Ingersoll-Rand LIFTSTAR 150 RLP Operating instructions

OPERATION AND MAINTENANCE MANUAL
FOR THE
AIR POWERED MAN-RIDING WINCH
LIFTSTAR 150 RLP
READ THIS MANUAL BEFORE USING THESE PRODUCT. This manual contains important safety,
installation, operation and maintenance information. Make this manual available to all persons responsible
for the operation, installation and maintenance of these product.
“As regards man-riding winches, it is the responsiblity of the owner or user of the winch to determine whether
the winch conforms with local regulations for personel use”
Always operate, inspect and maintain this winch in accordance with National Standards Safety Code of the
country where the material is used and respect the other applicable safety codes and particular regulations.
Refer all communications to the nearest lR/SAMIlA Material Handling Products Office or Distributor.
Form SAM0082
Edition 1
July 1995 PRODUCTION EQUIPMENT

DESCRIPTION PAGE Nbr.
SAFETY INFORMATION AND TRAINING
Danger, Warning, Caution and Notice .......................................................................... 3
SAFE OPERATING INSTRUCTIONS ......................................................................... 4
LABELLING -MARKING ............................................................................................ 4
SPECIFICATIONS ......................................................................................................... 5
Description .................................................................................................................... 5
Air connection drawing ................................................................................................ 6
INSTALLATION
Mounting .......................................................................................................................
Wire Rope .....................................................................................................................
Air Supply ....................................................................................................................
Motor .............................................................................................................................
Initial Operating Checks ...............................................................................................
OPERATION.
Controls ......................................................................................................................... 8
LUBRICATION -
Wire Rope .....................................................................................................................
Reduction Gear Assembly ............................................................................................
Seals and Bearings ........................................................................................................
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INSPECTION
Records and Reports .....................................................................................................
Frequent Inspection ......................................................................................................
Periodic Inspection .......................................................................................................
Winches not in Regular Use .........................................................................................
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TROUBLE SHOOTING .................................................................................................
MAINTENANCE
General Disassembly ....................................................................................................
Winch disassembly ......................................................................................................
Cleaning, Inspection and repair ....................................................................................
Winch assembly ..........................................................................................................
Air control valve disassembly and assembly ..............................................................
Air motor disassembly and assembly ..........................................................................
PA R-I’S
External band brake drawing and part list ...................................................................
Winch assembly drawing ............................................................................................
Winch assembly part list .............................................................................................
Brake gear assembly drawing .....................................................................................
Brakegear assembly part list ......................................................................................
Control valve assembly drawing and parts list ...........................................................
Air gear motor assembly drawing ...............................................................................
Air gear motor assembly part list ................................................................................
OPTIONS
Emergency stop ..........................................................................................................
Torque limitor .............................................................................................................
Press roller ..................................................................................................................
PAR-I’S ORDERING INFORMATION .......................................................................
GUARANTEE .................................................................................................................
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2

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 must
read understand this manual before operating the
product.
Training must be done by a qualified person to any
personnel involved with an air powered man-riding
winch
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures
which, if not followed, may result in a hazard. 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 personal 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 personal injury, death, or
substantial property damage if the
warning is ignored.
can
Caution is used to indicate the
presence of a hazard which willor
cause minor pcrsonnal injury or
property damage if the warning is
ignored.
Notice is used to notify people of
installation, operation, or maintenance
information which
hazard-related. is important but not
“MAN-LIFTING with this winch is STRICTLY
LIMITED to off-shore marine applications specifically
approved by maritime regulatory bodies. Regulatory
bodies, not manufacturer, have determined suitable use.
DO NOT USE FOR MAN-LIFTING applications not
specifically approved by regulatory bodies.
The use of a winch to lower, lift or suspend personnel
should be permitted only when other means of reaching the
worksite, such as ladders, stairways, aerial (bucket-type)
lifts or scaffolds, arc not feasible because of site conditions.
Presently Man-Riding winches are available built to
specifications published by :
Det Norske Veritas : Winches type approved and/or
certified by Det norskeVeritas (DNV) to meet Norwegian
Max-itime Directorate (NMD) or Norwegian Petroleum
Directorate (NPD) requirements.
In furnishing customers Man-Riding winches, Ingersoll-
Rand does not warrant the suitability of these winches for
any particular use. It is the owner and user’sresponsibility
to determine the suitability of a Man-Riding winch for a
particular application. Further, it is the owner and user’s
responsibility to check and satisfy all local, state, federal
and country requirements pertaining to the lifting and
lowering of persons.
Many agencies require additional redundant safety
devices on winches that IR/SAMIIA does not furnish.
Additional devices are often required to bring the
system up to elevator code standards.
Winches manufactured by IR/SAMIIA as an approved
Man-Riding to DEn and/or NMD/NPD requirements are
furnished with limitations ; approval for use in Man-Riding
applications automatically terminates for any of the
following reasons :
1- Winch does not meet other applicable codes or
standards.
2 - Winch is not part of an approved system.
3 - Winch is not properly maintained in a new condition
with all parts intact and properly adjusted.
4 - Winch is used in applications not approved by-codes and
regulations, or applications inconsistent with
manufacturer’s operating and maintenance manual.
5 - Changes in DEn or NMD/NPD standards or regulations
after Ingersoll-Rand’s initial shipment of the product.
6 - More than one winch is used to attach to a common
load.
Be sure to check all regulations, local and country, that
may apply to the use of a winch or winch system for
lifting and lowering people before using a Man-Riding
winch.
7 - The personel platform shall be designed by a properly
qualified engineer competent in this area.
Using other than genuine IR/SAMIIA Material Handling
parts will result in the void ofwarranty.
3

Failure to follow these rules will result in termination of
all applicable warranties. IR/SAMIIA assumesno
liability for any loss or damage resulting from operation
of Man-Riding winches if these operating instructions
are not followed.
1 - Winch operator must be in a position to always see the
personnel from transfer point to landing area.
2 - Personnel operating the winch or being transferred are
to have sufficient instruction/training concerning that
operation before any movement takes place.
3 - Lifting and lowering of personnel should be carried out
above the open sea whenever possible. All personnel
should wear life jackets approved by the appropriate
regulatory agency and a standby vessel should be in
the vicinity of the transfer.
3 - Hoisting of personnel by means of a winch should only
take place when other means of accomplishing this
work are not practical.
5 - The winch installation must be specially arranged and
accepted for personnel handling.
6 - Prior to any personnel movement, the entire system
should be inspected by the person in charge. It is that
individual’s responsibility to instruct and appoint the
winch operator.
7 - The lifting apparatus (basket, etc...) shall be inspected
and certified for personnel lifting prior to use.
8 - Do not operate without a surveyor’s site approval.
9 - Do not overload.
10 - Do not operate without testing. (See “Inspection and
Testing” procedures)
I I - Do not operate winch in a damaged condition.
12 - Do not operate winch that has not been properly
maintained or equipped.
13 - Do not attach winch to unsafe foundation. All bolts and
foundations for winch attachment should have a higher
load carrying capacity than the wire rope on the winch.
14 - Do not operate winch with any personnel nearthe line
of force or capable of coming into contact with
moving parts.
15 - All signs and warning notices must be posted
permanently on the winch.
16 - Always maintain three or more wraps of wire rope on
the drum.
17 - Never leave an unattended load suspended.
18 - Wire rope must spool off drum from the top away from
the operator.
The maximal lifting rated capacity of the winch is noticed
on one part of the winch.
On every air powered man-riding winch a sheet is clinched
as this model :
Each winch is supplied from the factory with the warning
label shown. If the label is not attached to your unit, order a
new label and install it. See the parts list for the part
number. Read and obey all warnings and other safety
information attached to this winch. Label may not be shown
actual size :
Failure to follow these warnings
nay result in death, severe injury
orproperty damage :
Do not operate this winch
before reading operation and
maintenance manual.
It is responsibility of the owner
or user to determine whether
the winch conforms with local
regulations for personnel use
Do not lift more than rated
load
Do not allow less than three
wraps of wire rope to remain or
drum at all times.
Do not operate a damaged or
malfunctioning winch.
Do not remove or obscure
warning labels
SAMIIA
Part of worldwide Ingersoll-Rand

SPECIFICATIONS
Rated working toad - 6th layer (metric ton) 150
Motor power (hp) 2
Working pressure (bar) 6.3
Average hoisting speed at rated toad (m/min) 0 to 30
Average lowering Speed at rated load (m/min) 0 to 60
Free air consumption (m3/min) 0 to 2.2
Weight without rope (Kg) 250
Recommended rope diameter (mm) 10
Minimum breaking load (Kg) 1500
CAPACITY (with 10 mm dia. rope)
Number of layers I 2 3 4 5 6 7
Capacity (m) 22 46 71 99 128 159,192
8 9
226 262
Rating limit -
The “Man-riding” winches have been designed and built for
the “oil and offshore” industry and more specifically to
conform with specifications asked for the Norwegian Oil
Ministry and the British Department of Energy.
There arc no norms for the use of “Man-riding” except
thosecurrentlydemanded by the offshore industry.
Thus it is the responsibility of the user to determine the
adaptability of this material for specific use and to ensure
that it conforms to any rules which may be applicable.
Nomenclature of winch : FEM 4 M (IS0 M ‘7)- Safety
load of stress FXM 2 (IS0 L 2)
This winch is supplied with a Tracability list for the main
parts which are under load together with a DNV “Type
Approval Certificate” S-1024
Construction : the winch has 4 constituent parts designed
for the most difficult tasks :
a) an engine block
b) a brake-control reducer block within the drum
c) a frame constructed mainly of two strutted flanges
d) a drum
Motor : Air motor with two ways of rotation
Reducer : rotary gear system with gears of specially treated
high grade steel mounted on roller bearings.
Brake : disc in large oil bath ensuring constant control of
the load when lowering. It works by decompression thus
ensuring automatic function of the brake in cast of air
failure. This “wet brake” ensures a constant level of braking
and is unaffected by exterior conditions.
Brake : direct on to a large drum ensuring constant control
of the load while lifting or lowering. It works by decom-
pression thus ensuring automatic function of the brake in
case of airfailure.
Drum : made of steel with cable fixing by a wedged box.
Frame : made of two strutted flanges.
Air supply to motor : by one hole ø1/2” BSP located on
thedistributor
Control : the winch is controlled by a single lever on the
winch distributor which allows any speed varifation
determined by the operator. This lever returns automatically
to zero thus stopping the load in the event of failure of the
operator.
Chassis skid : made of welded steel with 4 x 18diameter
fixing holesand 4 x 40 diameter holes for handling.
5

L
Prior to installing the winch, carefully inspect it for possible
hipping damage
Owner and users are advised to examine specific, local or
olher regulations, which may apply to a particular type of
use ofthis product before installing or putting winch to use.
Mounting
1 - If product is to be mounted in one position be sure the
mounting surface is even and of sufficient strength to
handle the rated load and prevent possible binding of the
winch.
2 - Make sure the mounting surface is flat to within l/32
inch (0,8 mm). Shim if necessary
3 - Mounting bolts must be 5/8 in. (16 mm) diameter, Grade
5.8 (classe 8.8) or better. Use self-locking nuts or nuts with
lockwashers.
4 - Torque mounting bolts evenly.
5 - Maintain a fleet angle between the sheave and winch of
no more than 1-1/2 degrees. For every inch of drum length,
the lead sheave must be at least 1.6 feet (0.5 m) from the
drum.
5 - Do not weld to any part of the winch
(Dwg. D6150001)
Bolt Hole Dimensions (SKID FRAME)
“A” 29.99 in. (533 mm)
“B” 8,838 in.(224.5mm)
“C” 0.71 in. (18 mm)
“D” 9.02 in. (229 mm)
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Wire rope
l Maintain at least 3 wraps of wire rope on the drum at
al1times.
l Install the wire rope to come off the drum in an
overwind position as indicated on the direction of
rotation tag.
Wire rope selection
Consult a reputable wire rope manufacturer or distributor
for assistance in selecting the appropriate type 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, 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.
Wire rope diameter for lifting 3/8 in. (10 mm) imperative.
Installing Wire Rope
1- Cut wire rope lo length in accordance with the wire rope
manufacturers instructions.
2 - Feed the end of the wire rope into the smaller anchor
hole in the wire rope drum and pull through approximately
one fool (0,3 m) of wire rope.
3 - Truck the end of the wire rope back into the wire rope
anchor pocket forming a loop in the wire rope.
4 - Insert the wire rope anchor and pull the wire rope
through the slot tightening the wire rope around the wire
rope anchor.
l Make sure the first
the drum flange. wrap of wire rope is flush against
5 - PulI the wire rope anchor into position in the drum
anchor pocket.
Wire Rope Spooling
To allow for uneven spooling and decrease in line pull
capacity as the drum fills up, use as short a cable as
practical. To rewind wire rope apply tension to eliminate
slack. This helps achieve level winding and tight spooling.
Safe Wire Rope Handling Procedures
1 - Always use gloves when handling wire rope.
2 - Never USCwire rope which is frayed or kinked.
3 - Never use wire rope as a sling
4 - Always ensure wire rope is correctly spooled and first
layer is tight.
Rigging
Make sure all wire rope blocks, tackle and fastenings have
sufficient safety margin to handle the required load. 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 manufacturers handbook for proper sizing, use
and care of wire rope.
Safe Installation Procedures
1 - Do not use wire rope as a ground 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 thedrum. The diameter of the lead sheave
must be at least 18 times the diameter of the wire rope.
5 - Always maintain at least three full 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
have be smaller than 5/8” in. (15,9 mm) for flexible lines
and l/2” in. (12,7 mm) for connectors, Before making final
connections, all air supply lines should be purged before
connecting to system 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.
Air Line lubricator
Always use an line lubricator with these motors. Use a
lubricator having an inlet and outlet at least as large as the
inlet on the motor. Install the lubricator in the air line just
ahead of the motor.
l Lubricator must be located no more than 10 ft. (3m)
from the motor.
The air line lubricator should be replenished daily and set to
provide 5 to 6 drops per minute of GRADE IS068 oil
(minimum viscosity 61,2 Cst at 40°C).
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Motor
For optimum performance and maximum durability of
parts, operate air motor at 90 PSI at 81scfm (6,3 bar/630
kpa at 2,2 cu.m/min) air pressure and volume. The winch
should be installed as near as possible to the compressor or
air receiver.
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.
a) When Firstrunning the motor some light oil should be
injected into the inlet connection to allow good lubrication.
b) When first operating the winch it is recommended that
the motor be driven slowly in both directions for a few
minutes.
For winches that have been in storage for a period more
than one month the following start-up procedure is
required.
1- Pour a small amount of gasoline fluid in the motor inlet
port.
2 - Operate the motor for 10 seconds to flush out any
impurities.
3 - Pour small amount of oil in the motor air inlet port.
4 - Operate the motor for an additional 2 to 3 seconds. The
winch is now ready to work.
The four most important aspects of winch operation are :
1- Follow all safety instructions when operating the winch.
2 - Allow only qualified people to operate the winch
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.
“‘As regard manriding winches, it is responsibility of the
owner or user of the winch to determine wether the winch
conform with local regulations for personnel use”
Winch control
The winch spring loaded manual control throttle is mounted
to the air motor.
When viewed from the air motor end move the control
throttle handle to the right (clockwise) to pay out wire rope.
When viewed from the air motor end move the control
throttle handle to the left (counterclockwise) to haul in wire
rope.
To ensure smooth operation of the winch sudden
movements of control valve should be avoided.

Wire rope
Refer the wire rope manufacturers recommendations. At a
minimum observe the following :
1 - Clean with a brush or steam if there is dirt, rock dust or
other foreign material on the surface of the rope
l Do not use an acid-based solvent or other cleaning
fluid.
2 - Apply a wire rope lubricant or SAE 30W oil.
3 - Brush, drip or spray lubricant weekly, or more
frequently, depending on severity of service.
Reduction Gear Assembly
Replace the oil in the reduction housing at least once every
year. If the winch is used at a normal frequency, the oil in
the reduction housing is suitable for one years operation
without changing. However, when the winch is used at a
high frequency, the oil may need to be changed on a more
frequent basis.
To ensure correct performance, highest efficiency and long
life, it is essential that the lubricating oil be maintained at
thecorrect level. 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 of thegears.
The reduction gear assembly is filled and shipped with oil
from the factory. Use only high quality lubricants in the
reduction gear assembly such as high grade EP type oil or
their equivalents. Fill the reduction gear assembly until the
working rim is covered.
Oil capacity : 3 litres.
Recommended oil :
GRADE SAE 80 W 90 - Kinematic
Viscosity : 145 mm2/s at 40°C
Seals and Bearings
If winch is disassembled, clean all parts thoroughly and
coat bearings and seals with clean grease. Use sufficient
grease to provide a good protective coat.
Storage
For exchange winches or winches that will not be operated
for extended periods pour a small amount oil into the motor
inlet port or supply line. Operate the motor for 2 to 4
seconds to lubricate the motor parts then plug the air inlet
port.
There are two types of inspection, the frequent inspection
performed by the operator while using the winch and
periodic inspections performed by qualified personnel.
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.
Any deficiency revealed through inspection must be
reported to an appointed person. A determination must be
made as to whether a deficiency constitutes a safety hazard
before resuming operation of the winch.
Records and Reports
Some form of inspection record must be maintained for
each winch, listing all points requiring periodic inspection.
A written report should be made monthly on the condition
of the critical parts of each winch. These reports should be
dated, signed by the person who performed the inspection,
and kept on file where they are readily available to
authorized personnel.
Frequent Inspection
On a winch in continuous service, frequent inspection
should be made at the beginning of each shift. In addition,
visual inspections should be conducted during regular
service for any damage or evidence of malfunction.
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OPERATION. Check for visual or abnormal noises
which could indicate a defect. Do not operate a winch
unless the wire rope feeds onto the winch drum
smoothly. If wire rope binds or jumps, clean and
lubricate the wire rope. If problem persists, replace the
wire rope. Do not operate the winch until all defects
have been corrected.

6 - WIRE ROPE
Besides the items in a frequent inspection, inspect for
the following :
2 - AIR SYSTEM. Check air lines, valves and other
components for leakage. Repair if necessary.
3 - WIRE ROPE. Wire rope is a consumable item which
must be replaced when worn. The following list is a
guide to the accepted standards by which wire rope
must be judged and is not presented as a substitute for
an experienced inspector :
a . Damage, such as bird cages, kinking, core protrusion,
crushing, heat damage, and main strand
displacement.
b . Corrosion and nicking
c . Wear of crown wires. Replace at 1/3 wear of any
crown wire.
d . Broken wires or strands, particularly at connections.
Replacement is necessary if one wireis broken at a
connection; six wires broken within one lay ; three
wires broken in one strand within one lay.
e . Lubrication.
Replace wire rope if any doubt exists as to wire rope
serviceability.
4 - WIRE ROPE REEVING. Check reeving and ensure
wire rope is properly secured to the drum.
5 - CONTROLS. See that controls function properly and
return to neutral when released.
Periodic Inspection
According to ANSI/ASME B30.7, frequency of periodic
inspection depends on the severity of usage : NORMAL,
yearly; HEAVY, semiannually; SEVERE, quarterly.
Disassembly may be required for HEAVY or SEVERE
usage. Keep accumulative records of periodic inspections to
provide a basis for continuing evaluation. Inspect all the
items in a frequent inspection plus the following:
1 - FASTESERS. Check, capscrew, nuts, pins and other
fasteners on winch and air system.Replace if missing
and tighten or secure if loose.
2 - ALL COMPONENTS. Inspect for wear, damage,
distortion, deformation and cleanliness. If external
evidence indicates the need, disassemble. Check gears,
shafts, bearings, springs and covers. Replace worn or
damaged parts. Clean, lubricate and reassemble.
3 - DRUM AND SHEAVES. Check for damage or
excessive wear. Replace if necessary.
4 - BRAKE. Perform functional load test on winch. Check
ability of the brake to hold rated load.
5 - LABELS AND TAGS. Check for presence and
legibility. Replace if necessary.
7
a-
b-
C-
d-
Build-up of dirt and corrosion. Clean if necessary.
Loose or damaged end connection. Replace if loose
or damaged.
Check wire rope anchor is secure.
Changes in the size of the rope diameter. Measure
the diameter from crown-to-crown. If nominal
diameter of wire rope has decreased more than l/64
in. (0.4 mm) replace the wire rope.
(see Dwg. D6310012)
C
C
FOUNDATION. Check for the continued ability to
sustain the imposed loads.
Winches Not in Regular Use
A winch which has been idle for a period of one month or
more, but less than six months, shall be given an inspection
conforming with the requirements of “Frequent Inspection”
before being placed into service.
A winch which has been idle for a period of over six
months shall be given a complete inspection conforming
with the requirements of “Periodic Inspection”. Standby
winches shall be inspected at least semiannually in
accordance with the requirements of “Frequent Inspection”.
If adnormal operating conditions apply, winches may
require a more frequent inspection.
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