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

Air Line Lubricator
(Refer to Dwg. MHTPA0191)
Always use an air line lubricator with these motors. The
lubricator must have an inlet and outlet at least as large as
the inlet on the motor. Install the air line lubricator as
close to the air inlet on the motor as possible.
l Lubricator must be located no more than 10 ft. (3 m)
from the motor.
The air line lubricator should be replenished daily and set
to provide 6 to 9 drops per minute of SAE 10W oil. A fine
mist will be exhausted from the throttle control valve
when the air line lubricator is functioning properly.
Air Line Filter
(Refer to Dwg. MHTPA0191)
It is recommended that an air line strainer/filter be
installed as close as practical to the motor air inlet port,
but before the lubricator, to prevent dirt from entering the
motor. The strainer/filter should provide 20 micron
filtration and include a moisture trap. Clean the strainer/
filter periodically to maintain its operating efficiency.
Regulator
Air Out
Lubricator Filter
Air In
(Dwg. MHTPA0l91)
Moisture in Air Lines
Moisture that reaches the air motor through air supply
lines is a primary factor in determining the length of time
between service overhauls. Moisture traps can help to
eliminate moisture. Other methods, such as an air receiver
which collects moisture before it reaches the motor, an
aftercooler at the compressor that cools the air to condense
and collect moisture prior to distribution through the
supply lines are also helpful.
Motor
For optimum performance and maximum durability of
parts, provide an air supply of 90 psig at 700 scfm (6.3
bar/630 kpa at 20 cum/m) for FA5MRA winches. The air
motor should be installed as near as possible to the
compressor or air receiver. Recommended pressures and
volumes are measured at the point of entry to the air
motor.
Electrical Grounding
l The Personnel Lifting System must be properly
grounded to conform to ANSI A10.22 standards.
Ensure electrical grounding is conducted by licensed
electricians in accordance with the latest edition of the
National Electric Code (ANSI/NFPA 70) and any
applicable local, state and national electric codes and
ordinances.
An electrical grounding lug is attached to the winch
siderail. Ensure winch is correctly grounded to the
Personnel Lifting System before using winch.
Wire Rope Line Speed Monitor
Winches are equipped with a battery operated line speed
monitor and overspeed indicator. Ensure the indicator
sensor is adjusted as described in ‘Adjustments’ in the
“WINCH MAINTENANCE” section.
The line speed monitor rechargeable battery will operate
for twenty-five eight hour days at 33% actual on time
(winch operation time). An amber light indicates the
battery requires recharging. Approximately one day of
operation remains when the recharge light indication
comes on. Refer to ‘Adjustments’ in the “WINCH
MAINTENANCE” section for recharging procedures.
Motor Exhaust and Muffler
(Refer to Dwg. MHTPA0646)
l Operator exposure to noise levels shall not exceed 90
dBA over an 8 hour period (Time Weighted Average
(TWA)). Ensure motor and pilot valve air is properly
exhausted and muffled.
Winch noise level ratings under factory test conditions:
1. 89 dBA during operation of winch without load in the
haul in direction.
2. 89 dBA during operation of winch without load in the
pay out direction.
These levels were achieved when the motor and pilot
valve air was exhausted through a 10 foot (3 metre) length
of hose and attached to a muffler.
Initial Operating Checks
Winches are tested for proper operation prior to leaving
the factory. Before the winch is placed into service the
following initial operating checks should be performed.
1. When first running the motor inject some light oil into
the inlet connection to provide initial lubrication.
2. When first operating the winch it is recommended that
the motor be driven slowly in both directions for a
few minutes.
10

For winches that have been in storage for a period of more
than one month the following start-up procedure is
required.
1. Give the winch an inspection conforming to the
requirements of “Winches Not in Regular Use” in the
“INSPECTION” section.
2. Pour a small amount of 10W oil in the motor inlet
port.
3. Operate the motor for 10 seconds in both directions to
flush out any impurities.
4. The winch is now ready for normal use.
The four most important aspects of winch operation are:
1. Follow all safety instructions when operating the
winch.
2. Allow only people trained in safety and operation of
this winch to operate this equipment.
3. Subject each winch to a regular inspection and
maintenance procedure.
4. Be aware of the winch capacity and weight of load at
all times.
l Operate this winch ONLY if wire rope is installed to
come off the drum for overwind operation. Refer to
Dwg. MHTPA0564.
l Operation of this winch in a safe manner, as part of a
Personnel Lifting System, requires that supervisors,
operators, and personnel being transported be
thoroughly instructed in the potential dangers involved
and the safety procedures established to minimize the
risks of accident, injury and property damage.
l Do not transport personnel and materials at the same
time. Safe operation, according to established
standards, require that personnel and materials are to
be transported separately.
l Visual inspections of the winch and entire Personnel
Lifting System must be conducted by designated
personnel instructed in safety, operation and
maintenance of this product before using the winch to
transport personnel. Any visual indication of damage
must be inspected, repaired and actions documented in
accordance with component manufacturers’
instructions to ensure the safety of personnel is not
compromised.
Personnel Lifting System
Owners are responsible for establishing, implementing and
ensuring that supervisors, operators, and personnel being
transported are instructed in operation and safety
procedures. Refer to ‘Training’ in the “WINCH
OPERATION” section.
1. Supervisors, operators and personnel being lifted
should check that winch, wire rope, working platform,
lifelines, safety belts (harnesses), etc. are present and
functional prior to authorizing personnel lifting.
2. Personnel being transported must be instructed in and
adhere to the safety procedures established including,
but not limited to, the following list:
a. Emergency Escape Procedures in accordance
with ANSI A10.22 Section 11.
b. Use of safety belts (harnesses) and rope grabs
(lifelines) in accordance with ANSI A10.22
Sections 11, 12.4 and 12.5.
3. Winch operators must be instructed in and adhere to
the procedures established to ensure proper and safe
operation of this winch as a component in a Personnel
Lifting System.
a.
b.
C.
d.
e.
Winch operators must remain at the winch
controls at all times when handling personnel and
materials.
At any indication of winch, or system, damage or
impending danger the winch operator must place
the winch in a safe condition and notify
designated personnel. Winch and system
operation must be suspended until all
discrepancies noted have been inspected, repaired
and system tested to ensure safe operation.
Voice communication must be established and
maintained between winch operator, personnel
being lifted and personnel located at each landing
(as applicable).
Winch operators must maintain at least 4 tight
wraps of wire rope on the drum at all times.
Wire rope shall be weighted on the end to prevent
line run when spooling onto the drum.
Initial Winch Operating Checks
l Initial operating checks specific to the entire
Personnel Lifting System should be established to
ensure system component compatibility.
Winches are tested for proper operation of all features
prior to shipping. Before the winch is placed into service
the following initial operating checks should be
performed.
1. When first running the motor inject a small amount of
oil into the inlet connection to provide initial and
immediate lubrication.
2. When first operating the winch run the motor slowly
in both directions for a few minutes.
3. Verify both drum brakes function as described in
‘Winch Testing’ in the “WINCH INSPECTION”
section. To adjust the brakes refer to ‘Winch
Adjustments’ in the “WINCH MAINTENANCE”
section.
11

4. Adjust and verify limit switch settings. To adjust the
limit switch set points refer to ‘Winch Adjustments’ in
the “WINCH MAINTENANCE” section.
5. Verify line speed monitor and overspeed alarm
operation as described in ‘Winch Testing’ in the
“WINCH INSPECTION” section.
6. Verify automatic drum brake emergency release
system operation as described in ‘Winch Testing’ in
the “WINCH INSPECTION” section.
Winch Component Operation
Pilot Air Throttle Control Lever
(Refer to Dwg. MHTPA0608)
Winch control lever directions are described as viewed
when facing the winch motor and apply to overwind
operation only. To ensure smooth operation of the winch
sudden movements of the control valve should be avoided.
1. To payout wire rope, lift up on the winch control
lever and move the lever to the right.
2. To haul in wire rope, lift up on the winch control
lever and move the winch control lever to the left.
Pilot Air Throttle Control Operation
Pay out
Directions as
viewed from the
motor end of
winch
(Dwg. MHTPAO608)
Manual Drum Brake
The manual drum brake may be applied by pushing down
on the brake handle and released by pulling up. If the
handle is pushed down fully, it should lock in that position
and prevent drum rotation, until released by the operator.
The brake must be kept properly adjusted to hold the
required load. To adjust the brake refer to ‘Winch
Adjustments’ in the “WINCH MAINTENANCE” section.
Automatic Drum Brake
The automatic drum brake is a spring applied, air released
brake. Using an air actuated, spring loaded cylinder the
brake automatically disengages when the motor is
operated. Air pressure in the cylinder overcomes spring
pressure to release the brake. When the pilot air throttle
control lever is placed in the neutral position, the air in the
cylinder is vented and the spring automatically engages
the brake to prevent drum rotation.
The cylinder clevis must be kept properly adjusted to hold
the required load. To adjust the brake refer to ‘Winch
Adjustments’ in the “WINCH MAINTENANCE” section.
Limit Switch
Pre-set limit switch settings prevent winch wire rope
payout and haul in by stopping air flow to the winch motor
when a set point has been reached. It is the owner’s and
operator’s responsibility to adjust winch operating limits
prior to using the winch to transport personnel. To adjust
the limit switch set points refer to ‘Winch Adjustments’ in
the “WINCH MAINTENANCE” section.
l Ensure limit switch operates properly and that limits
have been set before using winch to transport
personnel.
Line Speed Monitor and Overspeed Alarm
The Line Speed Monitor is a battery powered wire rope
line speed indicator system which determines line speed
by sensing drum rotation.
The Line Speed Monitor provides a visual alarm (flashing
red light) and digital readout (in feet) to allow the operator
to adjust throttle control to maintain wire rope line speed
at 100 feet per minute (30.5 metres per minute) or less.
Line Speed Monitors are factory pre-set to match the
winch installed on and cannot be adjusted. The overspeed
indicator light flashes when drum speed exceeds wire rope
line speeds of 100 feet per minute (+/- 10 feet) (30.5
metres per minute; +/- 3 metres) in either direction of
drum rotation.
The Line Speed Monitor battery should be recharged as
described in ‘Adjustments’ in the “WINCH
MAINTENANCE” section.
Winch Emergency Descent Procedure
l ANSI A10.22-1990 Section 11 defines the Personnel
Lifting System requirements for establishing
emergency escape methods and procedures. The
following procedure describing the use of the winch to
lower personnel or loads when the supply air to the
winch has been interrupted should only be used after
all other established methods have been exhausted.
The lowering speed of the load using the winch descent
procedure is dependent upon the weight of the load,
amount of cable on the drum, and position of the load in
the lifting system.
To use the winch to lower the load when the air supply has
been interrupted conduct the following:
1.
2.
3.
4.
12
Engage the manual band brake.
Depress the automatic band brake clevis and remove
cotter pin and pin to disconnect cylinder (110) from
brake lever.
Slowly disengage manual band brake using the brake
lever. Regulate speed of load using manual band
brake. If load does not lower engage band brake and
then conduct the following step.
Remove capscrews from motor adapter valve and
remove pilot valve/adapter assembly from winch
motor.

5. Use the manual band brake to throttle lowering speed
(if required) when lowering the load.
Training
Prior to using the Personnel Lifting System supervisors,
operators, service personnel, and personnel being
transported must be thoroughly instructed in the potential
dangers involved and the safety procedures established to
minimize the risks of accident, injury and property
damage.
Establishment of safe operating procedures for the
Personnel Lifting System should be based on ANSI
A10.22 specifications, OSHA regulations, all applicable
local, state and national standards, system component
manufacturers’s recommendations, and system designer
recommendations.
Records of training should be maintained and made
available to designated personnel for review.
To ensure continued satisfactory operation of the winch,
all points requiring lubrication must be serviced with the
correct lubricant at the proper time interval as indicated
for each assembly.
The lubrication intervals recommended in this manual are
based on intermittent operation of the winch eight hours
each day, five days per week. If the winch is operated
almost continuously or more than the eight hours each
day, more frequent lubrication will be required. Also, the
lubricant types and change intervals are based on
operation in an environment relatively free of dust,
moisture, and corrosive fumes. Use only those lubricants
recommended. Other lubricants may affect the
performance of the winch. Approval for the use of other
lubricants must be obtained from your Ingersoll-Rand
distributor. Failure to observe this precaution may result in
damage to the winch and/or its associated components.
INTERVAL
Startof eachshift
LUBRICATION CHECKS
Checkflow andlevel of air line
lubricator (approximately 6 to 9 drops
per minute required at maximum
motor speed).
Monthly
Checkwinch motor oil level.
Lubricate componentssupplied by
greasefittings.
Inspectandcleanor replaceair line
filter.
Yearly
Checkreduction gearoil level.
Drain and refill winch reduction gear
oil.
Drain andrefill winch motor oil.
Note: Intervals arebasedon winch operationin a normal
environment asdescribedin the “INSPECTION” section.In
‘Heavy’ or ‘Severe’ operating conditions adjust lubrication
intervals accordingly.
Recommended Lubricants
Oil
Temperature Type Oil
1. Below 32° F (0° C) SAE 10W
2. 32° to 80° F (0° to 27° C) SAE 20W
3. Above 80° F (27° C) SAE 30W
Grease
Temperature Type Grease
1. -20° to 50° F EP 1 multipurpose
(-30° to 10° C) lithium-based grease
2. 30° to 120° F EP 2 multipurpose
(-1° to 49° C) lithium-based grease
Motor
(Refer to Dwg. MHTPA0565)
Correct lubrication is one of the most important factors in
maintaining efficient winch operation. The motor is splash
lubricated by the oil in the motor housing and has no other
means of lubrication. It is therefore important to use only
quality, non-detergent motor oil to ensure maximum
performance and minimum downtime for repairs. Refer to
the ‘Recommended Lubricants’ section. Allow oil to settle
before topping off.
Oil capacity for the FA5MRA winch motor is 3 quarts
(2.8 litres). Add oil through the fill plug opening until oil
flows from the level plug hole. Add oil slowly to prevent
spilling.
The motor should be level-checked daily or at the start of
each shift after accumulated water has been drained off.
When motors are operated in temperatures below freezing,
wait long enough at end of shift for water to separate from
oil but not long enough for it to freeze. Drain the water
then refill to the level plug. If desired, all the oil may be
drained at the end of the shift and the motor refilled with
new oil.
13

Motor Lubrication Locations
Drain Plug
(Dwg. MHTPA0565)
‘Level Plug
Wire Rope
Follow the wire rope manufacturer’s instructions. At a
minimum, observe the following guidelines.
1. Clean with a brush or steam to remove dirt, rock dust
or other foreign material on the surface of the wire
rope.
l Do not use an acid-based solvent. Only use cleaning
fluids and lubricants specified by the wire rope
manufacturer.
2. Apply a wire rope lubricant, Ingersoll-Rand LUBRI-
LINK GREEN or SAE 30W oil.
3. Brush, drip or spray lubricant weekly, or more
frequently, depending on severity of service.
Reduction Gear Assembly
(Refer to Dwg. MHTPA0140)
The reduction gear assembly is filled and shipped with oil
from the factory. Check oil level before initial winch
operation. If the winch is used at a normal frequency
replace the oil in the reduction housing once every year.
To ensure correct performance, highest efficiency and
long life, it is essential that the lubricating oil be
maintained at the correct level. Rotate the drum until the
fill plug is located at top dead center then add oil up to the
level plug hole. Oil capacity for the reduction gear
assembly is 4 quarts (3.8 litres).
l Do not over fill. Excess oil will reduce operating
efficiency and increase oil temperature.
The recommended grade of oil must be used at all times
since the use of unsuitable oil may result in excessive
temperature rise, loss of efficiency and possible damage to
the gears. Refer to the ‘Recommended Lubricants’ section.
Use only high quality lubricants in the reduction gear
assembly such as motor oil, high grade EP type hydraulic
oil or their equivalents.
Reduction Gear Lubrication Plug Locations
Upright
(Dwg. MHTPA0140)
Drum Brakes
Lubricate pivot points, pins and shafts with recommended
grease to prevent corrosion of parts.
rum
Reduction Gear
Assembly
l Do not allow grease or oil to come into contact with
drum band brake linings.
Disc Brake (optional feature)
Oil from the reduction gear assembly also provides
lubrication for the disc brake. After an oil change or winch
overhaul remove the breather plug and pour 6 to 8 ounces
(0.2 litres) through the breather hole in the brake housing
to initially lubricate the brake discs. Refer to the
‘Recommended Lubricants’ section. Reinstall the breather
plug before operation of winch or brakes.
Seals and Bearings
If winch is disassembled, clean all parts thoroughly and
coat bearings and seals with clean grease. Refer to the
‘Recommended Lubricants’ section. Use sufficient grease
to provide a good protective coat. Lubricate grease fittings
monthly with 2 or 3 pumps of a grease gun.
Air Line Lubricator
Replenish lubricator daily and set to provide 6 to 9 drops
of oil per minute. Refer to the ‘Recommended Lubricants’
section for recommended oil.
Wire Rope Line Speed Monitor
Does not require lubrication.
Limit Switch
Does not require lubrication.
14

Inspection information is based in part on American
National Standards Institute Safety Codes (A10.22 and
B30.7).
Records and Reports
Personnel Lifting System
Owners are responsible for establishing and implementing
operation and safety procedure training for all personnel
involved in the use and operation of a Personnel Lifting
System.
1. PERSONNEL TRAINING. Records of training
provided to supervisors, operators, service personnel
and personnel being transported should be maintained
and made available to designated personnel for
review.
2. SYSTEM MAINTENANCE. Records of all service,
maintenance and testing performed on the Personnel
Lifting System should be maintained and made
available to designated personnel for review.
Winch Records and Reports
Inspection records, listing all points requiring inspection,
should be maintained for all load bearing equipment.
Written reports, based on Initial, Weekly and Quarterly
inspections, should be made on the condition of critical
parts as a method of documenting inspections. These
reports should be dated, signed by the person who
supervised the performance of the inspection, and kept on
file where they are readily available for review. A sample
winch ‘Inspection and Maintenance Report’ has been
provided at the end of this section.
Wire Rope Reports
Records should be maintained as part of a long-range wire
rope inspection program. Records should include the
condition of wire rope removed from service. Accurate
records will establish a relationship between visual
observations noted during frequent inspections and the
actual condition of wire rope as determined by periodic
inspections.
Personnel Lifting System wire rope records should be
maintained and made available to designated personnel for
review.
System Inspections and Tests
l Information provided by Ingersoll-Rand is applicable
only to the winch to assist in determining the condition
of the winch components described. References to
other Personnel Lifting System components are made
with respect to their relationship to the winch. For
specific information on system components other than
the winch, reference the manufacturers’ literature and
ANSI A10.22.
Personnel Lifting System inspections and tests of installed
components, functions and safety devices should be
established based on procedures derived from ANSI
A10.22 specifications, OSHA regulations, manufacturers’
literature and recommendations, system designer
recommendations and all applicable local, state and
national standards.
1. SYSTEM. Frequency of inspections:
a. Initial system inspection.
b. Daily checks and Weekly inspections.
c. Quarterly inspections.
System Initial and Quarterly Inspections
In addition to established Daily and Weekly inspections
conduct the following:
l The static drop test is only required for guided cage
systems.
1. INITIAL INSPECTION. With the cage at rated load,
on a guided cage system, using dead weights,
conduct a static drop test. This test is designed to
ensure the cage safety clamps engage and stop the
cage from falling. Perform requirements of the weekly
inspection.
2. QUARTERLY INSPECTION. With the cage empty,
on a guided cage system, conduct a static drop test.
This test is designed to ensure the cage safety clamps
engage and stop the cage from falling. Perform
requirements of the weekly inspection.
System Testing
Personnel Lifting System testing should be conducted in
accordance with the system specific instructional manual
and component manufacturers’ recommendations. A
system specific instruction manual must be compiled to
conform to the requirements of ANSI A10.22, and detail
the operation, maintenance and safety requirements of the
various components comprising the personnel lifing
system.
Winch Inspections
The following listed inspections apply only to the winch.
These inspections should be conducted when scheduled,
when indicated by winch performance and when the winch
is disassembled for repair.
Careful inspection on a regular basis will reveal
potentially dangerous conditions while still in the early
stages, allowing corrective action to be taken before the
condition becomes dangerous.
15

Damage revealed through inspection, or noted during
operation, must be reported to designated personnel
instructed in safety, operation and maintenance of this
equipment. A determination as to whether a condition
constitutes a safety hazard must be made, and the
correction of noted safety hazards accomplished and
documented by written report before placing the
equipment in service.
l All new, altered or modified equipment should be
inspected and tested by personnel instructed in safety,
operation and maintenance of this equipment to ensure
safe operation at rated specifications before placing
equipment in service.
l Never use a winch that inspection indicates is
damaged.
l Prior to using the winch to lift personnel, an initial
inspection should be conducted after assembly, major
repairs or alteration, and when the system has been
idle for periods of longer than one month.
Daily checks, weekly and quarterly inspections should be
performed on equipment in regular use.
1. Daily checks are visual examinations performed by
operators or personnel instructed in safety and
operation of this equipment and include observations
made during routine equipment operation.
2. Weekly inspections are thorough inspections
conducted by personnel instructed in safety, operation
and maintenance of this equipment. Weekly
inspections are also required prior to personnel lifting
if the system has been idle for periods in excess of one
week, but less than one month.
3. Quarterly inspections are a combination of weekly
inspection requirements and the performance of a
static drop test on guided cage systems only to verify
operation of the cage’s safety clamp.
Winch Daily Checks and Weekly Inspections
On equipment in continuous service, weekly inspections
are required. Maintain written ‘records of weekly
inspections to provide an accumulative basis for
continuing evaluation. Disassembly may be required as a
result of inspection findings.
In addition, daily checks, or visual inspections should be
conducted by operators during regular operation for
damage or evidence of malfunction.
1. WINCH (DAILY). At the beginning of the shift, prior
to operation, visually inspect winch housings,
controls, brakes, siderails and drum for indications of
damage. Do not operate the winch until all
discrepancies noted have been reviewed, inspected
further and corrected by personnel instructed in the
operation, safety and maintenance of this winch.
WINCH (WEEKLY). Inspect the following:
a. SIDE RAILS AND END UPRIGHTS. Check for
deformed, cracked or corroded main components.
Replace damaged parts.
b. FASTENERS. Check retainer rings, split pins,
capscrews, nuts, and other fasteners on winch,
including mounting bolts. Replace if missing or
damaged and tighten if loose.
C.
DRUM AND SHEAVES. Check for cracks, wear
or damage. Replace damaged parts.
2. WIRE ROPE. Visually inspect all wire rope which
can be expected to be in use during the day’s
operations. Inspect for wear and damage indicated by
distortion of wire rope such as kinking, “birdcaging,”
core protrusion, main strand displacement, corrosion,
broken or cut strands. If damage is evident, do not
operate winch until the discrepancies have been
reviewed and inspected further by an experienced
wire 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 check requirements, also inspect
for the following weekly:
a.
b.
C.
d.
e.
Ensure wire rope is spooled onto the drum for
overwind operation only and that a minimum of 2
inches (50 mm) clearance is maintained between
the outside edge of the drum flange and the
outermost layer of wire rope.
Buildup of dirt and corrosion. Clean with steam
or a stiff wire brush to remove dirt and corrosion
if necessary.
Loose, frayed or damaged end connection.
Replace if loose, frayed or damaged. Ensure ends
will not catch on personnel.
Ensure the wire rope is securely anchored in the
winch drum.
Verify wire rope diameter. Measure the diameter
of the wire rope from crown-to-crown throughout
the life of the wire rope. Recording of the actual
diameter should only be done with the wire rope
under equivalent loading and in the same
operating section as accomplished during
previous inspections. If the actual diameter of the
wire rope has decreased more than l/64 inch (0.4
mm) a thorough examination of the wire rope
should be conducted by an experienced inspector
to determine the suitability of the wire rope to
remain in service. (Refer to Dwg. MHTPA0056).
(Dwg. MHTPA0056)
16

3.
4.
5.
6.
7.
8.
9.
AIR SYSTEM (WEEKLY). Visually inspect all
connections, fittings, hoses and components for
indication of air leaks. Repair any leaks and replace
damaged components.
CONTROLS (DAILY AND WEEKLY). During
operation of winch, verify response to control is quick
and smooth. If winch responds slowly or movement is
unsatisfactory, do not operate winch until all problems
have been corrected.
BRAKES (WEEKLY). Ensure proper operation.
Verify each brake system will hold a 150% rated load
with full drum (as applicable to normal use) without
slipping. If indicated by poor operation or visual
damage, disassemble and repair brake(s). Check all
brake surfaces for wear, deformation or foreign
deposits. If drum brake lining thickness is 0.062 inch
(2 mm) or less anywhere along its edge replace brake
bands or linings. Clean and replace components as
necessary. Test each brake system independently.
LIMIT SWITCHES (WEEKLY). Verify winch limit
switches operate at the set limits. When actuated, limit
switches interrupt air flow to the motor in the
direction of winch operation only. Adjust limit
settings or repair to correct all noted discrepancies.
ALL COMPONENTS (WEEKLY). Inspect for wear,
damage, distortion, deformation and cleanliness. If
external evidence indicates damage, disassemble as
required to conduct a detailed inspection. Inspect
gears, shafts, bearings, springs and covers. Replace
worn or damaged parts. Clean, lubricate and
reassemble.
SUPPORTING STRUCTURE (WEEKLY). Check for
distortion, wear and continued ability to support
winch. Ensure winch is firmly mounted and that
fasteners are in good condition and tight.
LABELS AND TAGS (WEEKLY). Check for
presence and legibility of labels. Replace if damaged
or missing.
10. WIRE ROPE LINE SPEED MONITOR. Verify Line
Speed Monitor displays line speed and overspeed
alarm lights at 100 feet per minute (+/- 10 feet) (30.5
metres per minute; +/- 3 metres). If battery charge
light is on, charge battery.
11. WINCH EXHAUST AND MUFFLER. Visually
inspect exhaust hoses, connections and muffler for
damage. Ensure piping and muffler are correctly
installed and direct exhaust away from winch
operator. Operator noise levels must not exceed 90
dBA over an 8 hour period (Time Weighted Average
(TWA)).
12. Ensure electrical ground (earth) is firmly connected
and that wire is in good condition. Replace wire if
corroded or damaged.
Winch Initial and Quarterly Inspections
Disassembly may be required as a result of inspection
findings or in order to properly inspect the individual
components. Maintain written records of initial and
quarterly inspections to provide an accumulative basis for
continuing evaluation. Inspect all items listed in “Weekly
Inspection.” Also conduct the following:
1. INITIAL INSPECTION. Conduct all requirements of
‘Winch Daily and Weekly Inspection’ and ‘Winch
Testing’.
2. QUARTERLY INSPECTION. Conduct all
requirements of ‘Winch Daily and Weekly Inspection’
and ‘Winch Testing’.
Winches Not in Regular Service
1. Equipment which has been idle for a period of one
week or more, but less than one month, shall be given
an inspection conforming to the requirements of
“Daily and Weekly Inspections” before being placed
in service.
2. Equipment which has been idle for a period of over
one month shall be given an complete inspection
conforming with the requirements of “Initial and
Quarterly Inspections” before being placed in service.
17

INSPECTION AND MAINTENANCE REPORT
Ingersoll-Rand Force 5 Series Ansi Manrider® Air Winch
Model Number: Date:
Serial Number: Inspected by:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Inspection ( _ Weekly _ Quarterly _ Initial)
2. Discrepancy(s) noted during Daily Inspection Operating Environment:
3:-,Discrepancy(s) noted during maintenance Normal _ Heavy _ Severe _
4. Other:
Refer to the Parts, Operation and Maintenance Manual “INSPECTION” section for general inspection criteria. Also, refer to appropriate National Standards
and codes of practice. If in doubt about an existing condition contact the nearest Ingersoll-Rand Distributor or the factory for technical assistance.
CONDITION CORRECTIVE
COMPONENT ACTION NOTES
Pass Fail Repair Replace
Side Rails and End
Uprights
Manual Drum Band
Brake
(150% Load Test)
Automatic Drum Band
Brake
(150% Load Test)
Drum Band Brakes
(Visual Inspection)
Motor
Limit Switches
Controls
Air System
Fasteners
Reduction Gears
Labels and Tags
Shafts
Wire Rope Anchor
Wedge
Line Speed Monitor
and Overspeed Alarm
Other Components
(list in NOTES
section)
---
---
---
TESTING Pass Fail NOTES
Operational (No Load)
Operational (10% Load)
Operational (Maximum Test Load *)
*
Maximum winch operational test load is 125% of rated line pull.
Maximum brake test load is 150% of rated line pull; perform by raising the test load approximately 4 to 6 inches (100 to 150 mm).
18

This section provides basic troubleshooting information. Determination of specific causes to 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.
Load continues to move when
winch is stopped.
Winch does not lift load.
Throttle lever moves but winch
doesnot operate.
Motor runs hot or makes
excessive noise during
operation.
Winch runs slow.
CAUSE
No air supply to winch.
Winch is overloaded.
Automatic drum band brake does not release.
Limit switch engaged.
Shipping plugs may still be in place.
Automatic drum band brake is slipping.
Winch is overloaded.
SOLUTION
Check air supply line connections and hoses.
Reduce load to within rated capacity.
Pressurize brake release port and check for leakage.
Replace brake piston seals if leakage is found.
Shift pilot valve throttle lever in opposite direction.
If winch operates, adjust limit switch settings.
Remove shipping plugs in valve and motor exhaust
ports.
Check brake band adjustment and brake band lining
wear.
Reduce load to within rated capacity.
Pilot air throttle control valve sticking. Disassemble, inspect and repair the pilot air control
throttle valve.
Motor may be damaged.
Insufficient air supply.
Remove and disassemble motor. Examine all parts
and replace any that are worn or damaged.
Verify air supply pressure and volume at winch inlet
meets the requirements listed in the
Automatic drum band brake does not release.
“SPECIFCATIONS” section. Clean air line filter.
Dissassemble, inspect and repair the automatic drum
band.
Motor may be damaged.
Insufficient air supply.
Limit switch engaged.
Low oil level.
Improper lubrication.
Disassemble and clean the motor and replace any
broken or damaged parts.
Ensure the air pressure at the winch inlet is at least
90 psig (6.3 bar) at rated volume. Clean air line
filter.
Shift pilot valve throttle lever in opposite direction.
If winch operates, adjust limit switch settings.
Check oil level in the motor. Add oil as required to
obtain the proper level.
Replace oil with type recommended in the
“LUBRICATION” section.
Water in 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. Disassemble and repair motor.
Improper hose or fitting sizes. Check fittings, connections and hoses for correct
size and length. Replacepartsthat 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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