Ingersoll-Rand Man Rider MR150K Series User manual

Save These Instructions
Form MHD56490
Edition K
November 2021
CCN 45957115
Air Powered Man
Rider™Winch
MR150K Series
yProduct Information

2 MHD56490
Only allow Ingersoll Rand trained te hni ians to perform maintenan e on this produ t. For additional information
onta t Ingersoll Rand fa tory or nearest Distributor.
For additional supporting documentation refer to Table 1, p. 2.
Manuals can be downloaded from www.irmhdocs.s ysite.com
The use of other than genuine Ingersoll Rand repla ement parts may result in safety hazards, de reased
performan e and in reased maintenan e and will invalidate all warranties.
Original instru tions are in English. Other languages are a translation of the original instru tions.
Refer all ommuni ations to the nearest Ingersoll Rand Offi e or Distributor.
Table 1. Product Information Manuals
Publication Part/Document Number (CCN)
Product Safety Information Manual (Man Rider) MHD56251 (71402606)
Product Parts Information Manual MHD56489 (45957107)
Product Maintenance Information Manual MHD56492 (47512571)

MHD56490 3
Table of Contents
Produ t Des ription and Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Des ription and Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CE and ATEX Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Manufa turer's Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Spe ifi ations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Capa ity Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
M1 Tra eability and Type Approval Certifi ation (N4 / N5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting................................................................................... 8
AirSupply .................................................................................. 9
AirLines ................................................................................ 9
3-Way Ball Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Line Lubri ator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Shut Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WireRope ................................................................................. 10
Wire Rope Sele tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safe Wire Rope Handling Pro edure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wire Rope Spooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safe Installation Pro edures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rigging ................................................................................ 11
Rigging – Harness (riding belt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Wire Rope Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sla k Line Devi e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Limit Swit h Devi e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Motor ..................................................................................... 13
PressRoller................................................................................ 13
Pendent ................................................................................... 13
Initial Win h Operating Che ks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Training ................................................................................... 15
Program ............................................................................... 15
Planning Meeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Win h Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Win h Mounted Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Emergen y Stop and Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overload Devi e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remote Pendent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Win hBrakes .............................................................................. 16
Automati Dis Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Automati Drum Band Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Emergen y Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Emergen y Lowering Pro edure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Alternate Lifting/Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sla k Line Devi e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Win hes Not in Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 MHD56490
Storing the Win h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspe tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wire Rope Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenan e Interval Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Frequent Inspe tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Daily Inspe tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Quarterly Inspe tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspe tion Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overload Devi e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Automati Band Drum Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lubri ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Re ommended Lubri ants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General Lubri ation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Redu tion Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Seals and Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
WireRope.............................................................................. 24
Produ t Information Graphi s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air S hemati s (For MK2 before 11/19/2021). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air S hemati s (For MK3 after 11/19/2021) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table of Contents

MHD56490 5
Product Description and Intended Use
Description and Intended Use
This produ t is an air power-driven win h that has a gear motor. The win hes intended use is only for lifting a
person (Man Rider™) in a lifting harness and shall not be used for any other purpose.
The design life of the win h is based on the environment and amount of use. At the spe ified maintenan e interval,
the win h should be subje ted to a omplete inspe tion by an Ingersoll Rand trained te hni ian to determine the
remaining servi e life. Refer to ‘Maintenan e Intervals’ hart in Produ t Maintenan e Information Manual.
CE and ATEX Option
This produ t is in onformity with the most re ent European Standards, Classifi ation FEM 4m.
Only models with a CE and ATEX marking on the data (name) plate, lo ated on the produ t meet these
requirements. Refer to the Produ t Safety and Maintenan e Information Manuals for further explanation.
Figure 1. MHP4609
II 2G Ex h IIB T4 Gb X
II 2D Ex h IIIC T135°C Db X
Manufacturer's Address
Ingersoll Rand
Douai Operations
529, Avenue Roger Salengro
59450 Sin Le Noble, France
Phone: [phone]
Fax: [phone]

6 MHD56490
Specifications
Model Code Explanation
Example: MR150KA-1CE-B MR 150K A - 1 CE - B
MR = Man Rider
150K = Capacity 150 kg / 330 lbs
A = Air Power Source
1 = Lever Throttle Control
3xx = Remote Pilot Pendent (xx hose in m)
Certification:
CE = Standard (European Standards)
N4
N5
= CE and ABS Certified
= CE and DNV Certified
Options (Other):
A
B
= Manual Wire Rope Guide
= Pedestal Base
K
M1
W1
W2
W4
C
= Horizontal Wire Rope Takeoff Angle
= Typical Traceability
= ABS Witness Test
= DNV Witness Test
= Client Witness Test
= Operator Orientation Cover
Standard Features:
• Automatic Disc Brake and Drum Band Brake
• Winch Guard
• Vertical Rope Entry (underwound configuration)
• Grooved Drum for 7/16 in (10 mm) Wire Rope
• Main Air Emergency Stop Valve
• Emergency Lowering Device
• Upper and Lower Limit Switches
• Overload Protection
• Slack Line Device
• Press Roller (assisting spooling device)
• Air Line Accessories (water separator, regulator, filter, and lubricator)
• Stainless Steel Hoses
Table 2. Specifications Table
Air System Rated Performance (at rated pressure/volume) Temperatures
Working
Inlet
Pressure
Range
Air Consumption
(at rated pressure
and load)
(Full) Rated
Working Load
Line Speed with
Rated Load
Winch Nominal
Overload
Setting
Ambient
Operating
Temperature
Supply Air
Temperature
scfm m3/min lbs kg fpm m/min lbs kg F C F C
70 to 100 psig
(5 to 7 bar) 88 2.5 330 150 98 30 412 187 - 4º to
149º
- 20º
to 65º
32º to
149º
0º to
65º
Note: T.D. = Design Temperature is -20° C as defined by DNV and ABS requirements.
Sound
Pressure
Level (a) (b)
Air Supply Inlet
(NPT) Motor Drum Barrel
Diameter Net Weight (c) Drum Flange
Diameter
dBA inch mm HP kw inch mm lbs kgs inch mm
87 3/4 19 1.5 1.12 13.5 342 463 210 17.5 450
(a) Sound measurements have been made in accordance with ISO 11202, ISO 3744-3746 and ISO 4871 test specifications for sound from pneumatic
equipment. Readings shown are based on the average noise level of each winch configuration, proportionate to the utilized time in a regular cycle.
(b) Lpc (Peak Sound Pressure) does not exceed 130 dB
(c) Weight of standard winch without wire rope.

MHD56490 7
Table 3. Minimum and Maximum Wire Rope Size
Drum Barrel
Length
Wire Rope
Diameter
Cumulative Wire Rope Capacity
Storage Capacity Working Capacity
inch mm inch mm No. of Layer ft mNo. of Layer ft m
12 300 0.39 10 5 505 154 2 177 54
Capacity Information
This produ t is designed for lifting with a 10:1 minimum design fa tor at rated load.
M1 Traceability and Type Approval Certification (N4 / N5)
Load bearing parts are do umented to provide tra eability. Do umentation may in lude hemi al and physi al
properties of raw material, heat treating, and hardening, tensile and harpy tests as required for the part.
Type Approval Certifi ation (N4 / N5) in ludes the tra eability on load bearing parts as well as other requirements;
any load bearing part repla ement must follow the same ordering pro ess to ontinue ertifi ation.
CCAAUUTTIIOONN
!
Requirements must be stated when reordering load bearing parts for continued certification.
Refer to the Product Parts Information for specific part numbers. Material not designed for cold
weather may result in damage to the product.
SSppee iiffii aattiioonnss

8 MHD56490
Installation
Prior to installing the produ t, arefully inspe t it for possible shipping damage. Produ ts are supplied fully
lubri ated from the fa tory. Che k oil levels and adjust as ne essary before operating produ t. Refer to
“Lubri ation,” p. 24 for re ommended oils and lubri ation 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
Standards and Regulations!
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).
Mounting
Use the win h lifting lugs to move, position, or install the win h. Refer to “Spe ifi ations,” p. 6 for the weight of the
win h. If appli able, add the weight of the wire rope and other omponents to the win h weight. Lift win h 3 to 4
in h (75 to 100 mm) off the ground to make sure that the win h is balan ed before ontinuing installation.
WWAARRNNIINNGG
!
• Only use the lifting lugs on the winch for lifting or moving the winch.
• Do not weld to any part of the winch.
• Do not weld the winch to a structure. Make sure that the bolts are correct size and strength
to install the winch to the structure.
1. Make sure the win h is positioned to allow for proper spooling of the wire rope onto the drum. When installed
orre tly, the dire tion of the drum for lift is lo kwise as viewed from the motor end of the win h. Refer to
Figure 4, p. 26.
2. The win h mounting surfa e must be flat and of suffi ient strength to handle the rated load, plus the weight of
the win h and atta hed equipment. An inadequate foundation may ause distortion or twisting of the win h
uprights (endframes) and base resulting in win h damage.
3. Make sure the mounting surfa e is flat to within 0.005 in h (0.127 mm) per in h of the drum length. Shim if
ne essary.
4. Make sure that the win h is orre tly grounded to the personal lifting system before using.
5. Use 5/8 in h (16 mm), lass 8.8 or better mounting bolts. Tighten evenly and torque to 150 ft lbs (203 Nm) for dry
thread fasteners. If the fasteners are plated, lubri ated or a thread lo king ompound is used, torque to 99 ft lbs
(134 Nm). Use self-lo king nuts or nuts with lo kwashers.
6. Refer to “Rigging,” p. 11 for installation of wire rope and the Produ t Safety Information manual.
Table 4. Mounting Bolt Hole Dimensions
Mounting
Style
Dimensions Drum Length
A B C
inches mm inches mm inches mm inches mm
FA150 20 508 18 458
0.7 18 12 300LS-150 21 533 17.7 449
LS2–150 22 560 16.5 420
Note: Dec Mounting Holes incorporate FA150KG(i)MR, LS150RLP and LS2-150RLP Dec Mounting Patterns.

MHD56490 9
Table 5. Winch Foundation Bolt Forces (Calculated for 1st layer stall load)
Force Acting on Bolt
Vertical Wire Rope Entry
lbf N
Winch
Maximum Shear Force at One Foundation Bolt Connection 114 506
Maximum Tensile Force Shared by Rear Foundation Bolts 278 1236
Pedestal
Maximum Shear Force at One Foundation Bolt Connection 114 506
Maximum Tensile Force Shared by Rear Foundation Bolts 493 2192
Refer to Figure 5, p. 27.
Air Supply
The air supply must be lean, free from moisture and lubri ated to have good motor performan e and life
expe tan y. Foreign parti les, moisture and la k of lubri ation are the primary auses of premature motor wear and
breakdown.
The water separator, regulator, lubri ator, and filter are installed as standard on the outboard end of the win h.
CCAAUUTTIIOONN
!
It is recommended that a lockable isolation pressure relief valve, set to 110 - 120 psig (7.6 - 8.3
bar), be installed in the air supply line as close to the winch as possible.
NNOOTTIICCEE
!
• Do not operate the winch without the water separator, regulator, lubricator, and filter.
• Warranty will be void if any part of the water separator, regulator, lubricator, and filter
system is not used and maintained properly.
Air Lines
Inside diameter of air supply lines must not be less than size spe ified in Table 2, p. 6. Before making final
onne tions, all air supply lines should be purged with lean, moisture free air or nitrogen before onne ting to
main air inlet. Supply lines should be as short and straight as installation onditions will permit. Long transmission
lines and ex essive use of fittings, elbows, tees, globe valves, et . ause a redu tion in pressure due to restri tions
and surfa e fri tion in lines.
3-Way Ball Valve
Refer to Figure 13, p. 29. A 3-way ball valve is lo ated at the air inlet to the win h. One inlet to the 3-way ball valve is
to be onne ted to the Main Air Supply. The other inlet is available to be onne ted to an auxiliary air sour e, as
needed for Emergen y Lowering or Emergen y Raising in the event of Main Air Supply failure. Position lever to
open inlet on e auxiliary air has been onne ted.
Air Pressure Regulator
The air pressure regulator is install between water separator and filter. The regulator is preset and sealed at the
fa tory and has a prote tive over to ensure no adjustment to regulator is made unless ne essary.
Any adjustments shall be made by an Ingersoll Rand trained Servi e Te hni ian or a 1Qualified Person.
NNOOTTIICCEE
!
Not all products are CE approved, refer to products data (name) plate to see if this applies.
Air Line Lubricator
A lubri ator is installed as standard on this win h. The lubri ator should be replenished daily and set to provide 2 to
3 drops per minute of ISO VG 68 oil.
IInnssttaallllaattiioonn
1. Qualified Person: A Person who, by possession of a recognized degree in an applicable field or certificate of professional standing, or who by extensive knowledge, training, and experience has
successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

10 MHD56490
CCAAUUTTIIOONN
!
Shut off air supply before filling air line lubricator.
Air Line Filter
An air line filter is installed as standard on the win h. The filter provides a 5 mi ron filtration and in ludes a
moisture trap whi h is self-draining. Clean and hange the filter periodi ally to maintain its operating effi ien y.
Water Separator
The water separator is installed as standard on the win h. A small amount of water will drain from the plug at the
bottom of the housing. The filter should be repla ed yearly or as ne essary depending upon use.
Shut Off Valve
Refer to the Produ t Safety Information Manual for information.
Wire Rope
CCAAUUTTIIOONN
!
• A requirement to 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 underwound operation (normal application). Refer to
MHP2450 in Product Safety Information Manual.
NNOOTTIICCEE
Wire rope Storage!
Make sure to pull wire rope out of the way of moving equipment. Always stow in a slack condition.
Install Win h so that wire rope, when at take-off angle limits, does not onta t mounting surfa e or win h guard
panels. Install win h with single part wire rope reeving only. Refer to Figure 6, p. 27.
Wire Rope Selection
Consult a reputable wire rope manufa turer or distributor for assistan e in sele ting the appropriate type and size
of non rotating wire rope and, where ne essary, a prote tive oating. Use a wire rope whi h provides an adequate
safety fa tor to handle the a tual working load and meets all appli able industry, trade asso iation, federal, state
and lo al regulations.
When onsidering wire rope requirements the a tual working load must in lude not only the stati or dead load but
also loads resulting from a eleration, retardation and sho k load. Consideration must also be given to the size of
the win h wire rope drum, sheaves and method of reeving. Steel Wire rope onstru tion must be 10 mm EIPS 6 X
19 IWRC with a minimum breaking strength of 3372 lbs (15 kN) right lay to assist spooling. Refer to Table 6, p. 10.
Table 6. Wire Rope Size
Wire Rope Anchor Part No. Size
9631-0023 (38537445) 10 mm
Note: Wire rope diameter is fixed if grooved drum option is used.
IInnssttaallllaattiioonn

MHD56490 11
Installing Wire Rope
Refer to Figure 7, p. 27.
1. Cut wire rope to length in a ordan e with wire rope manufa ture’s instru tions.
2. Feed end of wire rope through drum an hor po ket hole.
3. Forming a loop, wrap loop around an hor, approximately 22 in hes (559 mm) of wire rope. Ensure dead end of
wire rope is fa ing away from the drum flange.
4. Pull wire rope an hor into position in drum an hor po ket.
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 make sure wire rope is orre tly spooled and the first layer is tight against drum.
• Always follow wire rope manufa turer’s re ommendation on use and maintenan e of wire rope.
Wire Rope Spooling
To ompensate for uneven spooling and the de rease in line pull apa ity as the drum fills up, use as short a wire
rope as pra ti al. When rewinding apply tension to the end of the wire rope to eliminate line sla k. This helps
a hieve level winding and tight spooling.
CCAAUUTTIIOONN
!
• To avoid damage to the rigging, the structure supporting the rigging and the winch, do not
use with a multi-reeving wire rope arrangement.
• Refer to DNV Standard OS E101, that provides further information regarding rigging.
NNOOTTIICCEE
!
The limit switch will require adjustment before and after spooling to full drum storage.
Safe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not atta h a welding ele trode to win h or wire rope.
3. Never run wire rope over a sharp edge. Use a orre tly sized sheave.
4. When a lead sheave is used, it must be aligned with enter of drum. The diameter of lead sheave must be at
least 18 times the diameter of wire rope. Refer to Dwg. MHP2449 in Produ t Safety Information Manual.
5. Requirement to maintain at least 5 tight wraps of wire rope on the drum at all times.
Rigging
The sheave arrangement with fastening to stru ture shall be dimensioned a ording to the same prin iple as the
win h itself. The geometry shall ensure free path for the person lifted or lowered and ensure no damage to wire
rope. The geometry shall ensure that the angle between wire rope and drum or sheave is within +/- 4 degrees. The
sheave arrangement shall be fitted with prote tion ensuring that derailing of wire rope does not o ur. The
diameter ratio between sheave and wire rope shall be in a ordan e with the manufa turer’s requirements but a
minimum 18:1. All fittings and onne tors will have at least the breaking strength of the wire rope. For the
terminations of wire ropes only spli es; aluminium pressed ferrules, non-ageing steel pressed ferrules, or wedge
so ket an horages may be used. U-bolt grips shall not be used as wire rope terminations for load arrying wire
ropes.
Table 7. Sheave Specifications
Winch Series Minimum Diameter of Sheave (mm) Design Factor x SWL for Sheave
MR150K 200 1.5
IInnssttaallllaattiioonn

12 MHD56490
Rigging – Harness (riding belt)
NNOOTTIICCEE
!
Harnesses shall be selected in accordance with local or other regulations. As a minimum, a
harness complying to en 361:2002 should be selected and shall be marked to show its compliance
to this standard. The user shall follow the manufacturer’s recommendations for proper use,
inspection, and disposal. Also, refer to Product Safety Information Manual before operation.
Manual Wire Rope Guide
Only allow personnel that are physi ally apable of simultaneously moving the wire rope guide handle through its
full travel range and operating the win h ontrol valve to use this equipment. Use a se ond operator to operate the
wire rope guide as ne essary.
WWAARRNNIINNGG
!
• Only use manual wire rope for even spooling of unloaded wire rope.
• Do not use wire rope guide to force heavily loaded wire rope into position.
• Remove manual wire rope guide for normal operation.
• Keep clear of pinch points at wire rope guide pivot and where wire rope enters guide.
• Do not place hand(s) on any part of the manual wire rope guide other then the handle grip
during wire rope spooling.
• Do not allow body or clothing between the travel stop and the manual wire rope guide bar.
Inspect wire rope guide prior to each use, and monitor operation during use.
• Do not use if wire rope guide is bent or damaged. Ensure manual wire rope guide is moved
the full length of the drum for even wire rope spooling.
Slac Line Device
The sla k wire devi e is preset at the fa tory for typi al take-off angle.
When sla k is dete ted in the payout dire tion and the win h drum stops rotating the win h must be “RESET”.
Refer to “Emergen y Stop and Reset,” p. 15.
CCAAUUTTIIOONN
!
Do not use slack wire device to spool wire rope onto drum.
Make sure the wire rope is properly wound on the drum.
The wire rope must pass underneath the roller when coming out of the drum, so that when a
tension is applied on the end of the wire rope, the slack wire device arm is lifted.
Refer to Figure 4, p. 26.
Limit Switch Device
Refer to Figure 6, p. 27.
The limit swit h devi e limits the amount of travel for payout and haul-in of the win h wire rope. Limit swit hes are
not intended as the primary means of stopping win h operation.
WWAARRNNIINNGG
!
It is the owner’s and operator’s responsibility to adjust winch operating limits prior to using the
winch.
This is a two person pro edure, one to adjust the limit swit h and the other to operate the win h.
1. Loosen aps rew (86) and rotate the a ess over (278) up to expose the adjustment ams (264).
2. Loosen s rew (263) on one of the ams (264), upper or lower. (Use a 7 mm wren h)
3. Rotate am until the emergen y stop valve is a tivated, ausing system air to vent.
IInnssttaallllaattiioonn

MHD56490 13
4. Hold am adjustment s rew in position and tighten s rew. Do not over tighten.
5. Reset the ontrol valve to allow air supply to flow ba k into the motor. Refer to “Emergen y Stop and Reset,” p.
15.
6. Repeat steps 1 through 5 operations for the se ond am.
7. Test the win h set points by operating win h through three omplete y les to make sure the limits are within
+/- 0.5 m of set points.
8. On e settings are at the desired limits lose the a ess over (278) and tighten aps rews (86). Do not over
tighten aps rews.
NNOOTTIICCEE
!
Activate the shut off valve and operate the winch in opposite direction at slow speed during one
turn when a top or bottom limit switch is actuated.
Motor
For optimum performan e and maximum durability of parts, provide an air supply of 70 to 100 psig (5 to 7 bar) at
the flow re ommended in “Spe ifi ations,” p. 6, as measured at the motor inlet. The win h should be installed as
near as possible to the ompressor or air re eiver.
Press Roller
Make sure the wire rope is positioned between press roller and drum barrel and spring frame, to keep press roller in
tight onta t with wire rope.
Pendent
Che k that all hose onne tions are tight and that hoses are not twisted or rimped.
Refer to Figure 12, p. 29.
Pendent lengths up to 66 ft (20 m) are available. Conta t the fa tory for pendent lengths greater than 66 ft (20 m).
CCAAUUTTIIOONN
!
To avoid damaging the pendent hose, make sure the strain relief cable, not the pendent hose, is
supporting the weight of the pendent.
Initial Winch Operating Chec s
Win hes are tested for proper operation prior to leaving the fa tory. Before the win h is pla ed into servi e the
following initial operating he ks should be performed.
1. When first running the motor inje t a small amount of light oil into the main inlet onne tion to provide initial
lubri ation.
2. Operate the win h in both dire tions with no load for a few minutes.
3. Che k operation of limit swit hes, lo king me hanisms and all safety devi es when equipped.
4. Che k foundation mounting fasteners are se ure.
5. Che k wire rope does not ome in onta t with the guard.
For win hes that have been in storage, the following start-up pro edures are required:
1. Give the win h an inspe tion onforming to requirements of “Win hes Not in Regular Use,” p. 17.
2. Che k oil levels in redu tion gear and dis brake, top off levels as required.
3. Pour a small amount of ISO VG32 (SAE 10w) oil in motor inlet port.
4. Operate motor for 15 se onds in both dire tions to flush out any impurities.
5. The win h is now ready for normal use.
IInnssttaallllaattiioonn

14 MHD56490
Operation
It is re ommended that the user and owner he k all appropriate and appli able regulations before pla ing this
produ t into use. Refer to Produ t Safety Information Manual before operating produ t.
The four most important aspe ts of produ t operation are:
1. Follow all safety instru tions when operating the produ t.
2. Allow only people trained in safety and operation of this win h to operate this equipment.
3. Subje t ea h produ t to a regular inspe tion and maintenan e pro edure.
4. Be aware of produ t apa ity and weight of load at all times.
WWAARRNNIINNGG
!
Do not lift loads over people.
CCAAUUTTIIOONN
!
Make sure the limit switch operates correctly and the man-riding device does not come into
contact with the sheave.
NNOOTTIICCEE
!
Refer to the Product Parts or Maintenance Information manuals for MHP drawings unless
specified on a page in this manual.
Operators must be physi ally ompetent. Operators must not have a health ondition whi h might affe t their
ability to a t, and they must have good hearing, vision and depth per eption. The win h operator must be arefully
instru ted in his duties and must understand the operation of the win h, in luding a study of the manufa turer’s
literature. The operator must thoroughly understand proper methods of hit hing loads and must have a good
attitude regarding safety. It is the operator’s responsibility to refuse to operate the win h under unsafe onditions.
1. Lifting and lowering speeds are operator ontrolled and should be as slow as pra ti al. Ingersoll Rand
re ommends that you do not ex eed 100 ft (30 m) per minute. Any appli able odes and standards should be
followed.
2. Personnel being lifted or lowered must be alert to obsta les and hazards during movement.
3. A personnel platform should not be used due to win hes rated load.
4. Tag lines shall be used where pra ti al.
5. The win h operator shall remain at the ontrols at all times when handling personnel.
6. Handling of personnel shall be dis ontinued upon indi ation of any impending danger.
WWAARRNNIINNGG
!
Maintain at least 5 wraps of wire rope on the drum at all times.
7. The man riding devi e shall be raised approximately 1 ft (30 m) and inspe ted to ensure that it is se ure prior to
personnel o upan y. Before raising or lowering personnel, the following onditions shall exist:
a. Wire rope shall be free of kinks.
b. Win h shall be reeved for single part line whi h avoids obstru tions and interferen e.
. The primary point of wire rope atta hment shall be entered over the man riding devi e to redu e tilting and
swinging the suspended person.
8. When personnel are suspended, a signal person must be provided unless operator has line of sight. Signals
must be visible to the operator at all times.
9. Rider suspension devi es shall be in a ordan e with all appli able odes and regulations, su h as ISO-EN 361
(harness, wire, pulleys..).
10. Bridles and asso iated hardware for the man riding devi e shall not be used for any other servi e.
11. If a sla k wire rope ondition o urs the hoisting me hanisms shall be inspe ted to assure wire rope is properly
spooled onto drum and through sheaves. When sla k wire has been dete ted, operator must determine and
re tify problem prior to resuming operation.

MHD56490 15
Training
Program
The employer shall provide and implement a training program for all supervisors and employees engaged in the
operation of raising, lowering or suspending personnel using proper suspension devises from a win h load line so
that they are familiar with the requirements of the hoisting system and are able to re ognize the asso iated hazards
and take appropriate measures. Re ords of training programs shall be maintained.
Planning Meeting
A meeting attended by the win h operator, signal persons, persons to be lifted and the person in harge of the task
to be performed is required to be held to plan and review the pro edures to be followed, in luding pro edures for
entering and leaving the man riding devi e, the use of safety equipment, signals, and the lift hart information.
NNOOTTIICCEE
!
This meeting shall be held prior to the beginning of personnel-hoisting operations at each new
work location and thereafter for any new employees assigned to the operation.
Winch Controls
The throttle ontrol provides the operator ontrol of the motor speed and dire tion of the drum rotation.
Prevent sudden movements of the ontrol valve. Sudden movement of the ontrol valve may a tivate the overload
devi e. If this o urs reset the win h by pressing the “ON” button of the emergen y stop devi e and smoothly
a tion the ontrol valve. Make sure the win h is not overloaded.
Winch Mounted Control
Refer to Figure 8, p. 28.
Refer to the label on the win h for take-off angle part number 45972643.
Vertical Wire Rope Ta e-off Angle (standard):
The operator should stand to the left of the motor and the sla k arms should be fa ing away. The ontrol lever is a
lift and shift; to haul-in, lever is shifted towards operator and the drum rotates lo kwise. To payout, lever is shifted
away from operator and the drum rotates ounter lo kwise.
NNOOTTIICCEE
!
For Horizontal take-off angle, the winch will require some adjustments to the control valve, slack
wire assembly and winch guard. Contact the authorized service center for instructions.
Emergency Stop and Reset
Refer to Figure 8, p. 28.
The emergen y stop button is lo ated at air inlet of win h on lo al ontrol models, and on pendent on remote
ontrol models. When a tivated, win h drum rotation will immediately ease.
1. To start win h operation depress the “RESET” button.
2. Operate the lift and shift ontrol lever to either ‘Haul-in’ or ‘Payout’ .
3. In event of an emergen y all win h operation an be stopped by pushing the emergen y stop button. This will
prevent air from rea hing win h motor, engage win h automati brake(s) and stop win h haul-in or payout
movement.
4. To reset Emergen y Stop Valve:
a. Rotate the emergen y stop button lo kwise to allow the button to “pop up”.
b. Depress and hold until the “RESET” button until the air es ape through the over plate area on the motor
end.
OOppeerraattiioonn

16 MHD56490
Overload Device
WWAARRNNIINNGG
!
This overload protection device is factory set at 125% maximum of the SWL at rated layer. Refer
to Specifications, p. 6.
The overload devi e is integrated into the win h air motor and prevents the win h from lifting a load greater than
the win h nominal overload setting. When an overload is dete ted, inlet supply air is stopped and the win h will not
operate. If the overload devi e is a tivated the load must be lowered and redu ed. Alternative methods should be
used to a omplish the task. Refer to “Emergen y Stop and Reset,” p. 15. To lower the load, first reset the win h by
pressing the “RESET” button of the emergen y stop valve and operate the win h ontrol for wire rope payout.
Remote Pendent
Refer to Figure 12, p. 29.
Provides remote win h ontrol at distan e up to 20 meters (66 ft) away from the win h motor. Pilot air hoses
onne t the pendent to the win h motor to provide win h operation. The pendent ontrol throttle is a two lever
movable ontrol station. Dire tion of win h drum rotation is determined by the pendent ontrol lever depressed.
Winch Bra es
Automatic Disc Bra e
The automati dis brake is a spring applied, air released brake. When the ontrol valve is in the neutral position,
the air in the brake is vented and the brake is engaged. The springs, a ting on the pressure plate, ompress the
brake fri tion and separator plates and engage the brake to prevent drum rotation.
Automatic Drum Band Bra e
The automati drum band brake is a spring applied, air released, externally mounted brake. When the ontrol valve
is pla ed in the neutral position, the air in the ylinder is vented allowing the spring tension to automati ally engage
the brake and prevent drum rotation.
Emergency Lowering
This devi e allows the person to be lowered safely in ase of main air supply failure.
Note: Recommended minimum load for Emergency Lowering is 200 lbs (91 g).
WWAARRNNIINNGG
!
• This is a two person procedure, one person to operate the emergency lowering device, the
other to maintain a line of sight on the person being lowered.
• The winch must be isolated from the main supply air system during this operation. Make
sure the Emergency Stop button is pressed down and latched in the OFF position.
• Communication must be established between the lifted person and winch operators.
Operators should be able to visually monitor lifted person until landed.
• If line of sight between operators and lifted person is not possible, signals must be conveyed
to the operators.
Emergency Lowering Procedure
Refer to Figure 10, p. 28.
1. In the event of air supply failure, press the Emergen y Stop button to the down and lat hed OFF position.
2. A tuate and hold the swit h nearer to the motor. Swit h #1 on Figure 10, p. 28. This will release the Dis Brake.
Then a tuate the swit h further from the motor. Swit h #2 on Figure 10, p. 28. This will release the Band Brake.
Toggle this swit h as ne essary to ontrol the des ent of the person, while ontinuing to hold Swit h #1 in the
a tuated position.
3. The signal-person shall maintain the line of sight of the person being lowered to make sure the person is not
being entangled in wire rope or other equipment on the rig. The signal person shall alert the operator to release
Swit h #2 to stop lowering temporarily to avoid hazards, as ne essary.
4. Continue to hold both the swit hes in the a tuated position in order to lower the person safely to the ground.
OOppeerraattiioonn

MHD56490 17
NNOOTTIICCEE
!
After each use of the emergency lowering device, reset the Emergency Stop Valve and verify the
main air supply is in proper working condition and able to fulfill its task.
Alternate Lifting/Lowering
The following information is provided to allow for emergen y lowering or lifting of a person if air supply is lost to
win h. These pro edures should be used if no other method of safely lowering personnel is available.
Three-Way Valve
Refer to Figure 13, p. 29.
This devi e allows the person to be moved the shortest way to safety in ase of normal air supply failure. In the
event of air supply failure, operate the three way valve from normal air supply to the emergen y inlet. For a single
emergen y lifting or lowering, a 50 liter bottle of ompressed air at minimum pressure (5 to 7 bar) an be used.
1. Open the emergen y power sour e. Rotate valve lever towards normal inlet air supply side.
2. Make sure that the downstream pressure is 5 to 7 bar.
3. Operate win h normally for lifting or lowering the person the shortest way to safety.
NNOOTTIICCEE
!
After each operation of emergency lifting/lowering system, return the three-way valve to the
main air inlet and verify the main air supply is in proper working condition and able to fulfil its
task.
Slac Line Device
Refer to Figure 4, p. 26.
The sla k wire rope devi e is intended to dete t sla k in the wire rope during time of operation in the payout
dire tion.
When lowering, in the event of sla k, the sla k wire devi e arm will lower by its own weight and a tivate a
pneumati swit h that stops the pilot air lowering signal to the motor. The win h is then stopped with both brakes
applied.
Winches Not in Regular Use
1. Equipment whi h has been idle for a period of one month or more, but less than six months, shall be given an
inspe tion onforming to the requirements of “Frequent Inspe tion,” p. 19 before being pla ed in servi e.
2. Equipment whi h has been idle for a period of over six months shall be given a omplete inspe tion onforming
with the requirements of ‘Periodi Inspe tion’ before being pla ed in servi e. Refer to Produ t Maintenan e
Information Manual.
3. Standby equipment shall be inspe ted at least semi-annually in a ordan e with the requirements of “Frequent
Inspe tion,” p. 19. In abnormal operating onditions equipment should be inspe ted at shorter intervals.
4. All oils must be drained and repla ed with new, and all grease avities shall be pa ked to the pres ribed limit.
Refer to “Lubri ation,” p. 24. Produ t must be operated for at least 15 se onds in both dire tions with well
lubri ated, dry air.
Storing the Winch
1. Always store the win h in a no load ondition.
2. Wipe off all dirt and water.
3. To prevent rust build up from internal ondensation, open lubri ator to allow more oil into win h and operate
with no load. If the win h is being stored away from and not onne ted to the main air supply, pla e small
amount of ISO VG32 or SAE 10W oil at air inlet port.
4. Oil the wire rope.
5. Pla e in a dry lo ation.
6. Before returning win h to servi e, follow instru tions for “Win hes Not in Regular Use,” p. 17.
OOppeerraattiioonn

18 MHD56490
Inspection
Inspe tion information is based in part on Ameri an So iety of Me hani al Engineers Safety Codes (ASME B30.7).
WWAARRNNIINNGG
!
All new or repaired equipment should be inspected and tested by Ingersoll Rand trained
Technicians to ensure safe operation at rated specifications before placing equipment in service.
Never use a winch that inspection indicates is damaged.
Frequent and periodi inspe tions should be performed on equipment in regular servi e. Frequent inspe tions are
visual examinations performed by operators or Ingersoll Rand trained Inspe tors and in lude observations made
during routine equipment operation. Periodi inspe tions are thorough inspe tions ondu ted by Ingersoll Rand
trained Te hni ians. ASME B30.7 states inspe tion intervals depend upon the nature of the riti al omponents of
the equipment and the severity of usage. Refer to Table 8, p. 18 and “Maintenan e Interval Chart,” p. 19. Careful
inspe tion on a regular basis will reveal potentially dangerous onditions while still in the early stages, allowing
orre tive a tion to be taken before the ondition be omes dangerous.
Defi ien ies revealed through inspe tion, or noted during operation, must be reported to designated personnel to
make sure that orre tive a tion is taken.
A determination as to whether a ondition onstitutes a safety hazard(s) must be de ided, and the orre tion of
noted safety hazard(s) a omplished and do umented by written report before pla ing the equipment in servi e.
Table 8. Inspection Classifications
Conditions Normal Heavy Severe
Typical Use (operating time) Infrequent Regular Continual/Constant
Load Range 60% of Capacity 75% of Times
Used
80% of Capacity 75% of Times
Used
100% of Capacity 75% of Times
Used
Installation Protected/Enclosed/Dry Not Sheltered/Exterior Full Exposure
Atmosphere Clean/Non-Corrosive Dirty/Non-Corrosive/
Freshwater Marine
Dirty/Corrosive/Saltwater
Marine
Climate Dry/Stable Temperature Wet/Moderate Temperature
Fluctuations
Wet/Severe Temperature
Fluctuations
Wire Rope Reports
Re ords should be maintained as part of a long-term wire rope inspe tion program. Re ords should in lude the
ondition of wire rope removed from servi e. A urate re ords will establish a relationship between visual
observations noted during frequent inspe tions and the a tual ondition of wire rope as determined by periodi
inspe tions.

MHD56490 19
Maintenance Interval Chart
Refer to Table 9, p. 19 for re ommended maintenan e s hedule.
NNOOTTIICCEE
Winch Load Test!
Do an annual winch load test for all applications.
Table 9. Maintenance Interval Chart
Severe Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days.
Water Separator Inspect system filter every 30 days.
Grease Fittings Lubricate grease fittings every 90 days.
It is recommended that the following work be completed by an Ingersoll Rand trained service technician or a Qualified
Person
Standard Components 1 year 2 years 3 years 4 years 5 years 6 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
Drum Shaft x x
Overload Device x x x x x x
Limit Switches x x x x x x
Emergency Brake Release x x x x x x
Automatic Band Brake (a) x x x x x x
(a) Do not disassemble Auto Band Brake Air Cylinder unless brake operation or visual inspection indicates a requirement.
NNOOTTIICCEE
!
• Annual Inspection and Load test shall be performed by an Ingersoll Rand Trained
Technicians unless directed otherwise by a *Qualified Person.
• Certification shall be done in every three years by an Ingersoll Rand Trained Technicians
unless directed otherwise by a *Qualified Person.
* Qualified Person: A person who, by possession of a re ognized degree in an appli able field or ertifi ate of
professional standing, or who by extensive knowledge, training, and experien e has su essfully demonstrated the
ability to solve or resolve problems relating to the subje t matter and work.
Frequent Inspection
On equipment in ontinuous servi e, a ‘Daily Inspe tion’ should be made by the operator at the beginning of ea h
shift and a ‘Quarterly Inspe tion’ should be ondu ted by an Ingersoll Rand trained Inspe tor or Qualified person
every 90 days and a re ord of the inspe tion maintained.
IInnssppee ttiioonn

20 MHD56490
Daily Inspection
Complete inspe tions prior to start of daily tasks. Condu t visual inspe tions during regular operation for
indi ations of damage or eviden e of malfun tion (su h as abnormal noises).
1. Lubricator: Adjust air line lubri ator drops 2 to 3 per minute of ISO VG 32 (SAE 10W) oil during win h operation.
2. Surrounding Area: Visually he k for win h oil leaks. Do not operate win h if leaking oil is found. Make sure the
surrounding area has no slippery surfa es and is obstru tion free.
3. Hoses and Fittings: Visually inspe t for damage, air leaks, and loose onne tions. Repair all leaks or damage
and tighten loose onne tions prior to starting daily tasks.
4. Wire Rope Anchor: Verify wire rope an hor is se urely installed.
5. Guards: Verify wire rope does not onta t drum guard during win h operation and that guards are se ure and
undamaged.
6. Winch: Visually inspe t win h housings, ontrol(s), external brake, siderails, uprights and drum for damage.
Che k that all external bolts are in pla e and se ure. Report damage to supervisor and request additional
inspe tion by an Ingersoll Rand trained Servi e Te hni ian.
7. Mounting: Visually inspe t win h mounting bolts. Che k bolts are tight, undamaged and free of orrosion.
8. Winch Operation: Power win h in both dire tions. Win h must operate smoothly without sti king, binding or
abnormal noises and have minimal vibration.
9. Control Valve or Pendent: Che k operation is smooth and win h is responsive to ontrol devi e movement.
Che k ontrol returns to neutral when released. If win h responds slowly or ontrol sti ks. Win h is to operate
without hesitation in both the payout and haul-in dire tions.
10. Motor: During operation he k motor housing for ex ess heat build up. Housing should not be hot to tou h.
Listen for grinding or kno king noises. If ex ess heat or noises are noted, do not operate until inspe ted by an
Ingersoll Rand trained Te hni ian.
11. Wire Rope Spooling: Visually he k reeving and make sure the wire rope feeds on and off the drum smoothly.
Verify spooling dire tion is orre t for win h and appli ation.
12. Bra es: Lift and lower the load a short distan e to test brakes. Brakes must hold load without slipping.
Automati brake must release when win h ontrol throttle is operated. If brakes do not hold load or do not
release properly, they must be adjusted or repaired.
WWAARRNNIINNGG
Brakes!
Worn or improperly functioning brakes may cause excessive heat buildup and sparks.
13. Wire Rope: Visually inspe t all wire rope expe ted to be in use during the day’s operations. Inspe t for wear and
damage indi ated by distortion of wire rope su h as kinking, “bird aging”, ore protrusion, main strand
displa ement, orrosion, broken or ut strands. If damage is evident, do not operate win h until the
dis repan ies have been reviewed and inspe ted further by personnel knowledgeable on wire rope safety and
maintenan e pro edures.
NNOOTTIICCEE
Periodic Inspection!
The full extent of wire rope wear cannot be determined by visual inspection. At any indication of
wear inspect wire rope in accordance with instructions in “Periodic Inspection”.
14. Limit Switches: Make sure the limit swit hes engage and prevent operation at the required set point and with
drum rotating in the orre t dire tion. Make sure the limit swit h properly resets.
15. Emergency Stop and Reset Valve: A tivate emergen y stop in payout and haul-in dire tions to ensure proper
operation. Valve must stop win h operation and brakes must set qui kly. Reset valve after test.
16. Slac Line Detection: Operate win h in payout dire tion until sla k line valve a tuates. Ensure win h stops
operating in lowering dire tion, but an still lift load, after emergen y stop reset.
17. Emergency Lowering Device: Che k the pressure gauge lo ated on the emergen y lowering en losure to ensure
tank has the proper psi supply of air. Do not operate the win h if there is no air supply in the tank.
18. Press Roller: Make sure the wire rope is positioned between press roller and drum barrel and springs keep press
roller in tight onta t with wire rope. Make sure of smooth and proper operation.
19. Labels and Tags: Che k for presen e and legibility. Repla e if ne essary.
IInnssppee ttiioonn