Ingersoll-Rand FA5, FA5T User Manual

Form MHD56037

WARNING

PARTS, OPERATION AND MAINTENANCE MANUAL

MODEL FA5 AND FA5T

(Dwg. MHP2107)

READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance
information. Make this manual available to all persons responsible for the
installation, operation and maintenance of these products.

Do not use this winch for lifting, supporting, or transporting people unless winch is
approved for Man RiderTM applications. Do not lift or support loads over people.

Always operate, inspect and maintain this winch in accordance with American Society of
Mechanical Engineers Standards Safety Code (ASME B30.7) and any other applicable
safety codes and regulations.

Form MHD56037
Edition 5
May 2006
71062103

© 2006 Ingersoll Rand Company

TABLE OF CONTENTS

Description Page No.

Safety Information

Danger, Caution, Warning and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safe Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Specifications

Model Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Performance Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation

Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Air Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Constant Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Initial Operating Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation

Winch Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Underwound Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Emergency Stop and Overload System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Overload Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Winch Overload Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Constant Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Winch Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Drum Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Lubrication

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Component Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Inspection

Records and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Winches not in Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Inspection and Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Troubleshooting

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance

Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

K5C2 Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Cleaning, Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

K5C2 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

K5C2E Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Parts Information

FA5 Winch Assembly Drawings Reference Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

FA5 Winch Drawings and Parts Lists Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

FA5 Winch Drawings and Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-76

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2 MHD56037 - Edition 5

SAFETY INFORMATION

f

DANGER

G

N

E

WARNING

This manual provides important information for all personnel
involved with the safe installation, operation and proper
maintenance of this product. Even if you feel you are familiar
with this or similar equipment, you should read this manual
before operating the winch.

Danger, Warning, Caution and Notice

Throughout this manual there are steps and procedures which, if
not followed, may result in a hazard. The following signal words
are used to identify the level of potential hazard.

Danger is used to indicate the presence of
a hazard which will cause severe injury,
death, or substantial property damage if
the warning is ignored.

WWAARRNNIINNG

CCAAUUTTIIOON

NNOOTTIICCE

Warning is used to indicate the presence
of a hazard which can cause severe injury,
death, or substantial property damage if
the warning is ignored.

Caution is used to indicate the presence o
a hazard which will or can cause injury or
property damage if the warning is
ignored.

Notice is used to notify people of
installation, operation, or maintenance
information which is important but not
hazard-related.

Safety Summary

• Do not use this winch for lifting, supporting, or transporting
people unless winch is approved for Man Rider
applications. Do not lift or support loads over people.

• The supporting structures and load-attaching devices used in
conjunction with this winch must provide an adequate safety
factor to handle the rated load, plus the weight of the winch
and attached equipment. This is the customer’s responsibili ty.
If in doubt, consult a registered structural engineer.

TM

The Occupational Safety and Health Act of 1970 generally places
the burden of compliance with the user, not the manufacturer.
Many OSHA requirements are not concerned or connected with
the manufactured product but are, rather, associated with the final
installation. It is the owner’s and user’s responsibility to
determine the suitability of a product for any particular use. It is
recommended that all applicable industry, trade association,
federal, state and local regulations be check ed. Read all operating
instructions and warnings before operation.

Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper rigging
techniques. Refer to ASME B30.9 for rigging information,
American Society of Mechanical Engineers, Three Park Avenue,
New York, NY 10015.

This manual has been produced by Ingersoll Rand to provide
dealers, mechanics, operators and company personnel with
information required to install, operate, maintain and repair the
products described herein.

It is extremely important that mechanics and operators be familiar
with servicing procedures of these products, or like or similar
products, and are physically capable of conducting the
procedures. These personnel shall have a general working
knowledge that includes:

1. Proper and safe use and application of mechanics common

hand tools as well as special Ingersoll
recommended tools.

2. Safety procedures, precautions and work habits established
by accepted industry standards.

Ingersoll Rand cannot know of, or provide all the procedures by
which product operations or repairs may be conducted and the
hazards and/or results of each method. If operation or
maintenance procedures not specifically recommended by the
manufacturer are conducted, it must be ensured that product
safety is not endangered by the actions taken. If unsure of an
operation or maintenance procedure or step, personnel should
place the product in a safe condition and contact supervisors and/
or the factory for technical assistance.

Rand or

Ingersoll Rand winches are manufactured in accordance with the

latest ASME B30.7 standards.

The National Safety Council, Accident Prevention Manual for
Industrial Operations, Eighth Edition and other recognized safety
sources make a common point: Employees who work near
suspended loads or assist in hooking on or arranging a load
should be instructed to keep out from under the load. From a
safety standpoint, one factor is paramount: conduct all lifting or
pulling operations in such a manner that if there were an
equipment failure, no personnel would be injured. This means
keep out from under a raised load and keep out of the intended
path of any load.

MHD56037 - Edition 5 3

SAFE OPERATING INSTRUCTIONS

The following warnings and operating instructions have been
adapted in part from American Society of Mechanical Engineers
(Safety) Standard ASME B30.7 and are intended to avoid unsafe
operating practices which might lead to injury or property
damage.

Ingersoll Rand recognizes that most companies who use winches
have a safety program in force at their facility. In the event that
some conflict exists between a rule set forth in this publication
and a similar rule already set by an individual company, the more
stringent of the two should take precedence.

Safe Operating Instructions are provided to make an operator
aware of dangerous practices to avoid and are not necessarily
limited to the following list. Refer to specific sections in the
manual for additional safety information.

1. Only allow personnel trained in safety and operation of this
product to operate and maintain this winch.

2. Only operate a winch if you are physically fit to do so.

3. When a “DO NOT OPERATE” sign is placed on winch, or
controls, do not operate winch until sign has been removed
by designated personnel.

4. Before each shift, check winch for wear and damage. Never
use a winch that inspection indicates is worn or damaged.

WARNING LABEL

5. Never lift a load greater than rated capacity of the winch.
Refer to labels attached to winch or to “SPECIFICATIONS”
section.

6. Keep hands, clothing, etc., clear of moving parts.

7. Never place your hand in the throat area of a hook or near
wire rope spooling onto or off of winch drum.

8. Always rig loads properly and carefully.

9. Be certain the load is properly seated in saddle of hook. Do
not support load on tip of hook.

10. Do not “side pull” or “yard”.

11. Always ensure that you, and all other people, are clear of the
path of the load. Do not lift a load over people.

12. Never use the winch for lifting or lowering people, and never
allow anyone to stand on a suspended load.

13. Ease slack out of wire rope when starting a lift or pull. Do
not jerk the load.

14. Do not swing a suspended load.

15. Do not leave a suspended load unattended.

16. Never operate a winch with twisted, kinked or damaged wire
rope.

17. Pay attention to the load at all times when operating the
winch.

18. Never use the winch wire rope as a sling.

19. After use, or when in a non-operational mode, winch should
be secured against unauthorized and unwarranted use.

Each unit is shipped from the factory with warning label shown.
If the label is not attached to your unit, order a new label and
install it. Refer to the parts list for part number. Label is shown
smaller than actual size.

(Dwg. 71060529)

4 MHD56037 - Edition 5

SPECIFICATIONS

Model Code Explanation

Example: FA5-24MK320P FA5 - 24 M K 320 P

Series (Capacity)

FA5 = Air Powered Winch (5 metric ton / 11,000 lbs.)

Drum Flange Height or Man Rider®:

- = Standard flange: 27 inch (660 mm) diameter

T = Tall flange: 35 inch (890 mm) diameter

MR =

Drum Length (Distance between drum flanges):

12 = 12 inch (306 mm)
16 = 16 inch (406 mm)

24 = 24 inch (610 mm) (Standard)

30 = 30 inch (760 mm)
36 = 36 inch (915 mm) Tall Flange Winch only

Drum Brake:

A = Automatic Drum Brake

M = Manual Drum Brake

X = None

Disc Brake:

K = Automatic Disc Brake

X = None

Control:

1 = Winch mounted lever throttle. (Standard)

* 2XX = Remote full flow lever throttle (XX = Specify hose length (feet). Maximum 20 ft. (6 metres))
* 3XX = Remote pilot pendant throttle (XX = Specify hose length (feet). Maximum 50 ft. (15 metres))
* 4XX = Remote pilot lever throttle (XX = Specify length (feet). Maximum 50 ft. (15 metres))
* 5XX = Remote electric over air throttle†

Options: **

7 = Drum Grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch) †

** C = Low Temperature Components; specify -10° C (14° F) or -20° C (-4° F)

D = Drum Divider Flange and additional wire rope anchor †

E = Construction Cage†

G = Drum Guard

L = Drum Locking Pin

** M1 = Material Traceability (typical material results) ††
** M2 = Material Traceability (actual material results) ††
** M3 = Material Traceability (actual material results for these parts in finished, as-delivered condition) ††

N =

P = Marine Grade Corrosion Preventative Finish

Q = Special paint U = Underwound wire rope operation †

S = Limit Switch (upper and lower) V = Press Roller
T = Tensioning Manifold W = Witness; please specify **
Z = Sandblast and Carbozinc Primer X = Testing; please specify

-E = Compliance with European Machinery Directive (includes Emergency Stop and Overload Protection)

Notes: * Remote throttles are provided with 10 feet (3 metres) of hose. Specify hose lengths greater than 10 feet. For lengths

Man RiderTM (Refer to FA5 Man RiderTM Supplement Form #MHD56042)

Type Approval – Specify:
A = American Bureau of Shipping (ABS); N = Det Norske Veritas (DNV); R = Lloyd’s Register of Shipping (LRS)

greater than 20 ft. (6 metres) with the Remote Full Flow Throttle, or 50 ft. (15 metres) with the Remote Pilot Lever and
Remote Pilot Pendant Throttles contact your Ingersoll
lengths are provided for reference only, order lengths in feet.

** Documentation, witness testing and material traceability available; must be requested at time of order . Specify option s or

contact the factory or your nearest Ingersoll Rand distributor for information.

† Not covered in this manual.

†† Refer to ‘Traceability’on page 8 for a description of the dif f erences between M1, M2 and M3.

Rand distributor or the factory for control acceptability. Metric

MHD56037 - Edition 5 5

Performance Graphs

FA5 Winch

(Dwg. MHP1890)

FA5T Winch

(Dwg. MHP1891)

6 MHD56037 - Edition 5

General Specifications:

Rated Operating Pressure 90 psig (6.3 bar)

Air System

Rated Performance

(at rated pressure / volume)

Air Motor Pipe Inlet Size 1.25 inch 32 mm 1.25 inch 32 mm

Minimum Air System Hose Size 1.5 inch 38 mm 1.5 inch 38 mm

Drum Barrel Diameter 15 inches 381 mm 15 inches 381mm

Drum Flange Diameter 27.25 inches 692 mm 35.25 inches 895 mm

* Drum Wire Rope

Storage Capacity

(feet / metres)

* Wire rope storage capacity based on wire rope top layer located a minimum of 1/2 inch (13 mm) below drum flange and meets ASME

B30.7. The wire rope storage capacities listed may vary from figures stated elsewhere.

Air Consumption

(at rated pressure and load)

Full Drum Line Pull 11,000 lbs 4,490 kgs 8,400 lbs 3,810 kgs

Mid Drum Line Speed 65 fpm 20 m/min. 80 fpm 24 m/min.
Max Stall Pull - 1st Layer 24,000 lbs 10,886 kgs 24,000 lbs 10,886 kgs
F A 5-24MX1 Ship Weight 1,920 lbs 873 kgs - - - - - -

F A 5T-24MX1 Ship Weight - - - - - - 2,115 lbs 961 kgs

Drum Length (inches)

12 874 ft 266 m
16 1181 ft 360 m

24 (Standard) 1795 ft 547 m

30 2256 ft 688 m

12 550 ft 168 m 1240 ft 378 m
16 746 ft 227 m 1681 ft 512 m

24 (Standard) 1138 ft 347 m 2564 ft 782 m

30 1431 ft 436 m 3225 ft 983 m

36 (Tall flange only) - - - - - - 3887 ft 1185 m

12 400 ft 122 m 886 ft 270 m
16 544 ft 166 m 1204 ft 367 m

24 (Standard) 832 ft 254 m 1841 ft 561 m

30 1047 ft 319 m 2318 ft 706 m

36 (Tall flange only) - - - - - - 2796 ft 852 m

700 scfm 20 cu.m/min. 700 scfm 20 cu.m/min.

0.625 inch 16 mm

0.75 inch 18 mm 0.75 inch 18 mm

0.875 inch 20 mm 0.875 inch 20 mm

FA5 FA5T

Model

Wire Rope Diameter

0.625 inch (16 mm) diameter

wire rope not recommended for

use on FA5T winch es.

Description of Operation

FA5 winches are air powered, planetary geared units designed for

lifting and pulling applications. FA5 winches are available with
either an internal automatic disc brake, a manual or automatic
band brake, or a combination of both.

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

The output from planetary reduction gear assembly is connected
to the wire rope drum through the output shaft.

MHD56037 - Edition 5 7

FA5 winches can be provided with an optional disc brake
assembly consisting of friction plates splined to a hub which in
turn is connected to the drive shaft from the air motor. Brake
friction plates are clamped to the drum shaft through a spring
applied piston. The brake remains applied until the winch control
valve is operated and winch payout or haul-in occurs. Air is
introduced into the brake piston chamber, which is formed
between brake piston and brake housing, causing the brake piston
to react, compressing brake springs and releasing friction plates
allowing motor shaft to rotate. A power failure or sudden loss of
air will immediately cause the spring applied brake to engage.

The drum band brake operates by applying a friction force
between drum brake band and winch drum. The manual brake
requires an operator to engage and disengage brake using a lever
located on top of brake band. The automatic drum band brake
operation is similar to disc brake operation; they are both fully
disengaged in the haul-in and payout direction.

Traceability

CAUTION

Load bearing parts are documented to provide traceability. The
documentation includes chemical and physical properties of raw
material, heat treating, hardening, tensile and charpy tests as
required for the part.

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 the actual parts are in compliance with the
requirements of the order based on specific inspection and testing
(i.e. results are actual material properties for these parts).

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 manufacturer) that parts are in compliance with
requirements of order based on non-specific inspection and
testing (i.e. results are typical material properties for these parts).

INSTALLATION

Prior to installing winch, carefully inspect it for possible shipping
damage.
Winches are supplied fully lubricated from the factory. Before
operation check oil levels and adjust as necessary. Use the proper
type of oil as recommended in “LUBRICATION” section.

• Owners and users are advised to examine specific, local or
other regulations, including American Society of Mechanical
Engineers Standards and/or OSHA Regulations which may
apply to a particular type of use of this product before
installing or putting winch to use.

Mounting

Refer to Dwg. MHP0133 and Table 1 on page 8, and Table 2 on
page 9.
Care must be taken when moving, positioning or mounting the
winch. In most cases, lifting lugs have been provided to assist in
handling the winch. If lug locations are improper for your specific
installation, great care should be taken to ensure that winch, when
lifted, will be properly balanced. Determine weight of your winch
by referring to “SPECIFICATIONS” section. Lift winch 3 to 4
inches (75 to 100 mm) off ground.
Verify winch is balanced and secure before continuing lift.
Mount winch so axis of drum is horizontal and that motor vent cap
is not more than 15° off top vertical center. If winch is to be
mounted in an inverted position, motor case must be rotated to
position vent cap at top.

1. The winch mounting surface must be flat and of sufficient
strength to handle rated load plus weight of winch and
attached equipment. An inadequate foundation may cause
distortion or twisting of winch uprights and side rails
resulting in winch damage.

2. Make sure mounting surface is flat to within 0.005 inch
(0.127 mm) per inch of drum length. Shim if necessary.
Refer to Table 1.

3. Mounting bolts must be 3/4 inch (18 mm) Grade 8 or better.
Use self-locking nuts or nuts with lockwashers.

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 or CHA are charpy
parts for use under extreme cold conditions. Traceability
requirements must be stated when reordering these parts for
continued certification.

4. Tighten 3/4 inch (18 mm) mounting bolts evenly and torque
to 380 ft lbs (515 Nm) for dry thread fasteners. If fasteners
are plated, lubricated or a thread locking compound is used,
torque to 280 ft lbs (380 Nm).

5. Maintain a fleet angle between sheave and winch of no more
than 1-1/2°. The lead sheave must be on a center line with
drum and, for every inch (25 mm) of drum length, be at least

1.6 feet (0.5 metre) from the drum. Refer to Dwg. MHP2123
on page 9.

6. Do not weld any part of winch.

Table 1–Mounting Surface Tolerance

Drum

Length

12 0.06 1.52
16 0.08 2.03
24 0.12 3.05
30 0.15 3.81
36 0.18 4.57

Winch Bolt Hole Mounting Dimension Drawing

(Dwg. MHP0133)

Mounting Surface Minimum Flatness

inch mm

8 MHD56037 - Edition 5

Table 2–Winch Bolt Hole Mounting Dimensions

CAUTION

NOTICE

Dimension

“A” FA5

“A” FA5T

“B” (with

Drum Brake)

“B” (without

Drum Brake)

“C”

Bolt Hole Qty each

Side Rail

* 36 inch drum length applies to FA5T (tall flange) only.

inch 31.25

mm 794

inch 34.25

mm 870

inch 7.5 9 10.5 10 11.5

mm 190 229 267 254 292

inch 6 6.25 9 12 14

mm 152 159 229 305 356

inch 13/16

mm 20

Drum Length (inches)

12 16 24 30 36*

4 5

- - -

Wire Rope

• Maintain at least 3 tight wraps of wire rope on drum at all
times.

• Install wire rope to come off drum for overwind operation.
(normal application.) Refer to Dwg. MHP2124

(Dwg. MHP2124)

on page 9.

(Dwg. MHP2123)

‘A’ = 1.6 feet (0.5 metre) per inch of drum length:

‘A’ = 19.2 feet (5.85 metres) for 12 inch drum.
‘A’ = 25.6 feet (7.80 metres) for 16 inch drum.
‘A’ = 38.4 feet (11.7 metres) for 24 inch drum.
‘A’ = 48.0 feet (14.6 metres) for 30 inch drum.
‘A’ = 57.6 feet (17.5 metres) for 36 inch drum.

Notes:

1. Maintain a minimum of 3 tight wraps of wire rope on drum at
all times.

2. Ensure wire rope does not exceed top layer requirement.
Refer to “SPECIFICATIONS” section.

• For underwound applications order the “U” option or
contact factory prior to operation.

Wire Rope Selection

Consult a reputable wire rope manufacturer or distributor for
assistance in selecting 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 actual working load
and that meets all applicable industry, trade association, federal,
state and local regulations.

When considering wire rope requirements the actual working load
must include not only static or dead load but also loads resulting
from acceleration, retardation and shock load. Consideration must
also be given to the size of winch wire rope drum, sheaves and
method of reeving. Wire rope construction should be 6 X 19 or 6
X 37 IWRC EIPS right regular lay. Refer to Table 3
minimum and maximum recommended wire rope sizes.

Table 3–Minimum and Maximum Wire Rope Size

Model

FA5 5/8 16

FA5T 3/4 20

Note: Maximum wire rope diameter is limited by size of wire
rope anchor hole. Refer to parts list for correct wire rope anchor
part numbers.

Minimum Maximum

inch mm inch mm

on page 9 for

7/8 22

MHD56037 - Edition 5 9

Installing Wire Rope

CAUTION

CAUTION

• To avoid disc brake damage when installing wire rope
pressurize brake with a minimum of 60 psi (4.1 bar) air from
an auxiliary source.

Refer to Dwg. MHP0166 on page 10.

1. Cut wire rope to length in accordance with wire rope
manufacturer’s instructions.

2. Feed end of wire rope into wire rope anchor hole in drum
and pull through approximately one foot (305 mm) of wire
rope.

(Dwg. MHP0166)

3. Wrap wire rope with wire a distance from the end equal to
wedge length plus one inch (25 mm).

4. Slide sleeve over end of wire rope so larger diameter of taper
bore is nearest the end of wire rope.

5. Spread end strands of wire rope and insert split wedge until
it is below the end of wire rope.

6. Pull sleeve over wire rope end until tight. Check that wire
rope strands stay in the slots located on split wedge.

7. Pull wire rope anchor into position in drum anchor pocket.

• Make sure first wrap of wire rope is tight and lays flush

against drum flange.

Support wire rope spool and have wire rope come off top of spool
and over top of winch drum. This will prevent damage to wire
rope.

Spooling Wire Rope onto Winch Drum

(Dwg. MHP2125)

Rigging

Make sure all wire rope blocks, tackle and fasteners have a
sufficient safety margin to handle required load under all
conditions. Do not allow wire rope to contact sharp edges or
make sharp bends which will cause damage to wire rope, use a
sheave. Refer to wire rope manufacturer’s handbook for proper
sizing, use and care of wire rope.

Safe Installation Procedures

1. Do not use wire rope as a ground (earth) for welding.

2. Do not attach a welding electrode to winch or wire rope.

3. Never run wire rope over a sharp edge. Use a correctly sized
sheave.

4. When a lead sheave is used, it must be aligned with center of
drum. The diameter of lead sheave must be at least 18 times
diameter of wire rope. Refer to Dwg. MHP2123

5. Always maintain at least three full, tight wraps of wire rope
on drum.

on page 9.

Safe Wire Rope Handling Procedures

1. Always use gloves when handling wire rope.

2. Never use wire rope which is frayed or kinked.

3. Never use wire rope as a sling.

4. Always ensure wire rope is correctly spooled and the first
layer is tight against drum.

5. Always follow wire rope manufacturers’ recommendation on
use and maintenance of wire rope.

Wire Rope Spooling

Refer to Dwg. MHP2125 on page 10.
To compensate for uneven spooling and decrease in line pull
capacity as drum fills up, use as short a wire rope as practical.
When rewinding apply tension to the end of wire rope to eliminate
slack. This helps achieve level winding and tight spooling.

10 MHD56037 - Edition 5

The air supply must be clean, free from moisture and lubricated to
ensure optimum motor performance. Foreign particles, moisture
and lack of lubrication are the primary causes of premature motor
wear and breakdown. Using an air filter, lubricator and moisture
separator will improve overall winch performance and reduce
unscheduled down time.

Air consumption for the FA5 and FA5T air motor is 700 scfm (20
cu. m/min.) at rated operating pressure of 90 psig (6.3 bar) at
winch motor inlet. If air supply varies from recommended, then
winch performance will change.

Air Supply

Air Lines

CAUTION

CAUTION

Air Pressure Regulator

Inside diameter of winch air supply lines must not be less than
sizes shown in Tab le 4
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 lines.

Table 4–Minimum Allowable Air Supply Line Sizes

Model inch mm

FA5

FA5T

Air Line Lubricator

Refer to Dwg. MHP0191 on page 11.
Always use an air line lubricator with these motors. T he lubricator
must have an inlet and outlet at least as large as inlet on motor.
Install air line lubricator as close to air inlet on motor as possible.

• Lubricator must be located no more than 10 ft. (3 m) from
motor.

• Shut off air supply before filling air line lubricator.

The 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 throttle control valve when air
line lubricator is functioning properly.

Air Line Filter

Refer to Dwg. MHP0191 on page 11.
It is recommended that an air line strainer/filter be installed as
close as practical to motor air inlet port, but before lubricator, to
prevent dirt from entering valve and motor. The strainer/filter
should provide 20 micron filtration and include a moisture trap.
Clean the strainer/filter periodically to maintain its operati ng
efficiency.

Air Out

on page 11. Before making final

1-1/2 38

Regulator

Air In

If an air pressure regulator is used, install between lubricator and
filter. Refer to Dwg. MHP0191

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 motor or an aftercooler at compressor that cools air to
condense and collect moisture prior to distribution through supply
lines are also helpful.

Mufflers

Make sure mufflers are installed in winch exhaust manifold and
control valve exhaust port. An additional muffler is used on
winches equipped with an emergency stop and overload device.
Check mufflers periodically to ensure they are functioning
correctly.

on page 11.

Motor

For optimum performance and maximum durability of parts,
provide an air supply of 90 psig at 700 scfm (6.3 bar/630 kPa at
20 cu. m/m) as measured at motor inlet. The air motor should be
installed as near as possible to compressor or air receiver.

Emergency Stop and Overload System (optional feature)

Refer to Dwg. MHP1492 on page 12.

old style

The air supply line is connected to the shutoff valve which is
connected to the air control valve. When Emergency Stop valve is
activated, a pilot signal is sent to the shut off pilot valve which
directs shutoff valve to cut off air to winch, immediately stopping
all winch movement.

• If winch continues to move (payout load) after shutoff valve
activates, brake(s) are not holding load and need to be
adjusted or repaired.

The overload system also activates shutoff valve. When Delta-P
valve senses a preset pressure difference between the two ports,
located on rotary housing, it directs a pilot signal to shutoff pilot
valve activating the shutoff valve. Refer to Dwg. MHP1491
page 12.

on

(Dwg. MHP0191)

MHD56037 - Edition 5 11

Lubricator

Filter

Emergency Stop and Overload System Components

CAUTION

(old style)

(Dwg. MHP1492)

Constant Tension (optional feature)

Refer to Dwg. MHP1865 on page 12 and Dwg. MHP1176 on
page 12.

The air supply line is connected to one of the two top ports on the
control valve. This will allow air to supply either the normal
control valve or the auxiliary valve.

• Use only one control valve to operate winch at any time.
Attempting to OVER-RIDE one control valve with the other
will result in total loss of winch control.

Air Schematic–Constant Tension Winches

Air Schematic–Emergency Stop and Overload System
(old style)

(Dwg. MHP1176)

Constant T ension Components

(Dwg. MHP1491)

(Dwg. MHP1865)

12 MHD56037 - Edition 5

Initial Operating Checks

CAUTION

WARNING

Winches are tested for proper operation prior to leaving factory.
Before winch is placed into service the following initial operating
checks should be performed.

1. When first running motor inject some light oil into inlet

connection to provide initial lubrication.

2. When first operating winch it is recommended that motor be

operated slowly in both directions for a few minutes.

OPERATION

For winches that have been in storage the following start-up
procedures are required.

1. Give the winch an inspection conforming to requirements of
“Winches Not in Regular Use” in the “INSPECTION”
section.

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. The winch is now ready for normal use.

The four most important aspects of winch operation are:

1. Follow all safety instructions when operating winch.

2. Allow only people trained in safety and operation of this
winch to operate this equipment.

3. Subject each winch to a regular inspection and maintenance
procedure.

4. Be aware of winch capacity and weight of load at all times.

• To avoid damage to rigging, the structure supporting rigging

and winch, do not “two-block” the end of wire rope.

* Two blocking occurs when winch wire rope is multi-reeved
using two separate sheave blocks which are allowed to come into
contact with each other during winch operation. When this occurs
extreme forces are exerted on wire rope and sheave blocks which
may result in equipment and or rigging failure.

Operators must be physically competent. Operators must have no
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 winch, including a study of the
manufacturers’ 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 winch under unsafe conditions.

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 lever . Shift control lever
in desired direction to payout or haul-in wire rope.
As viewed from the air motor end, move the control throttle
handle to the right (clockwise) to payout wire rope and to the left
(counterclockwise) to haul-in wire rope. A void sudden movements
of the control valve to ensure smooth operation of the winch.
When released, handle will return to the neutral or center position.
The sliding handle will drop down to engage and lock the control
handle in place.

Winch Mounted Throttle Control Valve Operation

Lift Slider

Handle

UP to

Unlock

Haul-In

Payout

Air Inlet Port

1-1/4 NPT

Brake Release Port

1/4 NPT

• Winch is not designed or suitable for lifting, lowering or

moving persons. Never lift loads over people.

The spring loaded, motor mounted, live air manual throttle
control valve is supplied as a standard feature on this winch.
Optional remote throttle controls are available. Reference model
code on the winch nameplate and compare it to the
“SPECIFICATIONS” section,
determine your configuration. The throttle controls provide
operator control of motor speed and direction of drum rotation.

New Style

Refer to Dwg. MHP1809 on page 13.
The spring loaded, live air, manual control throttle valve mounts
to the rotary housing.

MHD56037 - Edition 5 13

Winch Controls

on page 5 of this manual, to

Winch Mounted Air Throttle (standard feature)

Exhaust Port

1-1/2 NPT

(Dwg. MHP1809)

old style

Refer to Dwgs. MHP0165 on page 54 and MHP0566 on page 14.
The spring loaded, live air, manual control throttle valve mounts
to air motor.
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. A void sudden movements
of control valve to ensure smooth operation of winch.
When winch is not in use, engage latch to prevent inadvertent
movement of control throttle.

Winch Mounted Thro ttle Control Valve Operation
(old style)

(Dwg. MHP2043)

Remote Pilot Pendant Throttle (optional feature)

Refer to Dwg. MHP2233 on page 14 and MHP1311 on page 15.
Provides for remote winch control at distances of up to 50* feet
(15 metres) away from winch. The pendant pilot control throttle is
a two lever movable control station for winch operation. Pilot
pressure from pendant pilot control throttle activates winch
control valve. The winch control valve, located on winch motor,
controls motor speed and direction of drum rotation. Direction of
rotation is determined by the pendant lever depressed.

Dwg. MHP0566)

Underwound Operation (optional feature)

Underwound operation is where wire rope haul-in or payout is off
the bottom of drum. This is a special operation and requires a
winch specifically designed for this usage.

Underwound operation requires a reverse bias valve installed in
the control valve.

Control valve operation will be opposite as shown in Dwg.
MHP1809
handle up to unlock control lever. Move control throttle handle to
the left (counterclockwise) to payout, and to the right (clockwise)
to haul-in.

Remote Live Air Throttle (optional feature)

Refer to Dwgs. MHP2043 on page 14.
Provides for remote mounting of winch control at a fixed location
at up to 20 feet (6 metres) away from winch motor. Air hoses
connect throttle to winch motor to provide winch operation.

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 control valve to ensure smooth
operation of winch.

on page 13. As viewed from air motor end, lift slider

Pendant Hose and Operating Levers (new style)

Red

Yellow

Green

Haul-In

Load
Payout
Load

(Dwg. MHP2233)

14 MHD56037 - Edition 5

Pendant Hose and Operating Levers (old style)

CAUTION

NOTICE

(Dwg. MHP1311)

* For distances greater than 50 feet (15 metres) contact

Ingersoll

Rand Technical Sales for control suitability.

Emergency Stop Operation

(Dwg. MHP2047)

Remote Pilot Lever Throttle (optional feature)

Refer to Dwg. MHP0167 on page 56, item 358.
Provides for remote winch control at distances of up to 50* feet
(15 metres) away from winch. The lever pilot control throttle is a
fixed mount lever control station for winch operation. Pilot
pressure from lever pilot control throttle activates winch control
valve. The winch control valve, located on winch motor, controls
motor speed and direction of drum rotation. Direction of rotation
is determined by direction in which lever is shifted.

* For distances greater than 50 feet (15 metres) contact

Ingersoll

Rand Technical Sales for control suitability.

Emergency Stop and Overload System

Refer to Dwg. MHP2180 on page 52.
Air supply line is connected to air control valve. When emergency
stop or overload valve is activated, all winch movement will stop.

• If winch continues to move (payout load) after emergency
stop activates, brake(s) are not holding load and may require
adjustment or repair.

When control valve senses a preset pressure difference between
ports, a pilot signal is sent to stop flow of air, all winch movement
will stop.

• If winch overload occurs, overload device, if equipped, also
stops winch. T o operate winch after an overload, reduce load
and reset overload.

• Cannot be added to old style control valve. Refer to
MHP2036 on page 50.

Dwg.

Emergency Stop Reset

Refer to Dwg. MHP2048 on page 15.

1. Rotate red stop button, in counterclockwise direction until

red stop button ‘pops’ up.

2. Winch is ready to resume operation.

Emergency Stop Reset

Refer to Dwg. MHP2047on page 15.
Emergency stop device is located on the control valve. When
activated, winch drum rotation will immediately cease. T o activate
emergency stop, conduct the following:

1. Depress (push down) red palm valve, located on top of

MHD56037 - Edition 5 15

Emergency Stop (o ptional feature)

(Dwg. MHP2048)

control valve.

Overload Device

An overload device is available on winches with the emergency
shutoff option. Overload device operation is based on differential
pressure between air motor inlet and exhaust. The overload
device is factory preset to actuate at 150% (± 25%) of winch rated
capacity. When an overload condition is sensed, the valve poppet
closes, to cut off supply air to winch, stopping winch operation. If
an overload shutoff occurs, winch load must be reduced. Reset the
overload valve and operate winch in payout direction to lower
load. Refer to ‘Emergency Stop Reset’ section.

Checking Overload Valve Setting

1. Attach load line to a load that is calibrated to maximum load
for which winch is rated.

2. Move control lever to haul-in position. If winch does not lift
load, adjust the adjustment screw. Refer to ‘Overload Valve
Adjustment’ section
feature)” on page 26.

Setting the Overload

Refer to MHP2049 on page 16 and MHP2216 on page 27.
Attach load line to a load that is calibrated to 150% of winch rated
capacity. Shift control lever to haul-in position.

1. If overload valve activates, reset overload valve. Winch is
ready for normal operation.

2. If winch lifts load, lower load. Turn adjustment screw
counterclockwise in 1/4 turn increments until overload valve
activates when control lever is shifted to haul-in position.
After each 1/4 turn, retest winch.

Overload Valve Reset

“Overload Valve Adjustment (optional

2. To operate winch, depress appropriate ‘Haul-in’ or ‘Payout’
lever.

3. In event of an emergency all winch operation can be stopped
by pushing the emergency stop button. This will prevent air
from reaching winch motor, engage winch automatic
brake(s) and stop winch haul-in or payout movement.

4. If depressed, the ‘OFF’ button will also stop winch
operation.

5. To reset Emergency Stop Valve:
a. Locate serrated ring directly below emergency stop

button. Rotating serrated ring clockwise, will cause
emergency stop button to ‘pop up’.

b. Depress emergency stop valve ‘ON’ button.

Emergency Stop Operation (old style)

(Dwg. MHP1485)

Local Control Emergency Stop Valve Operation

(Dwg. MHP0754)

(Dwg. MHP2049)

Emergency Stop (optional feature)

Refer to Dwgs. MHP1485, MHP0754 on page 16 and MHP1892
on page 17.
The emergency stop device is located at air inlet of winc h on local
control models, and on pendant on remote control models. When
activated, winch drum rotation will immediately cease.

1. To star t winch operation depress the ‘ON’ button.

16 MHD56037 - Edition 5

Remote Pendant Emergency Stop Valve Operation

WARNING

(Dwg. MHP1892)

Winch Overload Device (optional feature)

The overload device is integrated into winch air motor control air
system and prevents winch from lifting a load greater than
overload value. Refer to “INSPECTION” section
an overload is detected, inlet supply air is stopped and winch will
not operate.
If overload device is activated load must be lowered and reduced.
To lower load and reset emergency stop valve:

1. Locate serrated ring directly below emergency stop button.
Rotating serrated ring clockwise, causes emergency stop
button to ‘pop up’.

2. Depress emergency stop valve ‘ON’ button.

3. Operate winch control in payout direction.

on page 21. If

• Ensure slack load line is taken up by operating winch control
valve with selector in NORMAL position. If selector lever is
placed in TENSION position the winch will immediately
attempt to establish line tension causing line to ‘snap’
resulting in injury or damage to property.

4. Operate winch normally to remove slack from load line.

5. Actuate valve to TENSION position to set winch to
automatically haul-in load line and maintain line tension.

Winch Brakes

Manual Drum Brake

Refer to Dwg. MHP0153 on page 48.
The manual drum brake may be applied by pushing down on
handle (104) and released by pulling up. If handle is pushed down
fully, it should lock in that position and prevent drum rotation,
until released by operator. The brake must be kept properly
adjusted to hold required load. Refer to ‘Adjustments’
in “MAINTENANCE” section for adjustment instructions.

Automatic Drum Brake (optional feature)

Refer to Dwg. MHP0153 on page 48.
The automatic drum brake is a spring applied, air released brake
which utilizes an air actuated, spring loaded cylinder (110), that
automatically disengages brake when motor is operated. Air
pressure in cylinder overcomes spring pressure to release brake.
When control valve is placed in neutral position, air in cylinder
(110) is vented and spring automatically engages brake to prevent
drum rotation.

The cylinder clevis (107) must be kept properly adjusted to hold
required load.

on page 26

Constant Tension (optional feature)

Refer to Dwg. MHP1865 on page 12.
With auxiliary valve in the NORMAL position, winch provides
normal operation. Placing valve selector in TENSIONING
position allows winch to automatically operate to haul-in slack
wire rope to maintain tension.

Auxiliary valve provides preset air pressure to air motor and disc
brake. This allows brake to be released and winch to overhaul
during TENSIONING operations. In this position, winch will
maintain constant tension on wire rope.

Auxiliary valve is pre-set at zero from the factory. Specific
adjustments must be made in the field. Adjustments can be
modified at anytime to accommodate the load conditions . Refer to
‘Regulator Adjustment’ in the “MAINTENANCE” section for
specific procedure.

Constant Tension (operation)

1. Place auxiliary valve in NORMAL position.

2. Operate winch normally to position end of load line.

3. Connect load line to load.

Automatic Disc Brake (optional feature)

Refer to Dwg. MHP0152 on page 46.
The automatic disc brake is a spring applied, air released brake.
Using an air actuated, spring loaded piston (10), the brake
automatically disengages when motor is operated and engages
when throttle is returned to neutral position.

Air pressure ported through brake housing (21) overcomes spring
(9) pressure and moves piston (10) which releases brake. When
control valve is placed in neutral position, air is vented, spring
pressure overcomes air pressure and spring (9) pressure moves
piston, engages brake and prevents drum rotation.

Drum Locking Pin (optional feature)

Refer to Dwg. MHP0155 on page 61.
The drum locking pin is mounted to winch on outboard upright,
opposite motor. It should be engaged if a load is left suspended.
The drum lock is operated by rotating a pin between a shallow
groove (disengaged) and a deep groove (engaged).

To Engage:

1. Rotate drum (80) to align one of the holes in flange with
locking pin (136). Pull out, straight away from outboard
upright, pull rod (140) and rotate counterclockwise 90°,
aligning pin (135) with deep groove in gland (138). Release

MHD56037 - Edition 5 17

pull rod and ensure locking pin engages and is seated in drum

WARNING

WARNING

hole and gland deep groove.

• Ensure that all braking mechanisms are engaged and all
personnel are clear of winch load and rigging before
disengaging locking pin.

• Extremely difficult locking pin release is an indication tha t
load is held by locking pin and braking mechanisms are not
functioning properly. Do not release locking pin until load
control is established.

To Disengage:

1. Pull out, straight away from outboard upright, pull rod (140)
and rotate clockwise 90°. Align pin (135) with the shallow
groove in gland (138) and release pull rod. Ensure locking
pin (136) is clear of the drum (80) flange and pin is seated in
gland shallow groove.

Limit Switch (optional feature)

Pre-set limit switch settings prevent winch wire rope payout and
haul-in by stopping air flow to the winch motor when a defined
set point has been reached. It is the owner’s and operator’s
responsibility to adjust winch operating limits prior to using
winch.
To adjust set points refer to ‘Adjustments’ in “MAINTENANCE”
section.

• Ensure limit switch set points are established and operating

properly before using winch.

18 MHD56037 - Edition 5

LUBRICATION

NOTICE

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.

The lubrication intervals recommended in this manual are based
on intermittent operation of winch eight hours each day, five days
per week. If winch is operated almost continuously or more than
the eight hours each day, more frequent lubrication will be
required. Also, lubricant types and change intervals are based on
operation in an environment relatively free of dust, moisture, and
corrosive fumes. Use only those lubricants recommended. Other
lubricants may affect winch performance. Approval for use of
other lubricants must be obtained from your Ingersoll
distributor. Failure to observe this precaution may result in
damage to winch and/or its associated components.

INTERVAL LUBRICATION CHECKS

Start of each shift Check flow and level of air line lubricator

(approximately 6 to 9 drops per minute
required at maximum motor speed).

Check winch motor oil level.

Monthly Lubricate components supplied by grease

fittings.
Inspect and clean or replace air line filter.
Check reduction gear oil level.

Yearly Drain and refill winch reduction gear oil.

Drain and refill winch motor oil.

Note: Intervals are based on winch operation in a normal
environment as described in the “INSPECTION” section. In
‘Heavy’ or ‘Severe’ operating conditions adjust lubrication
intervals accordingly.

Rand

Recommended Lubricants

Reduction Gear Recommended Lubricant

Recommended Grease

Temperature Type Oil

-20° to 50° F

(-30° to 10° C)

30° to 120° F

(-1° to 49° C)

• Do NOT use synthetic lubricants in air motor. Synthetic
lubricants will result in oil blowing by piston rings.

EP 1 multipurpose

lithium based grease

EP 2 multipurpose

lithium based grease

Component Lubrication

General Lubrication

Correct lubrication is one of the most important factors in
maintaining efficient winch operation.

1. The recommended grade of oil must be used at all times. Use
of unsuitable oil may result in excessive temperature rise,
loss of efficiency and possible damage to lubricated
components. Refer to ‘Recommended Lubricants’ section.

2. Drain and replace oil in motor, disc brake and reduction gear
after the first 50 hours of initial winch operation. Thereafter,
drain and replace oil according to operating environment
(yearly in NORMAL and HEAVY; quarterly in SEVERE), or
more frequently if desired.

3. Always inspect removed oil for evidence of internal damage
or contamination (metal shavings, dirt, water, etc.). If
indications of damage are noted, investigate and correct
before returning winch to service.

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

5. Always collect lubricants in suitable containers and dispose
of in an environmentally safe manner.

Temperature Type Oil

Below 32° F (0° C) ISO VG 68 (2 EP)

32° to 80° F (0° to 27° C) ISO VG 100 (3 EP) *

Above 80° F (27° C) ISO VG 150 (4 EP)

* Units are shipped from factory with ISO VG 100 (3 EP) lubri­cant. Reduction gear capacity is approximately 2 quarts (1.9
litres).

Air Motor and Disc Brake Recommended Lubricant

Temperature Type Oil

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. Motor oil capacity is approximately 3 quarts (2.8
litres).

MHD56037 - Edition 5 19

Motor

Refer to Dwg. MHP2126 on page 20.
The motor is splash lubricated by oil in motor housing and has no
other means of lubrication. It is therefore important to use only
good quality, non-deter gent motor oil to ensure maximum
performance and minimum downtime for repairs. Refer to
‘Recommended Lubricants’ section.

Oil capacity for the K5B-546 motor is 3 quarts (2.8 litres). Add
oil through filler opening until oil flows from level plug hole.
Add oil slowly to prevent spilling.

The motor should be level-checked daily or at the start of each
shift after any accumulated water has been drained 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. Drain water then refill to level plug (225),
located on side of motor housing (217). If desired, all oil may be
drained at end of shift and motor refilled with new oil.

K5B Motor Lubrication Locations

CAUTION

CAUTION

NOTICE

(Dwg. MHP2126)

To ensure correct performance, highest efficiency and long life, it
is essential that lubricating oil be maintained at correct level.
Rotate drum until fill plug is located at top dead center then add
oil up to level plug hole. Oil capacity for reduction gear assembly
is 4 quarts (3.8 litres).

Reduction Gear Lubrication Plug Locations

Air Throttle

Refer to Dwg. MHP0165 on page 54. Periodically, depending on
winch usage and severity of environment, lubricate lever air
throttle (local and remote) with recommended grease at grease
fitting (246).

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 surface of wire rope.

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

specified by wire rope manufacturer.

2. Apply Ingersoll Rand LUBRI-LINK-GREEN or ISO VG
100 (SAE 30W) oil as a wire rope lubricant.

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

Reduction Gear Assembly

(Dwg. MHP0140)

Disc Brake (optional feature)

Refer to Dwg. MHP1348 on page 20.
The friction plates and drive plates are in a self contained oil bath
and have no other means lubrication. After an oil change or winch
overhaul remove the breather plug (22) and pour a small amount
of oil [4 to 6 ounces (0.2 litres)] through breather hole in brake
housing. Allow oil to fully settle between fillings.

• If too much oil is added excess oil will be discharged through
breather plug when control valve is actuated.

Refer to Dwg. MHP0140 on page 20.
It is recommend that the first oil change be done after
approximately 50 hours initial operation. Always inspect removed
oil for evidence of internal damage (metal shavings, dirt, water,
etc.).
The reduction gear is filled to the correct levels prior to shipment
from the factory. Check oil level before initial winch operation.
This component is splash lubricated by oil in the housing and has
no other means of lubrication. It is therefore important to use high
quality Extreme Pressure (EP) rust and oxidation inhibited gear oil
to ensure maximum performance and minimum down time for
repair.

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

and increase oil temperature.

20 MHD56037 - Edition 5

(Dwg. MHP1348)

Seals and Bearings

If winch is disassembled, clean all parts thoroughly and coat
bearings and seals with clean grease. Refer to ‘Recommended
Lubricants’ section. Use sufficient grease to provide a good
protective coat. Lubricate grease fittings monthly with 2 or 3
pumps of a grease gun.

Drum Locking Pin (optional feature)

WARNING

NOTICE

Refer to Dwg. MHP0155 on page 61.
Lubricate at least once every month, depending on environment
and duty cycle, through grease fitting (139) located in gland (138)
with 2 or 3 pumps of a grease gun.

INSPECTION

If drum locking pin is disassembled, clean all parts thoroughly
and coat with clean grease. Refer to ‘Recommended Lubricants’
section. Use sufficient grease to provide a good protective coat.

Lubrication will help to prevent rust and allow easier locking pin
operation.

Inspection information is based in part on American Society of
Mechanical Engineers Standards Safety Codes (ASME B30.7).

• All new or repaired equipment should be inspected and
tested by personnel instructed in safety, operation and
maintenance of this equipment to ensure safe operation at
rated specifications before placing equipment in service.

• Never use a winch that inspection indicates is damaged.

Frequent and periodic inspections should be performed on
equipment in regular service. Frequent inspections are visual
examinations performed by operators or personnel trained in
safety and operation of this equipment and include observations
made during routine equipment operation. Periodic inspections
are thorough inspections conducted by personnel trained in safety ,
operation and maintenance of this equipment. ASME B30.7 states
inspection intervals depend upon the nature of critical
components of the equipment and severity of usage. The
inspection intervals recommended in this manual are based on
intermittent operation of winch eight hours each day, five days
per week, in an environment relatively free of dust, moisture, and
corrosive fumes. If winch is operated almost continuously, or
more than eight hours each day, more frequent inspections will be
required.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages, allowing
corrective action to be taken before condition becomes dangerous.
Deficiencies revealed through inspection, or noted during
operation, must be reported to designated personnel instructed in
safety, operation and maintenance of this equipment.
A determination as to whether a condition constitutes a safety
hazard(s) must be decided, and correction of noted safety
hazard(s) accomplished and documented by written report before
placing equipment in service.

Records and Reports

Inspection records, listing all points requiring periodic inspection
should be maintained for all load bearing equipment. Written
reports, based on severity of service, should be made on condition
of critical parts as a method of documenting periodic inspec tions.
These reports should be dated, signed by the person who
performed inspection, and kept on file where they are readily
available for authorized review.

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 actual condition of wire rope as determined by
periodic inspections.

Frequent Inspection

On equipment in continuous service, frequent inspection should
be made by operators at the beginning of each shift. In addition,
visual inspections should be conducted during regular operation
for indications of damage or evidence of malfunction (such as
abnormal noises).

1. WINCH. Prior to operation, visually inspect winch housings,
controls, brakes, side rails and drum for indications of
damage. Do not operate winch unless the wire rope feeds
onto drum smoothly. Any discrepancies noted must be
reviewed and inspected further by authorized personnel
instructed in operation, safety and maintenance of this winch.

2. WIRE ROPE. Visua lly inspect all wire rope which can be
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.

• 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 “Periodi c I ns p ection.”

3. AIR SYSTEM. Visually inspect all connections, fittings,
hoses and components for indication of air leaks. Repair any
leaks or damage.

4. PENDANT (optional feature). Ensure operation of pendant
levers is smooth and winch is responsive to pendant control.
Pendant levers must spring return to the neutral position
when released.

5. MANUAL THROTTLE LEVER. Ensure operation of
manual throttle lever is smooth and winch is responsive to
lever movement. Lever must return to neutral and lock in
place when released. If winch responds slowly or controls
stick, do not operate winch until all problems have been
corrected.

6. BRAKES. During winch operation test brakes. Brakes must
hold load without slipping. Automatic brakes must release
when winch motor throttle is operated. If brakes do not hold
load, or do not release properly, brakes must be adjusted or
repaired.

7. WIRE ROPE REEVING. Check reeving and ensure wire
rope is properly secured to the drum. Do not operate winch
unless wire rope feeds onto drum smoothly.

8. LUBRICATION. Refer to “LUBRICATION” section for
recommended procedures and lubricants.

9. LIMIT SWITCHES (optional feature). If equipped, ensure
limit switches engage and prevent operation at the required
set point and with drum rotating in correct direction. Ensure
limit switch properly resets.

MHD56037 - Edition 5 21

10. MOTOR. During operation check motor housing for excess
heat build up. Housing should not be hot to touch. Listen for
grinding or knocking noises. Ensure lubricated air supply
provides 6 to 9 drops per minute of ISO VG 32 (SAE 10W)
oil when winch is operated at rated capacity. Operate winch
slowly in both directions to verify operation.

Periodic Inspection

Periodic inspection intervals for winch use under various
conditions is listed below:

NORMAL HEAVY SEVERE

yearly semiannually quarterly

Disassembly may be required as a result of frequent inspection
findings or in order to properly inspect individual components.
Refer to “MAINTENANCE” section
written records of periodic inspections to provide an accumulative
basis for continuing evaluation. Inspect all items listed in
“Frequent Inspection.” Also inspect the following:

1. SIDE RAILS AND UPRIGHTS. Check for deformed,
cracked or corroded main components. Replace damaged
parts.

2. FASTENERS. Check retainer rings, split pins, capscrews,
nuts, and other fasteners on winch, including mounting bolts.
Replace if missing or damaged and tighten if loose.

3. DRUM AND SHEAVES. Check for cracks, wear or damage.
Replace if necessary.

4. WIRE ROPE. In addition to “Frequent Inspection”
requirements, also inspect for the following:
a. Build-up of dirt and corrosion. Clean with steam or a

stiff wire brush to remove dirt and corrosion if
necessary.

b. Loose or damaged end connection. Replace if loose or

damaged.
c. Check wire rope anchor is secure in drum.
d. Verify wire rope diameter. Measure diameter of wire

rope from crown-to-crown throughout life of wire rope.

Recording of actual diameter should only be done with

wire rope under equivalent loading and in same

operating section as accomplished during previous

inspections. If actual diameter of wire rope has

decreased more than 1/64 inch (0.4 mm) a thorough

examination of wire rope should be conducted by an

experienced inspector to determine suitability of wire

rope to remain in service. Refer to Dwg. MHP0056

page 22.

on page 26. Maintain

on

5. ALL COMPONENTS. Inspect for wear, damage, distortion,
deformation and cleanliness. If external evidence indicates
damage, disassemble as required to conduct a detailed
inspection. Inspect gears, shafts, bearings, sheaves, springs
and covers. Replace worn or damaged parts. Clean, lubricate
and reassemble.

6. BRAKES. Individually test brakes installed to ensure proper
operation. Brakes must hold a 125% rated load at mid drum
without slipping. If indicated by poor operation or visual
damage, disassemble and repair brake(s). Check all brake
surfaces for wear, deformation or foreign deposits. If brake
lining thickness is less than minimum as described in
“MAINTENANCE” section replace brakes. Clean and
replace components as necessary. Adjustments cannot be
made to disc brake. The disc brake must be repaired as
described in “MAINTENANCE” section.

7. FOUNDATION OR SUPPORTING STRUCTURE. Check
for distortion, wear and continued ability to support winch
and rated load. Ensure winch is firmly mounted and that
fasteners are in good condition and tight.

8. LABELS AND TAGS. Check for presence and legibility of
labels. Replace if damaged or missing.

9. LIMIT SWITCHES (optional feature). Operate winch in
both directions to activate limit switches. Limit switches
should engage (stop winch operation) at established settings
(+/- 2 feet [+/- 0.6 metres]). Reset limit switch by operating
winch in opposite direction. Refer to ‘Limit Switch
Adjustment’ in “MAINTENANCE” section.

10. DRUM GUARD (optional feature). Verify fasteners are tight
and in good condition. Ensure guard is in good condition.

11. EMERGENCY STOP VALVE (optional feature). During
winch operation verify emergency shut-off valve operation.
Valve must stop winch operation quickly. Valve must reset
properly. Refer to ‘Emergency Stop Valve’ in the
“OPERATION” section for procedures.

12. OVERLOAD DEVICE (optional feature). Ensure overload
device is properly set to stop winch when load exceeds
150% (+/- 25%) of winch rated capacity. If winch does not
shut down, contact your distributor or factory for repair
information.

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 requirements of “Frequent Inspection” 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 “Periodic Inspection” before being
place in service.

3. Standby equipment shall be inspected at least semi-annually
in accordance with requirements of “Frequent Inspection”.

(Dwg. MHP0056)

22 MHD56037 - Edition 5

INSPECTION AND MAINTENANCE REPORT

Ingersoll-Rand Force 5 Series FA5 and FA5T Air Winches

Model Number: Date:

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection
(_____ Quarterly _____ Semiannually _____ Yearly) Operating Environment:

2. Discrepancy(s) noted during Frequent Inspection

3. Discrepancy(s) noted during maintenance

4. Other: ___________________________

Refer to the Parts, Operation and Maintenance Manual “INSPECTION” section for general inspection criteria. Also, refer to appropriate
National Standards and Codes of practice. If in doubt about an existing condition, contact the nearest Ingersoll-Rand Distributor or the
factory for technical assistance.

COMPONENT

Uprights and
Side Rails

Drum Band Brake
(125% Load Test)

Disc Brake
(125% Load Test)

Drum Band Brake
(Visual Inspection)

Disc Brake
(Visual Inspection)

Motor
Limit Switches
Controls
Air System
Fasteners
Reduction Gears
Labels and Tags --­Shafts
Wire Rope Wedge --­Emergency Stop Valve --­Overload Device --­Wire Rope --­Other Components

(list in NOTES section)

CONDITION

Pass Fail Repair Replace

CORRECTIVE

ACTION

Normal ___ Heavy ___ Severe ___

NOTES

TESTING Pass Fail NOTES

Operational (No Load)
Operational (10% Load)
Operational (Maximum Test Load*)

* Maximum test load is 125% of rated line pull. Testing to more than 125% of rated load may be required to comply with standards and

regulations set forth in areas outside the USA.

This form may be copied and used as an inspection/maintenance record.

MHD56037 - Edition 5 23

TROUBLESHOOTING

This section provides basic troubleshooting information. Determination of spec ific causes to problems are best identified by thorough
inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief
guide to common winch symptoms, probable causes and remedies.

SYMPTOM CAUSE REMEDY

Winch will not operate. No air supply to winch. Check air supply line connections and hoses.

Winch is overloaded. Reduce load to within rated capacity.
Disc brake does not release. Pressurize disc brake release port and check for leakage. Replace brake

piston seals if leakage is found. Ensure air pressure at inlet to disc brake is
at least 50 psig (3.4 bar/340 kPa).

Shipping plugs may still be in
place.

Drum brake does not release. Disengage manual drum brake, or refer to ‘Automatic Drum Brake

Load continues to move when
winch is stopped.

Winch does not lift load or
does not lift rated capacity.

Throttle or pendant lever
moves but winch does not
operate.

Motor runs hot or makes
excessive noise during
operation.

Winch runs slow. Improper hose or fitting sizes. Check fittings, connections and hoses for correct size and length. Replace

Air lines freeze. Water in air supply. Install or drain air system moisture traps, moisture collec ting air receivers

Throttle lever hard to actuate,
or lever does not spring return
to neutral.

Automatic Drum Brake:

Brake cylinder will not
release.

Drum brake is slipping. Check drum brake adjustment on page 26 and brake band lining wear.
Winch is overloaded. Reduce load to within rated capacity.
Winch motor controls sticking. Check pendant/throttle levers spring return to normal (neutral) positions

Motor may be damaged. Remove and disassemble motor as described in the “MAINTENANCE”

Insufficient air supply. Verify air supply pressure and volume at winch inlet meets requirements

Motor may be damaged. Disassemble and clean motor and replace any broken or damaged parts.
Insufficient air supply. Ensure air pressure at winch inlet is at least 90 psig (6.3 bar/630 kPa) at

Air leak. Check hose and fitting connections. Inspect hose(s) for breaks. Tighten

Low oil level. Check oil level in motor. Add oil as required to obtain proper level.
Improper lubrication. Replace oil with type recommended in “LUBRICATION” section on

Water in oil. Drain and refill with recommended oil. Operate winch with no load

Damaged or broken piston or
connecting rod.

Motor may be damaged. Remove and disassemble motor as described in the “MAINTENANCE”

Brake(s) not releasing. Refer to brakes in “MAINTENANCE” section on page 26.

Valve body sticking in
bushing.

Drum brake out of adjustment. Adjust drum brake to maintain correct cylinder stroke.
Leaking cylinder seals. If air is noticed escaping from cylinder breather when attempting to

Dirty filter in air supply. Clean or replace filter .
Faulty dump valve. Check dump valve exhaust port. Air should exhaust when control valve

Remove shipping plugs in valve and motor exhaust ports.

Adjustment’

when released.

section
damaged.

listed in the “SPECIFICATIONS” section

rated volume. Clean air line filter.

fittings and repair or replace hoses as necessary.

page 19. Set lubricator to provide 6 to 9 drops of oil per minute at
maximum winch operating capacity.

slowly, in both directions. If noise still exists or motor overheats
disassemble and repair motor.

Disassemble and repair motor.

parts that may cause restricted air flow. Inspect air line filter.

section
parts.

and compressor aftercoolers. After corrective action has been taken,
disconnect lines at winch inlet and purge with clean, dry air or nitrogen.

Lubricate valve through grease fitting with recommended lubricant. Refer
to ‘Air Throttle’

release brake, replace or repair cylinder.

handle is in neutral. If no air escapes, replace dump valve.

on page 26.

on page 30. Examine all parts and replace any that are worn or

on page 5. Clean air line filter.

on page 30. Inspect all parts and replace all worn or damaged

on page 19 in “LUBRICATION” section.

24 MHD56037 - Edition 5