Ingersoll-Rand Force 5 MANRIDER FA2MRA User manual

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

Form MHD56082
PARTS, INSTALLATION AND OPERATION MANUAL
AIR
WINCHES
MODEL
FA2MRA MANRlDER* WINCH
* These instructions apply only to winches designed by Ingersoll-Rand 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 830.7) and all other applicable
local, state and federal safety codes and regulations.
Form MHD56082
Edition 4
November 1994
71146013
© 1994 Ingersoll-Rand Company
MATERIAL HANDLING

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 an injury. The
following signal wordsareusedto identify the level of
potential hazard.
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
importantbut not hazard-related.
Safety Summary
l This winch wasdesignedto meetANSI A10.22-1990
which limits its useaspart of a systemfor personnel
lifting. There are other components required to
complete the system.It is the usersresponsibility to
supply all other components necessaryto properly
completethe lifting systemin 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 useof a winch or
winch systemfor lifting and lowering people before
using a Man-Rider@ winch for personnel movement.
l The supporting structures and load-attaching devices
usedin conjunction with this winch must provide an
adequatesafety 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@ winchesaredesignedand
manufacturedto meetor exceedstandardsand
specificationsestablishedfor basemounteddrumhoistsas
definedby ASME B30.7 andfor thepurposeof personnel
handling asdefinedby ANSI A 10.22- 1990.
In furnishing customersMan-Rider@ winches,
Ingersoll-Rand doesnot warrant thesuitability of these
winchesfor any particular use.It isthe owner’s anduser’s
responsibility to determinethe suitability of this winch for
aparticular application.
Ingersoll-Rand Man-Rider@ winchesmanufacturedto
ANSI A10.22standardsaredesignedasacomponentin
thePersonnelLifting System.Ingersoll-Rand approval
for useof this winch in Man-Rider® applications
automaticallyterminatesfor any of the following reasons:
1.
2.
3.
4.
5.
Winch is not installed inan approvedpersonnellifting
system.
Winch is not properly maintained in a safeworking
condition, with all partsintact andproperly adjusted.
Winch is usedin applications not approvedby codes
andregulations, or application is inconsistentwith
manufacturer’soperation andmaintenancemanual.
More than onewinch is usedto attachto acommon
load.
Winch designor functions arealteredor changedin
anymannerfrom the purchasedoriginal without prior
approvalby Ingersoll-Rand.
This manualhasbeenproducedby Ingersoll-Rand to
provide companypersonnel,dealers,mechanicsand
operatorswith the information requiredto install, operate,
andmaintainthe productsdescribedherein.
It is extremelyimportant that mechanicsandoperatorsbe
familiar with the servicing proceduresof theseproducts,or
like or similar products, andarephysically capableof
conductingtheprocedures.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 repairsmaybe
conductedandthe hazardsand/or resultsof eachmethod.
If operationor maintenanceproceduresnot specifically
recommendedby the manufacturerareconducted,it must
beensuredthat product safetyis not endangeredby the
actionstaken.If unsureof anoperation or maintenance
procedureor step,personnelshouldplacethewinch in a
safecondition andcontactsupervisorsand/orthefactory
for technicalassistance.
2

The following warnings andoperating instructions have
beenadaptedin part from AmericanNational (Safety)
StandardsASME B30.7 andANSI A10.22, andare
intendedto avoid unsafeoperatingpracticeswhich might
leadto injury or property damage.
Ingersoll-Rand recognizesthat mostcompanieswho use
wincheshaveasafetyprogram in forceattheir facility. In
the eventthat aconflict existsbetweenarule setforth in
this publication andasimilar rule alreadysetby an
individual company,the morestringent of the two should
takeprecedence.
l Failure to follow theseoperating instructions may
result in death or property damage.Ingersoll-Rand
assumesno liability for any lossor damageresulting
from operation of Man-Rider@ winches if these
operating instructions are not followed.
SafeOperatingInstructions areprovided to makean
operatorawareof dangerouspracticesto avoid andarenot
necessarilylimited to the following list. Referto specific
sectionsin the manualfor additional safetyinformation.
1.
2.
3.
4.
5.
Winch operatormustbe in vocal contactwith
personnelbeing lifted (lowered) fromtransferpoint to
landing area.
Personnelsupervising,operatingthewinch and
personnelbeingtransferredareto beinstructed in
systemoperationandsafetyprior to personnellifting.
Only operateawinch if you arephysically fit to do
so.
Useof awinch to transport personnel(lifting and/or
lowering) should only takeplacewhenother meansof
accomplishingthis work arenot practical.
Whena“DO NOT OPERATE” sign is placedon the
winch, or winch controls, donot operatethe winch
until the signhasbeenremovedby designated
personnel.
Never lift aloadgreaterthan theratedcapacity of the
winch. Referto “SPECIFICATIONS” sectionfor
applicable utility andManRider®capacityratings.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Prior to use,inspectandtestthe personnellifting
systemto therequirementsof ANSI Al 0.22 Section
13(Inspection andTests).The winch operatorshallbe
instructed in the operation of this winch andthe
personnellifting systemper ANSI Al 0.22 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
defined in ANSI A10.22.Referto the
“INSTALLATION” section.All bolts and
foundations for winch attachmentmusthaveahigher
load carrying capacityrating thanthe maximum
capacity of the winch.
Do not operateadamagedwinch.
Do not operateawinch that hasnot beenproperly
maintainedor equipped.
Do not operatewinch with anypersonnelnearthe line
of force or capableof coming into contactwith
moving parts.
Labelsandwarning noticesmustremain permanently
posted,andbeclearly visible onthe winch.
Easethe slackout of thewire ropewhen startingalift.
Do notjerk the load.
Never leaveasuspendedload unattended.
Wire ropemustspool off drum from thetop away
from the operator(overwind). The direction of lift is
counterclockwise whenviewed from themotor endof
the winch.
Make surethe wire rope is properly anchoredto the
winch drum.Always maintain aminimum of four
tight wrapsof wire rope on the drum.
Payattentionto the load at all timeswhenoperating
the winch.
Never usethe winch wire rope asa sling.
Do not leavea load suspendedwhen winch is not in
use.
Ensuremuffler is positioned atthe point furthest away
from winch operator.
Do not uselimit switch settingsto regulatethe winch
stopping points. Limit switchesaredesignedasa
backupto operatoraccidentalover travel only.
Ensurethe endof thewire rope is weighted to prevent
line run.

Eachunit is shippedfrom the factory with thewarning
label shown If thelabel is not attachedto your unit, order
anew label andinstall. Seethepartslist for the part
number.Label isshownsmallerthanactual size.
WARNING
General Specifications
BatedOperatingPressure
Model
FA2-Utility Ratings FA2-ManRider® Ratings
90psig (6.2 bar)
Air System
Performance
(at rated pressure/ volume)
ConsumptionVolume
(atratedpressure) 335 scfm
BatedFull Drum Line Pull *
Line Speed- 3rdLayer
Max Stall Pull - 1stLayer
FA2MRA Net Weight 720lbs
Air Motor Pipe Inlet Size
Minimum Air SystemHoseSize
Drum Wire RopeStorage
r
Capacity **
(feet/ metres)
Drum Length (inches)
24
Wire Rope Diameter
808ft
..
* FA2 Utility rating of 3,500lbs.(1,558kg) is basedonrequirementsof ASME B30.7(5:1designfactorwith 7/l6 inch
(11 mm)wire rope.)
FA2 Manrider® rating of 2,200lbs. (1,000kg) isbasedonrequirementsof ANSI Al0.22 (8:1designfactorwith 7/16
inch (11mm)wire rope.)
** FA2 ManRider® wire ropestorageis basedon awinch with a 19inch (483 mm)diameterdrum flangeandon ANSI
Al0.22 standardswhich requirethe top layer to beatleast2 inches(51 mm)below thedrum flangediameter.
FA2 Utility wire ropestorageis basedon awinch with a 19inch (483 mm)diameterdrum flangeandon ASME/ANSI
B30.7 standardswhich requirethe top layer to beatleastl/2 inch (13 mm)belowthedrum flange diameter.
Capacitiesshownmayvary fromthosepublishedelsewhere.

Series (Capacity):
Model FA2 PersonnelLifting - 1.0metric tons / 2,200
lbs.
Utility Lifting - 1.6metric tons /3500 lbs.
Designation:
* MRA = Man Ride& ANSI A10.22-1990
Drum Length (Distance betweendrum flanges):
8 = 8 inch (203 mm)
12 = 12 inch (305 mm)
16 = 16 inch (406 mm)
24 = 24 inch (610 mm) [Standard]
30 =
30 inch (762 mm)
Brake: M = Manual Drum Brake [Standard]
A
K = Automatic Disc Brake
Control: 1 = Winch mounted lever throttle (Standard)
2xx
3xX
4xx
Options:
Z
P
G
7
= Drum Grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch)
*
= Automatic Drum Brake [Standard]
= Remote full flow lever throttle (XX = Specify hose length (feet). Max 20 ft. (6 metres)) **
= Remote pilot pendant throttle (XX = Specify hose length (feet). Max 50 ft. (15 metres)) **
= Remote pilot lever throttle. (XX = Specify hose length (feet). Max 50 ft. (15 metms)) **
= Sand blast and Carbozinc primer only
= Marine 812 top coat
= Drum Guard
Standard Features: (1) Line Speed Monitor.
(2) Adjustable upper and lower rotary limit switches.
(3) Piped away exhaust with muffler and 10 feet (3 meters) of exhaust hose.
(4) Copy of Operation and Maintenance Manual and ANSI A10.22 Standard supplied in
container attached to winch.
Model Code Explanation:
Example: FA2MRA24MAlG FA2 MRA 24 1
G
(5) Dual brakes (manual and automatic drum band brakes.
(6) Winch mounted automatic return, pilot air valve throttle lever.
**
Remote throttles are provided with 10 feet (3 metres) of hose. Specify hose lengths greater than IO feet. For lengths greater
than 20 ft. (6 metres) with the Remote Full Flow Throttle, or 50 ft. (15 metres) with the Remote Pilot Lever and Remote
Pilot Pendant Throttles contact Technical Sales for control acceptability. Metric lengths for reference only, order hose
lengths in feet.
Note: FA2MRA winches are shipped with a muffler, 10 feet (3 m) of exhaust hose and the necessary assembly attachments to
install the muffler at a distance far enough away from the operator to ensure noise level exposure of less than 90 dBA over
an eight hour period (Time Weighted Average (TWA)). The recommended distance is based on noise levels recorded
during factory testing. Refer to the “INSTALLATION” section for additional information.

Prior to installing the winch, carefully inspectit for
possibleshipping damage.
Winchesaresupplied fully lubricatedfromthe factory.
Before operationcheckoil levelsandadjustasnecessary.
Usethe propertype of oil asrecommendedin the
“LUBRICATION” section.
l Owners and users are advised to examine specific,
local or other regulations, including ANSI A10.22,
ASME B30.7and/or OSHA Regulations which may
apply to a particular type of useof this product before
installing or putting winch to use.
Mounting
Caremustbetakenwhenmoving, positioning or mounting
the winch. In mostcases,lifting lugshavebeenprovided
to assistin handling the winch. If thelug locations are
improper for your specific installation, greatcareshould
betakento ensurethat thewinch, whenlifted, will be
properly balanced.Determinetheweight of your winch by
referring to the “SPECIFICATIONS” section.Lift the
winch 3 to 4 inches(75 to 100mm)off theground. Verify
winch is balancedandsecurebeforecontinuing lift.
l Care must betaken 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 cablesto the
foundation structure when lifting and supporting the
winch assembly.
l Install the wire rope to comeoff the drum for
overwind operation ONLY. Failure to correctly spool
the wire rope will result in falling load, which can
causesevereinjury, death and property damage.Refer
to Dwg. MHTPA0661.
1.
2.
Ensurethewinch is positionedin amannerthat allows
for properspooling of thewire rope ontothe drum.
Wheninstalled correctly, thedirection of lift is
counterclockwiseasviewed fromthemotor endof the
winch (clockwise from outboardendof winch). Refer
to Dwg. MHTPA0661.
Mount thewinch sothe axis ofthe drumis horizontal
andthatthe motor vent capisnot morethan 15°off
top vertical center.If thewinch is to bemountedin an
inverted position, themotorcasemustberotatedto
position the vent capatthetop.
3. Thewinch mounting surfacemustbeflat andof
sufficient strengthto handlethe ratedload plus the
weight of thewinch andattachedequipment.An
inadequatefoundation maycausedistortion or
twisting of thewinch uprights and siderails resulting
in winch damage.
a. Make surethemounting surfaceis flat to within
l/l6 inch (2.0mm).Shim if necessary.
FA MRA SeriesWinch 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 nutsor nutswith
lockwashers.Referto Dwg. MHTPA0133 andTable 1
for mounting dimensioninformation. To determine
clamping loadtensileandshearstrengthrequirements
referto Dwg. MHTPA0606 andTable 2.
Winch Bolt Hole Mounting Dimensions
(Dwg. MHTPA0133)
6

Table 1
Bolt Hole Dimensions
Dimension Drum Length (inches)
24
in. 20
“A”
in. 11.5
"B"
0.6875
FA SeriesWinch Foundation Bolt Forces
Calculated for 1st Layer stall load (9,000 lbf)
1StLayerLine
Front
Maximum
shearforceat one
Totaltensile foundationbolt
loadwhichis connection
sharedbythe rearfoundationbolts
(Dwg. MHTPA0606)
Table 2
WinchFoundation Bolt Forces
Force Acting on Bolt Drum Length (inches)
Maximum Shear
Force at One
2,050
Foundation Bolt
Connection
Maximum Tensile
Force Shared by
lbf
10,270
Rear Foundation
Bolts
5. If 5/8 inch (16 mm)Grade8 mounting bolts areused,
tighten evenly andtorqueto 220 ft. lbs. (298 Nm) for
dry threadfasteners.If the fastenersareplated,
lubricated or athreadlocking compoundis used,
torqueto 170ft. lbs.(230Nm).
6. Maintain afleet anglebetweenthesheaveandwinch
of no morethan l-1/2°. The leadsheavemustbeon a
centerline with the drum andfor every inch of drum
length, beat least1.6feet(0.5 metre)from the drum.
Referto Dwg. MHTPA0487.
7. Do not weld to anypart of the winch.
Wire Rope
l Do not usewire rope which is lessthan 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 (50 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.
Lead Sheave
Note 1
Notes:
1. Maintain a minimum of 3 tight wraps of wire rope on
drum; 4 wraps required on MRA units.
2. 0.5 inch (13 mm) minimum allowed distance from top
wire rope layer to flange edge; 2 inch (51mm) minimum
on MRA units.
3. ‘A” = 1.6feet (0.5 metre) per inch of drum length; eg.,
for 12 inch drum length locate lead sheave 19.2 feet
(5.9 metres) from drum.
(Dwg.MHTPA0498)
Wire Rope Selection
Consult areputablewire ropemanufactureror distributor
for assistancein selectingthe appropriatetype andsizeof
wire ropeand,wherenecessary,aprotective coating. Use
awire ropewhich provides anadequatesafetyfactorto
handlethe actualworking load.
Whenconsideringwire roperequirementstheactual
working load must include not only the staticor dead
load but alsoloadsresulting from acceleration,retardation
andshockload. Consideration mustalsobegiven to the
sizeof the winch wire rope drum, sheavesandmethodof
reeving. Wire rope construction mustbe6 X 19or 6 X 37
IWRC right lay to permit correct installation of wire rope
anchor.Referto Table 3 for applicablewire rope sizes.

Table 3
Minimum and Maximum Wire Rope Size
I I
Minimum I Maximum
Model inch
5/8
7/16
* 7/l6 inch (11mm)wire ropemustbeusedon FA2
winchesusedfor personnellifting to conformto ANSI
Al 0.22standards.
l Useonly 7/16 inch (12 mm) wire rope on the
FA2MRA winch if used for personnel handling.
Installing Wire Rope
(Referto Dwg. MHTPA0166)
1. Cut wire ropeto length in accordancewith thewire
ropemanufacturer’sinstructions.
2. Feedthe endof the wire ropeinto the wire rope
anchorhole in the drum andpull through
approximately onefoot (305mm)of wire rope.
Wire
Split Wedge
(Dwg. MHTPA0166)
3. Wrapthewire rope with wire adistancefromthe end
equalto thewedgelength plus oneinch (25mm).
4. Slide the sleeveover theendof the wire ropesothe
larger diameterof the taperboreis nearesttheendof
thewire rope.
5. Spreadthe endstrandsof thewire rope andinsertthe
split wedgeuntil it is below theendof the wire rope.
6. Pull the sleeveover thewire ropeenduntil tight.
Checkthat thewire ropestrandsstayin theslots
locatedon thesplit wedge.
7. Pull the wire rope anchorinto position in thedrum
anchorpocket.
SafeWire Rope Handling Procedures
1. Always usegloveswhenhandling wire rope.
2. Never usewire ropewhich is frayedor kinked.
3. Neverusewire ropeasasling.
4. Always ensurewire ropeis correctly spooledandthe
first layer is tight againstthe drum.
Wire RopeSpooling
To compensatefor unevenspooling andthe decreasein
line pull capacity asthe drum fills up,useasshortawire
ropeaspractical. Whenrewinding applytensionto the end
of thewire ropeto eliminate line slack.This helpsachieve
level winding andtight spooling.
l Wire rope must bespooledat least2 inches (51 mm)
below the outer diameter of the drum flange. Refer to
Dwg. MHTPA0498.
Rigging
Make sureall wire ropeblocks,tackleandfastenershavea
sufficient safetymargin to handletherequired load under
all conditions. Do not allow wire ropeto contactsharp
edgesor makesharpbendswhich will causedamageto
wire rope,usea sheave.Referto thewire rope
manufacturer’shandbookfor proper sizing,useand careof
wire rope.
SafeInstallation Procedures
1.
2.
3.
4.
5.
Do not usewire ropeasaground(earth) for welding.
Do not attachawelding electrodeto winch or wire
rope.
Never run the wire ropeover asharpedge.Usea
correctly sizedsheave.
Whenaleadsheaveisused,it mustbealigned with
the centerof the drum.The diameterof the lead
sheavemustbe at least18timesthediameterof the
wire rope. Referto Dwg. MHTPA0498.
Always maintain atleastfour full, tight wrapsof wire
ropeon the drum.
Air Supply
The air supply mustbecleanandfreefrom moisture.
Air Lines
The inside diameterof thewinch air supply lines mustnot
belessthanthe sizesshownin Table4. Beforemaking
final connections,all air supply lines shouldbepurged
with clean,moisture freeair or nitrogen beforeconnecting
to winch inlet. Supply lines shouldbeasshort andstraight
asinstallation conditions will permit. Long transmission
lines andexcessiveuseof fittings, elbows,tees,globe
valvesetc.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
succeedingwrap istight against the previous one.
8

Table 4
Minimum Allowable Air Supply Line Sizes
Model
FA2
Air Line Lubricator
(Referto Dwg. MHTPA0191)
Always useanair line lubricator with thesemotors.The
lubricator musthavean inlet andoutlet at leastaslargeas
the inlet onthe motor. Install theair line lubricator as
closeto the air inlet on the motor aspossible.
l Lubricator must be located no more than 10ft. (3 m)
from the motor.
The air line lubricator should bereplenisheddaily andset
to provide 6 to 9 dropsper minute of SAE 10Woil. A fine
mist will beexhaustedfrom thethrottle control valve
whenthe air 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 beforethe lubricator, to preventdirt from enteringthe
motor. The strainer/filter should provide 20 micron
filtration andinclude amoisturetrap. Cleanthe strainer/
filter periodically to maintain its operating efficiency.
Regulator
Air Out
Lubricator
(Dwg. MHTPA0191)
Moisture in Air Lines
3’
Air In
Filter
Moisture thatreachesthe air motor through air supply
lines is aprimary factor in determining the length of time
betweenserviceoverhauls.Moisture trapscanhelp to
eliminate moisture.Othermethods,suchasanair receiver
which collectsmoisturebeforeit reachesthe motor, an
aftercooleratthe compressorthat coolsthe air to condense
andcollect moistureprior to distribution through the
supply lines arealsohelpful.
Motor
For optimum performanceandmaximumdurability of
parts,provide anair supply of 90 psigat335 scfm(6.2
bar/620kpaat 10cum/m) for FA2 winches.The air motor
shouldbeinstalled asnearaspossibleto the compressoror
air receiver.Recommendedpressuresandvolumes are
measuredatthe point of entry to the air motor.
Electrical Grounding
l The Personnel Lifting Systemmust beproperly
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 codesand
ordinances.
An electrical grounding lug is attachedto the winch
siderail. Ensurewinch is correctly groundedto the
PersonnelLifting Systembeforeusing winch.
Wire Rope Line SpeedMonitor
Ensurethe indicator sensoris adjustedasdescribedin the
“WINCH ADJUSTMENTS” section.
Motor Exhaust and Muffler
(Referto Dwg. MHTPA0646)
l Operator exposure to noise levels shall not exceed90
dBA over an 8 hour period (Time Weighted Average
(TWA)). Ensure motor and pilot valve air is properly
exhausted and muffled.
Winch noise level ratings underfactory testconditions:
1. 83dBA during operation of winch without load in the
haul in direction.
2. 87 dBA during operation of winch without load in the
pay out direction.
Theselevelswereachievedwhenthemotor andpilot
valve air wasexhaustedthrough a 10foot (3 metre)length
of hoseandattachedto amuffler.
Initial Operating Checks
Winchesaretestedfor proper operationprior to leaving
the factory. Beforethewinch is placedinto servicethe
following initial operating checksshouldbeperformed.
1. Whenfirst running the motor inject somelight oil into
the inlet connectionto provide initial lubrication.
2. Whenfirst operatingthe winch it is recommendedthat
themotor bedriven slowly in both directions for a
few minutes.
9

For winchesthathavebeenin storagefor aperiod of more
than onemonththe following start-upprocedureis
required.
1. Give the winch aninspection conforming to the
requirementsof “WinchesNot in RegularUse” in the
“INSPECTION” section.
2. Pourasmallamountof 10Woil in the motor inlet
port.
3. Operate the motor for 10 seconds in both directions to
flush out any impurities.
4. Thewinch is now ready for normal use.
The four mostimportant aspectsof winch operationare:
1. Follow all safetyinstructions whenoperatingthe
winch.
2. Allow only peopletrained in safetyandoperationof
this winch to operatethis equipment.
3. Subjecteachwinch to aregular inspectionand
maintenanceprocedure.
4. Be awareof the winch capacityandweight of load at
all times.
l Operate this winch ONLY if wire rope is installed to
comeoff the drum for overwind operation. Refer to
Dwg. MHTPA0564.
l Operation of this winch in a safemanner, aspart 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. Safeoperation, according to established
standards, require that personnel and materials are to
betransported separately.
l Visual inspections of the winch and entire Personnel
Lifting Systemmust beconducted 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 beinspected, 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
transportedareinstructedin operation andsafety
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 transportedmustbeinstructedin and
adhereto thesafetyproceduresestablishedincluding,
but not limited to, the following list:
a. EmergencyEscapeProceduresin accordancewith
ANSI A10.22Section 11.
b. Useof safetybelts(harnesses)andropegrabs
(lifelines) in accordancewith ANSI A10.22
Sections11, 12.4and 12.5.
3. Winch operatorsmustbeinstructedin andadhereto
theproceduresestablishedto ensureproper andsafe
operationof this winch asacomponentin aPersonnel
Lifting System.
a.
b.
C.
d.
e.
Winch operatorsmustremainatthe winch
controls at all timeswhenhandling personneland
materials.
At any indication of winch, or system,damageor
impending dangerthewinch operatormustplace
thewinch in asafecondition andnotify
designatedpersonnel.Winch andsystem
operationmustbesuspendeduntil all
discrepanciesnotedhavebeeninspected,repaired
andsystemtestedto ensuresafeoperation.
Voice communicationmustbeestablishedand
maintainedbetweenwinch operator,personnel
being lifted andpersonnellocatedateachlanding
(asapplicable).
Winch operatorsmustmaintain at least4 tight
wrapsof wire rope onthe drumat all times.
Wire rope shall beweightedonthe endto prevent
line run when spooling onto the drum.
Initial Winch Operating Checks
l Initial operating checksspecific to the entire
Personnel Lifting Systemshould beestablished to
ensure systemcomponent compatibility.
Winchesaretestedfor proper operationof all features
prior to shipping. Beforethe winch isplacedinto service
the following initial operating checksshould be
performed.
1. Whenfirst running the motor inject asmall amountof
oil into the inlet connectionto provide initial and
immediatelubrication.
2. Whenfirst operatingthe winch run the motor slowly
in both directions for afewminutes.
3. Verify both drumbrakesfunction asdescribedin
‘Winch Testing’in the “WINCH INSPECTION”
section.To adjustthe brakesreferto ‘Winch
Adjustments’in the “WINCH MAINTENANCE”
section.
4. Adjust andverify limit switch settings.To adjustthe
limit switch setpoints refer to ‘Winch Adjustments’in
the “WINCH MAINTENANCE” section.
10

5. Verify line speedmonitor andoverspeedalarm
operationasdescribedin ‘Winch Testing’ in the
“WINCH INSPECTION” section.
6. Verify automaticdrum brakeemergencyrelease
systemoperationasdescribedin ‘Winch Testing’ in
the “WINCH INSPECTION’ section.
Winch Component Operation
Pilot Air Throttle Control Lever
(Referto Dwg. MHTPA0608)
Winch control lever directions aredescribedasviewed
when facing thewinch motor andapply to overwind
operationonly. To ensuresmoothoperationof thewinch
suddenmovementsof the control valve should beavoided.
1. To payout wire rope, lift up on thewinch control
lever andmovethe lever to the right.
2. To haul in wire rope,lift up on the winch control
lever andmovethe winch control lever to the left.
Pilot Air Throttle Control Operation
Haul
Directions es
viewed form the
motor end of
winch
(Dwg. MHTPA0608)
Manual Drum Brake
Themanualdrumbrakemaybeapplied by pushing down
onthebrakehandleandreleasedby pulling up. If the
handleis pusheddown fully, it should lock in that position
andpreventdrumrotation, until releasedby the operator.
Thebrakemustbekept properly adjustedto hold the
required load.To adjustthe brakereferto ‘Winch
Adjustments’in the “WINCH MAINTENANCE” section.
Automatic Drum Brake
The automaticdrum brakeis aspring applied, air released
brake.Using anair actuated,spring loadedcylinder the
brakeautomatically disengageswhen themotor is
operated.Air pressurein the cylinder overcomesspring
pressureto releasethe brake.Whenthe pilot air throttle
control lever is placedin the neutral position, the air in the
cylinder is ventedandthe spring automatically engages
the braketo prevent drum rotation.
The cylinder clevis mustbekeptproperly adjustedto hold
the requiredload.To adjustthe brakereferto ‘Winch
Adjustments’in the “WINCH MAINTENANCE” section.
Limit Switch
Pre-setlimit switch settingspreventwinch wire rope
payout andhaul in by stoppingair flow to thewinch motor
when a setpoint hasbeenreached.It is the owner’sand
operator’sresponsibility to adjustwinch operating limits
prior to using the winch to transport personnel.To adjust
the limit switch setpoints referto ‘Winch Adjustments’in
the “WINCH MAINTENANCE” section.
l Ensure limit switch operates properly and that limits
have been setbefore using winch to transport
personnel.
Line SpeedMonitor and Overspeed Alarm
The Line SpeedMonitor is abattery poweredwire rope
line speedindicator systemwhich determinesline speed
by sensingdrum rotation.
TheLine SpeedMonitor provides avisual alarm(flashing
redlight) anddigital readout(in feet)to allow the operator
to adjustthrottle control to maintain wire ropeline speed
at 100feetperminute (30.5metresper minute) or less.
Line SpeedMonitors arefactory pre-setto matchthe
winch installed on andcannotbeadjusted.The over-speed
indicator light flasheswhen drutn speedexceedswire rope
line speedsof 100feetper minute (+/- 10feet) (30.5
metresper minute; +/- 3 metres)in either direction of
drumrotation.
The Line SpeedMonitor battery should berecharged
everytwo weeksby connectingthe battery chargerunit to
the monitor anda 110volt (ac)electrical source.
Winch Emergency DescentProcedure
(Referto Dwgs. MHTPB0210 andMHTPB0636)
l ANSI A10.22-1990 Section 11defines the Personnel
Lifting Systemrequirements for establishing
emergency escapemethods and procedures. The
following procedure describing the use of the winch to
lower personnel or loads when the supply air to the
winch hasbeeninterrupted should only be usedafter
all other established methods have beenexhausted.
The lowering speedof the loadusing thewinch descent
procedureis dependentuponthe weight of the load,
amountof cableonthe drum, andposition of the load in
thelifting system.
To usethe winch to lower the loadwhen the air supplyhas
beeninterrupted conductthe following:
1. Engagethemanual bandbrake.
2. Depressthe automaticbandbrakeclevis (107) and
removecotter pin (102)andpin (106)to dicsonnect
cylinder (110) from brakelever (105).
3. Slowly disengagemanualbandbrakeusing thebrake
lever (104). Regulatespeedof loadusing manualband
brake.If load doesnot lower engagebandbrakeand
then conductthe following step.
11

4. Removecapscrews(364) from motor adaptervalve
(468) andremovepilot valve/adapterassemblyfrom
winch motor.
5. Using manualbandbraketo throttle lowering speed(if
required) lower the load.
Training
Prior to using thePersonnelLifting Systemsupervisors,
operators,servicepersonnel,andpersonnelbeing
transportedmustbethoroughly instructedin thepotential
dangersinvolved andthe safetyproceduresestablishedto
minimize therisks of accident,injury andproperty
damage.
Establishmentof safeoperating proceduresfor the
PersonnelLifting Systemshould bebasedon ANSI
Al0.22 specifications,OSHA regulations, all applicable
local, stateandnational standards,systemcomponent
manufacturers’srecommendations,andsystemdesigner
recommendations.
Recordsof training should bemaintained andmade
availableto designatedpersonnelfor review.
To ensurecontinuedsatisfactoryoperationof 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 daysperweek.If thewinch is operated
almostcontinuously or morethanthe eight hourseach
day,morefrequentlubrication will berequired.Also, the
lubricant typesandchangeintervals arebasedon
operationin anenvironment relatively freeof dust,
moisture,andcorrosivefumes. Useonly thoselubricants
recommended.Other lubricants mayaffectthe
performanceof thewinch. Approval for theuseof other
lubricants mustbe obtainedfrom your Ingersoll-Rand
distributor. Failure to observethis precautionmay result in
damageto thewinch and/orits associatedcomponents.
INTERVAL
,Startof eachshift
Monthly
LUBRICATION CHECKS
Checkflow andlevel of air line
lubricator (approximately6 to 9
dropsper minuterequiredat
maximum motor speed).
Checkwinch motoroil level.
Lubricate componentssupplied by
greasefittings.
Inspectandcleanor replaceair
line filter.
Yearly Checkreductiongearoil level.
Drain and refill winch reduction
gearoil.
Drain andrefill winch motor oil.
Note: Intervalsarebasedon winch operationin a normal
environmentas describedin the “INSPECTION”section.
In ‘Heavy’or ‘Severe’operatingconditionsadjust
lubrication intervals accordingly.
RecommendedLubricants
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) SAE 30W
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
Iithium-basedgrease
(Referto Dwg. MHTPA0222)
Correctlubrication is oneof the mostimportant factorsin
maintaining efficient winch operation.The motor is splash
lubricated by the oil in the motor housing andhasno other
meansof lubrication. It is therefore important to useonly
quality, non-detergentmotor oil to ensuremaximum
performanceandminimum downtime for repairs.Referto
the ‘RecommendedLubricants’ section.Allow oil to settle
beforetopping off.
Oil capacityfor the FA2 winch motor is 3/8 quart(0.35
litres). Add oil through the fill plug openinguntil oil flows
from the level plug hole. Add oil slowly to prevent
spilling.
Themotor shouldbelevel-checkeddaily or atthe startof
eachshift afteraccumulatedwaterhasbeendrainedoff.
Whenmotorsareoperatedin temperaturesbelow freezing,
wait long enoughat endof shift for waterto separatefrom
oil but not long enoughfor it to freeze.Drain thewater
thenrefill to the level plug. If desired,all the oil maybe
drainedattheendof the shift andthe motor refilled with
newoil.
12

Motor Lubrication Locations
(FA2 Shown)
Fill Plug
Therecommendedgradeof oil mustbeusedatall times
sincetheuseof unsuitable oil mayresult in excessive
temperaturerise, lossof efficiency andpossibledamageto
the gears.Referto the ‘RecommendedLubricants’ section.
Useonly high quality lubricants in the reduction gear
assemblysuchasmotor oil, high gradeEPtype hydraulic
oil or their equivalents.
Reduction Gear Lubrication Plug Locations
Level Plug
Drain- Plug
(Dwg. MHTPA0222)
Wire Rope
Follow the wire ropemanufacturer’sinstructions. At a
minimum, observethe following guidelines.
1. Cleanwith abrushor steamto removedirt, rock dust
or other foreign material onthe surfaceof the wire
rope.
l Do not usean acid-based solvent. Only usecleaning
fluids and lubricants specified by the wire rope
manufacturer.
2. Apply awire ropelubricant, Ingersoll-Rand LUBRI-
LINK GREENor SAE30W oil.
3. Brush, drip or spraylubricant weekly, or more
frequently, dependingon severity of service.
Reduction Gear Assembly
(Referto Dwg. MHTPA0140)
The reduction gearassemblyis filled andshippedwith oil
from the factory. Checkoil level beforeinitial winch
operation.If the winch is usedatanormal frequency
replacethe oil in thereduction housing onceevery year.
To ensurecorrectperformance,highest efficiency and
long life, it is essentialthatthe lubricating oil be
maintainedatthe correctlevel. Rotatethe drumuntil the
fill plug is locatedattop deadcenterthen addoil up to the
level plug hole. Oil capacityfor the reduction gear
assemblyis l-l/2 quarts(1.4 litres).
l Do not over fill. Excessoil will reduce operating
efficiency and increase oil temperature.
Fill Plug
Position Reduction Gear
Level Plug
(Dwg. MHTPA0140)
Drum Brakes
Lubricate pivot points,pins andshaftswith recommended
greaseto preventcorrosion of parts.
l Do not allow greaseor oil to comeinto contact with
drum band brake linings.
Disc Brake (optional feature)
Oil from the reduction gearassemblyalsoprovides
lubrication for the disc brake.After anoil changeor winch
overhaul removethe breatherplug andpour 6to 8 ounces
(0.2 litres) through the breatherhole in thebrakehousing
to initially lubricate the brakediscs.Referto the
‘RecommendedLubricants’ section.Reinstall the breather
plug beforeoperationof winch or brakes.
Sealsand 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
Replenish lubricator daily andsetto provide 6to 9 drops
of oil per minute. Referto the ‘RecommendedLubricants’
sectionfor recommendedoil.
13

Wire Rope Line SpeedMonitor
Doesnot require lubrication.
Limit Switch
Doesnot require lubrication.
Inspection information is basedin part on American
National StandardsInstitute SafetyCodes(Al 0.22and
B30.7).
Records and Reports
Personnel Lifting System
Ownersareresponsiblefor establishingandimplementing
operation andsafetyproceduretraining for all personnel
involved in the useandoperationof aPersonnelLifting
System.
1.
2.
PERSONNELTRAINING. Recordsof training
provided to supervisors,operators,servicepersonnel
andpersonnelbeingtransportedshouldbemaintained
andmadeavailableto designatedpersonnelfor
review.
SYSTEM MAINTENANCE. Recordsof all service,
maintenanceandtestingperformedonthe Personnel
Lifting Systemshouldbemaintainedandmade
available to designatedpersonnelfor review.
Winch Records and Reports
Inspection records,listing all points requiring inspection,
should bemaintainedfor all load bearingequipment.
Written reports,basedonInitial, Weekly andQuarterly
inspections,shouldbemadeonthe condition of critical
partsasamethodof documentinginspections.These
reportsshould bedated,signedby thepersonwho
supervisedtheperformanceof the inspection, andkepton
file wherethey arereadily available for review. A sample
winch ‘InspectionandMaintenanceReport’hasbeen
provided atthe endof this section.
Wire Rope Reports
Recordsshouldbemaintainedaspart of along-rangewire
rope inspectionprogram.Recordsshould include the
condition of wire roperemovedfrom service.Accurate
recordswill establisharelationship betweenvisual
observationsnotedduring frequentinspectionsandthe
actualcondition of wire ropeasdeterminedby periodic
inspections.
PersonnelLifting Systemwire roperecordsshouldbe
maintainedandmadeavailableto designatedpersonnelfor
review.
SystemInspections and Tests
l Information provided by Ingersoll-Rand is applicable
only to the winch to assistin determining the condition
of the winch components described. Referencesto
other Personnel Lifting Systemcomponents are made
with respectto their relationship to the winch. For
specific information on systemcomponents other than
the winch, reference the manufacturers’ literature and
ANSI A10.22.
PersonnelLifting Systeminspectionsandtestsof installed
components,functions andsafetydevicesshouldbe
establishedbasedon proceduresderived from ANSI
A 10.22specifications,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.
SystemInitial and Quarterly Inspections
In addition to establishedDaily andWeekly inspections
conductthe following:
l The static drop test is only required for guided cage
systems.
INITIAL INSPECTION. With the cageat rated load,
on a guided cagesystem,using deadweights,
conductastatic droptest.This testis designedto
ensurethe cagesafetyclampsengageandstopthe
cagefrom falling. Performrequirementsoftheweekly
inspection.
QUARTERLY INSPECTION. With thecageempty,
on a guided cagesystem,conductastaticdroptest.
This testis designedto ensurethe cagesafetyclamps
engageandstopthe cagefrom falling. Perform
requirementsof theweekly inspection.
14

SystemTesting
PersonnelLifting Systemtesting shouldbeconductedin
accordancewith the systemspecific instructional manual
andcomponentmanufacturers’recommendations.A
systemspecific instruction manualmustbecompiledto
conform to the requirementsof ANSI A10.22, anddetail
the operation,maintenanceandsafetyrequirementsof the
various componentscomprising the personnellifing
system.
Winch Inspections
Thefollowing listed inspectionsapply only to thewinch.
Theseinspectionsshouldbeconductedwhen scheduled,
when indicated by winch performanceandwhenthe winch
is disassembledfor repair.
Careful inspection on aregular basiswill reveal
potentially dangerousconditions while still in the early
stages,allowing corrective actionto betakenbeforethe
condition becomesdangerous.
Damagerevealedthrough inspection, or notedduring
operation,mustbereportedto designatedpersonnel
instructed in safety,operationandmaintenanceof this
equipment.A determination asto whetheracondition
constitutesa safetyhazardmustbemade,andthe
correction of 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
safeoperation at rated specifications before placing
equipment in service.
l Never useawinch 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 systemhasbeen
idle for periods of longer than one month.
Daily checks,weekly andquarterly inspectionsshouldbe
performedonequipmentin regular use.
1. Daily checksarevisual examinationsperformedby
operatorsor personnelinstructed in safetyand
operationof this equipmentandinclude observations
madeduring routine equipmentoperation.
2. Weekly inspections arethorough inspections
conductedby personnelinstructedin safety,operation
andmaintenanceof this equipment.Weekly
inspectionsarealsorequired prior to personnellifting
if the systemhasbeenidle for periodsin excessof one
week,but lessthan onemonth.
3. Quarterly inspections areacombination of weekly
inspection requirementsandtheperformanceof a
static dropteston guided cagesystemsonly to verify
operationof the cage’ssafetyclamp.
Winch Daily Checksand Weekly Inspections
Onequipmentin continuous service,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 the beginning of the shift, prior
to operation,visually inspectwinch housings,
controls, brakes,siderails anddrum for indications of
damage.Do not operatethewinch until all
discrepanciesnotedhavebeenreviewed, inspected
further andcorrectedby personnelinstructedin the
operation,safetyandmaintenanceof this winch.
WINCH (WEEKLY). Inspectthe following:
a. SIDE RAILS AND END UPRIGHTS. Checkfor
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 ropewhich
canbeexpectedto bein useduring the day’s
operations.Inspectfor wearanddamageindicatedby
distortion of wire ropesuchaskinking, “birdcaging,”
coreprotrusion, main stranddisplacement,corrosion,
broken or cut strands. If damageis evident, do not
operatewinch until the discrepancieshavebeen
reviewed andinspectedfurther by anexperiencedwire
rope inspector.
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 maintainedbetween
the outsideedgeof the drum flange andthe
outermostlayer of wire rope.
b. Buildup of dirt andcorrosion. Cleanwith steam
or astiff wire brushto removedirt andcorrosion
if necessary.
c. Loose,frayedor damagedendconnection.
Replaceif loose,frayedor damaged.Ensureends
will not catchonpersonnel.
d. Ensurethewire ropeis securelyanchoredin the
winch drum.
15

e. Verify wire ropediameter.Measurethediameter
of thewire ropefrom crown-to-crownthroughout
the life of thewire rope.Recordingof the actual
diametershouldonly bedonewith the wire rope
underequivalent loading andin thesame
operatingsectionasaccomplishedduring
previous inspections.If theactualdiameterof the
wire ropehasdecreasedmorethan l/64 inch (0.4
mm)athorough examinationof thewire rope
shouldbeconductedby anexperiencedinspector
to determinethe suitability of thewire ropeto
remainin service.(Referto Dwg. MHTPA0056).
Crown
to
Crown
(Dwg. MHTPA0056)
3.
4.
5.
6.
7.
AIR SYSTEM (WEEKLY). Visually inspectall
connections,fittings, hosesandcomponentsfor
indication of air leaks.Repairany leaksandreplace
damagedcomponents.
CONTROLS (DAILY AND WEEKLY). During
operationof winch, verify responseto control isquick
andsmooth.If winch respondsslowly or movementis
unsatisfactory,donot operatewinch until all problems
havebeencorrected.
BRAKES (WEEKLY). Ensureproperoperation.
Verify eachbrakesystemwill hold a 150%ratedload
with full drum (asapplicableto normal use)without
slipping. If indicatedby poor operationor visual
damage,disassembleandrepairbrake(s).Checkall
brakesurfacesfor wear,deformationor foreign
deposits.If drumbrakelining thicknessis 0.062inch
(2 mm)or lessanywherealongits edgereplacebrake
bandsor linings. Cleanandreplacecomponentsas
necessary.Testeachbrakesystemindependently.
LIMIT SWITCHES(WEEKLY). Verify winch limit
switchesoperateatthe setlimits. Whenactuated,limit
switchesinterrupt air flow to the motor in the
direction of winch operationonly. Adjust limit
settingsor repair to correctall noteddiscrepancies.
ALL COMPONENTS(WEEKLY). Inspectfor wear,
damage,distortion, deformationandcleanliness.If
externalevidenceindicatesdamage,disassembleas
requiredto conductadetailedinspection.Inspect
gears,shafts,bearings,springsandcovers.Replace
worn or damagedparts.Clean,lubricate and
reassemble.
8.
9.
10.
11.
12.
SUPPORTING STRUCTURE (WEEKLY). Checkfor
distortion, wearandcontinuedability to support
winch. Ensurewinch is firmly mountedandthat
fastenersarein good condition andtight.
LABELS AND TAGS (WEEKLY). Checkfor
presenceand legibility of labels.Replaceif damaged
or missing.
WIRE ROPELINE SPEEDMONITOR. Verify Line
SpeedMonitor displays line speedandoverspeed
alarmlights at 100feetperminute (+/- 10feet) (30.5
metresperminute; +/- 3 metres).If batterycharge
light is on, chargebattery.
WINCH EXHAUST AND MUFFLER. Visually
inspectexhausthoses,connectionsandmuffler for
damage.Ensurepiping andmuffler arecorrectly
installed anddirect exhaustawayfrom winch
operator.Operatornoiselevels mustnot exceed90
dBA over an 8 hour period (Time WeightedAverage
(TWA)).
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 order to properly inspectthe individual
components.Maintain written recordsof initial and
quarterly inspectionsto provide anaccumulativebasisfor
continuing evaluation. Inspectall itemslisted in “Weekly
Inspection.” Also conductthe following:
1. INITIAL INSPECTION. Conductall requirementsof
‘Winch Daily andWeekly Inspection’and‘Winch
Testing’.
2. QUARTERLY INSPECTION. Conductall
requirementsof ‘Winch Daily andWeekly Inspection’
and‘Winch Testing’.
Winches Not in Regular Service
1. Equipmentwhich hasbeenidle for aperiod of one
weekor more, but lessthanonemonth, shall begiven
aninspection conforming to the requirementsof
“Daily andWeekly Inspections” beforebeing placed
in service.
2. Equipmentwhich hasbeenidle for aperiod of over
onemonth shall begiven ancompleteinspection
conforming with the requirementsof “Initial and
Quarterly Inspections” beforebeingplacedin service.
16

INSPECTION AND MAINTENANCE REPORT
Ingersoll-Rand Force 5 SeriesAnsi Manrider® Air Winch
Model Number: Date:
Serial Number: Inspected by:
Reasonfor Inspection: (Check Applicable Box)
1.ScheduledInspection( Weekly
2. Discrepancy(s)notedduring Daily Inspection Operating Environment:
3. Discrepancy(s)notedduring maintenance
4. Other:
Normal _ Heavy _ Severe_
Referto the Parts,OperationandMaintenanceManual “INSPECTION” sectionfor generalinspectioncriteria. Also, refer to appropriateNational Standards
andcodesof practice.If in doubtaboutan existing conditioncontactthenearestIngersoll-RandDistributor or the factoryfor technicalassistance.
CONDITION CORRECTIVE
COMPONENT ACTION NOTES
Pass Fail Repair Replace
SideRails andEnd
uprights
Manual Drum Band
Brake
(150%Load Test)
Automatic Drum Band
Brake
(150%Load Test)
Drum BandBrakes
(Visual Inspection)
Motor
Limit Switches
Controls
Air System
Fasteners
Reduction Gears
LabelsandTags
Shafts
---
Wire RopeAnchor
Wedge
Line SpeedMonitor
and OverspeedAlarm
Other Components
(list in NOTES
section)
TESTING Pass Fail NOTES
Operational(No Load)
Operational(10% Load)
Operational(Maximum TestLoad *)
l Maximum winch operationaltestloadis 125%of ratedline pull.
Maximum braketestload is 150%of ratedline pull; performby raisingthetest load approximately4 to 6 inches(100to 150mm).
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This section provides basic troubleshooting information. Determination of specific causesto problems are best identified by
thorough inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart
below provides a brief guide to common winch problems, probable causes and solutions.
PROBLEM
Winch will not operate.
Loadcontinuesto movewhen
winch is stopped.
Winch does not lift load.
Motor may be damaged.
Throttle lever moves but winch
does not operate.
Motor runs hot or makes
excessive noise during
operation.
Winch runs slow.
CAUSE SOLUTION
No air supplyto winch.
Winch is overloaded.
Automaticdrumbandbrakedoesnot release.
Checkair supply line connectionsand hoses.
Reduceload to within ratedcapacity.
Pressurizebrakereleaseport and checkfor leakage.
Replacebrakepiston sealsif leakageis found.
Limit switch engaged. Shift pilot valve throttle lever in oppositedirection.
If winch operates,adjustlimit switch settings.
Shippingplugsmaystill he in place. Removeshipping plugs in valve and motor exhaust
ports.
Automaticdrambandbrakeis slipping.
Check brake band adjustment and brake band lining
wear.
Winch is overloaded.
Pilot air throttle control valve sticking.
Reduce load to within rated capacity.
Disassemble, inspect and repair the pilot air control
throttle valve.
Remove and disassemble motor. Examine all parts
and replace any that are worn or damaged.
Insufficient air supply.
Verify air supply pressureandvolumeat winch inlet
meets the requirements listed in the
“SPECIPCATIONS”section.Clean air line filter.
Automatic drum band brake or optional disc
brake do not release.
Motor may be damaged.
Dissassemble, inspect and repair the automatic drum
band and/or optional disc brake.
Disassemble and clean the motor and replace any
broken or damaged parts.
Insufficient air supply. Ensure the air pressure at the winch inlet is at least
90 psig (6.2 bar) at rated volume. Clean air line
filter.
Limit switch engaged. Shift pilot valve throttle lever in opposite direction.
If winch operates, adjust limit switch settings.
Low oil level. Check oil level in the motor. Add oil as required to
obtain the proper level.
Improper lubrication. Replace oil with type recommended in the
“LUBRICATION” section.
Waterin oil. Drain and refill with recommended oil. Operate
winch with no load slowly, in both directions. If
noise still exists or motor overheats disassemble and
repair motor.
Damaged or broken piston or connecting rod.
Improper hose or fitting sizes.
Disassemble and repair motor.
Check fittings, connections and hoses for correct
size and length. Replace parts that may cause
restricted air flow. Inspect air line filter.
Motor may be damaged. Remove and disassemble motor as described in the
“MAINTENANCE” section. Inspect all parts and
replace all worn or damaged parts.
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I
PROBLEM SOLUTION
Air linesfreeze. Waterinairsupply.
Install ordrain airsystem moisture traps, moisture
collecting air receiversandcompress oraftercoolers.
After corrective action has been taken disconnect
lines atwinch inlet andpurgewith clean,dry air or
nitrogen
Automatic Drum Brake:
Drumbrakeoutofadjustment.
Dirty filterin airsupply.
Faultydumpvalve.
Adjustdrumbraketomaintaincorrectcylinder
stroke.
If airisnoticedescapingfromthecylinderbreather
when attempting torelease the brake replace or
repaircylinder.
Cleanorreplacefilter.
Checkdumpvalveexhaustport.Air shouldexhaust
whencontrolvalvehandleisin neutral.If noair
escapes,replacedumpvalve.
Limit Switch
Winchdoesnotoperatein one Limit switchengaged
direction.
LineSpeedMonitor andOverspeedAlarm
Operatewinch in oppositedirection. Adjust limit
switch settingsto rquired travel limits.
LineSpeedMonitordoesnot
showfeetperminuteindication. Low Battery.
Sensor maybe damaged orobstructed. Cleancapscrewheadsandsensor.Verity0.2inches
(+/-0.1inches)[5mm(+/-2.5mm)]clearance
between sensor and capscrew heads.
ITEM DESCRIPTION
QTY
PART ITEM DESCRIPTION
QTY
PART
NO. OF LABEL TOTAL NUMBER NO. OF LABEL TOTAL NUMBER
607 Nameplate
Rivet 4 71028849 618 Ground Connection 1 71149447
608 Exhaust 1 71042196 619 Line SpeedMonitor 1 71149405
609 Oil 1 71043616 620 Battery Charger 1 71149413
610 Air Supply 1 71046395
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