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