Product Instructions

FORCE 5 Infinity Man Rider

Air Winch
Model
FA150KGi-( )

Save These Instructions

Form MHD56470
Edition 5
March 2013
45925013
© 2013 Ingersoll-Rand
 ORIGINAL INSTRUCTION
Only allow Ingersoll Rand trained technicians to perform maintenance on this
product. For additional information contact Ingersoll Rand factory or nearest
Distributor.
For additional supporting documentation refer to Table 1 ‘Product Information Manuals’ on page 2.
Manuals can be downloaded from http://www.ingersollrandproducts.com.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate all
warranties.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
These are the “original instructions”. Other languages are a translation of the “original instructions”.

Table 1: Product Information Manuals

Part/Document
Publication Part/Document Number Publication
Number
Product Safety Information Manual MHD56251 Product Maintenance Information Manual MHD56471
Product Parts Information Manual MHD56472

PRODUCT DESCRIPTION
FA150KGi winches are air powered, planetary geared units designed for only
transporting personnel. FA150KGi winches are supplied with an internal automatic
disc brake and an automatic drum band brake.

Output from the externally mounted piston air motor is transmitted through a
coupling and shaft to the planetary reduction gear assembly.

The output from the planetary reduction gear assembly is connected to the wire
rope drum through the output shaft. The disc brake attaches to the inboard upright
at motor end and is connected to the input sun gear through brake shaft.

The disc brake is automatically applied when winch is in neutral or operated in the
haul-in direction; disengaged when winch is operated in the payout direction.

During winch operation a sprag type clutch in the disc brake allows drum rotation
in the haul-in direction with disc brake engaged. This ensures brake will respond
quickly to hold the load when winch operation stops. Operation of winch in payout
direction directs pressurized air to brake piston to overcome spring force and release
brake. When payout operation is complete air is vented and brake is automatically
applied.

The drum band brake operates by applying a friction force between the drum band
and winch drum. The automatic drum band brake operation is similar to the disc
brake with the following exceptions: the brake fully disengages in both the haul-in
and payout directions and has no sprag clutch.

This product is in conformity with the most recent European Standards.

Only models with a CE and ATEX marking on the data (name) plate, located on the
product meet these ATEX requirements, refer to Dwg. MHP2645 for ATEX rating.
Refer to the Product Safety and Maintenance Information Manuals for further
explanation.

II 2 GD c IIB 200°C X
(Dwg. MHP2584)

n Manufacture's Address
Ingersoll Rand
Kent Operations
20017 72nd Avenue South
Kent, WA 98032 USA

2 Form MHD56470 Edition 5

 SPECIFICATIONS
Model Code Explanation
Example: FA150KGiMR12A1-CE FA 150KGi MR 12 A 1 - CE

Series:

FA = Force 5 Infinity Air Powered

Capacity:
150KGi = 330 lbs (150 kg) Man Rider Rating
Designation:
MR = Man Rider
Drum Length:
12 = 12 inch (305 mm) standard
Brakes:
A = Automatic drum band brake and disc brake
Controls:

1 = Winch mounted lever throttle (standard)

Design Temperature:
Blank = 0 degrees C
C1M3 = - 4° F (- 20° C) ABS

C2M3 = - 4° F (- 20° C) DNV

Options:
7 = Drum grooving in sixteenths (e.g. "7" = 7/16")
A = Drum guard with manual rope guide
B = Winch pedestal base
H = Stainless steel braided hoses in lieu of standard rubber on limit switch
K = Stowage valve kit installed on winch
M1 = Material traceability certificates according to EN 10204 (Ex DIN 50049) 2.2 on load bearing parts
M2 = Material traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on load bearing parts
Material traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on load bearing parts in a finished, as delivered
M3 =
condition
N4 = Manufactured under ABS survey

N5 = Manufactured under DNV survey

P1 = Marine 812-X paint system (P - Paint standard)

R Emergency lowering system (equipped with 2 liter bottle)
Witness test Specify W1 = ABS W2 = DNV W3 = LRS W4 = Client witness of load test
CE Package (Compliant with European Machinery Directive, refer to “DECLARATION OF CONFORMITY”)
–CE =
NOTE: Man Rider Winch shall only be used for man riding application

Table 2: General Specifications

Maximum
Minimum Air Recomm- Sound Sound
Drum Foundation
Air Air Motor Pipe System Drum ended Pressur Power
Barrel Anchor Shear
System Inlet Size Hose Size (inside Flange Diameter Wire Rope e Level Level
Diameter Force at One
diameter) Size (1, 2) (1)
Capscrew (3)
Rated Operating Air Consumption
inch mm inch mm inch mm inch mm mm dBA dBA lbs N
Pressure (at rated load)
62 scfm (1.75
90 psig (6.3 bar) 1.25 NPT 32 0.75 19 10.75 273 19 483 10 85 96 75 334
cu.m/min)

1. Sound measurements have been made in accordance with ISO 11201, 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.
2. Lcp (Peak Sound Pressure) does not exceed 130 dB.
3. Occurs when wire rope take-off from drum equals zero degree angle of inclination. Values based on wire rope at third layer and rated line pull.

Form MHD56470 Edition 5 3

 Wire Rope Storage Capacity **
Line Speed @ 150 kg (330 lb) Load Minimum Load for Emergency Lowering
Layer 12 inch (305 mm) Drum
fpm mpm lb kg ft m
1 82 25 200 91 86 26
2 85 26 187 85 178 54
3 87 26.5 176 80 275 84
4 89 27 166 75 378 115
5 91 27.7 158 72 487 148
6 93 28.3 150 68 602 183
7 94 28.6 140 64 723 220
8 (1) 95 29 136 62 849 259
** Wire rope storage capacity based on DNV and NMD standards of 2.5 times wire rope diameter below drum flange. Wire rope storage capacities listed may vary from figures
stated elsewhere.
1. Full drum at rated operating pressure and line speed.

M2 – Material Traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on

n Capacity Information load bearing parts. Conformity documents affirm (by a department independent of
the manufacturing department) that actual parts are in compliance with
requirements of the order, based on specific inspection and testing (i.e. results are
FA150KGi Man Rider™ winches are designed for lifting with a 10:1 minimum design actual material properties for these parts).
factor at rated load.
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
n Traceability the manufacturing department) that the actual parts used in the product are in
compliance with the order, based on specific inspection and testing (i.e. results are
Load bearing parts are documented to provide traceability. Documentation includes actual material properties for these parts in a finished, as delivered condition).
chemical and physical properties of raw material, heat treating, hardening, tensile
and charpy tests as required for the part. Components with part numbers ending in CH are charpy parts for use under extreme
cold conditions. Traceability requirements must be stated when reordering these
Units with M1, M2 or M3 in the model code have traceable load bearing parts for continued certification.
components.

M1 – Material Traceability certificates according to EN 10204 (Ex DIN 50049) 2.2 on

load bearing parts. Conformity documents affirm (by the manufacturer) that parts
are in compliance with requirements of the order, based on non-specific inspection
and testing (i.e. results are typical material properties for these parts).

INSTALLATION
Winch gearbox and disc brake are supplied fully lubricated from factory. Check oil Table 3: Mounting Bolt Hole Dimensions
levels and adjust as necessary before operating winch.
Drum Length (inches)
Refer to “LUBRICATION” section on page 9 for recommended oils. Prior to Dimension
12
installing winch, carefully inspect it for possible shipping damage.
inch 20
“A”
CAUTION mm 508
inch 9
“B”
• Owners and users are advised to examine specific, local or other mm 229
regulations, including American Society of Mechanical Engineers (ASME)
and/or OSHA Regulations which may apply to a particular type of use of inch 0.69
“C”
this product before installing or putting product to use. mm 18

NOTICE
n Wire Rope
• Prior to installation refer to Product Safety Information Manual. CAUTION

n Mounting
Care must be taken when moving, positioning or mounting winch. Winch has lifting
lugs bolted to both uprights to assist in moving the unit. Attach hooks or a suitable
sling to these lugs when moving winch. Refer to “SPECIFICATIONS” section
on page 3 to determine winch weight.
Mount winch so drum axis is horizontal and motor control valve pad is not more
than 15 degrees off top vertical center. If winch is to be mounted in an inverted
position, the motor case must be rotated to position control valve pad at the top
and adequate clearance must be provided for control valve operation. Position
winch to provide unrestricted access to winch control valve. Do not mount winch in
a vertical position, with motor up or down. Reduction gear box lubrication is not
designed for this type of installation.
1. Winch mounting surface must be flat and of sufficient strength to handle rated
load plus the weight of the winch and attached equipment. An inadequate
foundation may cause distortion or twisting of the winch uprights and side rails
resulting in winch damage.
2. Make sure mounting surface is flat to within 1/16 inch (1.6 mm). Shim if necessary.
3. Mounting bolts must be 5/8 inch NC (16 mm) Grade 8 or better. Use self-locking
nuts or nuts with lockwashers. Refer to Table 3 ‘Mounting Bolt Hole
Dimensions’ on page 4.
4. Tighten mounting bolts evenly. Refer to “Torque Chart” in Product Maintenance
Information Manual for proper torque values.
5. Maintain a fleet angle between lead sheave and winch of no more than 1-1/2
degrees. The lead sheave must be on a center line with the drum and, for every
inch (25 mm) of drum length, be at least 1.6 ft (0.5 m) from the drum. Refer to
Product Safety Information Manual.
Refer to Dwg. MHP2288 on page 11, A. Drum.
• Maintain at least 3 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 Product Safety Information Manual.
Install winch so wire rope, when at take-off angle limits, does not contact mounting
surface or drum guard panels. Install winch with single part wire rope reeving only.
Refer to Dwg. MHP3149 on page 11. A. Adjust slack arm prior to use, for wire rope
take-off angle.
n Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor for assistance in selecting
the appropriate type and size of wire rope and, where necessary, a protective
coating. Use a wire rope which provides an adequate safety factor to handle the
actual working load and meets all applicable industry, trade association, federal,
state and local regulations.
When considering wire rope requirements the actual working load must include not
only the static or dead load but also loads resulting from acceleration, retardation
and shock load. Consideration must also be given to the size of the winch wire rope
drum, sheaves and method of reeving. Wire rope construction must be 10 mm EIPS
6 X 19 IWRC with a minimum breaking strength of 15,690 lbs (69.8 kN) right lay to
assist spooling. Refer to Table 4 ‘Wire Rope Size’ on page 5.
A minimum of 10:1 wire rope design factor is required with a wire rope to drum
diameter ratio following recommendations of the wire rope manufacturer with a
minimum ratio of 18:1.

4 Form MHD56470 Edition 5

Table 4: Wire Rope Size
Wire Rope Anchor
Size
Part No.
382–30543 3/8 inch (10 mm)
n Installing Wire Rope
Refer to Dwg. MHP2753 on page 11. A. Dead End of Wire Rope; B. Wire Rope
Anchor.
1. Cut wire rope to length in accordance with wire rope manufacturer’s
instructions.
2. Feed end of wire rope through drum anchor pocket hole.
3. Forming a loop, wrap loop around anchor, approximately 22 inches (559 mm)
of wire rope. Ensure dead end of wire rope is facing away from the drum flange.
4. Pull wire rope anchor into position in drum anchor pocket.
WARNING
• Install wire rope to come off drum in an underwound position. Improper
installation of wire rope can result in failure of disc brake to hold load and
prevent overload device operation.
• Do not allow wire rope to come in contact with drum guard panels during
winch operation. Wire rope could become worn and damaged. Adjust drum
guard panels to clear wire rope travel angle. Refer to ‘Drum Guard’ section
on page 5 and warning label 71459937.
CAUTION
• Make sure first wrap of wire rope is tight and lays flush against drum flange.
• Ensure correct wire rope anchor is used.
n Safe Wire Rope Handling Procedure
- Always use gloves when handling wire rope.
- Never use wire rope that is frayed or kinked.
- Never use wire rope as a sling.
- Always ensure wire rope is correctly spooled and the first layer is tight against
drum.
- Always follow wire rope manufacturer’s recommendation on use and
maintenance of wire rope.
n Wire Rope Spooling
To compensate for uneven spooling and the decrease in line pull capacity as the
drum fills up, use as short a wire rope as practical. When rewinding apply tension to
the end of the wire rope to eliminate line slack. This helps achieve level winding and
tight spooling.
n Rigging
The sheave arrangement with fastening to structure shall be dimensioned according
to the same principle as the winch 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 protection ensuring that derailing of
wire rope does not occur. The diameter ratio between sheave and wire rope shall
be in accordance with the manufacturer’s requirements but a minimum 18:1. All
fittings and connectors will have at least the breaking strength of the wire rope. For
the terminations of wire ropes only splices; aluminium pressed ferrules, non-ageing
steel pressed ferrules, or wedge socket anchorages may be used. U-bolt grips shall
not be used as wire rope terminations for load carrying wire ropes.
n Rigging – Harness (riding belt)
NOTICE
• 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 Safety Product Information Manual before
operation.
n Air Supply
Air supply must be clean, free from moisture and lubricated to ensure optimum
motor performance. Foreign particles, moisture and lack of lubrication are primary
causes of premature motor wear and breakdown. Using an air filter, lubricator and
moisture separator will improve overall winch performance and reduce
unscheduled downtime.
Air consumption is 62 scfm (1.75 cu.m/min) at rated operating pressure of 90 psig
(6.3 bar/630 kPa) at Emergency Stop Valve 1/2 inch NPT inlet. Exceeding 90 psi (6.3
bar/630 kPa) may cause inadvertent activation of the overload device. If air supply
varies from what is recommended, winch performance will change.
Install air line lubricator, filter and regulator as close as possible to air inlet on motor.
Lubricator must be located no more than 10 ft (3 m) from motor. Air line accessories
package comes standard, mounted to drum guard panel on opposite side of
operator.
Form MHD56470 Edition 5
NOTICE
• Recommend that a lockable isolation valve and pressure relief valve set to
110-120 psi (7.6-8.3 bar) be installed in the air supply line as close to the
winch as practical.
Refer to Dwg. MHP0191 on page 11, A. Air Out; B. Lubricator; C. Regulator; D. Air
In; E. Filter.
n Air Lines
The inside diameter of the winch air supply lines must not be less than the size shown
in Table 2 ‘General Specifications’ on page 3. Prior to making final connections, all
air supply lines should be purged with clean, moisture free air or nitrogen before
connecting to winch inlet. Supply lines should be as short and straight as installation
conditions will permit. Long transmission lines and excessive use of fittings, elbows,
tees, globe valves, etc. cause a reduction in pressure due to restrictions and surface
friction in the lines.
n Air Line Lubricator
Always use an air line lubricator with these motors. Lubricator must have an inlet
and outlet at least as large as the inlet on motor.
CAUTION
• Lubricator must be located no more than 10 ft (3 m) from the motor.
• Shut off air supply before filling air line lubricator.
Air line lubricator should be replenished daily and set to provide 6 to 9 drops per
minute of ISO VG 32 (SAE 10W) oil. A fine mist will be exhausted from the throttle
control valve when the air line lubricator is functioning properly.
n Air Line Filter
It is recommended that an air line strainer/filter be installed before the lubricator, to
prevent dirt from entering motor. Strainer/filter should provide 20 micron filtration
and include a moisture trap. Clean strainer/filter periodically to maintain its
operating efficiency.
n Air Pressure Regulator
An air pressure regulator is install between lubricator and filter as shown.
NOTICE
• Do not adjust regulator for a CE marked product, these are preset at factory.
Adjustment of regulator will effect overload settings and product may no
longer conform to CE regulations.
• Not all products are CE approved, refer to products data (name) plate to
see if this applies.
n Moisture in Air Lines
Moisture that reaches the air motor through air supply lines is a primary factor in
determining the length of time between service overhauls. Moisture traps can help
to eliminate moisture. Other methods, such as an air receiver which collects moisture
before it reaches the motor, or an aftercooler at the compressor that cools the air to
condense and collect moisture prior to distribution through the supply lines are also
helpful.
n Mufflers
Ensure mufflers are installed in exhaust ports of control valve and motor. Check
mufflers periodically to ensure they are functioning correctly.
n Drum Guard
A drum guard is standard on all MR and MR-CE winches.
Refer to the 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. Position panels to avoid wire
rope contact and install crossbar and nuts.
WARNING
• Do not allow wire rope to come in contact with drum guard panels during
winch operation. Wire rope could become worn and damaged. Adjust drum
guard panels to clear wire rope travel angle.
n Slack Line Detector
Adjustments
Refer to Dwg. MHP3149 on page 11 and MHP3147.
Prior to initial use adjust slack line as follows:
1. Payout wire rope to the desired position with no slack in wire rope.
2. Loosen capscrew located in center of cam actuator (208).
3. Tighten capscrew once adjustment to slack arm has been made.
5
n Limit Switch
Operate winch in both directions to activate limit switches. Limit switches should
engage at established setting +/- 2 ft (0.7 m), and prevent winch operation until reset
by shifting winch operating direction.
n Adjustments
Refer to Dwg. MHP2688 on page 11, A. Center Nut; B. Payout; C. Haul-In.
To adjust set points:
Follow instructions in the order they appear for limit switch adjustment (use two
people to make adjustments):
NOTICE
• These adjustments are for underwound wire rope applications only.
1. Remove cap from limit switch cover.
2. Unscrew center nut slightly.
3. PAYOUT: Rotate (1) screw clockwise while slowly paying out until winch shuts
off.
4. HAUL-IN: Rotate (2) screw counterclockwise while slowly hauling in until winch
shuts off.
5. Tighten center nut.
6. Reinstall cap on limit switch cover and tighten.
n Motor
For optimum performance and maximum durability of parts, provide recommended
air supply as measured at motor inlet. Refer to Table 2 ‘General Specifications’
on page 3. The air motor should be installed as near as possible to compressor or air
receiver.
OPERATION
It is recommended that the user and owner check all appropriate and applicable
regulations before placing this product into use. Refer to Product Safety Information
Manual before operating product.
The four most important aspects of product operation are:
1. Follow all safety instructions when operating the product.
2. Allow only people trained in safety and operation of this winch to operate this
equipment.
3. Subject each product to a regular inspection and maintenance procedure.
4. Be aware of product capacity and weight of load at all times.
WARNING
• Do not lift loads over people.
CAUTION
• Verify limit switch operation to ensure man riding device does not contact
sheave.
NOTICE
• Refer to Product Parts Information Manual for drawings unless specified
elsewhere.
Operators must be physically competent. Operators must not have a health
condition which might affect their ability to act, and they must have good hearing,
vision and depth perception. The winch operator must be carefully instructed in his
duties and must understand the operation of the winch, including a study of the
manufacturer’s literature. The operator must thoroughly understand proper
methods of hitching loads and must have a good attitude regarding safety. It is the
operator’s responsibility to refuse to operate the winch under unsafe conditions.
1. Lifting and lowering speeds are operator controlled and should be as slow as
practical. Ingersoll Rand recommends that you do not exceed 100 ft (30 m) per
minute. Any applicable codes and standards should be followed.
2. Personnel being lifted or lowered must be alert to obstacles and hazards during
movement.
3. A personnel platform should not be used due to winches rated load.
4. Tag lines shall be used where practical.
5. The winch operator shall remain at the controls at all times when handling
personnel.
6. Handling of personnel shall be discontinued upon indication of any impending
danger.
WARNING
• Maintain at least 3 wraps of wire rope on the drum at all times.
7. The man riding device shall be raised approximately 1 ft (30 cm) and inspected
to ensure that it is secure prior to personnel occupancy. Before raising or
lowering personnel, the following conditions shall exist:
a. Wire rope shall be free of kinks.
b. Winch shall be reeved for single part line which avoids obstructions and
interference.
6 Form MHD56470 Edition 5
n Initial Winch Operating Checks
Winches are tested for proper operation prior to leaving the factory. Before the winch
is placed into service the following initial operating checks should be performed.
1. When first running motor, inject light oil into inlet connection to provide initial
lubrication.
2. When first operating the winch, it is recommended that motor be driven slowly
in both directions for a few minutes.
3. Check Emergency Stop operation. Refer to “OPERATION” section on page 6.
4. Check Limit Switch operation. Refer to “OPERATION” section on page 6.
For winches that have been in storage the following start-up procedures are
required.
1. Give winch an inspection conforming to the requirements of ‘Winches Not in
Regular Use’ in “INSPECTION” section on page 9.
2. Pour a small amount of ISO VG 32 (SAE 10W) oil in motor inlet port.
3. Operate motor for 10 seconds in both directions to flush out any impurities.
4. Check to ensure oil levels are “full.”
5. The winch is now ready for normal use.
c. The primary point of wire rope attachment shall be centered over the man
riding device to reduce 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 devices shall be in accordance with all applicable codes and
regulations, such as ISO-EN 361 (harness, wire, pulleys..).
10. Bridles and associated hardware for the man riding device shall not be used for
any other service.
11. If a slack wire rope condition occurs the hoisting mechanisms shall be inspected
to assure wire rope is properly spooled onto drum and through sheaves. When
slack wire has been detected, operator must determine and rectify problem prior
to resuming operation.
n Training
n 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 winch load line so that they are
familiar with the requirements of the hoisting system and are able to recognize the
associated hazards and take appropriate measures. Records of training programs
shall be maintained.
n Planning Meeting
A meeting attended by the winch operator, signal persons, persons to be lifted and
the person in charge of the task to be performed is required to be held to plan and
review the procedures to be followed, including procedures for entering and leaving
the man riding device, the use of safety equipment, signals, and the lift chart
information.
NOTICE
• 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.
n Winch Controls
A spring loaded, motor-mounted, manual throttle control valve is supplied as a
standard feature on these winches. The throttle control provides operator control
of motor speed and direction of drum rotation.
Operate winch throttle control using smooth, even movements. Do not slam or jerk
throttle controls during operation.
n Winch Mounted Air Throttle
Refer to Dwg. MHP2976 on page 13, A. Lift Slider Handle UP to Unlock; B. Haul-In;
C. Payout.
The winch control throttle valve is spring loaded, full flow air and mounts to the
motor rotary housing.
To operate control valve, place palm of hand on control knob and wrap fingers
around flange of sliding handle. Squeeze fingers, lifting sliding handle up to unlock
control handle. Shift control handle in desired direction to payout or haul-in wire
rope. As viewed from air motor end, move control throttle handle to the right
(clockwise) to payout wire rope and to the left (counterclockwise) to haul-in wire
rope. Avoid sudden movements of handle to ensure smooth operation of winch.
When released, handle will return to neutral or center position, sliding handle will
drop down to engage and lock control handle in place.
n Emergency Stop
Refer to Dwgs. MHP3151 (old style) and MHP3187 on page 12, A. Emergency Stop
Button; B. On Button.
The Emergency Stop button, when activated, will immediately stop all winch
operations. The Emergency Stop button will remain depressed after activation. To
reset Emergency Stop button, twist (rotate) Emergency Stop button clockwise until
button releases and spring returns to its original position. Press “ON” button.
n Winch Brakes
n Automatic Disc Brake
The automatic disc brake is spring applied, air released. When the winch is operated
in payout direction, air pressure acting on the piston overcomes spring force and
releases brake. The brake automatically engages when winch operation is returned
from payout direction to neutral. When winch is in neutral or haul-in positions the
brake air is vented and brake springs apply the brake. The springs, acting on the
brake piston, compress brake friction and separator plates and engage brake to
prevent drum rotation in payout direction.
The cam type sprag clutch assembly allows drum rotation in haul-in direction with
brake plates engaged, but prevents drum from rotating in payout direction.
A minimum air pressure of 60 psi (410 kPa/4.1 bar) is required to release brake.
Disc brake adjustment is not required. If disc brake does not operate properly it must
be disassembled, inspected and repaired.
n Automatic Drum Band Brake
The automatic drum band brake is a spring applied, air released, externally mounted
brake which uses an air actuated, spring loaded cylinder to disengage the brake
when the motor is operated in either the haul-in or payout directions. Air pressure
directed to the cylinder overcomes spring force to release brake and allow drum to
rotate. When control valve is placed in neutral position, air in the cylinder is vented
which allows the cylinder spring to engage brake and prevent drum rotation.
Adjustments to cylinder clevis can be made to compensate for normal brake lining
wear. The drum brake must be kept properly adjusted to hold the required load.
Refer to ‘Adjustments’ in the “MAINTENANCE” section of Product Maintenance
Information Manual. If brake band cannot be adjusted to hold rated load, the brake
must be disassembled, inspected and repaired.
n Winch Motor
During normal operation moisture can collect in the motor housing. This
accumulation should be drained regularly. To drain, locate and remove oil level, pipe
plug (121) in bottom of motor housing (118). Any fluid drained should be disposed
of in an environmentally safe manner. Excess moisture in the housing will decrease
bearing life. In addition, freezing moisture can damage motor components.
WARNING
• Before operating winch replace any oil drained from motor while removing
any excess moisture. Refer to “LUBRICATION” on page 9.
n Slack Line Detector
CAUTION
• Slack line detector and limit switch functions are not operable when
emergency release valve is activated.
Refer to Dwg. MHP3147.
If slack line exists between winch and sheave, slack line detector limit switch valve
stops wire rope payout. When slack wire has been detected, operator must
determine and rectify problem prior to resuming operation.
Slack Line Detector arms may vary in design depending on required take-off angle.
Ensure correct arms are used for desired take-off angle.
WARNING
• Operator and signal persons must watch for any conditions that allow slack
wire rope to exist between sheave and lifted person which may not be
sensed by the slack wire detector. If slack wire condition is noticed, all winch
operations must cease until problem is rectified.
n Press Roller
Refer to Dwg. MHP2740.
Form MHD56470 Edition 5
The press roller, positioned between drum flanges, assists proper spooling of wire
rope onto the drum and maintains tight wraps when winch is not in operation.
Ensure wire rope is always trapped between press roller and drum barrel. Press roller
adjustments are not required.
n Limit Switches
Pre-set limit switch settings prevent winch wire rope payout and haul-in by stopping
air flow to the winch motor when a set point has been reached. It is the owner’s and
operator’s responsibility to adjust winch operating limits prior to using the winch to
transport personnel. To adjust the limit switch set points refer to the “INSTALLATION”
section on page 4.
n Stowage Valve (Optional)
Stowage valve is for use in applications where contact with the winch wire rope by
other equipment could occur. In the un-stowed position, the winch will operate as
usual. In the stowed position, the main air supply to the winch is shut off. Main supply
air is ported to the automatic disc brake, which holds the disc brake open. If other
equipment contacts the wire rope, the winch will be able to spool out, allowing wire
rope tension to decrease. A load of approximately 200 lbs (90 kg) is required to cause
the winch to spool out. None of the winch controls are operable in the stowed
position. The valve must be locked in either position to prevent inadvertent change
of valve position.
CAUTION
• If the stowage valve is not used and the wire rope is contacted by other
equipment, damage could occur to winch and/or wire rope. Damage to
winch may not be visible and could result in a catastrophic failure of the
winch.
n Stowing Winch
1. Haul-in winch until wire rope is in a stowed condition.
2. Press emergency stop button to shut off air supply to winch.
3. Release manual band brake.
4. Remove lock from the stowage valve.
5. Engage stowage valve by depressing red knob.
6. Reinstall lock on stowage valve.
n Un-Stow Winch
1. Remove lock from stowage valve.
2. Release stowage valve by pulling knob in an upward manner.
3. Reinstall lock on stowage valve.
n Emergency Lowering
The following information is provided to allow for emergency lowering of a person
if air supply is lost to winch. These procedures should be used if no other method of
safely lowering personnel is available.
Winch is equipped with two emergency lowering devices.
n Precautions
1. Emergency lowering operations must be performed by a minimum of two
personnel trained in the operation of the winch.
2. Communication must be established between lifted person and winch
operators. Operators should be able to visually monitor lifted person until
landed.
3. If line of sight between operators and lifted person is not possible, signals must
be conveyed to the operators.
4. The winch must be isolated from the supply air system during emergency
lowering operations.
n Procedure (-CE versions)
Use the following options for lowering in an emergency.
Automatic Band and Disc Brake:
The use of two people are required for this procedure. Both operators shall monitor
the lifted personnel.
1. Shut off main power supply at the source.
2. To activate emergency lowering device, remove pipe plug from valve body and
connect an air or nitrogen line of 60 psi (410 kPa/4.1 bar). Refer to Dwg. MHP2289
on page 13, A. Push button to release brake; B. Remove plug and connect
auxiliary air to port 1/4 inch NPT.
NOTICE
• With maximum rated load, lowering speed can reach 50 feet per minute (15
metres per minute).
3. Release of valve button stops emergency lowering and sets the disc brake. Speed
may be improved by moving throttle lever in payout direction.
4. Ensure emergency stop button is in the off position (not activated).
5. With one operator in control of the automatic drum brake, the other operator
presses and holds emergency release valve button to begin lowering.
6. Remove release lever from its stored location on winch.
7. Refer to Dwg. MHP3150 on page 13, A. Install release lever under cylinder clevis;
B. Disengage slowly.
8. Slowly release automatic band brake by pushing down on release lever. Do not
fully open band brake.
9. Drag band brake to control lowering speed.
7
10. If lowering speed becomes too fast, allow spring in brake cylinder to pull release
lever up, allowing further drag to band brake.
11. Return release lever to its stored location once emergency lowering operation
is completed.
12. If there is insufficient weight for Emergency Lowering Device to work refer to
‘Alternative Measures’ on page 8.
Three Way Valve (optional lowering procedure):
Refer to Dwg. MHP3143 on page 11, A. Normal Inlet Air Supply; B. Rotate handle
to use in normal condition; C. FRL; D. Emergency Lowering Inlet.
This device allows the person to be moved the shortest way to safety in case of
normal air supply failure. In the event of air supply failure, operate the three way
valve from normal air supply to the emergency inlet. For an emergency power
source, a 50 litre nitrogen bottle can be used.
1. Open the emergency power source. Rotate valve lever towards normal inlet air
supply side.
2. Ensure that downstream pressure is 5 to 7 bar.
3. Operate winch slowly to open brakes for lowering the person the shortest way
to safety.
NOTICE
• After each use of emergency lowering device, return the three-way valve
to the main air inlet and check the secondary power source is in proper
working condition and able to fulfil its task.
n Procedure (–E versions)
Use the following options for lowering in an emergency.
Manual Band Brake and Disc Brake
Have one operator stationed at the manual drum brake to slowly release and apply
the manual drum brake when the air disc brake is released by the Emergency
Lowering Device.
1. The winch is equipped with an Emergency Lowering Device. To activate the
Emergency Lowering Device, remove pipe plug from valve body and connect
an air or nitrogen line of 60 psi (410 kPa/4.1 bar). Ensure the Emergency Stop
button is in the off position (not activated). With one operator in control of the
manual drum brake, the other operator presses and holds the Emergency
Release valve button to begin lowering. With maximum rated load, lowering
speed can reach 10 feet per minute (3 metres per minute). Speed may be
improved by moving throttle lever in payout direction. Release of valve button
stops emergency lowering and sets the disc brake.
INSPECTION
Inspection information is based in part on American Society of Mechanical Engineers
Safety Codes B30.7.
WARNING
• 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 quarterly inspections should 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. Quarterly inspections are thorough inspections conducted
by Ingersoll Rand trained Service Technicians. ASME B30.7 states inspection
intervals depend upon the nature of the critical components of the equipment and
the severity of usage. Refer to ‘Inspection Classifications’ chart and ‘Maintenance
Intervals’ chart in Product Maintenance Information Manual for recommended
maintenance intervals.
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.
Deficiencies revealed through inspection, or noted during operation, must be
reported to designated personnel to ensure corrective action is taken.
A determination as to whether a condition constitutes a safety hazard(s) must be
decided, and the correction of noted safety hazard(s) accomplished and
documented by written report before placing the equipment in service.
n Wire Rope Reports
Records should be maintained as part of a long-range wire rope inspection program.
Records should include the condition of wire rope removed from service. Accurate
records will establish a relationship between visual observations noted during
frequent inspections and the actual condition of wire rope as determined by
quarterly inspections.
n Frequent Inspection
On equipment in continuous service, a ‘Daily Inspection’ should be made by the
operator at the beginning of each shift and a ‘Quarterly Inspection’ should be
conducted by an Ingersoll Rand trained Inspector every 90 days and a record of the
inspection maintained.
8 Form MHD56470 Edition 5
2. If there is insufficient weight for Emergency Lowering Device to work refer to
‘Alternative Measures’ on page 8.
Automatic Band Brake and Disc Brake
Have one operator stationed at the Emergency Lowering Device with second
operator visually monitoring suspended person. follow steps above in ‘Emergency
Lowering Procedure’ on page 7.
n Emergency Lowering Using Accumulator (optional feature)
Winch may be supplied with an accumulator. In an emergency lowering condition
open accumulator valve air tank and follow steps 1 through 11 above in ‘Automatic
Band and Disc Brake’ section on page 7. The use of two people are required for this
procedure.
n Alternative Measures
If brake release methods listed above do not allow the person to lower, there may
not be enough weight to overcome the natural mechanical resistance of winch
gearbox and motor. The minimum load for emergency lowering is 200 lbs (91 kg)
on the first layer.*
* Refer to Table 2 ‘General Specifications’ on page 3 or minimum load at different
layers.
1. If motor will not backdrive, attach a line to the man riding device and carefully
pull down suspended person.
WARNING
• The line used to pull down the Man Riding device must be attached in such
a manner as to NOT pull on the suspended person or tip the Man Riding
device.
2. Alternatively, send additional weight to the suspended person using another
line. This weight must be secure and evenly distributed. Never exceed the
capacity of the winch or man riding device.
CAUTION
• Any additional weight should be sent in small, easily handled bundles and
only enough to cause person to lower. When lowering person in this manner
the brake(s) can be used to control lowering by releasing air pressure or
applying the band brake.
n Daily Inspection
Complete inspections prior to start of daily tasks. Conduct visual inspections during
regular operation for indications of damage or evidence of malfunction (such as
abnormal noises).
1. Lubricator: Adjust air line lubricator drops [ISO VG 46 (SAE 10W)] per minute to
6 to 9 during winch operation.
2. Motor Oil Level: Check motor oil level. Drain condensate and top off oil level.
3. Surrounding Area: Visually check for winch oil leaks. Do not operate winch if
leaking oil is found. Ensure surrounding area has no slippery surfaces and is
obstruction free.
4. Hoses and Fittings: Visually inspect for damage, air leaks, and loose
connections. Repair all leaks or damage and tighten loose connections prior to
starting daily tasks.
5. Muffler: Visually check for restrictions or external damage. Clear restrictions or
replace if damaged.
6. Wire Rope Anchor: Verify wire rope anchor is securely installed.
7. Guards: Verify wire rope does not contact drum guard during winch operation
and that guards are secure and undamaged.
8. Winch: Visually inspect winch housings, control(s), external brake, siderails,
uprights and drum for damage. Check that all external bolts are in place and
secure. Report damage to supervisor and request additional inspection by an
Ingersoll Rand trained service technician.
9. Mounting: Visually inspect winch mounting bolts. Check bolts are tight,
undamaged and free of corrosion.
10. Winch Operation: Power winch in both directions. Winch must operate
smoothly without sticking, binding or abnormal noises and have minimal
vibration.
11. Control Valve: Check operation is smooth and winch is responsive to control
device movement. Lever must return to neutral and lock in place when released.
If winch responds slowly or control sticks, do not operate until problems are
corrected. Winch is to operate without hesitation in either payout and haul-in
direction.
12. Wire Rope Spooling: Visually check reeving and ensure wire rope feeds on and
off the drum smoothly. Verify spooling direction is correct for winch and
application.
13. Brakes: Lift and lower the load a short distance to test brakes. Brakes must hold
load without slipping. Automatic brake must release when winch control
throttle is operated. If brakes do not hold load or do not release properly, they
must be adjusted or repaired.
WARNING
• Worn or improperly functioning brakes may cause excessive heat buildup
and sparks.
14. Wire Rope: Visually inspect all wire rope expected to be in use during the day’s
operations. Inspect for wear and damage indicated by distortion of wire rope
such as kinking, “birdcaging,” core protrusion, main strand displacement,
corrosion, broken or cut strands. If damage is evident, do not operate winch until
the discrepancies have been reviewed and inspected further by personnel
knowledgeable on wire rope safety and maintenance procedures.
NOTICE
• 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 “Quarterly Inspection”. Refer to Product Maintenance Information
Manual.
15. Limit Switches: Ensure limit switches engage and prevent operation at the
required set point and with drum rotating in the correct direction. Ensure limit
switch properly resets.
16. Emergency Stop Valve: Activate emergency stop in payout and haul-in
directions to ensure proper operation. Valve must stop winch operation and
brake must set quickly. Reset valve after test.
17. Slack Line Detection: Operate winch in payout direction until slack line valve
actuates. Ensure winch stops running in lowering direction, but can still lift load.
18. Press Roller: Ensure wire rope is positioned between press roller and drum
barrel and springs keep press roller in tight contact with wire rope. Ensure
smooth and proper operation.
19. Motor: During operation check motor housing for excess heat build up. Housing
should not be hot to touch. Listen for grinding or knocking noises. If excess heat
or noises are noted, do not operate until inspected by an Ingersoll Rand trained
service technician.
n Quarterly Inspection
Complete a ‘Quarterly Inspection’ on a recurring basis to provide regular winch
monitoring.
In addition to the requirements of ‘Daily Inspection’ also inspect the following:
1. Power Supply:
- Inlet air pressure to the winch is 90 psi (6.3 bar) at full throttle with nominal
system usage
- Filter, regulator and lubricator are installed and functioning
- Air filter is clean, drain if necessary
- Air supply regulator is set to 90 psi (6.3 bar)
2. Rigging:
- Correct size wire rope is being used. 10 mm minimum
- Wire rope take-off angle is within design limits
3. Visual Integrity:
- All Components - Inspect for wear, damage, distortion, deformation and
cleanliness. If external evidence indicates damage, contact Ingersoll Rand
Service Technician to disassemble as required to conduct a detailed
inspection
- No part of the winch has been welded onto
- Fasteners - Check external retainer rings, split pins, capscrews, nuts and other
fasteners on winch, including mounting bolts
- Drum and Sheaves - Check for cracks, wear or damage
- Press Roller - Inspect rollers for wear and grooves. Ensure rollers freely rotate.
Replace rollers if worn or grooved. Replace bearings if rotation is rough or
stiff
LUBRICATION
To ensure continued satisfactory operation of winch, all points requiring lubrication
must be serviced with correct lubricant at proper time interval as indicated for each
assembly.
Refer to ‘Maintenance Interval’ chart in Product Maintenance Information Manual
for recommended lubrication intervals. Use only those lubricants recommended.
Other lubricants may affect product performance. Approval for use of other
lubricants must be obtained from your Ingersoll Rand distributor. Failure to observe
this precaution may result in damage to winch and/or its associated components.
Table 5: Lubrication Intervals
Component Interval
Check Air Line Lubricator
Daily
Check Motor Oil Level
Check Reduction and Disc Brake Oil 3 Months
Change Motor Oil
1 Year or 1,000 Hours
Change Gearbox Oil
of Product Operation
Change Disc Brake Oil
n Recommended Lubricants
Table 6: Reduction Gear and Disc Brake Recommended Lubricant Grade
Temperature Grade Type
Below 32° F (0° C) 2 EP (ISO VG 68)
32° to 80° F (0° to 27° C) 3 EP (ISO VG 100) *
Above 80° F (27° C) 4 EP (ISO VG 150)
* Units are shipped from factory with 3 EP (ISO VG 100) lubricant.
Form MHD56470 Edition 5
-Slack Line Detector - Inspect rollers for wear and grooves. Ensure rollers freely
rotate
- Ensure drum guard is capable of adequately guarding personnel
- No modifications have been performed on the winch
- Check motor, gearbox and disc brake for oil leakage
4. Labeling / Marking:
- Data (name) plate is attached and legible
- Warning tags and labels are attached, legible and in correct places on winch
5. Wire Rope Spooling:
- A minimum of 3 dead wraps remain on drum in fully paid-out position
- Proper freeboard is maintained at full haul-in position (minimum 1 inch (26
mm) for 10 mm wire rope)
- Wire rope is properly lubricated
6. Operational Checks:
- Automatic Band Brake and Disc Brake: Ensure that both brakes hold the load.
- Limit Switches - Operate winch in the haul-in direction until limit switch
engages. Ensure winch stops running in haul-in direction, and operate in
payout. Operate winch in payout direction until limit switch engages. Ensure
winch stops operating in payout direction, and will operate in haul-in
direction
- Line Speed - Raise and lower (5 ft. min. distance) a 485 lbs (220 kg) load at
first layer to verify line speed. Line speed to be 60 fpm (18 m/min). Line speed
to be recorded after warm-up
n Winches Not in Regular Use
1. Equipment which has been idle for a period of one month or more, but less than
six months, shall be given an inspection conforming to the requirements of
‘Frequent Inspection’ on page 8 before being placed in service.
2. Equipment which has been idle for a period of over six months shall be given a
complete inspection conforming with requirements of ‘Quarterly Inspection’ in
maintenance manual before being placed in service. Refer to Product
Maintenance Information Manual.
3. Standby equipment shall be inspected at least semiannually in accordance with
requirements of ‘Frequent Inspection’ on page 8. In abnormal operating
conditions equipment should be inspected at shorter intervals.
4. All oils must be drained and replaced with new, and all grease cavities shall be
packed to the prescribed limit. Refer to “LUBRICATION” section on page 9.
Product must be operated for at least 15 seconds in both directions with well
lubricated, dry air.
n Storing The Winch
1. Always store the winch in a no load condition.
2. Wipe off all dirt and water.
3. Oil the wire rope.
4. Place in a dry location.
5. Before returning winch to service, follow instructions for ‘Winches Not In Regular
Use’ in the “INSPECTION” section on page 8.
6. Mufflers and Breathers. All mufflers and breathers must be removed and
replaced with threaded plugs to prevent dust and moisture from entering motor
and valve assemblies.
7. Rotary Limit Switch. Product equipped with a rotary limit switch must be stored
with the limit switch not activated.
Table 7: Air Motor Recommended Lubricant Grade
Temperature Grade Type
Below 32° F (0° C) ISO VG 32 (SAE 10W)
32° to 80° F (0° to 27° C) ISO VG 68 (SAE 20W) *
Above 80° F (27° C) ISO VG 100 (SAE 30W)
* Units are shipped from factory with ISO VG 68 (SAE 20W) lubricant.
Table 8: Recommended Grease Grade
Temperature Grade Type
-20° to 50° F (-30° to 10° C) EP 1 multipurpose lithium based grease
30° to 120° F (-1° to 49° C) EP 2 multipurpose lithium based grease
n Motor
Refer to Dwg. MHP2271 on page 13, A. Fill/Breather Plug; B. Motor Case; C. Level
Plug Position; D. Drain Plug Position.
CAUTION
• Do not use synthetic or detergent lubricants in air motor. Synthetic
lubricants will result in oil blowing by piston rings.
The oil level in the motor should be checked daily or at the start of each shift after
accumulated water has been drained off. To drain, locate and remove oil level, pipe
plug (121) in bottom of motor housing (118). Any fluid drained should be disposed
of in an environmentally safe manner.
Correct lubrication is one of the most important factors in maintaining efficient
winch operation. The motor is splash lubricated by the oil in the motor housing and
has no other means of lubrication. It is therefore important to use only high quality,
Extreme Pressure (EP) rust and oxidation inhibiting gear oils or non-detergent motor
oils to ensure maximum performance and minimum downtime for repairs.
9
Add oil through filler opening until oil flows from level plug hole. Add oil slowly to
prevent spilling. Refer to Table 9 ‘Motor Oil Capacity’ on page 10. Allow oil to settle NOTICE
before topping off.
• Always drain oil into a suitable container and inspect drained oil for
When motors are operated in temperatures below freezing, wait long enough at evidence of damage, metal shavings, dirt, water, etc. Dispose of oil in an
end of shift for water to separate from oil but not long enough for it to freeze. Failure environmentally safe manner.
to drain the water when the winch is to remain idle for a protracted period at low
temperatures may result in the oil splasher freezing fast. Drain the water then refill 3. Collect drained oil and dispose of properly. Reinstall the reduction gear carrier
to the level plug. If desired, all the oil may be drained at the end of the shift and the plugs.
motor refilled with new oil.
To Fill:
1. Rotate winch drum to align reduction gear plugs to the fill position. Fill plug
Table 9: Motor Oil Capacity position is at top center.
Capacity 2. Remove fill plug located on housing.
3. Fill slowly with recommended oil, refer to Table 10 ‘Reduction Gear and Disc
pint litres Brake Capacities’ on page 10.
0.5 0.236 4. Reinstall plug.

CAUTION
n Reduction Gear and Disc Brake Lubrication • Do not overfill. Excess oil will reduce operating efficiency and increase oil
Refer to Dwg. MHP2297 on page 13, A. Fill Plug Position; B. Inboard Upright; C. temperature.
Drain Plug; D. Drum; E. Reduction Gear Assembly. • The use of unsuitable oil may result in excessive temperature rise, loss of
efficiency and possible damage to the gears. Use only high quality rust and
oxidation inhibiting lubricant.
CAUTION
• Do not over fill. Excess oil will reduce operating efficiency and increase oil
n Disc Brake Fill/Drain Procedures
temperature. Refer to Dwg. MHP2297 on page 13 and MHP3152.
• Only use synthetic lubricant in reduction gear and disc brake.
The reduction gear and disc brake are filled with oil from the factory. Check oil level Disc Brake Drain:
before initial winch operation. 1. Remove drain and level plugs.
2. Collect drained oil and dispose of properly.
Reduction gear and disc brake components are splash lubricated by oil in the
housings and have no other means of lubrication. It is therefore important to use Disc Brake Fill:
high quality, Extreme Pressure (EP) rust and oxidation inhibited gear oils to ensure 1. Install drain plug.
maximum performance and minimum downtime for repairs. 2. Remove level plug.
3. Add oil slowly until oil is level with level plug port.
4. Install level plug.
Table 10: Reduction Gear and Disc Brake Capacities
Capacity
Reduction Gear Disc Brake
n Air Line Lubricator
qt ml qt ml An air line lubricator should be installed in air supply line as close as possible to motor
inlet, but no more than 10 ft (3 m) away. Use ISO VG 46 (SAE 10W) oil in lubricator.
0.74 700 0.21 200 Adjust lubricator to provide 6 to 9 drops per minute at maximum motor speed.

n Initial Reduction Gear Assembly Oil Change

n Wire Rope
1. Drain and replace oil in the motor and reduction gear after the first 50 hours of
initial winch operation. Thereafter, drain and replace oil according to the Follow wire rope manufacturer’s instructions. At a minimum, observe the following
intervals recommended. guidelines.
2. Always inspect removed oil for evidence of internal damage or contamination
(metal shavings, dirt, water, etc.). If indications of damage are noticed, 1. Clean with a brush or steam to remove dirt, rock dust or other foreign material
investigate and correct before returning winch to service. on wire rope surface.
3. After winch operation, allow oil to settle before topping off.
4. Always collect lubricants in suitable containers and dispose of in an CAUTION
environmentally safe manner.
• Do not use an acid-based solvent. Only use cleaning fluids specified by the
n Reduction Gear Fill/Drain Procedures wire rope manufacturer.
2. Apply a wire rope lubricant.
Refer to Dwg. MHP2297 on page 13 and MHP2719. 3. Brush, drip or spray lubricant weekly, or more frequently, depending on severity
of service.
NOTICE
• There are two plugged holes, located 180 degrees apart, on reduction n Seals and Bearings
housing. To fill or drain reduction gear oil, winch drum must be rotated to
align plugs for fill and drain operations. If product is disassembled, clean all parts thoroughly and replace bearings and seals.
Refer to ‘Recommended Lubricants’ section on page 9. Use sufficient grease to
To Drain: provide a good protective coat.
1. Rotate winch drum to align reduction gear carrier plugs to the drain position.
Drain plug is located at bottom center.
2. Remove reduction gear carrier drain and fill plugs.

WARRANTY
Ingersoll Rand Limited Warranty
Ingersoll Rand Company (“IR”) warrants to the original user its material handling
products (“Products”) to be free of defects in material and workmanship for a period
of one year from the date of purchase. IR will, at its option either (1) repair, without
cost, any Product found to be defective, including parts and labor charges, or (2)
replace such Products or refund the purchase price, less a reasonable allowance for
depreciation, in exchange for the Product. Repairs or replacements are warranted
for the remainder of the original warranty.
IR's maximum liability is limited to the purchase price of the Product and in no event
shall IR be liable for any consequential, indirect incidental or special damages of any
nature arising from the sale or use of the Product, whether in contract, tort or
otherwise.
Note: Some states do not allow limitations on incidental or consequential damages,
so that the above limitations may not apply to you. This warranty gives you specific
legal rights and you may also have other rights which may vary from state to state.

If any Product proves defective within its original one-year warranty period, it should
be returned to any Authorized Product Service Distributor, transportation prepaid
with proof of purchase or warranty card. This warranty does not apply to Products
which IR has determined to have been misused or abused, improperly maintained
by the user, or where the malfunction or defect can be attributed to the use of non-
genuine IR repair parts.
Fulcrum series electric winch, product code 405-002: 2 year warranty.
Winch and Hoist Solutions Extended Warranty This option provides a price for
extending the Ingersoll Rand Winch and Hoist Solutions Warranty from the
standard one (1) year to two (2) years from the date of purchase. All other provisions
of the standard warranty to remain in effect.

IR MAKES NO OTHER WARRANTY, CONDITION OR REPRESENTATION OF ANY
KIND WHATSOEVER, EXPRESSED OR IMPLIED, STATUTORY OR OTHERWISE,
AND ALL IMPLIED WARRANTIES AND CONDITIONS RELATING TO
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY
DISCLAIMED.
For additional information or quotations for warranties falling outside of these
parameters, please contact your Client Services Representative with your
requirements.

10 Form MHD56470 Edition 5

 PRODUCT INFORMATION GRAPHICS

B B
A
Main Air
C Supply
B

Rotate handle
to use
in normal
A Drum A condition

Emergency
Lowering
Inlet
D
(Dwg. MHP2288) C
FRL
A
Air Out (Dwg. MHP3143)
C
Regulator

D A 0°
30°
Air In
Adjust slack arm
prior to use, for
wire rope take-off
angle.
B
Lubricator E
Filter

(Dwg. MHP0191)
IR

A
Dead End of
Wire Rope (Dwg. MHP3149)

Wire Rope
B
Anchor

(Dwg. MHP2688)
(Dwg. MHP2753)

Form MHD56470 Edition 5 11

 PRODUCT INFORMATION GRAPHICS (CONTINUED)
Auto
Auto Band Brake
Disc Brake Cylinder
Cylinder

Winch Control
Emergency Valve
Brake
Release Torque
Emergency Valve Limiter Winch Motor
Brake Valve Optional Emergency
Release Lowering System
Air Source

Relief
Valve
Slack Line Payout Haul-in 125 psi
Limit Limit Haul-in Payout Drain
Limit
Switch Switch Valve
Switch
Reservoir
Winch Control
Check Ball
Valve
Valve Valve
Pilot
Valve
Shut-off
Valve
Stop

On

Filter
3 Way
Ball Valve
Regulator Lubricator

Main Air
Source

(Dwg. MHP3146)

A Emergency
Stop Button

B
On Button

(Dwg. MHP3151)

A
Emergency B
Stop Button On Button

(Dwg. MHP3187)

12 Form MHD56470 Edition 5

 PRODUCT INFORMATION GRAPHICS (CONTINUED)

A Push Button
to Release
Brake
Lift Slider
A
Handle
UP to Unlock
C
Payout

B Haul-in

B Remove Plug
and Connect
Auxiliary Air
to Port 1/4” NPT

(Dwg. MHP2289)

(Dwg. MHP2976)

D E
A
Fill Plug Drum Reduction Gear
Position Assembly

Disengage
slowly B

B
Inboard
Upright A

Drain Install release

C lever under
Plug
cylinder clevis

(Dwg. MHP2297)

A Fill/Breather (Dwg. MHP3150)

Plug

Motor
B
Case

C
Level Plug
Position

Drain Plug
D
Position

(Dwg. MHP2271)

Form MHD56470 Edition 5 13

 SERVICE NOTES

14 Form MHD56470 Edition 5

 SERVICE NOTES

Form MHD56470 Edition 5 15

www.ingersollrandproducts.com