ratings.
• Keep everyone clear of load path.
• Keep a minimum of three wraps of wire rope on drum at all
times.
• Immediately stop operation if load does not respond to winch
control.
• Wear hearing and eye protection.
• Ensure brakes hold prior to making complete lift by lifting load
a short distance and releasing control.
• Use only in a well ventilated area.
• Keep clear of motor exhaust.
• Do not allow wire rope storage to exceed drum flange diameter.
• Always shut off air or power supply before servicing or leaving
winch unattended.
• Do not remove or obscure this or any other warning label.

6MHD56114 - Edition 4
SPECIFICATIONS
Model Code Explanation: (Example FA2.5A-LXK1G) FA 2.5 A - L X K 1 G
Series
FA =Force 5 Air Powered
Capacity: (Based on wire rope at mid drum)
2.5 =(2-1/2 tons (5,000 lbs [2,273 kg])
Generation:
A=Third Generation
Drum Length: (Refer to drum length chart)
S = Short (7 inches [178 mm])
S = Medium (13-1/2 inches [343 mm])
L=Long (20 inches [508 mm])
R = Extra Long (24 inches [610 mm])
Drum Brake:
A = Automatic Drum Brake (increases the overall winch length 2.75 inches (70 mm))
M = Manual Drum Brake (increases the overall winch length 2.75 inches (70 mm))
X=None
Disc Brake:
K=Automatic Disc Brake (Standard)
X=None
Control:
1=Winch mounted lever throttle (Standard)
** 2XX = Remote full flow lever throttle (maximum 20 ft/6 m)
** 3XX = Remote pilot pendant throttle (standard = 6 ft/1.8 m; maximum 66 ft/20 m)
** 4XX = Remote pilot lever throttle (maximum 66 ft/20 m)
5XX = Remote electric over air throttle †
Options:
7 = Drum grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch) †
C = Low Temperature Components; specify -10° C (14° F) or -20° C (-4° F)
D = Drum divider flange and additional wire rope anchor †
E = Construction Cage †
F = Free spool clutch (available only with manual drum brake)
G=Drum Guard
H = Open Front frame for horizontal pulling
*** M1 = Material Traceability (typical material results) ††
*** M2 = Material Traceability (actual material results) ††
*** M3 = Material Traceability (actual material results for these parts in finished, as-delivered condition) ††
N = Type Approval - Specify: • American Bureau of Shipping (ABS)
• Det Norske Veritas (DNV) • Lloyd’s Register of Shipping (LRS)
P = Marine 812 Finish
Q = Special Paint
T = Tensioning Manifold
U = Underwound*†
V = Press Roller
Z = Sandblast and Carbozinc primer only
-E = Compliance with European Community Machinery Directive: • Muffler • Overload Device
• Main air supply emergency shut off • Drum Guard • CE Documentation
Notes: *
**
***
†
††
Available only with auto disc brake.
Remote throttles are provided with 6 feet (1.8 metres) of hose. Specify hose lengths greater than 6 feet (1.8 metres).
Contact your Ingersoll-Rand distributor or the factory for control acceptability for hose lengths greater than 60 feet
(18.3 metres). Metric lengths are provided for reference only, order lengths in feet.
Documentation, witness testing and material traceability available; must be requested at time of order. Specify options or
contact the factory or your nearest Ingersoll-Rand distributor for information.
Not covered in this manual.
Refer to ‘Traceability’ on page 8 for a description of the differences between M1, M2 and M3.

MHD56114 - Edition 4 7
General Specifications
Winch Net Weight (without wire rope)
Winch Wire Rope Storage Capacities (feet/metres)
Air System
Rated Operating Pressure 90 psig (6.3 bar/630 kPa)
Air Consumption
(at rated pressure and load) 700 scfm 20 cu.m/min
Rated Performance
(at rated pressure / volume)
Mid Drum Line Pull 5,000 lbs 2,273 kg
Mid Drum Line Speed 114 fpm 35 metres/min
Air Motor Pipe Inlet Size 1.5 inch NPT 1.5 inch NPT
Minimum Air System Hose Size 1.5 inches 38 mm
Drum Barrel Diameter 9.25 inches 235 mm
Drum Flange Diameter 17 inches 432 mm
Model lbs kg Model lbs kg
FA2.5A-SXK1 670 304 FA2.5A-SXK2 676 307
FA2.5A-SMK1 728 330 FA2.5A-SMK2 734 333
FA2.5A-SAK1 750 340 FA2.5A-SAK2 756 343
FA2.5A-SMX1 693 314 N/A N/A N/A
FA2.5A-SAX1 715 324 FA2.5A-SAX2 721 327
FA2.5A-MXK1 710 322 FA2.5A-MXK2 716 325
FA2.5A-MMK1 768 348 FA2.5A-MMK2 774 351
FA2.5A-MAK1 790 358 FA2.5A-MAK2 796 361
FA2.5A-MMX1 733 335 N/A N/A N/A
FA2.5A-MAX1 755 343 FA2.5A-MAX2 761 345
FA2.5A-LXK1 750 340 FA2.5A-LXK2 756 343
FA2.5A-LMK1 808 367 FA2.5A-LMK2 814 369
FA2.5A-LAK1 830 377 FA2.5A-LAK2 836 379
FA2.5A-LMX1 773 351 N/A N/A N/A
FA2.5A-LAX1 795 361 FA2.5A-LAX2 801 363
FA2.5A-RXK1
Contact factory for information
FA2.5A-RXK2
Contact factory for information
FA2.5A-RMK1 FA2.5A-RMK2
FA2.5A-RAK1 FA2.5A-RAK2
FA2.5A-RMX1 N/A
FA2.5A-RAX1 FA2.5A-RAX2
Drum Length Storage Notes
Wire Rope Diameter
3/8 inch 10 mm 7/16 inch 11 mm 1/2 inch 13 mm 5/8 inch 16 mm
inches mm feet metres feet metres feet metres feet metres
7178
Full Drum Storage
less 2 wire rope
layers
448 137 335 102 248 76 124 38
13-1/2 343 888 271 666 203 495 151 251 77
20 508 1,328 405 998 304 743 227 378 115
24 610 1,598 487 1,200 366 895 273 456 139
7178
Full Drum Storage
less 1/2 inch (13 mm)
(meets ANSI B30.7)
519 158 396 121 300 91 164 50
13-1/2 343 1,029 314 788 240 600 183 330 101
20 508 1,538 469 1,180 360 900 274 497 152
24 610 1,851 564 1,388 423 1,085 331 599 183
7178
Full Drum Storage
593 181 460 140 356 109 206 63
13-1/2 343 1,176 359 915 279 712 217 416 127
20 508 1,758 536 1,371 418 1,068 326 625 191
24 610 2,116 645 1,651 503 1,287 392 754 230

8MHD56114 - Edition 4
Performance Curve
(Dwg. MHP2519)
Description
FA2.5A winches are air powered, planetary geared units designed
for lifting and pulling applications. FA2.5A winches are supplied
with either an internal automatic disc brake, a manual or
automatic externally mounted drum band brake, or a combination
of both.
The output from an externally mounted piston air 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 disc brake attaches to the outboard upright opposite the
motor end and is connected to the intermediate sun gear through
the brake shaft. The disc brake is automatically applied when the
winch is in the neutral or operated in the haul-in positions;
disengaged when the winch is operated in the payout direction.
During winch operation a sprag type clutch in the disc brake
allows drum rotation in the haul-in direction with the disc brake
engaged. This ensures the brake will respond quickly to hold the
load when winch operation stops. Operation of the winch in the
payout direction directs pressurized air to the disc brake
diaphragm to overcome spring tension and release the brake.
When the payout operation is complete the air is vented and the
brake is automatically applied.
The drum band brake operates by applying a friction force
between the brake band and the winch drum. The manual brake
requires an operator to engage and disengage the brake using a
handle located on the brake band. The automatic drum band brake
operation is similar to the disc brake with the following
exception: the automatic drum band brake fully disengages in
both the haul-in and payout directions.
Traceability
Load bearing parts are documented to provide traceability.
Documentation includes chemical and physical properties of raw
material, heat treating, and hardening, tensile and charpy tests as
required for the part.
Units with M1, M2 or M3 in the model code have traceable load-
bearing components.
M1–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 2.2 on load bearing parts. Conformity documents
affirm (by the manufacturer) that parts are in compliance with the
requirements of the order based on non-specific inspection and
testing (i.e. results are typical material properties for these parts).
M2–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 3.1b on load bearing parts. Conformity documents
affirm (by a department independent of the manufacturing
department) that the actual parts are in compliance with the
requirements of the order based on specific inspection and testing
(i.e. results are actual material properties for these parts).
M3–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 3.1b on load bearing parts. Conformity documents
affirm (by a department independent of the manufacturing
department) that the actual parts used in the product are in
compliance with the order based on specific inspection and testing
(i.e. results are actual material properties for these parts in a
finished, as delivered condition).
Components with part numbers ending in CH are charpy parts for
use under extreme cold conditions. Traceability requirements must
be stated when reordering these parts for continued certification.
1000
2000
3000
4000
5000
6000
7000
8000
9000
0
020 40 60 80 100 120 140 160 180 200 220 240 260 280 300
200
300
900
800
700
600
500
400
Line Speed - (ft/min)
Line Pull - (lbs)
1st wrap line pull
mid drum
full drum
1st wrap flow
mid drum
full drum
Line Pull - (kg)
4082
3626
3175
2722
2268
5.7
8.5
11.3
25.5
22.7
19.8
16.9
14.2
Line Speed - (m/min)
612 18 24 31 37 43 48 55 61
67
73 79 85 91
1814
1361
907
454
Air Consumption (scfm)
Air Consumption (m3/min)

MHD56114 - Edition 4 9
INSTALLATION
Prior to installing the winch, carefully inspect it for possible
shipping damage.
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.
CAUTION
• Owners and users are advised to examine specific, local or
other regulations, including American National Standards
Institute and/or OSHA Regulations which may apply to a
particular type of use of this product before installing or
putting winch to use.
Mounting
Refer to Dwg. MHP0124 on page 9.
Care must be taken when moving, positioning or mounting the
winch. Ensure that the winch, when lifted, will be properly
balanced. Determine the weight of the winch by referring to the
“SPECIFICATIONS” section. Lift the winch 3 to 4 inches (75 to
100 mm) off the ground. Verify winch is balanced and secure
before continuing lift. Mount the winch so the axis of the drum is
horizontal and the motor control valve pad is not more than 15° off
top vertical center. If the winch is to be mounted in an inverted
position, the motor case must be rotated to position the control
valve pad at the top and adequate clearance must be provided for
control valve operation.
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 uprights and side
rails resulting in winch damage.
2. Make sure the mounting surface is flat to within 0.005 inch
(0.127 mm) per inch of drum length. Shim if necessary.
Refer to Table 1 on page 9.
3. Mounting bolts must be 3/4 inch-NC (18 mm) Grade 8 or
better. Refer to Table 2 on page 9. Use self-locking nuts or
nuts with lockwashers.
4. Tighten mounting bolts evenly and torque to 380 ft lbs (515
Nm) for dry thread fasteners. If the fasteners are plated,
lubricated or a thread locking compound is used, torque to
280 ft lbs (380 Nm).
WARNING
• Winch frame material is not suitable for welding. FA2.5A
winches must only be mounted by bolting to a suitable
foundation. Do not attempt to mount the winch by welding to
a foundation structure. Refer to warning label part number
71270813.
5. Maintain a fleet angle between the lead sheave and winch of
no more than 1-1/2°. The lead sheave must be on a center line
with the drum and, for every inch (25 mm) of drum length, be
at least 1.6 feet (0.5 metre) from the drum. Refer to Dwg.
MHP0498 on page 11.
6. Do not weld to any part of the winch.
(Dwg. MHP0124)
Table 1 - Mounting Tolerances
Drum Length Mounting Surface Minimum Flatness
inch mm
70.04 0.89
13.5 0.07 1.72
20 0.10 2.54
24 0.12 3.05
Table 2 - Mounting Bolt Hole Dimensions
Dimension Drum Length (inches)
7 13.5 20 24 7 13.5 20 24
“A” in. 9.54 16.04 22.54 26.54 12.31 18.81 25.31 29.31
mm 242 408 573 674 313 478 643 744
“B” in. 15
mm 381
“C” in. 0.81
mm 20.6
WARNING
Welded mountings
can fail.
Can cause severe
injury or death.
Do not weld, braze or
solder to winch. 71270813

10 MHD56114 - Edition 4
Wire Rope
CAUTION
• Maintain at least 3 tight wraps of wire rope on the drum at
all times. Refer to Dwg. MHP0498 on page 11.
Standard and Open Frame (Face) Winch
Install the winch such that the wire rope, when at the take-off
angle limits, does not contact the mounting surface. Refer to Dwg.
MHP1013 on page 10.
WARNING
• Exceeding wire rope take-off angles will cause the wire rope
to come into contact with the winch frame supports resulting
in damage to the wire rope and winch.
Wire 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 that 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. Wire rope
construction must be EIPS 6 X 19 IWRC right lay.
Note: To maintain 5:1 safety factor ratio 1/2 inch (13 mm) wire
rope must be used.
(Dwg. MHP1013)
Installing Wire Rope
Refer to Dwg. MHP0652 on page 11.
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 end of the wire rope into the wire rope anchor hole
in the drum and pull through approximately three feet (1
metre) of wire rope.
3. Forming a large loop with the wire rope, insert the end back
into the top of the anchor hole.
4. Place the wire rope wedge into the wire rope anchor pocket in
the drum. Install the wedge such that the wire rope will wrap
around the wedge as shown in Dwg. MHP0652 on page 11.
5. Pull the wire rope into position in the drum anchor pocket. Ensure
the wire rope is installed below the edge of the drum flange
diameter. Use of a copper drift or similar tool may be required to
fully insert wire rope and wedge into the anchor pocket.
CAUTION
• Make sure the first wrap of wire rope is tight and lays flush
against the drum flange.
• Ensure the correct wire rope anchor is used.
• Install wire rope to come off the drum in an overwind
position. Improper installation of wire rope can result in
failure of the disc brake to hold load. Refer to Dwg. MHP0652
on page 11.
Table 3 - Wire Rope Size
Wire Rope
Anchor
Part No.
Minimum Maximum
inch mm inch mm
25539 3/8 10 5/8 16

MHD56114 - Edition 4 11
Wire Rope Installation
(Dwg. MHP0652)
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 the first
layer is tight against the drum.
5. Always follow wire rope manufacturer’s recommendations
on use and maintenance of wire rope.
Wire Rope and Fleet Angle Installation Drawing
(Dwg. MHP0498)
‘A’ = 1.6 feet (0.5 metre) per inch of drum length:
‘A’ = 11.2 feet (3.41 metres) for 7 inch drum.
‘A’ = 21.6 feet (6.58 metres) for 13-1/2 inch drum.
‘A’ = 32 feet (9.75 metres) for 20 inch drum.
‘A’ = 38.4 feet (11.7 metres) for 24 inch drum.
Notes:
1. Maintain a minimum of 3 tight wraps of wire rope on drum at
all times.
2. Refer to “Winch Wire Rope Storage Capacities” for
additional information.
Wire Rope Spooling
Refer to Dwg. MHP2450 on page 11.
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.
Support wire rope spool and have wire rope come off top of spool
and over top of winch drum. This will prevent damage to wire rope.
(Dwg. MHP2450)
Rigging
Make sure all wire rope blocks, tackle and fasteners have a
sufficient safety margin adequate enough 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 the wire rope manufacturer's 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 18 times the diameter of the wire rope. Refer to Dwg.
MHP0498 on page 11.
5. Always maintain at least three full, tight wraps of wire rope
on the drum.
Lead Sheave
(centered on drum)
1-1/2˚
Maximum
Note 2
Note 1
‘A’
Drum
Flange
90˚
CORRECT
Wire Rope
Spooling
Wire Rope
Spooling
Wire Rope
Spooling
Spool
INCORRECT
Winch
Drum
Spool
Winch
Drum
CORRECT
Underwound
Overwound
Spool
Winch
Drum

12 MHD56114 - Edition 4
Air Supply
The air supply must be clean, free from moisture and lubricated to
ensure optimum motor performance. Foreign particles, moisture
and lack of lubrication are the primary causes of premature motor
wear and breakdown. Using an air filter, lubricator and moisture
separator will improve overall winch performance and reduce
unscheduled down time.
The air consumption is 700 scfm (20 cu. m/min) at rated operating
pressure of 90 psig (6.3 bar/630 kPa) at the winch motor inlet. If
air supply varies from recommended, then winch performance
will change.
Air Lines
The inside diameter of the winch air supply lines must be at least
1-1/2 inch (38 mm). Before making final connections, all air
supply lines should be purged with clean, moisture free air or
nitrogen before connecting to winch 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 the lines.
Air Line Lubricator
Refer to Dwg. MHP0191 on page 12.
Always use an air line lubricator with these motors. The lubricator
must have an inlet and outlet at least as large as the inlet on the
motor directional control valve. Install the air line lubricator as
close to the air inlet on the motor as possible.
CAUTION
• Lubricator must be located no more than 10 ft. (3 m) from
the 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 throttle control valve when air
line lubricator is functioning properly.
Air Line Filter
Refer to Dwg. MHP0191 on page 12.
Place the strainer/filter as close as practical to the motor air inlet
port, but upstream from, the lubricator, to prevent dirt from
entering the motor. The filter/strainer should provide 20 micron
filtration and include a moisture trap. Clean the filter/strainer
periodically to maintain its operating efficiency.
(Dwg. MHP0191)
Air Pressure Regulator
Refer to Dwg. MHP0191 on page 12.
If an air pressure regulator is used, install between the lubricator
and filter.
Moisture 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 the motor, or an aftercooler at the compressor that cools
the air to condense and collect moisture prior to distribution
through the supply lines are also helpful.
Ball Valve Shut Off
Refer to Dwg. MHP2459 on page 12.
Install in air supply line upstream of control valve. Ensure ball
valve is conveniently located and easily accessible. Advise
operators and support personnel of its location and use.
(Dwg. MHP2459)
Style Description of Part Part Number
Full Flow Fitting, Nipple 51704
Ball Valve 71404628
Pilot Pendant Control Fitting, Nipple 71311252
Ball Valve 71416911
Lubricator
Air Out Regulator
Air In
Filter
Open
Closed
Ball Valve
Air
Flow
Fitting,
Nipple

MHD56114 - Edition 4 13
Mufflers
Make sure mufflers are installed in winch exhaust manifold and
control valve exhaust port. An additional muffler is used on
winches equipped with an emergency stop and overload device.
Check mufflers periodically to ensure they are functioning
correctly.
Motor
For optimum performance and maximum durability of parts,
provide a lubricated air supply of 700 scfm (20 cu. m/min) at 90
psig (6.3 bar/630 kPa). Recommended pressures and volumes are
measured at the point of entry to the air motor directional control
valve.
Emergency Stop and Overload System
Refer to Dwg. MHP2434 on page 54.
Air supply line is connected to air control valve. When emergency
stop or overload valve is activated, all winch movement will stop.
CAUTION
• If winch continues to move (payout load) after emergency
stop activates, brake(s) are not holding load and may require
adjustment or repair.
When control valve senses a preset pressure difference between
ports, a pilot signal is sent to stop flow of air, all winch movement
will stop.
Initial 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 some light oil into the
inlet connection to provide initial lubrication.
2. 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 ISO VG 32 (SAE 10W) oil in the
motor inlet port.
3. Operate the motor for 10 seconds in both directions to flush
out any impurities.
4. Check to ensure oil levels are “full”.
5. The winch is now ready for normal use.

14 MHD56114 - Edition 4
OPERATION
It is recommended that the user and owner check all appropriate
and applicable regulations before placing this product into use.
The four most important aspects of winch operation are:
1. Follow all safety instructions when operating the winch.
2. Allow only people trained in safety and operation of this
winch to operate this equipment.
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.
CAUTION
CAUTION
• To avoid damage to the rigging, the structure supporting the
rigging and the winch, do not “two-block*” the end of the wire
rope.
* Two blocking occurs when the winch wire rope is multi reeved
using two separate sheave blocks which are allowed to come into
contact with each other during winch operation. When this occurs
extreme forces are exerted on the wire rope and sheave blocks
which may result in equipment and or rigging failure.
WARNING
WARNING
• The winch is not designed or suitable for lifting, lowering or
moving people. Never lift loads over people.
Operators must be physically competent. Operators must not have
a health condition which might affect their ability to act, and they
must have good hearing, vision and depth perception. The winch
operator must be carefully instructed in his duties and must
understand the operation of the winch, including a study of the
manufacturer’s literature. The operator must thoroughly
understand proper methods of hitching loads and must have a
good attitude regarding safety. It is the operator’s responsibility to
refuse to operate the winch under unsafe conditions.
Winch Controls
A spring loaded, motor mounted, manual throttle control valve is
supplied as a standard feature on these winches. Optional remote
pendant controls are also available. Reference the model code on
the winch nameplate and compare it to the “SPECIFICATIONS”
section on page 6 to determine winch configuration. The throttle
control provides operator control of the motor speed and direction
of drum rotation.
Operate winch throttle control using smooth, even movements. Do
not slam or jerk throttle controls during operation.
Winch Mounted Control Valve
Refer to Dwg. MHP1809 on page 14.
The spring loaded, live air, manual control valve mounts to 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 lever. Shift control lever
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 control valve to ensure smooth operation of winch.
When released, handle will return to neutral or center position.
The sliding handle will drop down to engage and lock control
handle in place.
Winch Mounted Throttle Control Valve Operation
(Dwg. MHP1809)
Remote Mounted Control Valve (optional feature)
Refer to Dwg. MHP2043 on page 14.
Provides for remote mounting of winch control at a fixed location
at up to 20 feet (6 metres) away from winch motor. Air hoses
connect throttle to winch motor to provide winch operation.
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 control valve to ensure smooth
operation of winch.
Remote Mounted Control Valve
(Dwg. MHP2043)
Haul-In
Brake Release Port
1/4 NPT
Air Inlet Port
1-1/4 NPT
Payout
Lift Slider
Handle
UP to
Unlock
Exhaust Port
1-1/2 NPT
To Brake
Threaded
Ports

MHD56114 - Edition 4 15
Remote Pilot Pendant Control (optional feature)
Refer to Dwg. MHP2233 on page 15.
Provides for remote winch control at distances of up to 50* feet (15
metres) away from winch. The pendant pilot control throttle is a
two lever movable control station for winch operation. Pilot
pressure from pendant pilot control throttle activates winch control
valve. The winch control valve, located on winch motor, controls
motor speed and direction of drum rotation. Direction of rotation is
determined by the pendant lever pressed.
Pendant Hose and Operating Levers
(Dwg. MHP2233)
Press pendant levers using smooth, even movements. To operate
winch using pendant:
1. To haul-in, press ‘RIGHT’ lever.
2. To payout, press ‘LEFT’ lever.
3. To throttle operating speed, regulate amount pendant lever is
pressed. Press lever fully for maximum speed; partially for
slower speeds.
4. To stop haul-in or payout operation, release pendant lever.
Lever will spring return to off position and winch operation
will stop.
Remote Pilot Lever Throttle (optional feature)
Refer to Dwg. MHP2444, item 358 on page 56.
Provides for remote winch control at distances of up to 50* feet
(15 metres) away from winch. The lever pilot control throttle is a
fixed mount lever control station for winch operation. Pilot
pressure from lever pilot control throttle activates winch control
valve. The winch control valve, located on winch motor, controls
motor speed and direction of drum rotation. Direction of rotation
is determined by direction in which lever is shifted.
* For distances greater than 50 feet (15 metres) contact
Ingersoll-Rand Technical Support for control suitability.
Underwound Operation (optional feature)
Underwound operation is where wire rope haul-in or payout is off
the bottom of drum. This is a special operation and requires a
winch specifically designed for this usage.
Underwound operation requires a reverse bias valve installed in
the control valve.
Control valve operation will be opposite as shown in Dwg.
MHP1809 on page 14. As viewed from air motor end, lift slider
handle up to unlock control lever. Move control throttle handle to
the left (counterclockwise) to payout, and to the right (clockwise)
to haul-in.
Emergency Stop (optional feature)
Refer to Dwg. MHP2047 on page 15.
Emergency stop device is located on the control valve. When
activated, winch drum rotation will immediately cease. To activate
emergency stop, conduct the following:
1. Press (push down) red palm valve, located on top of control
valve.
Emergency Stop Operation
(Dwg. MHP2047)
NOTICE
• If winch overload occurs, overload device, if equipped, also
stops winch. To operate winch after an overload, reduce load
and reset overload.
Emergency Stop Reset
Refer to Dwg. MHP2048 on page 16.
1. Rotate red stop button, in counterclockwise direction until
red stop button ‘pops’ up.
2. Winch is ready to resume operation.
Payout
Load
Haul-In
Load
Red
Green
Yellow

16 MHD56114 - Edition 4
Emergency Stop Reset
(Dwg. MHP2048)
Overload Device (optional feature)
An overload device is available on winches with the emergency
shutoff option. Overload device operation is based on differential
pressure between air motor inlet and exhaust. The overload device
is factory preset to actuate at 150% (± 25%) of winch rated
capacity. When an overload condition is sensed, the valve poppet
closes, to cut off supply air to winch, stopping winch operation. If
an overload shutoff occurs, winch load must be reduced. Reset the
overload valve and operate winch in payout direction to lower
load. Refer to ‘Emergency Stop Reset’ section on page 15.
Overload Valve Adjustment
Refer to Dwg. MHP2216 on page 16.
5/16 in. or 8 mm open ended wrench required.
1. Adjust overload valve by turning adjustment screw located at
bottom of control valve.
2. Rotating adjustment screw clockwise will increase pressure
required to activate overload valve.
WARNING
• This adjustment can cause overload device to NOT activate
before winch’s overload limit is exceeded. This procedure
should only be done by personnel trained in testing and
servicing this winch.
3. Rotating adjustment screw counterclockwise will decrease
pressure required to activate overload valve.
Overload Valve Adjustment
(Dwg. MHP2216)
Checking Overload Valve Setting
1. Attach load line to a load that is calibrated to maximum load
for which winch is rated.
2. Move control lever to haul-in position. If winch does not lift
load, adjust the adjustment screw. Refer to ‘Overload Valve
Adjustment’ section on page 16.
Setting the Overload
Attach load line to a load that is calibrated to 150% of winch rated
capacity. Shift control lever to haul-in position.
1. If overload valve activates, reset overload valve. Winch is
ready for normal operation.
2. If winch lifts load, lower load. Turn adjustment screw
counterclockwise in 1/4 turn increments until overload valve
activates when control lever is shifted to haul-in position.
After each 1/4 turn, retest winch.
Overload Valve Reset
(Dwg. MHP2049)

MHD56114 - Edition 4 17
Winch Brakes
Automatic Disc Brake
The automatic disc brake is a spring applied, air released brake.
When the winch is operated in the payout direction air pressure
acting on the diaphragm overcomes spring pressure and releases
the brake. The brake automatically engages when winch operation
is returned from the payout direction to neutral or when shifted to
the haul-in direction. When the winch is in the neutral or haul-in
positions the brake air is vented and the brake springs apply the
brake. The springs, acting on the pressure plate, compress the
brake friction and separator plates and engage the brake to prevent
drum rotation in the payout direction.
The cam type sprag clutch assembly allows drum rotation in the
haul-in direction with the brake plates engaged, but prevents the
drum from rotating in the payout direction.
Disc brake adjustment is not required. If the disc brake does not
operate properly it must be disassembled, inspected and repaired.
WARNING
• If the brake is disassembled, the friction and separator plates
must be correctly installed as shown in the
“MAINTENANCE” section of this manual. Failure to
correctly install the friction and separator plates can cause the
brake to slip.
Manual Drum Brake (optional feature)
Refer to Dwg. MHP1375 on page 17.
The manual drum brake may be applied by pushing down on the
handle (135) and released by pulling up. By pushing the handle
down fully it will go over-center and lock in that position,
preventing drum rotation. The drum brake must be kept properly
adjusted to hold the required load. Refer to ‘Adjustments’ in the
“MAINTENANCE” section. If brake band cannot be adjusted to
hold the rated load, the brake must be disassembled, inspected and
repaired.
Drum Brake Handle Operation
(Dwg. MHP1375)
Automatic Drum Brake (optional feature)
The automatic drum brake is a spring applied, air released,
externally mounted brake which uses an air actuated, spring
loaded cylinder to automatically disengage the brake when the
motor is operated in either the haul-in or payout directions. Air
pressure directed to the cylinder overcomes spring pressure to
release the brake and allow the drum to rotate.
When the control valve is placed in the neutral position, the air in
the cylinder is vented which allows the cylinder spring to
automatically engage the brake and prevent drum rotation.
Adjustments to the cylinder clevis can be made to compensate for
normal brake lining wear. The drum brake must be kept properly
adjusted to hold the required load. Refer to ‘Adjustments’ in the
“MAINTENANCE” section. If brake band cannot be adjusted to
hold rated load, the brake must be disassembled, inspected and
repaired.
Constant Tension Manifold (optional feature)
Refer to Dwg. MHP2436 on page 58.
With auxiliary valve (744) in the ‘NORMAL’ position, the winch
control valve will provide normal winch operation. With auxiliary
valve selector in the ‘TENSIONING’ position, the winch will
automatically haul-in wire rope to maintain tension.
The auxiliary valve provides a preset air pressure to the air motor
and disc brake. This allows the brake to be released, and winch to
over haul during ‘TENSIONING’ operations. In this position the
winch will maintain a constant tension on the wire rope.
The auxiliary valve comes set at zero from the factory. All
adjustments must be made in the field. These adjustments can be
changed at any time to accommodate the current load. Refer to
‘Adjustments’ in the “MAINTENANCE” section for procedures.
Operation
Place auxiliary valve in ‘NORMAL’ position and use winch
control to position the end of load line at the load. Connect load
line to the load and use winch control to remove all slack from the
load line.
CAUTION
• Ensure slack load line is taken up by operating winch control
valve with selector in NORMAL position. If selector lever is
placed in TENSION position the winch will immediately
attempt to establish line tension causing line to ‘snap’
resulting in injury or damage to property.
Actuate auxiliary valve to ‘TENSIONING’ position. Winch will
automatically haul-in to maintain tension on load line.

18 MHD56114 - Edition 4
Free Spool (optional feature)
Refer to Dwg. MHP2414 on page 63.
The Free Spool option allows wire rope to be spooled from the
drum without operating winch motor.
During normal winch operations the free spool is in non-free spool
position. The output shaft connects outboard upright to drum. The
free spool handle is in the ‘DOWN’ position.
WARNING
• To avoid damage to mounting structure and winch, the winch
drum must be stationary and there must be no load on wire
rope during Free Spool operation.
Free Spool Position:
1. Engage drum band brake to lock drum in position.
2. Pull handle (512) out.
3. Rotate handle (512) counterclockwise, 180° to the ‘UP’
position.
4. Release handle. Ensure handle is engaged in slots in detent
plate (514).
The drum is now in free spool. During free spool operations use
drum band brake to control drum speed during wire rope payout.
Non Free Spool Position:
Before operating winch with motor, ensure winch is not in free
spool mode.
1. Engage drum band brake.
2. Pull handle (512) out.
3. Rotate handle clockwise, 180° to the ‘DOWN’ position. This
connects winch drum to outboard upright. If required, band
brake can be released and drum slowly rotated by hand to
assist in lining up output shaft (28) splines with upright.
4. Release handle. Ensure handle is engaged in slot in detent
plate (514).
Free Spool Operation
(Dwg. MHP1322)
Drum
Engaged
Position
Step 1.
Step 2.
Step 3.
Drum
Free Spool
Position
NOTE: Reverse prodedure
before operating winch.

MHD56114 - Edition 4 19
INSPECTION
Inspection information is based in part on American Society of
Mechanical Engineers (ASME B30.7).
WARNING
• 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.
• 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 personnel trained in
safety and operation of this equipment and include observations
made during routine equipment operation. Periodic inspections
are thorough inspections conducted by personnel trained in the
safety, operation and maintenance of this equipment.
ASME B30.7 states inspection intervals depend upon the nature of
the critical components of the equipment and the severity of
usage. The inspection intervals recommended in this manual are
based on intermittent operation of the winch eight hours each day,
five days per week, in an environment relatively free of dust,
moisture, and corrosive fumes. If the winch is operated almost
continuously or more than the eight hours each day, more frequent
inspections will be required.
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 instructed in
safety, operation and maintenance of this equipment. A
determination as to whether a condition constitutes a safety hazard
must be decided, and the correction of noted safety hazards
accomplished and documented by written report before placing
the equipment in service.
Records and Reports
Inspection records, listing all points requiring periodic inspection
should be maintained for all load bearing equipment. Written
reports, based on severity of service, should be made on the
condition of critical parts as a method of documenting periodic
inspections. These reports should be dated, signed by the person
who performed the inspection, and kept on file where they are
readily available for authorized review.
Wire Rope Reports
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, side rails, uprights and drum for indications
of damage. 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
knowledgeable on wire rope safety and maintenance
procedures.
NOTICE
• The full extent of wire rope wear cannot be 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.
4. BRAKES. During winch operation test brakes. Brakes must
hold load without slipping. Automatic brakes must release
when winch motor throttle or pendant is operated. If brakes
do not hold load, or do not release properly, the brakes must
be adjusted or repaired.
5. WIRE ROPE REEVING. Check reeving and ensure wire
rope is properly secured to the drum. Do not operate the
winch unless the wire rope feeds onto the drum smoothly.
6. LUBRICATION. Refer to the “LUBRICATION” section for
recommended procedures and lubricants.
7. PENDANT (optional feature). Ensure operation of pendant
buttons are smooth and that winch is responsive to pendant
control. Pendant buttons must spring return to neutral
position when released.
8. MANUAL THROTTLE LEVER. Ensure operation of
manual throttle lever is smooth and winch is responsive to
lever movement. Lever must return to neutral when released.
If winch responds slowly or control sticks, do not operate
winch until all problems have been corrected.
9. MOTOR. During operation check motor housing for excess
heat build up. Housing should not be hot to the touch. Listen
for grinding or knocking noises in the motor. There should
be no grinding or knocking noises. Ensure lubricated air
supply provides 6 to 9 drops per minute of ISO VG 32
(10W) oil. Operate motor slowly in both directions to verify
operation.