Ingersoll-Rand Force 5i Series User manual

Save These Instructions
Form MHD56434
Edition H
December 2020
CCN 45899762
Force 5i Air Winch
FA2.5i and FA2.5i-CE
FA5i and FA5i-CE
FA5Ti and FA5Ti-CE
(-CE compliant with European Directives)
yProduct Information

2 MHD56434
Only allow Ingersoll Rand trained tec nicians to perform maintenance on t is product. For additional information
contact Ingersoll Rand factory or nearest Distributor.
For additional supporting documentation, refer to Table 1, p. 2.
Manuals can be downloaded from www.irmhdocs.s ysite.com
T e use of ot er t an genuine Ingersoll Rand replacement parts may result in safety azards, decreased
performance and increased maintenance and will invalidate all warranties.
Original instructions are in Englis . Ot er languages are a translation of t e original instructions.
Refer all communications to t e nearest Ingersoll Rand Office.
Table 1. Product Information Manual
Publication Name Document Number (CCN)
Product Safety Information Manual (Non-Man Rider) MHD56250 (71402598)
Product Parts Information Manual MHD56287

MHD56434 3
Table of Contents
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mounting................................................................................... 9
WireRope ................................................................................. 11
Wire Rope Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safe Wire Rope Handling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wire Rope Spooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rigging ................................................................................ 12
Safe Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DrumGuard ............................................................................... 12
AirSupply ................................................................................. 13
AirLines ............................................................................... 13
Air Line Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Moisture in Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mufflers................................................................................ 14
Motor ..................................................................................... 14
Tensioning System (optional feature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Limit Switc es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PressRoller................................................................................ 14
Initial Winc Operating C ecks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Winc Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Winc Mounted Air T rottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remote Full Flow Air T rottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remote Pilot Pendant T rottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remote Pilot Lever T rottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Underwound Operation (optional feature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Emergency Stop and Overload System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Overload System (CE Models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Tensioning System (optional feature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Tensioning System (operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Winc Brakes .............................................................................. 17
Manual Drum Band Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Automatic Drum Band Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Automatic Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drum Locking Pin (optional feature). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Limit Switc es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wire Rope Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Frequent or Daily Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4 MHD56434
Winc es Not in Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Storing t e Winc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor ..................................................................................... 25
Reduction Gear and Disc Brake Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DiscBrake ................................................................................. 26
Drum Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
WireRope ................................................................................. 26
Product Information Grap ics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of Contents

MHD56434 5
Product Description
Infinity series winc es are air powered, planetary geared units designed for and intended for use as utility winc es,
wit a Mec anism Classification of M5. T ey s all not be used for lifting or moving personnel. T ey may be used to
pull or lift loads at various wire rope take-off angles. Winc es can be equipped, wit eit er an internal automatic
disc brake, a manual or automatic band brake, or a combination of bot disc and band brake.
T e output from an externally mounted piston air motor is transmitted t roug a coupling and s aft to t e
planetary reduction gear assembly. Output from t e planetary reduction gear assembly is connected to t e wire
rope drum t roug t e output s aft.
T e disc brake assembly consisting of friction plates splined to a ub w ic in turn is connected to t e drive s aft
from t e air motor. Brake friction plates are clamped to t e drum s aft t roug a spring applied piston. T e brake
remains applied until t e winc control valve is operated and winc pay out or aul-in occurs. Air is introduced into
a c amber, w ic is formed between brake piston and brake ousing, causing t e brake piston to react,
compressing brake springs and releasing friction plates allowing motor s aft to rotate. A power failure or sudden
loss of air will immediately cause t e spring applied brake to engage. T e band brake operates by applying a
friction force between brake band and winc drum. T e manual brake requires an operator to engage and
disengage brake using a andle located on top of brake band. T e automatic band brake operation is similar to disc
brake operation; t ey are bot fully disengaged in t e aul-in and payout direction.
T e design life of t e winc is based on t e application and its maintenance. Refer to Table 9, p. 20.
CE winc es in addition to t e above ave drum guard, upper and lower limit switc es, overload protection and
emergency stop as standard features, and are compliant wit CE directives.

6 MHD56434
Specifications
Model Code Explanation
Example: FA5i-24MK1P FA5i - 24 M K 1 P
Series (Capacity):
FA2.5i = 5,000 lbs (2.5 metric ton)
FA5i = 11,000 lbs (5 metric ton)
FA5Ti = 8,400 lbs (4 metric ton)
Drum Flange Height:
- = Standard ange
T = Tall ange
Drum Length (Distance between drum anges):
24 = Standard (Refer to Table 4 ‘Available Drum Lengths’ on page 4 for drum lengths)
Drum Brake:
A = Automatic Drum Brake
M = Manual Drum Brake
X = None
Disc Brake:
K = Automatic Disc Brake
X = None
Control:
1 = Winch mounted lever throttle (Standard)
* 2XX = Remote full ow [XX = Specify hose length (feet). Maximum 20 ft (6 metres)]
* 3XX = Remote pilot pendant throttle [XX = Specify hose length (feet). Maximum 66 ft (20 metres)]***
* 4XX = Remote pilot lever throttle [XX = Specify length (feet). Maximum 66 ft. (20 metres)]***
* 5XX = Remote electric over air throttle *** †
Options: **
7 = Drum Grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch) †
B = Extended Warranty
** CM = Low Temperature Components; C1M3 = -20° ABS, C2M3 = -20° DNV
D = Drum Divider Flange and additional wire rope anchor †
E = Construction Cage †
G = Drum Guard
J = Air Line Accessories (not mounted to winch)
L = Drum Locking Pin
** M1 = Material Traceability (typical material results) ††
** M2 = Material Traceability (actual material results) ††
** M3 = Material Traceability (actual material results for these parts in nished, as-delivered condition) ††
N4 = Manufactured under American Bureau of Shipping (ABS) Survey
N5 = Manufactured under Det Norske Veritas (DNV) Survey
P = Marine 812 Grade Corrosion Preventative Finish
P1 = Marine 812-X Grade Corrosion Preventative Finish
Q = Adjustable Accu-Spool™ †
R = Slack Wire Rope Detector W1 = ABS witness test
S = Limit Switch (upper and lower) W2 = DNV witness test
U = Underwound W3 = LRS witness test
V = Press Roller (not available with drum
divider) W4 = Client witness test
-CE = Compliance with European Machinery Directive and EN 14492–1 Y = Overload protection with emergency stop on lever throttle valve
Notes:
* Remote throttles are provided with 6 feet (2 metres) of hose. Specify hose lengths greater than 6 feet. For lengths greater than 20 feet (6 metres) with the Remote
Full Flow Throttle, or 66 feet (20 metres) with the Remote Pilot Lever and Remote Pilot Pendant Throttles contact your Ingersoll Rand distributor for control
acceptability. Metric lengths are provided for reference only, order lengths in feet. (Used with Disc and Auto Band Brake only.)
** Documentation, witness testing and material traceability available; must be requested at time of order. Specify options or contact the factory or your nearest
Ingersoll Rand distributor for information.
*** Not available with -CE option, or units equipped with limit switches.
† Not covered in this manual.
†† Refer to ‘Traceability’ on page 4 for a description of the dierences between M1, M2 and M3.
All -E models are manufactured to previous European Machinery directives. Refer to Data (Name) Plate on winch to determine model. If winch is a custom build also refer to
the Declaration of Conformity for serial number break.

MHD56434 7
Table 2. Specifications
Models
Air System Rated Performance (at rated pressure/volume)
Rated
Operat-
ing
Pressure
Air
Consump-
tion (at
rated
pressure
and load)
Full Drum
Line Pull
Full Drum
Line Speed
Mid Drum
Line Speed
Max Stall Pull
1st Layer Force
Limit
Fac-
tor
Maximum
Freeboard Net Weight(a)
scfm
cu.
m/
min
lbs kgs fpm m/
min fpm m/ min lbs kgs inch mm lbs kgs
FA2.5i
90 psig
(630 kPs/
6.3 bar)
700 20
5000 2273
132 40
145 44 10500 4763
N/A 0.5 13 1190 540
FA2.5i-
CE
70 psig
(480 kPs/
6.3 bar)
98 30 1.6 1.3 32 1265 574
FA5i 90 psig
(630 kPs/
6.3 bar)
11000 5000 54 16 65 20
29000 13154 N/A 0.5 13
1895 860
FA5Ti 8400 3818 98 30 80 24 2170 984
FA5i-CE 80 psig
(550 kPs/
5.5 bar)
11000 5000 52 16 65 20
25900 11748 1.6 1.6 40
1985 900
FA5Ti-
CE 8400 3818 98 30 80 24 2300 1043
(a) Weight of standard winch without wire rope.
Table 3. Specifications
Models
Air Motor Pipe
Inlet Size
Minimum Air
System Hose
Size (inside
diameter)
Drum Barrel
Diameter
Drum Flange
Diameter
Recommended
Wire Rope
Size
(standard)
Sound
Pres-
sure
Level
Sound
Power
Level
Maximum
Foundation
Anchor Shear
Force at one
Capscrew
inch mm inch mm inch mm inch mm inch mm dBA dBA lbs N
FA2.5i/
FA2.5i-CE
1.25 32 1.5 38
10.75 273 19 483 5/8 16
97 109
2210 9830
FA5i/
FA5i-CE
15 381
27 686
3/4 20
4850 21570
FA5Ti/
FA5Ti-CE 35 889 4114 18300
Sound measurements ave been made in accordance wit ISO 11201, ISO 3744-3746 and ISO 4871 test
specifications for sound from pneumatic equipment. Readings s own are based on t e average noise level of eac
winc configuration, proportionate to t e utilized time in a regular cycle.
Lpc (Peak Sound Pressure) does not exceed 130 dB. Performance based on 90 psig (6.3 bar/630 kPa) operating
pressure.
Table 4. Available Drum Lengths
Models
Drum Lengths
in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm
FA2.5i/
FA2.5i-
CE
8 203
12 305 16 406 20 508 24
(a)
610
(a) 30 762 36 915 40 (b)
1016
(b)
42
(b)
1067
(b)
50
(b)
1270
(b)
FA5i/
FA5i-CE
— —
FA5Ti/
FA5Ti-
CE
(a) Standard Length
(b) Special, contact factory
Refer to sales literature for winc drum wire rope storage capacities.
SSppeecciiffiiccaattiioonnss

8 MHD56434
NNOOTTIICCEE
!
All -E winch models are manufactured to previous European Machinery directives. Refer to Data
(Name) Plate on winch to determine model. If winch is a custom build also refer to the
Declaration of Conformity for serial number break.
Traceability
Load bearing parts are documented to provide traceability. Documentation includes c emical and p ysical
properties of raw material, eat treating, ardening, tensile and c arpy tests as required for t e part.
Units wit M1,M2 or M3 in t e model code ave traceable load bearing components.
M1 – Material Traceability certificates according to EN 10204 (Ex DIN 50049) 2.2 on load bearing parts. Conformity
documents affirm (by t e manufacturer) t at parts are in compliance wit requirements of t e order, based on non-
specific inspection and testing (i.e. results are typical material properties for t ese parts).
M2 – Material Traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on load bearing parts. Conformity
documents affirm (by a department independent of t e manufacturing department) t at actual parts are in
compliance wit requirements of t e order, based on specific inspection and testing (i.e. results are actual material
properties for t ese parts).
M3 – Material Traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on load bearing parts. Conformity
documents affirm (by a department independent of t e manufacturing department) t at t e actual parts used in t e
product are in compliance wit t e order, based on specific inspection and testing (i.e. results are actual material
properties for t ese parts in a finis ed, as delivered condition).
Components wit part numbers ending in CH are c arpy parts for use under extreme cold conditions. Traceability
requirements must be stated w en reordering t ese parts for continued certification.
SSppeecciiffiiccaattiioonnss

MHD56434 9
Installation
Prior to installing t e product, carefully inspect it for possible s ipping damage. Products are supplied fully
lubricated from t e factory. C eck oil levels and adjust as necessary before operating product. Refer to
“Lubrication,” p. 24 for recommended oils and lubrication intervals.
WWAARRNNIINNGG
!
Product not installed properly may fall or cause a load to fall resulting in sever injury or death.
Before installation refer to Product Safety Manual and all safety warnings pertaining to this
product.
CCAAUUTTIIOONN
!
Always install, operate, inspect, and maintain this product in accordance with all applicable
standards and regulations (state, country, and federal, etc.). For example In the USA, the
applicable standards are American Society of Mechanical Engineers (ASME) and National Fire
Protection Agency (NFPA).
Mounting
Care must be taken w en moving, positioning or mounting t e winc . In most cases, lifting lugs ave been
provided to assist in andling t e winc . If lug locations are improper for your specific installation, great care
s ould be taken to ensure t at winc , w en lifted, will be properly balanced. Determine weig t of your winc by
referring to “Specifications,” p. 6. Add weig t of wire rope and ot er installed options as necessary. Lift winc 3 to
4 inc es (75 to 100 mm) off ground. Verify winc is balanced and secure before continuing lift. Mount winc so axis
of drum is orizontal and t at motor vent cap is not more t an 15° off top vertical center. If winc is to be mounted
in an inverted position, motor case must be rotated to position vent cap to t e top.
1. T e winc mounting surface must be flat and of sufficient strengt to andle rated load plus weig t of winc
and attac ed equipment. An inadequate foundation may cause distortion or twisting of winc uprig ts and
siderails resulting in winc damage.
2. Make sure mounting surface is flat to wit in 0.005 inc (0.127 mm) per inc of drum lengt . S im if necessary.
Refer to Table 5, p. 9.
3. Mounting bolts must be Grade 8 or better. Use self-locking nuts or nuts wit lockwas ers. Refer to Table 6, p.
10.
4. Tig ten mounting bolts evenly and torque to specification in torque c art. Refer to ‘TORQUE CHART’ in Product
Maintenance Manual.
5. Maintain a fleet angle between s eave and winc of no more t an 1-1/2°. T e lead s eave must be on a center
line wit drum and, for every inc (25 mm) of drum lengt , be at least 1.6 feet (0.5 metre) from t e drum. Refer
to Product Safety Information Manual.
6. Do not weld to any part of winc .
Refer to Figure 1, p. 10.
Table 5. Mounting Surface Tolerance
Drum Length
Mounting Surface Minimum Flatness
inch mm
8 0.04 1.02
12 0.06 1.52
16 0.08 2.03
20 0.10 2.54
24 0.12 3.05
30 0.15 3.81
36 0.18 4.57

10 MHD56434
Table 6. Mounting Bolts
Models
Mounting Bolts
inch mm
FA2.5i/FA2.5i-CE 5/8 16
FA5i/FA5i-CE
3/4 18
FA5Ti/FA5Ti-CE
Refer to Figure 1, p. 10.
Table 7. Winch Bolt Hole Mounting Dimensions
Models Dimension
Drum Lengths (inches)
8 12 16 20 24 30 36 40 42 50
FA2.5i (a)
”A”
inch 30
(b)
(b)
mm 508
“B” (c)
inch 7 9 7.5 9 10 12
mm 178 229 190 229 254 305
“B”(d)
inch 6 8 7 8 9 11
mm 152 203 178 203 229 279
“C”
inch 0.6875
mm 17.5
Bolt Hole Qty
each siderail 3 4 4
FA5i ”A”
inch
N/A
31.25
mm 794
FA2.5i-CE ”A”
inch 34.25
mm 870
FA5Ti/
FA5Ti-CE
(e)
“B” (c)
inch 7.5 9 10 10.5 10 11
mm 190 229 254 267 254 279
“B” (d)
inch 6 6.25 8.5 9 12 14
mm 152 159 216 229 305 356
“C”
inch 0.8125
mm 20
Bolt Hole Qty
each siderail 4(4) 5
(a) 30 and 36 inch Drum with Band Brake will require 5 bolts, without Band Brake 4 bolts.
(b) Contact Factory
(c) Drum with Manual or Automatic Drum Brake
(d) Drum without Manual or Automatic Drum Brake
(e) 20 inch Drum with Band Brake will require 5 bolts, without Band Brake 4 bolts.
36 inch Drum with Band Brake will require 6 bolts, without Band Brake 5 bolts.
Figure 1. MHP0133
A
B
A
B B
C
DRUM
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MHD56434 11
Wire Rope
CCAAUUTTIIOONN
!
• Maintain at least 5 tight wraps of wire rope on the drum at all times.
• 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).
NNOOTTIICCEE
!
For horizontal applications order the “H” option or contact factory prior to operation.
Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor for assistance in selecting t e appropriate type and size
of wire rope and, w ere necessary, a protective coating. Use a wire rope w ic provides an adequate safety factor
to andle t e actual working load and meets all applicable industry, trade association, federal, state and local
regulations.
W en considering wire rope requirements t e actual working load must include not only t e static or dead load but
also loads resulting from acceleration, retardation and s ock load. Consideration must also be given to t e size of
t e winc wire rope drum, s eaves and met od of reeving. Maximum wire rope diameter is limited by t e wire
rope anc or. It is recommended t at wire rope construction be 6 X 19 or 6 X 37 IWRC rig t lay. Refer to Table 8,
below for recommended sizes.
Table 8. Minimum and Maximum Wire Rope Size
Models
Minimum Maximum
inch mm inch mm
FA2.5i/FA2.5i-CE
5/8 16
5/8 16
FA5i/FA5i-CE
7/8 22
FA5Ti/FA5Ti-CE 3/4 20
Notes:
1. Maximum wire rope diameter is limited by size of wire rope anchor hole. Refer to roduct arts
Information Manual for correct wire rope anchor part numbers.
2. Wire rope diameter is fixed if grooved drum option is used.
Installing Wire Rope
NNOOTTIICCEE
!
When installing wire rope, pressurize disc brake with a minimum of 45 psi (3.1 bar) air from an
auxiliary source. If winch is equipped with an auto brake cylinder, pressurize with a minimum of
80 psi (5.5 bar) air from an auxiliary source.
Refer to Figure 5, p. 27.
1. Cut wire rope to lengt in accordance wit wire rope manufacturer’s instructions.
2. Feed end of wire rope t roug drum anc or pocket ole.
3. Forming a loop, wrap loop around anc or, approximately 22 inc es (559 mm) of wire rope.
4. Pull wire rope anc or into position in drum anc or pocket. Ensure no extra (open end) of wire rope is extending
out of drum anc or pocket.
CCAAUUTTIIOONN
!
Make sure first wrap of wire rope is tight and lays flush against drum flange.
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12 MHD56434
Safe Wire Rope Handling Procedure
• Always use gloves w en andling wire rope.
• Never use wire rope t at is frayed or kinked.
• Never use wire rope as a sling.
• Always make sure wire rope is correctly spooled and t e first layer is tig t against drum.
• Always follow wire rope manufacturer’s recommendation on use, lubrication, and maintenance of wire rope.
Wire Rope Spooling
To compensate for uneven spooling and t e decrease in line pull capacity as t e drum fills up, use as s ort a wire
rope as practical. W en rewinding apply tension to t e end of t e wire rope to eliminate line slack. T is elps
ac ieve level winding and tig t spooling.
Rigging
Make sure all wire rope blocks, tackle and fasteners ave a sufficient safety margin to andle required load under all
conditions. Do not allow wire rope to contact s arp edges or make s arp bends w ic will cause damage to wire
rope, use a s eave. 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 (eart ) for welding.
2. Do not attac a welding electrode to winc or wire rope.
3. Never run wire rope over a s arp edge. Use a correctly sized s eave.
4. W en a lead s eave is used, it must be aligned wit center of drum. T e diameter of lead s eave must be at
least 18 times t e diameter of wire rope. Refer to Figure 2, p. 12.
5. Always maintain at least five full, tig t wraps of wire rope on drum.
Figure 2. MHP2449
Drum Guard
Use of a drum guard is recommended on all winc es, and is standard on -CE winc es. Refer to t e Product Parts
Information Manual.
Drum guard panels must be adjusted to suit wire rope departure angle. To reposition drum guard panels remove
nuts and slide out crossbar or remove t e screws on current design guard. Position panels to avoid wire rope
contact and install crossbar and nuts or t e screws.
WWAARRNNIINNGG
!
Do not allow wire rope to come in contact with drum guard panels during winch operation. Wire
rope will be damaged. Adjust drum guard panels to clear wire rope travel angle.
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MHD56434 13
Air Supply
T e air supply must be clean, free from moisture and lubricated to ensure optimum motor performance. Foreign
particles, moisture and lack of lubrication are t e primary causes of premature motor wear and breakdown. Using
an air filter, lubricator and moisture separator will improve overall product performance and reduce unsc eduled
downtime. Install an emergency s ut-off valve in t e control valve inlet line.
Refer to Figure 4, p. 27.
Refer to Table 2, p. 7 for motor air consumption and rated operating pressure. If air supply varies from w at is
recommended, product performance will c ange.
Install air line lubricator, filter and regulator as close as possible to air inlet on motor. Lubricator must be located no
more t an 10 ft (3 m) from motor. Air line accessories package can also be mounted to t e winc guard panel on
t e operator’s side or opposite.
Air Lines
Inside diameter of air supply lines must not be less t an size specified in Table 2, p. 7. Before making final
connections, all air supply lines s ould be purged wit clean, moisture free air or nitrogen before connecting to
main air inlet. Supply lines s ould be as s ort and straig t 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 lines.
Air Line Lubricator
Always use an air line lubricator wit t ese motors. T e lubricator must ave an inlet and outlet at least as large as
inlet on motor.
CCAAUUTTIIOONN
!
• Lubricator must be located no more than 10 ft (3 m) from motor.
• Shut off air supply before filling air line lubricator.
T e air line lubricator s ould be replenis ed daily and set to provide 2 to 3 drops per minute of ISO VG 32 (SAE
10W) oil. A fine mist will be ex austed from control valve w en air line lubricator is functioning properly.
Air Line Filter
It is recommended t at an air line strainer/filter be installed before t e lubricator to prevent dirt from entering t e
motor. T e strainer/filter s ould provide 20 micron filtration and include a moisture trap. Clean t e strainer/filter
periodically to maintain its operating efficiency.
NNOOTTIICCEE
!
When air filter is used ensure it allows air to pass through at products rated scfm. Refer to
Specifications, p. 7.
Air Pressure Regulator
If an air pressure regulator is used, install between lubricator and filter.
NNOOTTIICCEE
!
• Do not adjust regulator for a CE marked product, these are preset at factory and pressure
gauges are not provided. Adjustment of regulator will effect overload settings and product
will no longer conform to CE regulations.
• Not all products are CE approved, refer to products data (name) plate to see if this applies.
Moisture in Air Lines
Moisture t at reac es t e air motor t roug air supply lines is a primary factor in determining t e lengt of time
between service over auls. Moisture traps can elp to eliminate moisture. Ot er met ods, suc as an air receiver
w ic collects moisture before it reac es motor, or an aftercooler at compressor t at cools air to condense and
collect moisture prior to distribution t roug supply lines, are also elpful.
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14 MHD56434
Mufflers
Ensure mufflers are installed in winc motor ex aust manifold and control valve ex aust port. An additional muffler
is used on winc es equipped wit an emergency stop and overload device. C eck mufflers periodically to ensure
t ey are functioning correctly.
Motor
For optimum performance and maximum durability of parts, provide recommended air supply as measured at
motor inlet. Refer to Table 2, p. 7. Winc s ould be installed as near as possible to compressor or air receiver.
Tensioning System (optional feature)
Refer to Figure 11, p. 28.
T e air supply line is connected to one of t e two top ports on t e control valve. T is will allow air to supply eit er
t e normal control valve or t e auxiliary valve.
WWAARRNNIINNGG
!
Use only one control valve to operate winch at any time. Attempting to OVERRIDE one control
valve with the other will result in total loss of winch control.
Limit Switches
Limit switc es are standard on -CE winc es.
Pre-set limit switc settings prevent winc wire rope payout and aul-in by stopping air flow to t e winc motor
w en a defined set point as been reac ed. It is t e owner’s and operator’s responsibility to adjust winc operating
limits prior to using winc .
NNOOTTIICCEE
!
Settings for limit switch are for an overwound operation only.
To adjust set points:
Follow instructions in t e order t ey appear for limit switc adjustment (use two people to ma e adjustments).
Refer to Figure 13, p. 28.
1. Remove cap from limit switc cover.
2. Partially unscrew center nut.
3. PAYOUT: Rotate (#1) screw (counterclockwise) w ile slowly paying out until winc s uts off.
4. HAUL-IN: Rotate (#2) screw (clockwise) w ile slowly auling in until winc s uts
5. Tig ten center nut.
6. Reinstall cap on limit switc cover and tig ten.
WWAARRNNIINNGG
!
Ensure limit switch set points are established and operating properly before putting winch into
service.
Press Roller
Ensure wire rope is positioned between press roller and drum barrel and springs keep press roller in tig t contact
wit wire rope.
Initial Winch Operating Chec s
Winc es are tested for proper operation prior to leaving t e factory. Before t e winc is placed into service t e
following initial operating c ecks s ould be performed.
1. W en first running t e motor inject a small amount of lig t oil into t e inlet connection to provide initial
lubrication.
2. C eck oil level in motor, reduction gear assembly and disc brake are correct. Top off levels as required before
IInnssttaallllaattiioonn

MHD56434 15
operation as described in t e “Lubrication,” p. 24.
3. Operate winc in bot directions wit no load.
4. C eck operation of brakes.
5. C eck operation of limit switc es, locking mec anisms and all safety devices w en equipped.
6. C eck foundation mounting fasteners are secure.
7. Install drum guard w en provided.
For winc es t at ave been in storage, t e following start-up procedures are required.
1. Give t e winc an inspection conforming to requirements of “Winc es Not in Regular Use,” p. 22.
2. Pour a small amount of ISO VG 32 (SAE 10W) oil in motor inlet port.
3. Operate motor in bot directions to flus out any impurities.
4. T e winc is now ready for normal use.
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16 MHD56434
Operation
Winch Controls
T e spring loaded, motor mounted, live air manual t rottle control valve is supplied as a standard feature on t is
winc . Optional remote t rottle controls are available. Reference model code on t e winc data (name) plate and
compare it to “Specifications,” p. 6, to determine your configuration. T e t rottle controls provide operator control
of motor speed and direction of drum rotation.
Winch Mounted Air Throttle
Refer to Figure 6, p. 27.
T e winc control t rottle valve is spring loaded, full flow air and mounts to t e motor rotary ousing.
To operate control valve, place palm of and on control knob and wrap fingers around flange of sliding andle.
Squeeze fingers, lifting sliding andle up to unlock control andle. S ift control andle in desired direction to
payout or aul-in wire rope. As viewed from air motor end, move control t rottle andle to t e rig t (clockwise) to
payout wire rope and to t e left (counterclockwise) to aul-in wire rope. Avoid sudden movements of andle to
ensure smoot operation of winc . W en released, andle will return to neutral or center position, sliding andle
will drop down to engage and lock control andle in place.
Remote Full Flow Air Throttle
Refer to Figure 12, p. 28.
Provides for remote mounting of winc control at a fixed location at up to 20 feet (6 metres) away from winc
motor. Air oses connect t rottle to winc motor to provide winc operation.
Move control t rottle andle to t e rig t (clockwise) to payout wire rope and to t e left (counterclockwise) to aul-in
wire rope. Avoid sudden movements of control valve to ensure smoot operation of winc .
Remote Pilot Pendant Throttle
Refer to Figure 14, p. 29.
Provides for remote winc control at distances of up to 66* feet (20 metres) away from winc . T e pilot pendant
control t rottle is a two function movable control station for winc operation. Pilot pressure from pendant control
activates winc control valve. T e winc control valve, located on winc motor, controls motor speed and direction
of drum rotation. Direction of drum rotation is determined by t e pendant lever/button depressed.
Remote Pilot Lever Throttle
Provides for remote winc control at distances of up to 66* feet (20 metres) away from winc . T e lever pilot
control t rottle is a fixed mounted lever control station for winc operation. Pilot pressure from lever pilot control
t rottle activates winc control valve. T e winc control valve, located on winc motor, controls motor speed and
direction of drum rotation. Direction of drum rotation is determined by t e direction in w ic lever is s ifted.
* For distances greater t an 50 feet (15 metres) contact Ingersoll Rand Tec nical Sales for control suitability.
Underwound Operation (optional feature)
Underwound operation allows wire rope aul-in or payout off t e bottom of drum. T is is a special operation and
requires a winc specifically designed for t is usage.
Emergency Stop and Overload System
Emergency Stop and Overload System are standard on -CE winc es.
Refer to Figure 7, p. 27.
W en emergency stop or overload valve is activated, winc drum rotation will immediately cease.
CCAAUUTTIIOONN
!
If winch continues to move (payout load) after emergency stop activates, brake(s) are not
holding load and will require adjustment or repair.
W en control valve senses a preset pressure difference between ports, a pilot signal is sent to stop flow of air,
winc drum rotation will immediately cease.

MHD56434 17
Emergency Stop
Emergency stop device is located on t e control valve. W en activated, winc drum rotation will immediately
cease. To activate emergency stop, depress (pus down) red palm valve, located on top of control valve.
NNOOTTIICCEE
!
If winch overload occurs, overload device, if equipped, also stops winch. To operate winch after
an overload, reduce load and reset overload.
Emergency Stop Reset:
1. Rotate red stop button, in (counterclockwise) direction until red stop button ‘pops’ up.
2. Winc is ready to resume operation.
Pendant Control:
Refer to “Emergency Stop” section and Figure 15, p. 29.
Overload System (CE Models only)
T e winc utilizes a direct acting load limiter to limit t e maximum line pull to 160% of t e rated line pull. T e
limiter is a pressure regulator t at limits t e supply air to a pressure t at will not allow t e winc to pull beyond
160% of t e rated line pull.
Chec ing Overload Valve Setting:
Proper test and adjustment of overload s ould only be performed by an Ingersoll Rand trained tec nician. T e
winc s all not be able to lift a load greater t an 160% of t e rated utility load. If t is is possible, adjustment is
required.
Tensioning System (optional feature)
Refer to Figure 16, p. 29.
Wit auxiliary valve in t e NORMAL position, winc provides normal operation. Placing valve selector in
TENSIONING position allows winc to automatically operate to aul-in slack wire rope to maintain tension.
Auxiliary valve provides preset air pressure to air motor and disc brake. T is allows brake to be released and winc
to over aul during TENSIONING operations. In t is position, winc will maintain constant tension on wire rope.
Auxiliary valve is pre-set at zero from t e factory. Specific adjustments must be made in t e field. Adjustments can
be modified at any time to accommodate t e load conditions. Refer to ‘Regulator Adjustment’ in t e Product
Maintenance Information Manual.
Tensioning System (operation)
1. Place auxiliary valve in NORMAL position.
2. Operate winc normally to position end of load line.
3. Connect load line to load.
WWAARRNNIINNGG
!
Ensure slack load line is taken up by operating winch control valve with selector in NORMAL
position. If selector lever is placed in TENSION position the winch will immediately attempt to
establish line tension causing line to ‘snap’ resulting in injury or damage to property.
4. Operate winc normally to remove slack from load line.
5. Actuate valve to TENSION position to set winc to automatically aul-in load line and maintain line tension.
Winch Bra es
Manual Drum Band Bra e
T e manual drum band brake is applied by pus ing down on andle and released by pulling up. If andle is pus ed
down fully, it s ould lock in t at position and prevent drum rotation, until released by operator. T e brake must be
kept properly adjusted to old rated load.
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18 MHD56434
Automatic Drum Band Bra e
T e automatic drum band brake is a spring applied, air released brake w ic utilizes an air actuated, spring loaded
cylinder, t at automatically disengages brake w en motor is operated. Air pressure in cylinder overcomes spring
pressure to release brake. W en control valve is placed in neutral position, air in cylinder is vented and spring
automatically engages brake to prevent drum rotation.
T e brake must be kept properly adjusted to old rated load.
NNOOTTIICCEE
!
Extended exposure to corrosive atmospheres can cause the band brake lining to adhere to the
drum. It is recommended when winch is not in operation and in a no load condition that the band
brake be left in a released position.
Automatic Disc Bra e
T e automatic disc brake is a spring applied, air released brake. Using an air actuated, spring loaded piston, t e
brake automatically disengages w en motor is operated and engages w en t rottle is returned to neutral position.
Air pressure ported t roug brake ousing overcomes spring pressure and moves piston w ic releases brake.
W en control valve is placed in neutral position, air is vented, spring pressure overcomes air pressure and spring
pressure moves piston, engages brake and prevents drum rotation.
NNOOTTIICCEE
!
A minimum of 45 psig is required to release the brake.
Drum Loc ing Pin (optional feature)
Figure 3. MHP2772
TOP
Engaged
Disengaged
Drum Lock
Assembly
Grease Fitting
T e drum locking pin assembly is mounted on t e outboard uprig t, opposite motor. Handle movement must be
parallel to t e winc base. It s ould be engaged if a load is left suspended. T e word ‘TOP’ is stamped into t e
andle for correct orientation and must be visible from above.
To engage Drum Loc ing Pin:
W en facing t e andle, pull andle away from t e outboard uprig t and pivot it to t e left. Handle pivot capscrew
will be in closest position to drum flange. Operate winc very slowly until locking pin engages one of t e drum
flange oles.
WWAARRNNIINNGG
!
• Ensure that all braking mechanisms are engaged and all personnel are clear of winch load
and rigging before disengaging locking pin.
• Extremely difficult locking pin release is an indication that load is held by locking pin and
braking mechanisms are not functioning properly. Do not release locking pin until load
control is established.
To disengage Drum Loc ing Pin:
W en facing t e andle, pull andle away from t e outboard uprig t and pivot it to t e rig t. Handle pivot
capscrew will be in furt est position from drum flange.
OOppeerraattiioonn

MHD56434 19
Limit Switches
Limit switc es are standard on -CE winc es.
Pre-set limit switc settings prevent winc wire rope payout and aul-in by stopping air flow to t e winc motor
w en a set point as been reac ed. It is t e owner’s and operator’s responsibility to adjust winc operating limits
prior to using t e winc . To adjust t e limit switc set points, refer to “Limit Switc es,” p. 14.
OOppeerraattiioonn

20 MHD56434
Inspection
Inspection information is based in part on American Society of Mec anical Engineers Safety Codes (ASME B30.7).
WWAARRNNIINNGG
!
• All new or repaired equipment should be inspected and tested by Ingersoll Rand Trained
Service Technicians to ensure safe operation at rated specifications before placing
equipment in service.
• Never use a winch that inspection indicates is damaged.
Frequent and periodic inspections s ould be performed on equipment in regular service. Frequent inspections are
visual examinations performed by operators or Ingersoll Rand Trained Inspectors and include observations made
during routine equipment operation. Periodic inspections are t oroug inspections conducted by Ingersoll Rand
Trained Service Tec nicians or Qualified personnel. ASME B30.7 states inspection intervals depend upon t e nature
of t e critical components of t e equipment and t e severity of usage. Refer to ‘Inspection Classifications’ c art and
‘Maintenance Intervals’ c art for recommended maintenance intervals.
Careful inspection on a regular basis will reveal potentially dangerous conditions w ile still in t e early stages,
allowing corrective action to be taken before t e condition becomes dangerous.
Deficiencies revealed t roug inspection, or noted during operation, must be reported to designated personnel to
ensure corrective action is taken.
A determination as to w et er a condition constitutes a safety azard(s) must be decided, and t e correction of
noted safety azard(s) accomplis ed and documented by written report before placing t e equipment in service.
Wire Rope Reports
Records s ould be maintained as part of a long-term wire rope inspection program. Records s ould include t e
condition of wire rope removed from service. Accurate records will establis a relations ip between visual
observations noted during frequent inspections and t e actual condition of wire rope as determined by periodic
inspections.
Maintenance Intervals
NNOOTTIICCEE
!
Perform an annual winch load test for all applications.
Table 9. Maintenance Intervals
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days.
Grease Fittings Lubricate grease fittings every 90 days.
Auto Band Brake Check band brake adjustment every 90 days.
It is recommended that the following work be completed by an Ingersoll Rand service technician or a Qualified Person
Standard Components 1 year 2 years 3 years 4 years 5 years 10 years
Inspect Motor X X
Inspect Disc Brake X X
Inspect Gearbox X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X X X
Inspect Drum, Housings and Main Frames X X
Emergency Shut-Off Valve X X X X X X
Drum Shaft X X
Brake Shaft X X
Drive Shaft X X