Ingersoll-Rand FORCE 5i Man Rider FA2i-MRA User manual

Product Information
Model FA2i-MRA (ANSI) Man RiderTM
Save These Instructions
®
Form MHD56331
Edition 1
September 2005
71468110
©2005 Ingersoll-Rand Company

2Form MHD56331 Edition 1
Only allow Ingersoll-Rand trained Technicians to perform maintenance on this winch. For additional information contact Ingersoll-Rand or
nearest Distributor.
Refer to Product Safety Information Manual for Man Rider Winches Form MHD56251, contact factory for the Product Maintenance Manual Form MHD56332 and Product
Parts Information.
Manuals can be downloaded from www.winchandhoistsolutions.com
The use of other than genuine Ingersoll-Rand replacement parts may result in safety hazards, decreased performance, increased maintenance and may invalidate all warranties.
The original language of this manual is English.
Refer all communications to the nearest Ingersoll-Rand Office or Distributor.
PRODUCT DESCRIPTION
NOTICE
• This winch was designed to meet ANSI A10.22-1990 which limits its use as
part of a system for personnel lifting. For information defining the Personnel
Lifting System requirements read ANSI A10.22 and all associated
manufacturer’s component literature. A copy of ANSI A10.22-1990 is provided
with this product.
The FA2i (ANSI) Man Rider Winch Series are air powered, planetary geared units
designed for transporting personnel. Winches are provided with an internal
automatic disc brake and either a manual or automatic band brake.
The output from an externally mounted piston air motor is transmitted through a
coupling and shaft to the planetary reduction gear assembly.
The output from planetary reduction gear assembly is connected to the wire rope
drum through the output shaft.
FA2i-MRA Winch disc brake assembly consists of friction plates splined to a hub
which in turn is connected to the drive shaft from the air motor. Brake friction plates
are clamped to the drum shaft through a spring applied piston. The brake remains
applied until the winch control valve is operated and winch payout or haul-in occurs.
Air is introduced into the chamber, which is formed between brake piston and brake
housing, causing the brake piston to react, compressing brake springs and releasing
friction plates allowing motor shaft to rotate. A power failure or sudden loss of air
will immediately cause the spring applied brake to engage.
The drum band brake operates by applying a friction force between drum brake band
and winch drum. The manual brake requires an operator to engage and disengage
brake using a lever located on top of brake band. The automatic drum band brake
operation is similar to disc brake operation; they are both fully disengaged in the
haul-in and payout direction.

Form MHD56331 Edition 1 3
SPECIFICATIONS
Model Code Explanation
Example: FA2i-MRA2MK1G FA2i - MRA 24 M K 1 G
Series (Capacity):
FA2i =Infinity Winch Personnel Lifting - 1,000 kgs / 2,200 lbs
Designation:
*MRA=Man RiderTM ANSI A10.22-1990
Drum Length (Distance between drum flanges):
12 = 12 inch (305 mm)
16 = 16 inch (406 mm)
24 =24 inch (610 mm) Standard (Refer to Table 4 on page 4 for drum lengths)
30 = 30 inch (762 mm)
36 = 36 inch (914 mm)
Brake:
M=Manual Band Brake [Standard]
A = Automatic Band Brake
K=Automatic Disc Brake [Standard]
Control:
1 = Winch mounted lever throttle (Standard)
3XX = Remote pilot pendant throttle with warning light [XX = Specify hose length (feet). Maximum 66 ft. (20 metres)] **
5XXX = Remote electric-over air throttle [XXX = Specify control cable length (feet)] **
Options:
7 = Drum Grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch)
A = Winch guard with manual level wind (only available with Auto Band Brake)
B = Extended Warranty
F1 = Filter, lubricator, regulator mounted on winch in position 1
F2 = Filter, lubricator, regulator mounted on winch in position 2 (opposite of 1)
G=Winch Guard
J = Air Line Accessories
P = Marine 812 finish
P1 = Marine 812-X paint system
R = Slack wire rope detector
V = Press Roller
W = Client witness of load test
X = Special testing; specify
Z = Sand blast and Carbozinc primer only
Notes:
* 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) Dual brakes (manual band brake and automatic disc brake).
(6) Winch mounted throttle lever with automatic return.
** Remote throttles are provided with 6 feet (2 metres) of hose. Specify hose lengths greater than 10 feet. For lengths greater than 66 ft (20 m) please contact
your Ingersoll-Rand distributor or the factory for control acceptability. Metric lengths are provided for reference only, order lengths in feet.
FA2i-MRA winches are shipped with a muffler, 6 feet (2 mm) 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.

4Form MHD56331 Edition 1
INSTALLATION
Prior to installing the winch, carefully inspect it for possible shipping damage.
Winches are supplied fully lubricated from the factory.
Check oil levels and adjust as necessary before operating winch. Refer to
“LUBRICATION” section for recommended oils and lubrication intervals.
CAUTION
• Owners and users are advised to examine specific, local or other regulations,
including American National Standards Institute and/or OSHA Regulations
which may apply to a particular type of use of this product before installing or
putting winch to use.
Mounting
Refer to Dwg. MHP0133 on page 11, A. Drum; Table 5 on page 4 and Table 6 on
page 4.
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 lug locations are
improper for your specific installation, great care should be taken to ensure that
winch, when lifted, will be properly balanced. Determine weight of your winch by
referring to “SPECIFICATIONS” section. Lift winch 3 to 4 inches (75 to 100 mm) off
ground. Verify winch is balanced and secure before continuing lift. Mount winch so
axis of drum is horizontal and that motor vent cap is not more than 15° off top
vertical center. If winch is to be mounted in an inverted position, motor case must
be rotated to position vent cap to the top.
1. The winch mounting surface must be flat and of sufficient strength to handle
rated load plus weight of winch and attached equipment. An inadequate
foundation may cause distortion or twisting of winch uprights and side rails
resulting in winch damage.
2. Make sure mounting surface is flat to within 0.005 inch (0.127 mm) per inch of
drum length. Shim if necessary. Refer to Table 5 on page 4.
3. Mounting bolts must be Grade 8 or better. Use self-locking nuts or nuts with
lockwashers. Refer to Table 6, “Mounting Bolts,” on page 4.
4. Tighten mounting bolts evenly and torque to specification in torque chart. Refer
to ‘Torque Chart’ in Product Maintenance Information Manual Form MHD56332.
5. Maintain a fleet angle between sheave and winch of no more than 1-1/2°. The
lead sheave must be on a center line with drum and, for every inch (25 mm) of
drum length, be at least 1.6 feet (0.5 metre) from the drum. Refer to Product
Safety Information Manual Form MHD56251.
6. Do not weld to any part of winch.
Table 1: Specifications
Model
Air System Air Motor Pipe
Inlet Size
Minimum Air
System Hose Size
(inside diameter)
Drum
Barrel Diameter
Drum Flange
Diameter Net Weight *
Rated Operating
Pressure
Air Consumption
(at rated pressure and load)
scfm cu.m/min inch mm inch mm inch mm inch mm lbs kgs
FA2i-MRA 90 psig
(630 kPs/6.3 bar) 335 10 1.0 25 1.25 32 9.25 235 17 432 720 327
* Weight of standard winch without wire rope. Shipping weight 1,087 lbs (493 kg).
Table 2: Rated Performance (at Rated Pressure/Volume)
Model
Full Drum Lifting Capacity * Stall Pull Required Rope Size ** Drum Rope Storage Capacity ***
Personnel Utility Personnel Utility
lbs kgs lbs kgs lbs kg in mm ft mft m
FA2i-MRA 2,200 1,000 3,520 1,600 9,000 4,090 7/16 12 808 246 1,000 305
* Man Rider rating of 2,200 lbs (1,000 kg) is based on requirements of ANSI A10.22 [8:1 design factor with 7/16 inch (11 mm) wire rope]. Utility rating of 3,500 lbs (1,558
kg) is based on requirements of ASME B30.7 [5:1 design factor with 7/16 inch (11 mm) wire rope].
** Rope construction: Only 6 x 19, 6 x 37 classification, or rotation-resistance ropes, all with IWRC, shall be used.
*** Man Rider wire rope storage is based on a winch with a 19 inch (483 mm) diameter drum flange and on ANSI A10.22 standards which require the top layer to be at least
2 inches (51 mm) below the drum flange diameter. Utility wire rope storage is based on a winch with a 19 inch (483 mm) diameter drum flange and on ASME/ANSI B30.7
standards which require the top layer to be at least 1/2 inch (13 mm) below the drum flange diameter.
Capacities shown may vary from those published elsewhere.
Table 3: Drum Speed at Third layer (half drum)
Model
At 330 lbs / 136 kg At Personnel Rating At Utility Rating
Up Down Up Down Up Down
fpm m/min fpm m/min fpm m/min fpm m/min fpm m/min fpm m/min
FA2i-MRA 95 29.3 52 15.8 91 28 71 22 66 20 120 37
Table 4: Available Drum Lengths
in mm in mm in mm in mm in mm
12 305 16 406 24* 610* 30 762 36 914
* Standard Length; Refer to sales literature for winch drum wire rope storage capacities.
Table 5: Mounting Surface Tolerance
Drum
Length
Mounting Surface Minimum Flatness
inch mm
12 0.06 1.52
16 0.08 2.03
20 0.10 2.54
24 0.12 3.05
Table 6: Mounting Bolts
inch mm
5/8 16

Form MHD56331 Edition 1 5
Wire Rope
CAUTION
• Use only 7/16 inch (11 mm) wire rope on a winch designed to conform with
ANSI A10.22 standards.
• 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. MHP2449 in Product Safety Information Manual “Winch Safe
Operating Practices” for Man Rider Winches Form MHD56251.
• Do not use wire rope as a ground (earth) for welding.
• Do not attach a welding electrode to winch or wire rope.
• Install wire rope to come off drum for overwind operation (normal
application). Refer to Dwg. MHP2450 in Product Safety Information Manual
“Winch Safe Operating Practices” for Man Rider Winches Form MHD56251.
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 and meets all applicable industry, trade association, federal,
state and local regulations.
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. Maximum wire rope diameter is limited by the
wire rope anchor. It is recommended that wire rope construction be 6 X 19 or 6 X 37
IWRC right lay.
Installing Wire Rope
NOTICE
• When installing wire rope, pressurize brake with a minimum of 45 psi (3.1
bar) air from an auxiliary source.
Refer to Dwg. MHP2686 on page 11, A. Anchor; B. Wire Rope.
1. Cut wire rope to length in accordance with wire rope manufacturer’s instructions.
2. Feed end of wire rope through drum anchor pocket hole.
3. Forming a loop, wrap loop around anchor, approximately 22 inches (559 mm) of
wire rope.
4. Pull wire rope anchor into position in drum anchor pocket. Ensure no extra (open
end) of wire rope is extending out of drum anchor pocket.
CAUTION
• Make sure first wrap of wire rope is tight and lays flush against drum flange.
Safe Wire Rope Handling Procedure
-Always use gloves when handling wire rope.
-Never use wire rope that is frayed or kinked.
-Never use wire rope as a sling.
-Always ensure wire rope is correctly spooled and the first layer is tight against
drum.
-Always follow wire rope manufacture’s recommendation on use and
maintenance of wire rope.
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.
Rigging
Make sure all wire rope blocks, tackle and fasteners have a sufficient safety margin to
handle 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 wire rope manufacturer’s instructions 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 wire rope over a sharp edge. Use a correctly sized sheave.
4. When a lead sheave is used, it must be aligned with center of drum. The diameter
of lead sheave must be at least 18 times diameter of wire rope. Refer to Dwg.
MHP0498 in Product Safety Information Manual Form MHD56251.
5. Always maintain at least four full, tight wraps of wire rope on drum.
Electrical Grounding
WARNING
• 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
To adjust line speed monitor, contact nearest distributor or factory. It is not
recommended to change settings from preset factory ones.
Motor Exhaust and Muffler
Refer to Dwg. MHP0646.
WARNING
• 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. 83 dBA during operation of winch without load in the haul-in direction.
2. 87 dBA during operation of winch without load in the payout 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.
Table 7: Bolt Hole Dimensions
Dimension Drum Length
12 in. (305 mm) 16 in. (406 mm) 24 in. (610 mm) 30 in. (762 mm) 36 in. (914 mm)
“A” in. 20
Contact Factory
mm 508
“B” in. 9.00* 7.50 10.00
mm 229* 190 254
“C” in. 0.6875
mm 17.5
Table 8: Winch Foundation Bolt Forces
Force Acting on Bolt Drum Length
12 in. (305 mm) 16 in. (406 mm) 24 in. (610 mm) 30 in. (762 mm) 36 in. (914 mm)
Maximum Shear Force
at One Foundation
Bolt Connection
lbf
Contact Factory
2.050
Contact Factory
N9,188
Maximum Tensile
Force Shared by Rear
Foundation Bolts
lbf 10,270
N46,032