Ingersoll-Rand force 5 Man-Rider FA2.5MRA 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 MHD56085
PARTS, OPERATION AND MAINTENANCE MANUAL
TM
AIR WINCHES
MODEL
FA2.5MRA MANRIDER* WINCH
* Instructions contained in this manual apply only to winches designed by Ingersoll-Rand,
and that are identified for personnel lifting by a permanent nameplate attached to the winch
at the factory.
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance informa-
tion. Make this manual available to all persons responsible for the operation,
installation and maintenance of these products.
The winch is only part of the Personnel Lifting System. For information defining the
Personnel Lifting System requirements read ANSI A10.22 and all associated manufactur-
ers’ component literature. A copy of ANSI A10.22-1990 is provided with this product.
Always operate, inspect and maintain this winch in accordance with American National
Standards Institute Safety Codes (ANSI A10.22 and ASME B30.7) and all other applicable
local, state and federal safety codes and regulations.
Form MHD56085
Edition 1
April 1995
INGERSOLL-RAND®
71146278
© 1995 Ingersoll-Rand Company
MATERIAL HANDLING

Safety Information
Danger,Warning,Caution andNotice ........................................................................................................................... 3
SafetySummary.............................................................................................................................................................
3
Winch SafeOperatingInstructions ................................................................................................................................4
WinchWarningLabels ...................................................................................................................................................
5
Winch Specifications
GeneralSpecificationsChart .........................................................................................................................................5
Model CodeChart ..........................................................................................................................................................
6
Winch Installation
Mounting ........................................................................................................................................................................
7
Wire Rope.......................................................................................................................................................................
8
Rigging ...........................................................................................................................................................................
9
SafeInstallation Procedures
...........................................................................................................................................
9
Air System......................................................................................................................................................................
9
Motor .............................................................................................................................................................................
10
Electrical Grounding .....................................................................................................................................................
10
Wire RopeLine SpeedMonitor ....................................................................................................................................
10
Motor ExhaustandMuffler ...........................................................................................................................................
10
Initial OperatingChecks...............................................................................................................................................
10
Winch Operation
PersonnelLifting System......................................................................
........................................................................
11
Initial Winch OperatingChecks
....................................................................................................................................
11
Winch ComponentOperation........................................................................................................................................
12
WinchEmergencyDescentProcedure
..........................................................................................................................
12
Training .........................................................................................................................................................................
13
Winch Lubrication
RecommendedLubricants .............................................................................................................................................13
Motor .............................................................................................................................................................................
13
Wire Rope......................................................................................................................................................................
14
ReductionGearAssembly.............................................................................................................................................14
Disc Brake(optional feature)........................................................................................................................................14
SealsandBearings ........................................................................................................................................................
14
Air Line Lubricator .......................................................................................................................................................
14
Winch Inspection
RecordsandReports......................................................................................................................................................
15
WireRopeReports........................................................................................................................................................
15
SystemInspectionsandTests
........................................................................................................................................
15
Winch Inspections.........................................................................................................................................................
15
WinchesNot in RegularService...................................................................................................................................
17
Winch Troubleshooting
Winch TroubleshootingCharts ..................................................................................................................................
19-20
Winch Maintenance
Winch Adjustments.......................................................................................................................................................
21
Disassembly
...................................................................................................................................................................
23
Cleaning,InspectionandRepair ...................................................................................................................................
25
Winch Assembly ...........................................................................................................................................................
25
Winch Testing................................................................................................................................................................
28
Winch AssemblyDrawings andPartsLists Tableof Contents....................................................................................
29
Parts Ordering Information
ReturnGoodsPolicy .....................................................................................................................................................
46
Warranty...............................................................................................
.........................................................................
47
2

This manualprovides important information for all
personnelinvolved with the safeinstallation, operation
andpropermaintenanceof this product. Even if you feel
you arefamiliar with this or similar equipment,you should
readthis manualbeforeoperatingtheproduct.
Danger, Warning, Caution and Notice
Throughout this manualtherearestepsandprocedures
which, if not followed, mayresult in aninjury. The
following signal wordsareusedto identify thelevel of
potential hazard.
Safety Summary
Dangeris usedto indicate the
presenceof ahazardwhich will
causesevereinjury, death,or
substantialproperty damageif the
warning is ignored.
Warning is usedto indicate the
presenceof ahazardwhich can
causesevereinjury, death,or
substantialproperty damageif the
warning is ignored.
Caution is usedto indicate the
presenceof ahazardwhich will or
cancauseinjury or property damage
if thewarning is ignored.
Notice is usedto notify peopleof
installation, operation,or
maintenanceinformation which is
important but not hazard-related.
l This winch was designed to meet ANSI A10.22-1990
which limits its use as part of a system for personnel
lifting. There are other components required to
complete the system. It is the users responsibility to
supply all other components necessary to properly
complete the lifting system in accordance with the
regulations that pertain to the lifting application.
l It is the owner’s and user’s responsibility to check
and to conform to all regulations (local, state, federal
and country) that may apply to the use of a winch or
winch system for lifting and lowering people before
using a Man-Rider@ winch for personnel movement.
l 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 Man-Rider@ winches aredesignedand
manufacturedto meetor exceedstandardsand
specificationsestablishedfor basemounteddrum hoistsas
defined by ASME B30.7 andfor thepurposeof personnel
handling asdefinedby ANSI A10.22 - 1990.
In furnishing customers Man-Rider@ winches,
Ingersoll-Rand doesnot warrant the suitability of these
winchesfor anyparticular use.It is the owner’s anduser’s
responsibility to determinethe suitability of this winch for
aparticular application.
Ingersoll-Rand Man-Rider@ winches manufacturedto
ANSI A10.22 standardsaredesignedasacomponentin
the PersonnelLifting System. Ingersoll-Rand approval
for useof this winch in Man-Rider@ applications
automatically terminatesfor any of thefollowing reasons:
1. Winch is not installed in anapprovedpersonnellifting
system.
2. Winch is not properly maintained in asafeworking
condition, with all partsintact andproperly adjusted.
3. Winch is usedin applications not approvedby codes
andregulations, or application is inconsistent with
manufacturer’soperation andmaintenancemanual.
4. More thanonewinch is usedto attachto acommon
load.
5. Winch designor functions arealteredor changedin
any mannerfrom thepurchasedoriginal without prior
approvalby Ingersoll-Rand.
This manualhasbeenproducedby Ingersoll-Rand to
provide companypersonnel,dealers,mechanicsand
operatorswith theinformation required to install, operate,
andmaintain theproductsdescribedherein.
It is extremely important that mechanicsandoperatorsbe
familiar with the servicing proceduresof theseproducts,or
like or similar products,andarephysically capableof
conducting theprocedures.Thesepersonnelshall havea
generalworking knowledge that includes:
1. Properandsafeuseandapplication of common
mechanics’handtools aswell asspecial
Ingersoll-Rand or recommendedtools.
2. Safetyprocedures,precautionsandwork habits
establishedby acceptedindustry standards.
Ingersoll-Rand cannot know of, nor provide all the
proceduresby which product operationsor repairsmay be
conductedandthe hazardsand/orresultsof eachmethod.
If operationor maintenanceproceduresnot specifically
recommendedby themanufacturerareconducted,it must
beensuredthat product safetyis not endangeredby the
actionstaken.If unsureof anoperation or maintenance
procedureor step,personnelshould placethe winch in a
safecondition andcontactsupervisorsand/or thefactory
for technical assistance.
3

Thefollowing warnings andoperatinginstructions have
beenadaptedin part from AmericanNational (Safety)
StandardsASME B30.7 andANSI A10.22, andare
intendedto avoid unsafeoperatingpracticeswhich might
leadto injury or property damage.
Ingersoll-Rand recognizesthatmostcompanieswho use
wincheshaveasafetyprogramin forceattheir facility. In
theeventthat aconflict existsbetweenarule setforth in
this publication andasimilar rule alreadysetby an
individual company,themorestringentof thetwo should
takeprecedence.
l Failure to follow these operating instructions may
result in death or property damage. Ingersoll-Rand
assumes no liability for any loss or damage resulting
from operation of Man-Rider@ winches if these
operating instructions are not followed.
SafeOperatingInstructions areprovided to makean
operatorawareof dangerouspracticesto avoid andarenot
necessarilylimited to thefollowing list. Referto specific
sectionsin themanualfor additional safetyinformation.
1.
2.
3.
4.
5.
Winch operatormustbein vocal contactwith
personnelbeing lifted (lowered)from transferpoint to
landing area.
Personnelsupervising, operatingthe winch and
personnelbeing transferredareto beinstructed in
systemoperationandsafetyprior to personnellifting.
Only operateawinch if you arephysically fit to do
so.
Useof awinch to transportpersonnel(lifting and/or
lowering) should only takeplacewhen other meansof
accomplishingthis work arenot practical.
Whena “DO NOT OPERATE” sign is placedon the
winch, or winch controls, donot operatethe winch
until thesignhasbeenremovedby designated
personnel.
Neverlift aload greaterthantheratedcapacity of the
winch. Referto “SPECIFICATIONS” sectionfor
applicableutility and ManRider® capacityratings.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Prior to use,inspectandtestthepersonnellifting
systemto therequirementsof ANSI A10.22 Section
13(Inspection andTests).The winch operatorshall be
instructedin the operationof this winch andthe
personnellifting systemperANSI A10.22 Section5
(Operation of Hoist).
Winch only: Referto ‘Testing’ proceduresin the
“WINCH INSPECTION” sectionof this manualfor
winch information.
Installation of the winch mustbespecially arranged
andapprovedfor personnelhandling asacomponent
in aPersonalHandling Systemasdescribedand
definedin ANSI A10.22. Referto the
“INSTALLATION” section.All bolts and
foundationsfor winch attachmentmusthaveahigher
loadcarrying capacityrating than themaximum
capacityof thewinch.
Do not operateadamagedwinch.
Do not operateawinch that hasnot beenproperly
maintainedor equipped.
Do not operatewinch with any personnelneartheline
of forceor capableof coming into contactwith
moving parts.
Labelsandwarning noticesmustremainpermanently
posted,andbeclearly visible on the winch.
Easethe slackout of the wire ropewhen starting alift.
Do notjerk the load.
Neverleaveasuspendedload unattended.
Wire ropemustspooloff drum from thetop away
from the operator(overwind). The direction of lift is
counterclockwisewhen viewed from themotor endof
thewinch.
Make surethe wire ropeis properly anchoredto the
winch drum.
Payattention to theload atall timeswhen operating
thewinch.
Neverusethe winch wire ropeasasling.
Do not leaveaload suspendedwhen winch is not in
use.
Ensuremuffler is positioned atthepoint furthest away
from winch operator.
Do not uselimit switch settingsto regulatethewinch
stoppingpoints. Limit switchesaredesignedasa
backupto operatoraccidentalover travel only.
Ensuretheendof thewire ropeis weighted to prevent
line run.

Eachunit is shippedfrom the factory with the warning
label shown. If the label is not attachedto your unit, order
anew label andinstall. Seethepartslist for thepart
number.Label is shownsmallerthan actualsize.
General Specifications Model FA2.5MRA
1
I
Utility Rating * ANSI ManRider®
Rating *
RatedOperatingPressure 90 psig (6.2 bar)
Air System
ConsumptionVolume
(atratedpressure)
RatedFull Drum Line Pull *
Line Speed- 3rdLayer (UP)
3,520 lbs
108fpm
Performance I
[at rated pressure / volume)
Line Speed- 3rdLayer (DOWN)
148 fpm
Max Stall Pull - 1stLayer
FA2.5MRA NetWeight
l0,000 lbs
Air Motor Pipe Inlet Size
Minimum Air System Hose Size
l-1/4 inch
1-1/2 inch
Drum Wire Rope Storage
Capacity ***
(feet / metres)
Drum Length (inches) Wire Rope Diameter
8
269 feet
12 404 feet
16
539 feet
24 808 feet
30
1010feet
* FA2.5 Utility rating of 3,500Ibs.(1,558kg) is basedon requirementsof ASME B30.7 (5:l designfactor with 7/16
inch (11 mm) wire rope.)
FA2.5 Manrider® rating of 2,200lbs. (1,000kg) is basedon requirementsof ANSI A10.22 (24:1drum to wire rope
ratio) andfactory recommended8:1safetydesignfactor of 8:1 using 7/16 inch (11 mm) wire rope.)
** Line speedratingsfor PersonnelLifing describethedesigncapabilities of the winch. Operatorsmustlimit winch
speedto amaximum of 100feetperminute (30.5metresper minute) when using the winch asapersonnellifting
deviceto comply to ANSI A10.22.
*** FA2.5 ManRider® wire ropestorageis basedon awinch with a 19inch (483 mm) diameterdrum flange andonANSI
A10.22 standardswhich require thetop layerto beatleast2 inches(51 mm) below the drum flangediameter.
Capacitiesshownmayvary from thosepublishedelsewhere.
5

Model Code Explanation
Example: FA2.5MRA24MA1G FA2.5 MRA 24 M A 1 G
Model FA2.5 Personnel Lifting - 1 metric ton / 2,200 lbs.
Utility Lifting - 1.6 metric tons/ 3,500 lbs.
Designation:
MRA = Man Rider@ ANSI A10.22-1990 *
Drum Length (Distance between drum flanges):
=
8 inch
(203 mm)
= 12inch (305mm)
= 16inch
(406 mm)
=
24 inch (610 mm) (Standard)
8
12
16
24
30
Brake: M
A
K
Control: 1
3xX
sxxx
options: Z
P
G
7
= 30 inch
(762 mm)
= Manual Drum Brake (Standard)
= Automatic Drum Brake (Standard)
= Automatic Disc Brake
= Winch mounted lever throttle (Standard)
= Remotepilot pendantthrottle with warning light (XX = Specifyhoselength (feet)) **
= Remoteelectric throttle control (XXX = Specify hoselength (feet)) **
= SandblastandCarbozincprimeronly
= Marine 812top coat
= Drum Guard
= Drum Grooving (Number= wire ropesizein sixteenths,e.g.7/16inch)
*
StandardFeatures: (1)
(2) Line SpeedMonitor.
(3) Adjustableupperandlower rotarylimit switches.
(4) Pipedawayexhaustwith muffler and 10feet (3 metres)of exhausthose.
Copyof OperationandMaintenanceManual andANSI A10.22 Standardsuppliedin
(5) containerattachedto winch.
Manual andAutomatic Drum BandBrake.
**
Note:
Remotependantsareprovided with standardlength 10feet(3metres)hose.Specify hoselengthsgreaterthan 10feet.For
lengthsgreaterthan50ft. (15metres)with theRemotePilot PendantThrottle or RemotePilot Electric Throttles contact
Technical Salesfor control acceptability. Metric lengthsfor referenceonly, orderlengthsrequiredto bein feet.
FA2.5MRA winchesareshippedwith amuffler, 10feet (3 m)of exhausthoseandthenecessaryassemblyattachmentsto
install themuffler at adistancefar enoughawayfrom theoperatorto ensurenoiselevel exposureof lessthan90 dBA over
aneight hour period(Time WeightedAverage(TWA)). The recommendeddistanceis basedon noiselevels recorded
during factory testing.Referto the “INSTALLATION” sectionfor additional information.
Series (Capacity):
6

Prior to installing the winch, carefully inspectit for
possible shipping damage.
Winches aresupplied fully lubricated from the factory.
Before operationcheckoil levels andadjustasnecessary.
Usetheproper type of oil asrecommendedin the
“LUBRICATION” section.
l Owners and users are advised to examine specific,
local or other regulations, including ANSI A10.22,
ASME B30.7 and/or OSHA Regulations which may
apply to a particular type of use of this product before
installing or putting winch to use.
Mounting
Caremustbetakenwhen moving, positioning or mounting
the winch. In mostcases,lifting lugs havebeenprovided
to assistin handling the winch. If thelug locations are
improper for your specific installation, greatcareshould
betakento ensurethat the winch, whenlifted, will be
properly balanced.Determinetheweight of your winch by
referring to the “SPECIPICATIONS” section.Lift the
winch 3 to 4 inches(75 to 100mm) off the ground. Verify
winch is balancedandsecurebeforecontinuing lift.
l Care must be taken when lifting the winch.
Determine winch center of gravity and arrange lifting
straps to raise the winch evenly.
l If the winch is mounted to a portable foundation,
always attach the lifting straps or cables to the
foundation structure when lifting and supporting the
winch assembly.
l Install the wire rope to come off the drum for
overwind operation ONLY. Failure to correctly spool
the wire rope will result in falling load, which can
cause severe injury, death and property damage. Refer
to Dwg. MHTPA0661.
1.
2.
Ensurethe winch is positioned in amannerthat allows
for proper spooling of thewire ropeonto the drum.
When installed correctly, thedirection of lift is
counterclockwise asviewed from themotor endof the
winch (clockwise from outboardendof winch). Refer
to Dwg. MHTPA0661.
Mount the winch sothe axis of thedrum is horizontal
andthat themotor vent capis not morethan 15” off
top vertical center.If the winch is to bemountedin an
inverted position, themotor casemustberotatedto
position the vent capatthetop.
3. The winch mounting surfacemustbeflat andof
sufficient strengthto handlethe ratedload plus the
weight of thewinch andattachedequipment.An
inadequatefoundation may causedistortion or
twisting of the winch uprights andsiderails resulting
in winch damage.
a. Make surethemounting surfaceis flat to within
l/16 inch (2.0mm). Shim if necessary.
FA MRA Series Winch Wire Rope
Take Off Diagram (Overwind Operation Only)
Arrows indicate
direction of wire rope
haul in for overwind
operation
(Dwg. MHTPA0661)
4. Recommendedmounting bolts: 5/8 inch (16 mm)
Grade8 or better.Useself-locking nuts or nuts with
lockwashers.Referto Dwg. MHTPA0133 andTable 1
for mounting dimensioninformation. To determine
clamping load tensile andshearstrengthrequirements
refer to Dwg. MHTPA0692 andTable 2.
Winch Bolt Hole Mounting Dimensions
(Dwg. MHTPA0133)
7

Table 1: Bolt Hole Dimensions
Wire Rope
Dimension Drum Length (inches)
8* 12* 16 24 30
* 3 Bolt holespersiderail.
FA2.5MRA Winch Foundation Bolt Forces
Calculated for 1st Layer stall load [9,680 Ibf (2,176 N)]
1st Layer Line
Radius = 5.7 inches
(145 mm)
356,mm
Rear
Maximum
shear force at one
rear foundation bolts
(Dwg. MHTPA0692)
Table 2: Winch Foundation Bolt Forces
Force Acting on Bolt Drum Length (inches)
8 12 16 24 30
11,080 I
Bolts **
* Maximumshearforceoccurswhenwire ropeis ata0° angle.
** Maximumtensileforceoccurswhenwire ropeis ata 36” angle.
5. Use 5/8 inch (16mm) Grade8mounting bolts.
Tighten evenly andtorqueto 220ft. lbs. (298Nm) for
dry threadfasteners.If the fastenersareplated,
lubricated or athreadlocking compoundis used,
torqueto 170ft. lbs. (230Nm).
6. Maintain afleet anglebetweenthe sheaveandwinch
of no morethan l-1/2”. The leadsheavemustbeon a
centerline with thedrum andfor every inch of drum
length, beatleast 1.6feet(0.5metre)from the drum.
Referto Dwg. MHTPA0498.
7. Do not weld to any part of the winch.
l Do not use wire rope which is less than 7/16 inch (11
mm) minimum nominal diameter.
l Maintain at least 4 tight wraps of wire rope on the
drum at all times. Ensure wire rope top layer is a
minimum of 2 inches (51 mm) below drum flange edge.
Refer to Dwg. MHTPA0498.
l To prevent wire rope “line run” ensure a weight
greater than the total weight of the longest ‘wire rope
pay out to sheave’ length is attached to the end of the
wire rope. 7/16 inch IWRC wire rope average weight
per foot: 0.35 lbs/foot (0.52 kg/metre).
Wire Rope and Drum Diagram
Lead Sheave
Maximum
Note 1’
(Dwg. MHTPA0498)
Notes:
1. Always maintain aminimum of 4 tight wrapsof wire
ropeon thedrum.
2. The minimum allowed distancefrom top of wire rope
layer to drum flange edgeis 2 inches(51mm).
3. 1.6feet(0.5metre)per inch of drum length; eg.,for
12inch drum length locateleadsheave19.2feet(6
metres)from drum.
Wire Rope Selection
Consult areputablewire ropemanufactureror distributor
for assistancein selectingthe appropriatetype andsizeof
wire ropeand,wherenecessary,aprotective coating. Use
awire ropewhich provides anadequatesafetyfactor to
handletheactualworking load.
Whenconsidering wire roperequirementsthe actual
working load mustinclude not only the staticor dead
load but alsoloadsresulting from acceleration,retardation
andshockload. Considerationmustalsobegiven to the
sizeof the winch wire ropedrum, sheavesandmethodof
reeving. Wire ropeconstruction mustbe6 X 19or 6 X 37
IWRC right lay to permit correctinstallation of wire rope
anchor.Referto Table 3 for applicable wire ropesizes.
8

Table 3: Minimum and Maximum Wire Rope Size
Maximum
Model
Utility ..........
7/16
FA2.5
ManRider*
* 7/16inch(11mm)wireropemustbe.usedonFA2.5MRA
winchesusedforpersonnellifting toconformtoANSI
A10.22standards.
Safe Wire Rope Handling Procedures
1. Always usegloves when handling wire rope.
2. Never usewire rope which is frayed or kinked.
3. Never usewire rope asasling.
4. Always ensurewire ropeis correctly spooledandthe
first layer is tight againstthe drum.
Wire Rope Spooling
To compensatefor uneven spooling andthe decreasein
line pull capacity asthe drum fills up, useasshort awire
rope aspractical. When rewinding apply tension to theend
of the wire ropeto eliminate line slack.This helpsachieve
level winding andtight spooling.
l Use only 7/16 inch (12 mm) wire rope on the
FA2.5MRA winch if used for personnel handling.
Installing Wire Rope
(Referto Dwg. MHTPA0166)
1. Cut wire ropeto length in accordancewith the wire
ropemanufacturer’sinstructions.
2. Feedthe endof the wire ropeinto the wire rope
anchorhole in thedrum andpull through
approximately onefoot (305mm) of wire rope.
Wire
Split Wedge
(Dwg. MHTPA0166)
3.
4.
5.
6.
7.
Wrap the wire ropewith wire adistancefrom theend
equalto the wedgelength plus oneinch (25 mm).
Slide the sleeveover theendof thewire ropesothe
larger diameterof the taperboreis nearestthe endof
the wire rope.
Spreadthe endstrandsof thewire ropeandinsert the
split wedgeuntil it is below theendof thewire rope.
Pull the sleeveover the wire ropeenduntil tight.
Checkthat the wire ropestrandsstayin the slots
locatedon the split wedge.
Pull the wire ropeanchorinto position in the drum
anchorpocket.
l Wire rope must be spooled at least 2 inches (51 mm)
below the outer diameter of the drum flange. Refer to
Dwg. MHTPA0498.
Rigging
Make sureall wire rope blocks, tackle andfastenershavea
sufficient safetymargin to handle therequired load under
all conditions. Do not allow wire ropeto contactsharp
edgesor makesharpbendswhich will causedamageto
wire rope, use a sheave. Referto thewire rope
manufacturer’shandbook for proper sizing, useandcareof
wire rope.
Safe Installation Procedures
1. Do not usewire rope asaground (earth) forwelding.
2. Do not attachawelding electrodeto winch or wire
rope.
3. Never run the wire rope over asharpedge.Usea
correctly sizedsheave.
4. When aleadsheaveis used,it mustbealigned with
the centerof the drum. The diameterof the lead
sheavemustbeat least24timesthediameterof the
wire rope.Refer to Dwg. MHTPA0498.
5. Always maintain at least
four full, tight wrapsof wire
ropeon the drum.
Air Supply
The air supply must beclean andfreefrom moisture.
Air Lines
The inside diameterof the winch air supply lines mustnot
belessthan the sizesshown in Table 4. Before making
final connections,all air supply lines should bepurged
with clean,moisture free air or nitrogen beforeconnecting
to winch inlet. Supply lines should beasshort andstraight
asinstallation conditions will permit. Long transmission
lines andexcessiveuseof fittings, elbows,tees,globe
valves etc.causeareduction in pressuredueto restrictions
andsurfacefriction in the lines.
l Make sure the first wrap of wire rope is tight and lays
flush against the drum flange. Also ensure that each
succeeding wrap is tight against the previous one.
Table 4: Minimum Allowable Air Supply Line Sizes
Model inch
FA2.5MRA l-1/2

Air Line Lubricator
(Referto Dwg. MHTPA0191)
Always useanair line lubricator with thesemotors.The
lubricator musthaveaninlet andoutlet atleastaslargeas
theinlet onthemotor.Install theair line lubricator as
closeto theair inlet on themotor aspossible.
l Lubricator must be located no more than 10 ft. (3 m)
from the motor.
The air line lubricator should bereplenisheddaily andset
to provide 6 to 9 dropsperminute of SAE 10Woil. A fine
mist will beexhaustedfrom the throttle control valve
whentheair line lubricator is functioning properly.
Air Line Filter
(Referto Dwg. MHTPA0191)
It is recommendedthat anair line strainer/filter be
installed ascloseaspractical to themotor air inlet port,
but beforethelubricator, to preventdirt from entering the
motor.The strainer/filter shouldprovide 20 micron
filtration andinclude amoisturetrap.Cleanthe strainer/
filter periodically to maintain its operatingefficiency.
Air out
Regulator
Air In
Lubricator Filter
(Dwg. MHTPA0191)
Moisture in Air Lines
Moisture thatreachestheair motor through air supply
lines is aprimary factorin determining the length of time
betweenserviceoverhauls.Moisture trapscanhelp to
eliminate moisture.Othermethods,suchasanair receiver
which collectsmoisturebeforeit reachesthe motor, an
aftercooleratthecompressorthatcools the air to condense
andcollect moistureprior to distribution through the
supply lines arealsohelpful.
Motor
For optimumperformanceandmaximum durability of
parts,provide anair supply of 90psig at700 scfm(6.2
bar/620kpaat 20 cum/m) for FA2.5MRA winches.The
air motorshouldbeinstalled asnearaspossibleto the
compressoror air receiver.Recommendedpressuresand
volumesaremeasuredatthepoint of entry to the air
motor.
Electrical Grounding
l The Personnel Lifting System must be properly
grounded to conform to ANSI A10.22 standards.
Ensure electrical grounding is conducted by licensed
electricians in accordance with the latest edition of the
National Electric Code (ANSI/NFPA 70) and any
applicable local, state and national electric codes and
ordinances.
An electrical grounding lug is attachedto the winch
siderail. Placeground wire into the lug andsecurein place
with the setscrew.Attach otherendof wire asrequiredto
establishanelectrical ground.Ensurewinch is correctly
groundedto thePersonnelLifting Systembeforeusing
winch.
Wire Rope Line Speed Monitor
Winchesareequippedwith abatterypoweredline speed
monitor andoverspeedindicator. Ensurethe indicator
sensoris adjustedasdescribedin the “WINCH
ADJUSTMENTS” section.
The line speedmonitor rechargeablebattery will operate
for twenty-five eight hour daysat 33%actual on time
(winch operationtime). An amberlight indicates the
batteryrequiresrecharging.Approximately onedayof
operationremainswhentherechargelight indication
comeson.Referto the “MAINTENANCE” sectionfor
rechargingprocedures.
Motor Exhaust and Muffler
(Referto Dwg. MHTPA0646)
l Operator exposure to noise levels shall not exceed 90
dBA over an 8 hour period (Time Weighted Average
(TWA)). Ensure motor and pilot valve air is properly
exhausted and muffled.
Winch noiselevel ratingsunderfactory testconditions:
1. 83dBA during operationof winch without load in the
haul in direction.
2. 87dBA during operationof winch without load in the
pay out direction.
Theselevels wereachievedwhen themotor andpilot
valve air wasexhaustedthrough a 10foot (3 metre)length
of hoseandattachedto amuffler.
Initial Operating Checks
Winchesaretestedfor properoperationprior to leaving
thefactory. Beforethewinch is placedinto servicethe
following initial operatingchecksshould beperformed.
1. Whenfirst running themotor inject somelight oil into
theinlet connectionto provide initial lubrication.
2. Whenfirst operatingthewinch it is recommendedthat
themotor bedriven slowly in both directions for a
few minutes.
10

For winchesthathave beenin storagefor aperiod of more
than onemonththe following start-upprocedureis
required.
1. Give thewinch aninspection conforming to the
requirementsof “Winches Not in RegularUse” in the
“INSPECTION” section.
2. Pour a small amount of 10Woil in the motor inlet
port.
3. Operatethe motor for 10secondsin both directions to
flush out any impurities.
4. The winch is now readyfor normal use.
The four mostimportant aspectsof winch operation are:
1. Follow all safetyinstructions whenoperatingthe
winch.
2. Allow only peopletrained in safetyandoperationof
this winch to operatethis equipment.
3. Subjecteachwinch to aregular inspection and
maintenanceprocedure.
4. Beawareof the winch capacityandweight of load at
all times.
l Operate this winch ONLY if wire rope is installed to
come off the drum for overwind operation. Refer to
Dwg. MHTPA0564.
l Operation of this winch in a safe manner, as part of a
Personnel Lifting System, requires that supervisors,
operators, and personnel being transported be
thoroughly instructed in the potential dangers involved
and the safety procedures established to minimize the
risks of accident, injury and property damage.
l Do not transport personnel and materials at the same
time. Safe operation, according to established
standards, require that personnel and materials are to
be transported separately.
l Visual inspections of the winch and entire Personnel
Lifting System must be conducted by designated
personnel instructed in safety, operation and
maintenance of this product before using the winch to
transport personnel. Any visual indication of damage
must be inspected, repaired and actions documented in
accordance with component manufacturers’
instructions to ensure the safety of personnel is not
compromised.
Personnel Lifting System
Ownersareresponsiblefor establishing,implementing and
ensuringthat supervisors,operators,andpersonnelbeing
transportedareinstructed in operationandsafety
procedures.Referto ‘Training’ in the “WINCH
OPERATION” section.
1. Supervisors,operatorsandpersonnelbeing lifted
shouldcheckthat winch, wire rope,working platform,
lifelines, safetybelts (harnesses),etc.arepresentand
functional prior to authorizing personnellifting.
2. Personnelbeing transportedmustbeinstructed in and
adhereto the safetyproceduresestablishedincluding,
but not limited to, the following list:
a. EmergencyEscapeProceduresin accordance
with ANSI A10.22 Section 11.
b. Useof safetybelts (harnesses)andropegrabs
(lifelines) in accordancewith ANSI A10.22
Sections 11, 12.4and 12.5.
3. Winch operatorsmustbeinstructedin andadhereto
the proceduresestablishedto ensureproper andsafe
operation of this winch asacomponentin aPersonnel
Lifting System.
a. Winch operatorsmustremain atthe winch
controls at all times when handling personneland
materials.
b.
C.
d.
e.
At any indication of winch, or system,damageor
impending dangerthe winch operatormustplace
the winch in asafecondition andnotify
designatedpersonnel.Winch andsystem
operation must besuspendeduntil all
discrepanciesnotedhavebeeninspected,repaired
andsystemtestedto ensuresafeoperation.
Voice communication mustbeestablishedand
maintained betweenwinch operator,personnel
being lifted andpersonnellocatedateachlanding
(asapplicable).
Winch operatorsmustmaintain atleast4 tight
wrapsof wire rope on the drum at all times.
Wire rope shall beweightedon the endto prevent
line run when spooling onto thedrum.
Initial Winch Operating Checks
l Initial operating checks specific to the entire
Personnel Lifting System should be established to
ensure system component compatibility.
Winchesaretestedfor proper operationof all features
prior to shipping. Before the winch is placedinto service
thefollowing initial operating checksshould be
performed.
1. Whenfirst running the motor inject asmall amountof
oil into the inlet connection to provide initial and
immediatelubrication.
2. When first operating the winch run the motor slowly
in both directions for afew minutes.
3. Verify both drum brakesfunction asdescribedin
‘Winch Testing’ in the “WINCH INSPECTION’
section.To adjustthe brakesrefer to ‘Winch
Adjustments’in the “WINCH MAINTENANCE”
section.
11

4. Adjust andverify limit switch settings.To adjustthe
limit switch setpoints referto ‘Winch Adjustments’in
the “WINCH MAINTENANCE” section.
5. Verify line speedmonitor andoverspeedalarm
operationasdescribedin ‘Winch Testing’in the
“WINCH INSPECTION’ section.
6. Verify automaticdrumbrakeemergencyrelease
systemoperationasdescribedin ‘Winch Testing’in
the “WINCH INSPECTION’ section.
Winch Component Operation
Pilot Air Throttle Control Lever
(Referto Dwg. MHTPA0608)
Winch control lever directions aredescribedasviewed
whenfacing thewinch motorandapply to overwind
operationonly. To ensuresmoothoperationof thewinch
suddenmovementsof thecontrol valve should beavoided.
1. To payout wire rope,lift up on thewinch control
lever andmovethelever to theright.
2. To haul in wire rope,lift up onthe winch control
lever andmovethewinch control lever to theleft.
Pilot Air Throttle Control Operation
Haul in Pay out
Directions as
viewed from the
motor end of
winch
(Dwg. MHTPA0608)
Manual Drum Brake
The manualdrum brakemaybeappliedby pushing down
onthebrakehandleandreleasedby pulling up. If the
handleis pusheddown fully, it shouldlock in that position
andpreventdrumrotation, until releasedby the operator.
The brakemustbekeptproperly adjustedto hold the
requiredload.To adjustthebrakerefer to ‘Winch
Adjustments’in the“WINCH MAINTENANCE” section.
Automatic Drum Brake
The automaticdrumbrakeis aspringapplied, air released
brake.Using anair actuated,springloadedcylinder the
brakeautomatically disengageswhenthemotor is
operated.Air pressurein thecylinder overcomesspring
pressureto releasethebrake.Whenthepilot air throttle
control lever is placedin theneutralposition, theair in the
cylinder is ventedandthespring automatically engages
thebraketo preventdrumrotation.
The cylinder clevis mustbekeptproperly adjustedto hold
therequiredload.To adjustthebrakerefer to ‘Winch
Adjustments’in the“WINCH MAINTENANCE” section.
Limit Switch
Pre-setlimit switch settingspreventwinch wire rope
payout andhaul in by stoppingair flow to the winch motor
whenasetpoint hasbeenreached.It is the owner’sand
operator’sresponsibility to adjustwinch operating limits
prior to using the winch to transportpersonnel.To adjust
thelimit switch setpoints refer to ‘Winch Adjustments’in
the “WINCH MAINTENANCE” section.
l Ensure limit switch operates properly and that limits
have been set before using winch to transport
personnel.
Line Speed Monitor and Overspeed Alarm
TheLine SpeedMonitor is abatterypoweredwire rope
line speedindicator systemwhich determinesline speed
by sensingdrumrotation.
The Line SpeedMonitor provides avisual alarm (flashing
redlight) anddigital readout(in feet)to allow the operator
to adjustthrottle control to maintain wire ropeline speed
at 100feetperminute (30.5metresperminute) or less.
Line SpeedMonitors arefactory pre-setto matchthe
winch installed on andcannotbeadjusted.The overspeed
indicator light flasheswhen drum speedexceedswire rope
line speedsof 100feetperminute (+/- 10feet) (30.5
metresperminute; +/- 3 metres)in either direction of
drum rotation.
Winch Emergency Descent Procedure
(Referto Dwgs.MHTPA0669 andMHTPB0636)
l ANSI A10.22-1990 Section 11 defines the Personnel
Lifting System requirements for establishing
emergency escape methods and procedures. The
following procedure describing the use of the winch to
lower personnel or loads when the supply air to the
winch has been interrupted should only be used after
all other established methods have been exhausted.
The lowering speedof the load using the winch descent
procedureis dependentupon the weight of the load,
amountof cableon the drum, andposition of theload in
thelifting system.
To usethewinch to lower theload when the air supply has
beeninterrupted conductthefollowing:
1.
2.
3.
4.
12
Engagethemanualbandbrake.
Depressthe automaticbandbrakeclevis (107) and
removecotterpin (102) andpin (106) to dicsonnect
cylinder (110) from brakelever (105).
Slowly disengagemanualbandbrakeusing the brake
lever (104). Regulatespeedof load using manual band
brake.If load doesnot lower engagebandbrakeand
thenconductthefollowing step.
Removecapscrews(364)from motor adaptervalve
(468)andremovepilot valve/adapterassemblyfrom
winch motor.

5. Usethemanualbandbraketo throttle lowering speed
(if required) when lowering theload.
Training
Prior to using the PersonnelLifting Systemsupervisors,
operators,servicepersonnel,andpersonnelbeing
transportedmustbethoroughly instructed in thepotential
dangersinvolved andthesafetyproceduresestablishedto
minimize therisks of accident,injury andproperty
damage.
Establishmentof safeoperatingproceduresfor the
PersonnelLifting Systemshould bebasedon ANSI
A 10.22specifications, OSHA regulations,all applicable
local, stateandnational standards,systemcomponent
manufacturers’srecommendations,andsystemdesigner
recommendations.
Recordsof training should bemaintainedandmade
available to designatedpersonnelfor review.
To ensurecontinued satisfactoryoperation of the winch,
all points requiring lubrication mustbeservicedwith the
correctlubricant atthepropertime interval asindicated
for eachassembly.
The lubrication intervals recommendedin this manualare
basedon intermittent operationof thewinch eight hours
eachday, five daysper week.If thewinch is operated
almostcontinuously or morethan theeight hourseach
day,morefrequentlubrication will berequired. Also, the
lubricant typesandchangeintervals arebasedon
operationin anenvironment relatively freeof dust,
moisture,andcorrosive fumes.Useonly thoselubricants
recommended.Otherlubricants mayaffectthe
performanceof the winch. Approval for theuseof other
lubricants mustbeobtainedfrom your Ingersoll-Rand
distributor. Failure to observethis precautionmay result in
damageto the winch and/or its associatedcomponents.
INTERVAL
Startof eachshift
LUBRICATION CHECKS
Checkflow andlevelofairline
lubricator(approximately6to9drops
perminuterequiredatmaximum
motorspeed).
Monthly Checkwinchmotoroil level. Lubricatecomponentssuppliedby
greasefittings.
Inspectandcleanorreplaceairline
filter.
Yearly Checkreductiongearoil level. Drainandrefill winchreductiongear
oil.
Drainandrefill winchmotoroil.
Note:Intervalsarebasedonwinchoperationin anormal
environmentasdescribedin the“INSPECTION” section.In
‘Heavy’or‘Severe’operatingconditionsadjustlubrication
intervalsaccordingly.
Recommended Lubricants
Oil
Temperature Type Oil
1. Below 32° F (0° C) SAE l0w
2. 32” to 80°F (0° to 27° C) SAE20W
3. Above 80°F (27° C) SAE30W
Grease
Temperature
1. -20° to 50° F
(-30° to 10°C)
2. 30° to 120°F
(-1° to 49° C)
Motor
Type Grease
EP 1multipurpose
lithium-based grease
EP2 multipurpose
lithium-based grease
(Refer to Dwg. MHTPA0758)
Correct lubrication is oneof themostimportant factorsin
maintaining efficient winch operation.The motor is splash
lubricated by the oil in themotor housing andhasno other
meansof lubrication. It is thereforeimportant to useonly
quality, non-detergentmotor oil to ensuremaximum
performanceandminimum downtime for repairs.Referto
the ‘RecommendedLubricants’ section.Allow oil to settle
beforetopping off.
Oil capacity for the FA2.5MRA winch motor is 3 quarts
(2.8 litres). Add oil through thefill plug opening until oil
flows from the level plug hole. Add oil slowly to prevent
spilling.
The motor should belevel-checkeddaily or atthe startof
eachshift after accumulatedwaterhasbeendrained off.
When motorsareoperatedin temperaturesbelow freezing,
wait long enoughatendof shift for waterto separatefrom
oil but not long enoughfor it to freeze.Drain the water
then refill to thelevel plug. If desired,all the oil may be
drained atthe endof the shift andthemotor refilled with
new oil.
13

Motor Lubrication Locations Reduction Gear Lubrication Plug Locations
Fill Cap
BothSides)
Drain Plug Level Plug
(Dwg. MHTPA0758)
Wire Rope
Follow thewire ropemanufacturer’sinstructions. At a
minimum, observethefollowing guidelines.
1. Cleanwith abrushor steamto removedirt, rock dust
or otherforeign material on the surfaceof the wire
rope.
l Do not use an acid-based solvent. Only use cleaning
fluids and lubricants specified by the wire rope
manufacturer.
2. Apply awire ropelubricant,
Ingersoll-Rand LUBRI-
LINK-GREEN or SAE 30Woil.
3. Brush,drip or spraylubricant weekly, or more
frequently, dependingon severity of service.
Reduction Gear Assembly
(Referto Dwg. MHTPA0140)
Thereductiongearassemblyis filled andshippedwith oil
from thefactory. Checkoil level beforeinitial winch
operation.If thewinch is usedatanormal frequency
replacetheoil in thereduction housing onceevery year.
To ensurecorrectperformance,highestefficiency and
long life, it is essentialthatthelubricating oil be
maintainedatthecorrectlevel. Rotatethedrum until the
fill plug is locatedattop deadcenterthen addoil up to the
level plug hole. Oil capacityfor thereduction gear
assemblyis l-1/2 quarts(1.4 litres).
l Do not over fill. Excess oil will reduce operating
efficiency and increase oil temperature.
Position Drum
\ Reduction Gear
(Dwg. MHTPA0140)
Drum Brakes
Lubricate pivot points, pins andshaftswith recommended
greaseto preventcorrosion of parts.
l Do not allow grease or oil to come into contact with
drum band brake linings.
Disc Brake (optional feature)
Oil from thereduction gearassemblyalsoprovides
lubrication for thediscbrake.After an oil changeor winch
overhaulremovethebreatherplug andpour 6 to 8 fluid
ounces(0.2litres) through thebreatherhole in the brake
housingto initially lubricate thebrakediscs.Referto the
‘RecommendedLubricants’ section.Reinstall thebreather
plug beforeoperationof winch or brakes.
Seals and Bearings
If winch is disassembled,cleanall partsthoroughly and
coatbearingsandsealswith cleangrease.Referto the
‘RecommendedLubricants’ section.Usesufficient grease
to provide agoodprotective coat.Lubricate greasefittings
monthly with 2 or 3pumpsof agreasegun.
Air Line Lubricator
Replenishlubricator daily andsetto provide 6 to 9 drops
of oil perminute. Referto the ‘RecommendedLubricants’
sectionfor recommendedoil.
Wire Rope Line Speed Monitor
Doesnot requirelubrication.
Limit Switch
Doesnot requirelubrication.
Therecommendedgradeof oil mustbeusedat all times
sincetheuseof unsuitableoil mayresult in excessive
temperaturerise,lossof efficiency andpossibledamageto
thegears.Referto the ‘RecommendedLubricants’ section.
Useonly high quality lubricants in thereduction gear
assemblysuchasmotor oil, high gradeEPtype hydraulic
oil or their equivalents.
14

Inspection information is basedin partonAmerican
National StandardsInstitute SafetyCodes(A10.22 and
B30.7).
Records and Reports
Personnel Lifting System
Ownersareresponsiblefor establishingandimplementing
operation andsafetyproceduretraining for all personnel
involved in theuseandoperationof aPersonnelLifting
System.
1. PERSONNELTRAINING. Recordsof training
provided to supervisors,operators,servicepersonnel
andpersonnelbeing transportedshouldbemaintained
andmadeavailable to designatedpersonnelfor
review.
2. SYSTEM MAINTENANCE. Recordsof all service,
maintenanceandtesting performedon thePersonnel
Lifting Systemshouldbemaintainedandmade
available to designatedpersonnelfor review.
Winch Records and Reports
Inspection records,listing all points requiring inspection,
should bemaintainedfor all loadbearingequipment.
Written reports,basedon Initial, Weekly and Quarterly
inspections, shouldbemadeon thecondition of critical
partsasamethodof documentinginspections.These
reports should bedated,signedby thepersonwho
supervisedtheperformanceof theinspection,andkept on
file wherethey arereadily available for review. A sample
winch ‘InspectionandMaintenanceReport’hasbeen
provided attheendof this section.
Wire Rope Reports
Recordsshould bemaintained aspartof along-rangewire
ropeinspection program.Recordsshouldinclude the
condition of wire roperemovedfrom service.Accurate
recordswill establisharelationship betweenvisual
observationsnotedduring frequentinspectionsandthe
actual condition of wire ropeasdeterminedby periodic
inspections.
PersonnelLifting Systemwire roperecordsshould be
maintained andmadeavailable to designatedpersonnelfor
review.
System Inspections and Tests
l Information provided by Ingersoll-Rand is applicable
only to the winch to assist in determining the condition
of the winch components described. References to
other Personnel Lifting System components are made
with respect to their relationship to the winch. For
specific information on system components other than
the winch, reference the manufacturers’ literature and
ANSI A10.22.
PersonnelLifting Systeminspections andtestsof installed
components,functions andsafetydevicesshould be
establishedbasedon proceduresderived from ANSI
A10.22 specifications,OSHA regulations, manufacturers’
literature andrecommendations,systemdesigner
recommendationsandall applicable local, stateand
national standards.
1. SYSTEM. Frequencyof inspections:
a. Initial systeminspection.
b. Daily checksandWeekly inspections.
c. Quarterly inspections.
System Initial and Quarterly Inspections
In addition to establishedDaily andWeekly inspections
conduct the following:
l The static drop test is only required for guided cage
systems.
1.
2.
INITIAL INSPECTION. With the cage at rated load,
on a guided cage system, using deadweights,
conduct astaticdrop test.This testis designedto
ensurethecagesafetyclampsengageandstopthe
cagefrom falling. Performrequirementsof the weekly
inspection.
QUARTERLY INSPECTION. With thecage empty,
on a guided cage system, conduct astatic drop test.
This testis designedto ensurethecagesafetyclamps
engageandstopthe cagefrom falling. Perform
requirementsof the weekly inspection.
System Testing
PersonnelLifting Systemtesting should beconductedin
accordancewith the systemspecific instructional manual
andcomponentmanufacturers’recommendations.A
systemspecific instruction manual mustbecompiled to
conform to therequirementsof ANSI A10.22, anddetail
the operation,maintenanceandsafetyrequirementsof the
various componentscomprising thepersonnellifting
system.
Winch Inspections
The following listed inspections apply only to the winch.
Theseinspectionsshould beconductedwhen scheduled,
when indicated by winch performanceandwhen the winch
is disassembledfor repair.
Careful inspection on aregular basiswill reveal
potentially dangerousconditions while still in the early
stages,allowing corrective action to betakenbeforethe
condition becomesdangerous.
15

Damagerevealedthrough inspection, or notedduring
operation,mustbereportedto designatedpersonnel
instructedin safety,operationandmaintenanceof this
equipment.A determinationasto whetheracondition
constitutesasafetyhazardmustbemade,andthe
correctionof notedsafetyhazardsaccomplishedand
documentedby written report beforeplacing the
equipmentin service.
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.
l Prior to using the winch to lift personnel, an initial
inspection should be conducted after assembly, major
repairs or alteration, and when the system has been
idle for periods of longer than one month.
Daily checks,weekly andquarterly inspectionsshould be
performedonequipmentin regular use.
1. Daily checks arevisual examinationsperformedby
operatorsor personnelinstructedin safetyand
operationof this equipmentandinclude observations
madeduring routine equipmentoperation.
2. Weekly inspections arethorough inspections
conductedby personnelinstructedin safety,operation
andmaintenanceof this equipment.Weekly
inspectionsarealsorequiredprior to personnellifting
if thesystemhasbeenidle for periodsin excessof one
week,but lessthanonemonth.
3. Quarterly inspections areacombination of weekly
inspectionrequirementsandtheperformanceof a
staticdroptest on guided cage systems only to verify
operationof thecage’ssafetyclamp.
Winch Daily Checks and Weekly Inspections
On equipmentin continuousservice,weekly inspections
arerequired.Maintain written recordsof weekly
inspectionsto provide anaccumulativebasisfor
continuing evaluation.Disassemblymayberequired asa
result of inspectionfindings.
In addition, daily checks,or visual inspectionsshould be
conductedby operatorsduring regular operation for
damageor evidenceof malfunction.
1. WINCH (DAILY). At thebeginning of the shift, prior
to operation,visually inspectwinch housings,
controls,brakes,siderailsanddrum for indications of
damage.Do notoperatethe winch until all
discrepanciesnotedhavebeenreviewed, inspected
further andcorrectedby personnelinstructed in the
operation,safetyandmaintenanceof this winch.
WINCH (WEEKLY). Inspectthe following:
a. SIDERAILS AND END UPRIGHTS. Check for
deformed,crackedor corrodedmain components.
Replacedamagedparts.
b. FASTENERS.Checkretainerrings, split pins,
capscrews,nuts,andother fastenerson winch,
including mounting bolts. Replaceif missing or
damagedandtighten if loose.
c. DRUM AND SHEAVES.Checkfor cracks,wear
or damage.Replacedamagedparts.
2. WIRE ROPE.Visually inspectall wire rope which
canbeexpectedto bein useduring the day’s
operations.Inspectfor wearanddamageindicated by
distortion of wire rope suchaskinking, “birdcaging,”
coreprotrusion, main stranddisplacement,corrosion,
brokenor cut strands. If damageis evident, do not
operatewinch until the discrepancieshavebeen
reviewedandinspectedfurther by anexperienced
wire ropeinspector.
l 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 the
following instructions.
In addition to daily checkrequirements,alsoinspect
for the following weekly:
a. Ensurewire ropeis spooledonto the drum for
overwind operationonly andthat aminimum of 2
inches(50mm) clearanceis maintained between
theoutsideedgeof thedrum flange andthe
outermostlayer of wire rope.
b. Buildup of dirt andcorrosion. Clean with steam
or astiff wire brushto removedirt andcorrosion
if necessary.
c. Loose,frayedor damagedendconnection.
Replaceif loose,frayed or damaged.Ensureends
will not catchon personnel.
d. Ensurethe wire ropeis securelyanchoredin the
winch drum.
e. Verify wire ropediameter.Measurethe diameter
of thewire ropefrom crown-to-crown throughout
thelife of thewire rope.Recording of the actual
diametershould only bedonewith the wire rope
underequivalent loading andin the same
operatingsectionasaccomplishedduring
previousinspections.If the actualdiameterof the
wire ropehasdecreasedmorethan l/64 inch (0.4
mm)athorough examination of the wire rope
shouldbeconductedby anexperiencedinspector
to determinethe suitability of the wire rope to
remainin service.(Referto Dwg. MHTPA0056).
Crown
to
Crown
16

3.
4.
5.
6.
7.
8.
9.
AIR SYSTEM (WEEKLY). Visually inspect all
connections,fittings, hosesandcomponentsfor
indication of air leaks.Repairany leaksandreplace
damagedcomponents.
CONTROLS (DAILY AND WEEKLY). During
operationof winch, verify responseto control is quick
andsmooth.If winch respondsslowly or movementis
unsatisfactory,do not operatewinch until all problems
havebeencorrected.
BRAKES (WEEKLY). Ensureproperoperation.
Verify eachbrakesystemwill hold a 150%ratedload
with full drum (asapplicable to normal use)without
slipping. If indicated by poor operation or visual
damage,disassembleandrepair brake(s).Checkall
brakesurfacesfor wear,deformation or foreign
deposits.If drum brakelining thicknessis 0.062inch
(2 mm) or lessanywhere along its edgereplacebrake
bandsor linings. Clean andreplacecomponentsas
necessary.Testeachbrakesystemindependently.
LIMIT SWITCHES (WEEKLY). Verify winch limit
switchesoperateatthe setlimits. Whenactuated,limit
switchesinterrupt air flow to themotor in the
direction of winch operation only. Adjust limit
settingsor repair to correctall noteddiscrepancies.
ALL COMPONENTS (WEEKLY). Inspectfor wear,
damage,distortion, deformation andcleanliness.If
external evidenceindicates damage,disassembleas
required to conduct adetailedinspection. Inspect
gears,shafts,bearings,springsandcovers.Replace
worn or damagedparts.Clean,lubricate and
reassemble.
SUPPORTINGSTRUCTURE (WEEKLY). Checkfor
distortion, wearandcontinued ability to support
winch. Ensurewinch is firmly mountedandthat
fastenersarein good condition andtight.
LABELS AND TAGS (WEEKLY). Checkfor
presenceandlegibility of labels. Replaceif damaged
or missing.
10. WIRE ROPELINE SPEEDMONITOR. Verify Line
SpeedMonitor displays line speedandoverspeed
alarmlights at 100feetper minute (+/- 10feet) (30.5
metresperminute; +/- 3 metres).If battery charge
light is on, chargebattery.
11. WINCH EXHAUST AND MUFFLER. Visually
inspectexhausthoses,connectionsandmuffler for
damage.Ensurepiping andmuffler arecorrectly
installed anddirect exhaustawayfrom winch
operator.Operatornoiselevels mustnot exceed90
dBA over an8 hour period (Time WeightedAverage
(TWA)).
12. Ensureelectrical ground (earth)is firmly connected
andthat wire is in goodcondition. Replacewire if
corrodedor damaged.
Winch Initial and Quarterly Inspections
Disassemblymay berequired asaresult of inspection
findings or in orderto properly inspectthe individual
components.Maintain written recordsof initial and
quarterly inspectionsto provide anaccumulative basisfor
continuing evaluation. Inspect all itemslisted in “Weekly
Inspection.” Also conduct the following:
1. INITIAL INSPECTION. Conduct all requirementsof
‘Winch Daily andWeekly Inspection’ and‘Winch
Testing’.
2. QUARTERLY INSPECTION. Conduct all
requirementsof ‘Winch Daily andWeekly Inspection’
and‘Winch Testing’.
Winches Not in Regular Service
1. Equipment which hasbeenidle for aperiod of one
weekor more,but lessthan onemonth, shall begiven
aninspection conforming to therequirementsof
“Daily andWeekly Inspections” beforebeing placed
in service,
2. Equipment which hasbeenidle for aperiod of over
onemonth shall begiven ancompleteinspection
conforming with therequirementsof “Initial and
Quarterly Inspections” beforebeing placedin service.
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INSPECTION AND MAINTENANCE REPORT
Ingersoll-Rand Force 5 Series Ansi Manrider® Air Winch
Model Number:
Serial Number: Date:
Inspected by:
Reason for Inspection: (Check Applicable Box)
1.ScheduledInspection ( _ Weekly _ Quarterly _ Initial)
2. Discrepancy(s)notedduring Daily Inspection OperatingEnvironment:
3. Discrepancy(s)notedduring maintenance
4. Other: Normal _ Heavy _ Severe_
Refer to the Parts, Operation and Maintenance Manual “INSPECTION” section for general inspection criteria. Also, refer to appropriate
and codes of practice.. If in doubt about an existing condition contact the nearest Ingersoll-Rand Distributor or the factory for technical assistance.
CONDITION CORRECTIVE
COMPONENT ACTION NOTES
Pass Fail Repair Replace
SideRails andEnd
Uprights
Manual Drum Band
Brake
(150%LoadTest)
AutomaticDrum Band
(150%LoadTest)
Drum BandBrakes
(Visual Inspection)
Motor
Limit Switches
Controls
Air System
TESTING
Onerational(No Load) Pass Fail NOTES
Operational (10% Load)
Onerational(Maximum TestLoad *)
*
Maximum winch operational test load is 125% of rated line pull.
Maximum brake test load is 150% of rated line pull; perform by raising the test load approximately 4 to 6 inches (100 to 150 mm).
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This sectionprovides basictroubleshooting information. Determination of specific causesto problemsarebestidentified by
thorough inspectionsperformedby personnelinstructed in safety,operation andmaintenanceof this equipment.The chart
below provides abrief guide to commonwinch problems,probablecausesandsolutions.
PROBLEM
Winch will not operate.
Loadcontinuesto movewhen
winch is stopped.
Winchdoesnot lift load.
Motormaybedamaged.
Throttlelever movesbut winch
doesnot operate.
Motorrunshot or makes
excessivenoiseduring
operation.
Winchrunsslow.
CAUSE
No air supply to winch.
Winchisoverloaded.
Automaticdrumbandbrakedoesnotrelease.
Limit switchengaged.
Shipping plugs maystill bein place.
Automatic drumbandbrakeis slipping.
Winch is overloaded.
Pilot air throttle control valve sticking.
Insufficient air supply.
Automatic drumbandbrakeor optional disc
brakedo not release.
Motor maybedamaged.
Insufficient air supply.
Limit switch engaged.
Lowoil level.
Improperlubrication.
Waterin oil.
Damagedor brokenpiston or connecting rod.
Improperhoseor fitting sizes.
Motor maybedamaged.
SOLUTION
Checkair supply line connectionsandhoses.
Reduceload to within ratedcapacity.
Pressurizebrakereleaseportandcheckforleakage.
Replacebrakepistonsealsif leakageisfound.
Shift pilot valve throttle lever in oppositedirection.
If winch operates,adjustlimit switch settings.
Removeshipping plugs in valve andmotor exhaust
ports.
Checkbrakebandadjustmentandbrakebandlining
wear.
Reduceloadto within ratedcapacity.
Disassemble,inspectandrepairthepilot air throttle
control valve.
Removeanddisassemblemotor.Examine all parts
andreplaceany that areworn or damaged.
Verify air supply pressureandvolume atwinch inlet
meetstherequirementslisted in the
“SPECIFCATIONS”section.Cleanairlinefilter.
Dissassemble,inspectandrepairthe automaticdrum
bandand/oroptional discbrake.
Disassembleandcleanthe motorandreplaceany
brokenor damagedparts.
Ensurethe air pressureatthe winch inlet is at least
POpsig (6.2bar)atratedvolume. Cleanair line
filter.
Shift pilot valve throttle lever in oppositedirection.
If winch operates,adjustlimit switch settings.
Checkoil level in the motor.Add oil asrequiredto
obtaintheproperlevel.
Replaceoil with type recommendedin the
“LUBRICATION” section.
Drain andrefill with recommendedoil. Operate
winch with no load slowly, in both directions. If
noisestill existsor motoroverheatsdisassembleand
repairmotor.
Disassembleandrepairmotor.
Checkfittings, connectionsandhosesfor correct
sizeandlength. Replacepartsthat maycause
restrictedair flow. Inspectair line filter.
Removeanddisassemblemotor asdescribedin the
“MAINTENANCE” section.Inspectall partsand
replaceall worn or damagedparts.
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