Ingersoll-Rand FORCE 5i Man Rider FA150KGi Product information

Brand: Ingersoll-Rand

Model: FORCE 5i Man Rider FA150KGi

Type: Product information

Product Information

Model

FA150KGi

Save These Instructions

Form MHD56470

Edition 4

January 2011

45925013

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 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.

Original instructions are in English. Other languages are a translation of the original instructions.

Refer all communications to the nearest Ingersoll Rand Office or Distributor.

Table 1: Product Information Manuals

Publication Part/Document Number Publication Part/Document Number

Product Safety Information Manual (Man Rider) 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.

2 Form MHD56470 Edition 4

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

C1 =

- 4° F (- 20° C) ABS

C2 =

- 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

M3 =

Material traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on load bearing parts in a finished, as delivered

condition

N1 = ABS (Copy of Type Approval certificates)

N2 = DNV (Copy of Type Approval certificates)

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 =

CE Package (Compliance with European Machinery Directive, refer to “DECLARATION OF CONFORMITY” on page 15)

NOTE: Man Rider Winch should only be used for man riding application

Table 2: General Specifications

Air

System

Air Motor Pipe

Inlet Size

Minimum Air

System

Hose Size (inside

diameter)

Drum

Barrel

Diameter

Drum

Flange Diameter

Recomm-

ended Wire

Rope Size

Sound

Pressure

Level

(1, 2)

Sound

Power

Level

(1)

Maximum

Foundation

Anchor Shear

Force at One

Capscrew (3)

Rated Operating

Pressure

Air Consumption

(at rated load)

inch mm inch mm inch mm inch mm mm dBA dBA lbs N

90 psig (6.3 bar)

62 scfm (1.75

cu.m/min)

1.25 NPT 32 0.75 19 10.75 273 19 483 10 85 96 75 334

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 4

Layer

Line Speed @ 150 kg (330 lb) Load Minimum Load for Emergency Lowering

Wire Rope Storage Capacity **

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.

Capacity Information

FA150KGi Man Rider™ winches are designed for lifting with a 5:1 minimum safety

factor at rated load.

Traceability

Load bearing parts are documented to provide traceability. Documentation includes

chemical and physical properties of raw material, heat treating, hardening, tensile

and charpy tests as required for the part.

Units with M1, M2 or M3 in the model code have traceable load bearing components.

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

load bearing parts. Conformity documents affirm (by 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).

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

load bearing parts. Conformity documents affirm (by a department independent of

the manufacturing department) that actual parts are in compliance with requirements

of the order, based on specific inspection and testing (i.e. results are actual material

properties for these parts).

M3 – Material Traceability certificates according to EN 10204 (Ex DIN 50049) 3.1b on

load bearing parts. Conformity documents affirm (by a department independent of

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

actual material properties for these parts in a finished, as delivered condition).

Components with part numbers ending in CH are charpy parts for use under extreme

cold conditions. Traceability requirements must be stated when reordering these parts

for continued certification.

ATEX

Refer to labeling on product, located near or on data (name) plate, for specific ATEX

designation. Product not marked as such, are not suitable for use in any potentially

explosive atmosphere (ATEX). Refer to Product Safety and Maintenance Information

Manuals for further explanation.

II 2 GD c IIB 200°C X

(Dwg. MHP2584)

INSTALLATION

Winch gearbox and disc brake are supplied fully lubricated from factory. Check oil

levels and adjust as necessary before operating winch.

Refer to “LUBRICATION” section on page 9 for recommended oils. Prior to

installing winch, carefully inspect it for possible shipping damage.

CAUTION

• Owners and users are advised to examine specific, local or other regulations,

including American Society of Mechanical Engineers (ASME) and/or OSHA

Regulations which may apply to a particular type of use of this product before

installing or putting product to use.

NOTICE

• Prior to installation refer to Product Safety Information Manual.

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 tightening 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.

Table 3: Mounting Bolt Hole Dimensions

Dimension

Drum Length (inches)

“A”

inch

508

“B”

inch

229

“C”

inch

0.69

Wire Rope

CAUTION

• 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.

4 Form MHD56470 Edition 4

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.

Table 4: Wire Rope Size

Wire Rope Anchor

Part No.

Size

382–30543 3/8 inch (10 mm)

Note: Wire rope diameter is fixed if grooved drum option is used.

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.

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.

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, 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.

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.

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.

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.

PAYOUT: Rotate (1) screw clockwise while slowly paying out until winch shuts

off.

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.

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.

Form MHD56470 Edition 4

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.

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.

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.

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.

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.

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.

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.

Form MHD56470 Edition 4

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.

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.

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.

Press Roller

Refer to Dwg. MHP2740.

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.

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.

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.

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

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.

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.

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 7.

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 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.

Form MHD56470 Edition 4

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.

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.

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.

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).

Lubricator: Adjust air line lubricator drops [ISO VG 46 (SAE 10W)] per minute to

6 to 9 during winch operation.

Motor Oil Level: Check motor oil level. Drain condensate and top off oil level.

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.

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.

Muffler: Visually check for restrictions or external damage. Clear restrictions or

replace if damaged.

Wire Rope Anchor: Verify wire rope anchor is securely installed.

Guards: Verify wire rope does not contact drum guard during winch operation and

that guards are secure and undamaged.

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.

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:

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)

Rigging:

- Correct size wire rope is being used. 10 mm minimum

- Wire rope take-off angle is within design limits

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

- 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

Labeling / Marking:

- Data (name) plate is attached and legible

- Warning tags and labels are attached, legible and in correct places on winch

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

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

Form MHD56470 Edition 4

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.

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.

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.

Rotary Limit Switch. Product equipped with a rotary limit switch must be stored

with the limit switch not activated.

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

of Product Operation

Change Gearbox Oil

Change Disc Brake Oil

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.

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

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.

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 9. Allow oil to settle

before topping off.

When motors are operated in temperatures below freezing, wait long enough at end

of shift for water to separate from oil but not long enough for it to freeze. Failure 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

to the level plug. If desired, all the oil may be drained at the end of the shift and

the motor refilled with new oil.

Table 9: Motor Oil Capacity

Capacity

pint litres

0.5 0.236

Reduction Gear and Disc Brake Lubrication

Refer to Dwg. MHP2297 on page 13, A. Fill Plug Position; B. Inboard Upright; C.

Drain Plug; D. Drum; E. Reduction Gear Assembly.

CAUTION

• Do not over fill. Excess oil will reduce operating efficiency and increase oil

temperature.

• 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

before initial winch operation.

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 high quality,

Extreme Pressure (EP) rust and oxidation inhibited gear oils to ensure maximum

performance and minimum downtime for repairs.

Table 10: Reduction Gear and Disc Brake Capacities

Capacity

Reduction Gear Disc Brake

qt ml qt ml

0.74 700 0.21 200

n Initial Reduction Gear Assembly Oil Change

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

intervals recommended.

2. Always inspect removed oil for evidence of internal damage or contamination

(metal shavings, dirt, water, etc.). If indications of damage are noticed,

investigate and correct before returning winch to service.

3. After winch operation, allow oil to settle before topping off.

4. Always collect lubricants in suitable containers and dispose of in an

environmentally safe manner.

n Reduction Gear Fill/Drain Procedures

Refer to Dwg. MHP2297 on page 13 and MHP2719.

NOTICE

• There are two plugged holes, located 180 degrees apart, on reduction

housing. To fill or drain reduction gear oil, winch drum must be rotated to

align plugs for fill and drain operations.

To Drain:

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.

Form MHD56470 Edition 4

NOTICE

• Always drain oil into a suitable container and inspect drained oil for evidence

of damage, metal shavings, dirt, water, etc. Dispose of oil in an

environmentally safe manner.

3. Collect drained oil and dispose of properly. Reinstall the reduction gear carrier

plugs.

To Fill:

1. Rotate winch drum to align reduction gear plugs to the fill position. Fill plug

position is at top center.

2. Remove fill plug located on housing.

3. Fill slowly with recommended oil, refer to Table 10 ‘Reduction Gear and Disc Brake

Capacities’ on page 9.

4. Reinstall plug.

CAUTION

• Do not overfill. Excess oil will reduce operating efficiency and increase oil

temperature.

• 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.

n Disc Brake Fill/Drain Procedures

Refer to Dwg. MHP2297 on page 13 and MHP3152.

Disc Brake Drain:

1. Remove drain and level plugs.

2. Collect drained oil and dispose of properly.

Disc Brake Fill:

1. Install drain plug.

2. Remove level plug.

3. Add oil slowly until oil is level with level plug port.

4. Install level plug.

Air Line Lubricator

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. Adjust lubricator to provide 6 to 9 drops per minute at maximum motor

speed.

Wire Rope

Follow wire rope manufacturer’s instructions. At a minimum, observe the following

guidelines.

1. Clean with a brush or steam to remove dirt, rock dust or other foreign material

on wire rope surface.

CAUTION

• Do not use an acid-based solvent. Only use cleaning fluids specified by the

wire rope manufacturer.

2. Apply a wire rope lubricant.

3. Brush, drip or spray lubricant weekly, or more frequently, depending on severity

of service.

Seals and Bearings

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 provide

a good protective coat.

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.

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.

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.

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.

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.

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 4

PRODUCT INFORMATION GRAPHICS

Drum

(Dwg. MHP2288)

Air Out

Regulator

Lubricator

Air In

Filter

(Dwg. MHP0191)

Wire Rope

Anchor

Dead End of

Wire Rope

(Dwg. MHP2753)

Emergency

Lowering

Inlet

Rotate handle

to use

in normal

condition

FRL

Main Air

Supply

(Dwg. MHP3143)

0°

Adjust slack arm

prior to use, for

wire rope take-off

angle.

30°

(Dwg. MHP3149)

(Dwg. MHP2688)

Form MHD56470 Edition 4

PRODUCT INFORMATION GRAPHICS (CONTINUED)

3 Way

Ball Valve

Main Air

Source

Filter

Regulator

Emergency

Brake

Release

Valve

Emergency

Brake

Release

Air Source

Slack Line

Limit

Switch

Payout

Limit

Switch

Payout

Haul-in

Limit

Switch

Haul-in

Pilot

Valve

Relief

Valve

Reservoir

125 psi

Drain

Valve

Ball

Valve

Check

Valve

Torque

Limiter

Valve

Winch Motor

Winch Control

Valve

Winch Control

Valve

Auto

Band Brake

Cylinder

Auto

Disc Brake

Cylinder

Lubricator

Optional Emergency

Lowering System

Shut-off

Valve

Stop

(Dwg. MHP3146)

Emergency

Stop Button

On Button

(Dwg. MHP3151)

Emergency

Stop Button

On Button

(Dwg. MHP3187)

12 Form MHD56470 Edition 4

PRODUCT INFORMATION GRAPHICS (CONTINUED)

Haul-in

Payout

Lift Slider

Handle

UP to Unlock

(Dwg. MHP2976)

Drum

Reduction Gear

Assembly

Fill Plug

Position

Drain

Plug

Inboard

Upright

(Dwg. MHP2297)

Fill/Breather

Plug

Motor

Case

Level Plug

Position

Drain Plug

Position

(Dwg. MHP2271)

Push Button

to Release

Brake

Remove Plug

and Connect

Auxiliary Air

to Port 1/4” NPT

(Dwg. MHP2289)

Install release

lever under

cylinder clevis

Disengage

slowly

(Dwg. MHP3150)

Form MHD56470 Edition 4 13

SERVICE NOTES

14 Form MHD56470 Edition 4

DECLARATION OF CONFORMITY

(CS) PROHLÁŠENÍ O SHODĚ (DA) OVERENSSTEMMELSESERKLÆRING (DE) KONFORMITÄTSERKLÄRUNG (EL) ∆ΗΛΩΣΗ ΑΝΑΓΝΩΡΙΣΗΣ (ES) DECLARACIÓN

DE CONFORMIDAD (FI) VAKUUTUS NORMIEN TÄYTTÄMISESTÄ (FR) CERTIFICAT DE CONFORMITÉ (HU) MEGFELELŐSÉGI NYILATKOZAT (IT)

DICHIARAZIONE DI CONFORMITÀ (LT) ATBILSTĪBAS DEKLARĀCIJA (LV) ATITIKTIES DEKLARACIJA (NL) SCHRIFTELIJKE VERKLARING VAN

CONFORMITEIT (NO) KONFORMITETSERKLÆRING (PT) DECLARAÇÃO DE CONFORMIDADE (PL) DEKLARACJA ZGODNOŚCI (SK) PREHLÁSENIE O

ZHODE (SL) IZJAVA O SKLADNOSTI (SV) FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

Ingersoll Rand 529, Avenue Roger Salengro, 59450 Sin Le Noble, France

Declare under our sole responsibility that the product: Pneumatic Winches

(CS) Prohlašujeme na svou zodpovědnost, že produkt: Pneumatický kladkostroj (DA) Erklærer som eneansvarlig, at nedenstående produkt: Pneumatisk lift

(DE) Erklären hiermit, gemäß unserer alleinigen Verantwortung, daß die Geräte: Druckluft-Kettenzugn (EL) Δηλώνουμε ότι με δική μας ευθύνη το προϊόν:

Πνευματικός ανυψωτήρας (ES) Declaramos que, bajo nuestra responsabilidad exclusiva, el producto: Polipasto neumático (FI) Vakuutamme ja kannamme yksin

täyden vastuun siitä, että tuote: Paineilmanostin (FR) Déclarons sous notre seule responsabilité que le produit: Palans pneumatiques (HU) Kizárólagos

felelősségünk tudatában kijelentjük, hogy a termék: Pneumatikus emelő (IT) Dichiariamo sotto la nostra unica responsabilità che il prodotto: Paranco

pneumatico (LT) Prisiimdami visà atsakomybæ pareiðkiame, kad gaminys: Pneimatiskās vinčas (LV) Deklarejam tikai uz musu atbildibu, ka šis ražojums:

Pneumatiniai suktuvai (NL) Verklaren, onder onze uitsluitende aansprakelijkheid, dat het produkt: Pneumatische takel (NO) Erklærer på ære og samvittighet at

produktet: Pneumatisk talje (PT) Declaramos sob a nossa exclusiva responsabilidade que o produto: Guinchos Pneumáticos (PL) Przyjmując pełną

odpowiedzialność, oświadczamy, że produkt: Wciągnik pneumatyczny (SK) Záväzne prehlasujeme, že výrobok: pneumatický kladkostroj (SL) Pod polno

odgovornostjo izjavljamo, da je izdelek: Pnevmatsko dvigalo (SV) Intygar enligt vårt ansvar att produkten: Tryckluftsdrivna lyftdon

Model: FA150KGiMR12A1-( )-CE / Serial Number Range: KG0015381 and up

(CS) Model: / Rozsah výrobních čísel: (DA) Model: / Serienummerområde: (DE) Modell: / Seriennummernbereich: (EL) Μοντέλο: / Κλίμακα σειριακών αριθμών:

(ES) Modelo: / Números de serie: (FI) Malli: / Sarjanumeroalue: (FR) Modèle: / Gamme de numéros de série: (HU) Modell: / Gyártási szám-tartomány: (IT)

Modello: / Gamma delle matricole: (LT) Modelis: / Serijos numeriø eilë: (LV) Modelis: / Sçrijas numuru diapazons: (NL) Model: / Serienummer: (NO) Modell: /

Serienr: (PT) Modelo: / Gama de Nos de Série: (PL) Model: / Zakres numerów serii: (SK) Model: / Rozsah výrobných čísiel: (SL) Model: / Območje serijskih

številk: (SV) Modell: / Serienummer, mellan:

To which this declaration relates, is in compliance with provisions of Directive(s): 2006/42/EC (machinery), 94/9/EC (ATEX)

(CS) Ke kterým se toto prohlášení vztahuje, odpovídají ustanovením směrnic: (DA) som denne erklæring vedrører, overholder bestemmelserne i følgende

direktiv(er): (DE) auf das sich diese Erklärung bezieht, der folgenden Richtlinie entspricht: (EL) στο οποίο αναφέρεται αυτή η δήλωση, πληροί τις διατάξεις της

Οδηγίας: (ES) a los que se refiere la presente declaración, cumplen con todo lo establecido en las directivas: (FI) johon tämä vakuutus viittaa, täyttää

direktiiveissä: (FR) Objet de ce certificat, est conforme aux prescriptions des Directives: (HU) Amelyekre ezen nyilatkozat vonatkozik, megfelelnek a következő

irányelvek előírásainak: (IT) a cui si riferisce la presente dichiarazione è conforme alle normative delle direttive: (LT) Uz kuru šī deklarācija attiecas, atbilst

direktīvas(u) nosacījumiem: (LV) Kuriems taikoma ši deklaracija, atitinka šios direktyvos (-ų) nuostatas: (NL) waarop deze verklaring betrekking heeft overeenkomt

met de bepalingen van directieven: (NO) som denne erklæringen gjelder for, oppfyller bestemmelsene i direktivene: (PT) Ao qual se refere a presente declaração,

está de acordo com as provisões da(s) Directiva(s): (PL) Którego dotyczy niniejsza deklaracja, jest zgodny z wymogami dyrektyw: (SK) Na ktorý sa toto prehlásenie

vzt’ahuje, je v súlade s ustanoveniami Smernice (Smerníc): (SL) Na katerega se ta izjava o skladnosti nanaša, v skladu z določili smernic. (SV) Som detta intyg

avser, överensstämmer med följande direktiv:

By using the following Principle Standards: EN 292-1; EN 292-2; EN418; EN983; F.E.M.1.001; F.E.M.9.511; EN 13463-1; pr EN 13463-5; EN 1127-1

(CS) Použitím následujících zákonných norem: (DA) ved at være i overensstemmelse med følgende hovedstandard(er): (DE) Unter Anlehnung an die folgenden

Grundnormen entsprechen: (EL) Χρησιμοποιώντας ια παρακάτω κύρια πρότυπα: (ES) conforme a los siguientes estándares: (FI) esitetyt vaatimukset seuraavia

perusnormeja käytettäessä: (FR) En observant les normes de principe suivantes: (HU) A következő elvi szabványok alkalmazása mellett: (IT) Seguendo i principi

standard indicati di seguito: (LT) Izmantojot šādus galvenos standartus: (LV) Remiantis šiais pagrindiniais standartais: (NL) overeenkomstig de volgende

hoofdstandaards: (NO) Ved å bruke følgende prinsipielle standarder: (PT) observando as seguintes Normas Principais: (PL) Spełniając wymogi nastźpujących

głównych norm: (SK) Pri dodržaní nasledovných noriem: (SL) Uporabljeni osnovni standardi: (SV) Genom att använda följande principstandard:

Date: May, 2010

(CS) Datum: Květen, 2010 (DA) Dato: Maj, 2010 (DE) Datum: Mai, 2010 (EL) Ηµεροµηνία: Μάιος, 2010 (ES) Fecha: Mayo, 2010 (FI) Päiväys: Toukokuu, 2010

(FR) Date: Mai, 2010 (HU) Dátum: 2010 május (IT) Data: Maggio, 2010 (LT) Datums: Maijs 2010 (LV) Datums: Gegužė 2010(NL) Datum: Mei, 2010 (NO)

Dato: Mai, 2010 (PT) Data: Maio, 2010 (PL) Data: Maj 2010 (SK) Dátum: Máj 2010 (SL) Datum: Maj 2010 (SV) Datum: Maj, 2010

Approved By:

(CS) Schválil: (DA) Godkendt af: (DE) Genehmigt von: (EL) Eγκρίθηκε από: (ES) Aprobado por: (FI) Hyväksytty: (FR) Approuvé par: (HU) Jóváhagyta: (IT)

Approvato da: (LT) Apstiprināja: (LV) Patvirtinta: (NL) Goedgekeurd door: (NO) Godkjent av: (PT) Aprovado por: (PL) Zatwierdzone przez: (SK) Schválil:

(SL) Odobril: (SV) Godkänt av:

Aaron Williamson- IREP - Seattle, WA USA

Engineering Product Manager

Form MHD56470 Edition 4 15