Ingersoll-Rand Force 5 MANRIDER FA5MRA 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 MHD56086
PARTS, OPERATION AND MAINTENANCE MANUAL
AIR
WINCHES
MODEL
FA5MRA 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 MHD56086
Edition 1
March 1995
71146286
© 1995 Ingersoll-Rand Company
MATERIAL HANDLING

This manual provides important information for all
personnel involved with the safe installation, operation
and proper maintenance of this product. Even if you feel
you are familiar with this or similar equipment, you should
read this manual before operating the product.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures
which, if not followed, may result in an injury. The
following signal words are used to identify the level of
potential hazard.
Danger is used to indicate the
presence of a hazard which will
cause severe injury, death, or
substantial property damage if the
warning is ignored.
Warning is used to indicate the
presence of a hazard which can
cause severe injury, death, or
substantial property damage if the
warning is ignored.
Caution is used to indicate the
presence of a hazard which will or
can cause injury or property damage
if the warning is ignored.
Notice is used to notify people of
installation, operation, or
maintenance information which is
important but not hazard-related.
Safety Summary
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-Riders winches are designed and
manufactured to meet or exceed standards and
specifications established for base mounted drum hoists as
defined by ASME B30.7 and for the purpose of personnel
handling as defined by ANSI A10.22 - 1990.
In furnishing customers Man-Rider@ winches,
Ingersoll-Rand does not warrant the suitability of these
winches for any particular use. It is the owner’s and user’s
responsibility to determine the suitability of this winch for
a particular application.
Ingersoll-Rand Man-Rider® winches manufactured to
ANSI A10.22 standards are designed as a component in
the Personnel Lifting System. Ingersoll-Rand approval
for use of this winch in Man-Rider@ applications
automatically terminates for any of the following reasons:
1. Winch is not installed in an approved personnel lifting
system.
2. Winch is not properly maintained in a safe working
condition, with all parts intact and properly adjusted.
3. Winch is used in applications not approved by codes
and regulations, or application is inconsistent with
manufacturer’s operation and maintenance manual.
4. More than one winch is used to attach to a common
load.
5. Winch design or functions are altered or changed in
any manner from the purchased original without prior
approval by Ingersoll-Rand.
This manual has been produced by Ingersoll-Rand to
provide company personnel, dealers, mechanics and
operators with the information required to install, operate,
and maintain the products described herein.
It is extremely important that mechanics and operators be
familiar with the servicing procedures of these products, or
like or similar products, and are physically capable of
conducting the procedures. These personnel shall have a
general working knowledge that includes:
1. Proper and safe use and application of common
mechanics’ hand tools as well as special
Ingersoll-Rand or recommended tools.
2. Safety procedures, precautions and work habits
established by accepted industry standards.
Ingersoll-Rand can not know of, nor provide all the
procedures by which product operations or repairs may be
conducted and the hazards and/or results of each method.
If operation or maintenance procedures not specifically
recommended by the manufacturer are conducted, it must
be ensured that product safety is not endangered by the
actions taken. If unsure of an operation or maintenance
procedure or step, personnel should place the winch in a
safe condition and contact supervisors and/or the factory
for technical assistance.
2

The following warnings and operating instructions have
been adapted in part from American National (Safety)
Standards ASME B30.7 and ANSI A10.22, and are
intended to avoid unsafe operating practices which might
lead to injury or property damage.
Ingersoll-Rand recognizes that most companies who use
winches have a safety program in force at their facility. In
the event that a conflict exists between a rule set forth in
this publication and a similar rule already set by an
individual company, the more stringent of the two should
take precedence.
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.
Safe Operating Instructions are provided to make an
operator aware of dangerous practices to avoid and are not
necessarily limited to the following list. Refer to specific
sections in the manual for additional safety information.
1.
2.
3.
4.
5.
Winch operator must be in vocal contact with
personnel being lifted (lowered) from transfer point to
landing area.
Personnel supervising, operating the winch and
personnel being transferred are to be instructed in
system operation and safety prior to personnel lifting.
Only operate a winch if you are physically fit to do
so.
Use of a winch to transport personnel (lifting and/or
lowering) should only take place when other means of
accomplishing this work are not practical.
When a “DO NOT OPERATE” sign is placed on the
winch, or winch controls, do not operate the winch
until the sign has been removed by designated
personnel.
Never lift a load greater than the rated capacity of the
winch. Refer to “SPECIFICATIONS” section for
applicable utility and ManRider® capacity ratings.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Prior to use, inspect and test the personnel lifting
system to the requirements of ANSI A10.22 Section
13 (Inspection and Tests). The winch operator shall be
instructed in the operation of this winch and the
personnel lifting system per ANSI A10.22 Section 5
(Operation of Hoist).
Winch only: Refer to ‘Testing’ procedures in the
“WINCH INSPECTION” section of this manual for
winch information.
Installation of the winch must be specially arranged
and approved for personnel handling as a component
in a Personal Handling System as described and
defined in ANSI A10.22. Refer to the
“INSTALLATION” section. All bolts and
foundations for winch attachment must have a higher
load carrying capacity rating than the maximum
capacity of the winch.
Do not operate a damaged winch.
Do not operate a winch that has not been properly
maintained or equipped.
Do not operate winch with any personnel near the line
of force or capable of coming into contact with
moving parts.
Labels and warning notices must remain permanently
posted, and be clearly visible on the winch.
Ease the slack out of the wire rope when starting a lift.
Do not jerk the load.
Never leave a suspended load unattended.
Wire rope must spool off drum from the top away
from the operator (overwind). The direction of lift is
counterclockwise when viewed from the motor end of
the winch.
Make sure the wire rope is properly anchored to the
winch drum.
Pay attention to the load at all times when operating
the winch.
Never use the winch wire rope as a sling.
Do not leave a load suspended when winch is not in
use.
Ensure muffler is positioned at the point furthest away
from winch operator.
Do not use limit switch settings to regulate the winch
stopping points. Limit switches are designed as a
backup to operator accidental over travel only.
Ensure the end of the wire rope is weighted to prevent
line run.
3

Each unit is shipped from the factory with the warning
label shown. If the label is not attached to your unit, order
a new label and install. See the parts list for the part
number. Label is shown smaller than actual size.
\L

Description
The FA5MRA winch are air powered, planetary geared
units designed for lifting and pulling applications. When
incorporated into an approved personnel lifting system and
operated as instructed by the procedures defined in this
manual as well as the requirements of ANSI Al0.22-1990,
the FA5MRA winch can be used to transfer personnel.
These winches are provided with a spring actuated, air
released drum band brake and a manually operated drum
band brake. The spring actuated drum band brake
automatically applies when the motor throttle control lever
is returned to the neutral position, when the pendant (if
equipped) control button is released, and if there is a loss
of air pressure.
The output from the externally mounted air piston motor is
transmitted through a coupling and shaft to the planetary
reduction gear assembly.
The output from the planetary reduction gear assembly is
connected to the wire rope drum through the output shaft.
The line speed monitor and overspeed alarm provide the
operator with winch operating line speed rate and
indication of overspeed at the winch, and indication of
overspeed on the pendant (if equipped).
The winch mounted throttle control lever must be lifted
before operating in either the pay out or haul in directions
and will return to the neutral position when released.
The limit switch assembly prevents winch operation
beyond established haul in and pay out setpoints. The
setpoints are adjustable.
General Specifications Model FA5MRA
Rated Operating Pressure
Utility Rating * ANSI ManRider®
Rating *
90 psig (6.3 bar)
Air System
Drum Wire Rope Storage
Capacity **
(feet / metres)
Drum Length (inches)
16 683 feet
24 1024 feet
30 1280 feet
36 1536 feet
* FA5 Utility rating of 7,040 lbs. (3,200 kg) is based on requirements of ASME B30.7 (5: 1 design factor with 5/8 inch
(16 mm) wire rope.)
FA5 Manrider® rating of 4,400 lbs. (2,000 kg) is based on requirements of ANSI Al0.22 (24:1 drum to wire rope
ratio) and factory recommended 8: 1 safety design factor of 8: 1 using 5/8 inch (16 mm) wire rope.)
** FA5 ManRider® wire rope storage is based on a winch with a 27 inch (686 mm) diameter drum flange and on ANSI
A 10.22 standards which require the top layer to be at least 2 inches (5 1 mm) below the drum flange diameter.
Capacities shown may vary from those published elsewhere.
5

Model Code Explanation
Example: FA5MRA24MA1G FA5 MRA
Series (Capacity):
Model FA5 Personnel Lifting - 2 metric tons / 4,400 lbs.
Utility Lifting - 3.2 metric tons / 7,100 lbs.
Designation:
* MRA = Man Rider@ ANSI A10.22-1990
Drum Length (Distance between drum flanges):
8 = 8 inch (203 mm)
12 = 12 inch (305 mm)
16 = 16 inch (406 mm)
20 = 20 inch (508 mm)
24 = 24 inch (610 mm) [Standard]
24 A
30 = 30 inch (762 mm)
36 = 36 inch (914 mm)
Brake:
M = Manual Drum Brake (Standard)
A = Automatic Drum Brake (Standard)
K = Automatic Disc Brake
Control:
1 = Winch mounted lever throttle (Standard)
3XX = Remote pilot pendant throttle with warning light (XX = Specify hose length (feet)) **
5XXX = Remote electric throttle control (XXX = Specify hose length (feet)) **
options:
Z = Sand blast and Carbozinc primer only
P = Marine 812 top coat
G = Drum Guard
7 = Drum Grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch)
* Standard Features: (1) Line Speed Monitor.
(2) Adjustable upper and lower rotary limit switches.
(3) Piped away exhaust with muffler and 10 feet (3 metres) of exhaust hose.
(4) Copy of Operation and Maintenance Manual and ANSI A10.22 Standard supplied in container
attached to winch.
(5) Manual and Automatic Drum Band Brake.
G
**
Remote pendants are provided with standard length 10 feet (3 metres) hose. Specify hose lengths greater than 10 feet. For
lengths greater than 50 ft. (15 metres) with the Remote Pilot Pendant Throttle or Remote Pilot Electric Throttles contact
Technical Sales for control acceptability. Metric lengths for reference only, order lengths required to be in feet.
Note: FA5MRA 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.
6

Prior to installing the winch, carefully inspect it for
possible shipping damage.
Winches are supplied fully lubricated from the factory.
Before operation check oil levels and adjust as necessary.
Use the proper type of oil as recommended in the
“LUBRICATION” section.
3. The winch mounting surface must be flat and of
sufficient strength to handle the rated load plus the
weight of the winch and attached equipment. An
inadequate foundation may cause distortion or
twisting of the winch uprights and side rails resulting
in winch damage.
a. Make sure the mounting surface is flat to within
l/16 inch (2.0 mm). Shim if necessary.
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
Care must be taken when moving, positioning or mounting
the winch. In most cases, lifting lugs have been provided
to assist in handling the winch. If the lug locations are
improper for your specific installation, great care should
be taken to ensure that the winch, when lifted, will be
properly balanced. Determine the weight of your winch by
referring to the “SPECIFICATIONS” section. Lift the
winch 3 to 4 inches (75 to 100 mm) off the ground. Verify
winch is balanced and secure before continuing lift.
FA MRA Series Winch Wire Rope
Take Off Diagram (Overwind Operation Only)
take off
for
overwind operation
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. Ensure the winch is positioned in a manner that allows
for proper spooling of the wire rope onto the drum.
When installed correctly, the direction of lift is
counterclockwise as viewed from the motor end of the
winch (clockwise from outboard end of winch). Refer
to Dwg. MHTPA0661.
2. Mount the winch so the axis of the drum is horizontal
and that the motor vent cap is not more than 15” off
top vertical center. If the winch is to be mounted in an
inverted position, the motor case must be rotated to
position the vent cap at the top.
Arrows indicate
direction of wire rope
haul in for overwind
operation
(Dwg. MHTPA0661)
4.
Recommended mounting bolts: 3/4 inch (18 mm)
Grade 8 or better. Use self-locking nuts or nuts with
lockwashers. Refer to Dwg. MHTPA0133 and Table 1
for mounting dimension information. To determine
clamping load tensile and shear strength requirements
refer to Dwg. MHTPA0692 and Table 2.
Winch Bolt Hole Mounting Dimensions
(Dwg. MHTPA0133)

Table 1: Bolt Hole Dimensions
Wire Rope
Dimension
31.25
* 5 bolts per siderail.
FA5MRA Winch Foundation Bolt Forces
Calculated for 1st Layer stall load [24,900 Ibf (110,755 N)]
1st Layer Line
Radius = 7.6 inches
(198 mm)
Rear
Maximum
shear force at one
foundation bolt
connection
Total tensile 794 mm
load which is
shared by the
rear foundation bolts
(Dwg. MHTPA0701)
Table 2: Winch Foundation Bolt Forces
Force Acting on Bolt 8
Drum Length (inches)
12 16 24 30 36
** Maximum tensile force occurs when wire rope is at a 42” angle.
5. Use 3/4 inch (18 mm) Grade 8 mounting bolts.
Tighten evenly and torque to 380 ft. lbs. (5 15 Nm) for
dry thread fasteners. If the fasteners are plated,
lubricated or a thread locking compound is used,
torque to 280 ft. lbs. (380 Nm).
6. Maintain a fleet angle between the sheave and winch
of no more than l-1/2”. The lead sheave must be on a
center line with the drum and for every inch of drum
length, be at least 1.6 feet (0.5 metre) from the drum.
Refer to Dwg. MHTPA0498.
7. Do not weld to any part of the winch.
l Do not use wire rope which is less than 5/8 inch (16
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. 5/8 inch IWRC wire rope average weight
per foot: 0.72 lbs/foot (1.07 kg/metre).
Wire Rope and Drum Diagram
Lead Sheave
(Dwg. MHTPA0498)
Drum
-Flange
Notes:
1. Always maintain a minimum of 4 tight wraps of wire
rope on the drum.
2. The minimum allowed distance from top of wire rope
layer to drum flange edge is 2 inches (5 1 mm).
3. 1.6 feet (0.5 metre) per inch of drum length; eg., for
12 inch drum length locate lead sheave 19.2 feet (6
metres) from drum.
Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor
for assistance in selecting the appropriate type and size of
wire rope and, where necessary, a protective coating. Use
a wire rope which provides an adequate safety factor to
handle the actual working load.
When considering wire rope requirements the actual
working load must include not only the static or dead
load but also loads resulting from acceleration, retardation
and shock load. Consideration must also be given to the
size of the winch wire rope drum, sheaves and method of
reeving. Wire rope construction must be 6 X 19 or 6 X 37
IWRC right lay to permit correct installation of wire rope
anchor. Refer to Table 3 for applicable wire rope sizes.
8

* 5/8 inch (16 mm) wire rope mustbeusedon FA5MRA
winches usedfor personnellifting to conform to ANSI
A10.22 standards.
l Use only 5/8 inch (16 mm) wire rope on the FA5MRA
winch if used for personnel handling.
Installing Wire Rope
(Refer to Dwg. MHTPA0166)
1. Cut wire rope to length in accordance with the wire
rope manufacturer’s instructions.
2. Feed the end of the wire rope into the wire rope
anchor hole in the drum and pull through
approximately one foot (305 mm) of wire rope.
Wire
Split Wedge’
(Dwg. MHTPA0166)
3. Wrap the wire rope with wire a distance from the end
equal to the wedge length plus one inch (25 mm).
4. Slide the sleeve over the end of the wire rope so the
larger diameter of the taper bore is nearest the end of
the wire rope.
5. Spread the end strands of the wire rope and insert the
split wedge until it is below the end of the wire rope.
6. Pull the sleeve over the wire rope end until tight.
Check that the wire rope strands stay in the slots
located on the split wedge.
7. Pull the wire rope anchor into position in the drum
anchor pocket.
Safe Wire Rope Handling Procedures
1. Always use gloves when handling wire rope.
2. Never use wire rope which is frayed or kinked.
3. Never use wire rope as a sling.
4. Always ensure wire rope is correctly spooled and the
first layer is tight against the drum.
Wire Rope Spooling
To compensate for uneven spooling and the decrease in
line pull capacity as the drum fills up, use as short a wire
rope as practical. When rewinding apply tension to the end
of the wire rope to eliminate line slack. This helps achieve
level winding and tight spooling.
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 sure all wire rope blocks, tackle and fasteners have a
sufficient safety margin to handle the required load under
all conditions. Do not allow wire rope to contact sharp
edges or make sharp bends which will cause damage to
wire rope, use a sheave. Refer to the wire rope
manufacturer’s handbook for proper sizing, use and care of
wire rope.
Safe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not attach a welding electrode to winch or wire
rope.
3. Never run the wire rope over a sharp edge. Use a
correctly sized sheave.
4. When a lead sheave is used, it must be aligned with
the center of the drum. The diameter of the lead
sheave must be at least 24 times the diameter of the
wire rope. Refer to Dwg. MHTPA0498.
5. Always maintain at least four full, tight wraps of wire
rope on the drum.
Air Supply
The air supply must be clean and free from moisture.
Air Lines
The inside diameter of the winch air supply lines must not
be less than the sizes shown in Table 4. Before making
final connections, all air supply lines should be purged
with clean, moisture free air or nitrogen before connecting
to winch inlet. Supply lines should be as short and straight
as installation conditions will permit. Long transmission
lines and excessive use of fittings, elbows, tees, globe
valves etc. cause a reduction in pressure due to restrictions
and surface friction in the lines.
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
FA5MRA l-1/2