Only allow Ingersoll Rand trained technicians to perform maintenance on these products. For additional information contact Ingersoll Rand or nearest Distributor.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance, increased maintenance and will invalidate all warranties. The original language of this manual is English.
Manuals can be downloaded from www.ingersollrandproducts.com
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
SAFETY INFORMATION
WARNING
•Failure to follow these warnings may result in death or severe injury.
Additional information available on page 5.
nGeneral
•Do not operate before reading manual(s) supplied with this product
-Read all documentation supplied with the product.
-Contact factory if in doubt about installation, operation, inspection and maintenance instructions.
-Do not discard manuals. Keep manuals readily available for all personnel.
•Always install, operate, inspect and maintain this product in accordance with all applicable standards and regulations (local, state, country, federal, etc.)
nWinch Installation
•Ensure winch is correctly installed
-Never weld on any part of the winch.
-All supporting structure, mounting hardware and load attaching hardware must be in accordance with all applicable standards, codes and regulations.
-When moving the winch ensure that proper rigging is used and do not lift winch over personnel.
-Ensure proper selection and installation of wire rope and sheaves. Sheaves and sheave mounting must be designed and selected in accordance with all applicable standards, codes and regulations. Improper installation of wire rope or sheave can cause uneven spooling and wire rope damage that could cause a load to drop.
-Ensure wire rope is correctly rated for the application.
-Power supplied to the winch must meet Ingersoll Rand specifications for the winch. All connections must be tight and installation made with hoses, cables and fittings that are new or in good condition and rated for the power supplied. Use in a well ventilated area.
-Use a muffler to reduce noise level to acceptable limits. Pipe away the exhaust where possible to prevent oil mist creating a slippery environment.
-Installation personnel should be trained and knowledgeable in winch installation.
•Do not remove or obscure any warning label or tag
-Ensure warning label(s) or tag(s) are visible to the personnel in the area.
-If warning label(s) or tag(s) are damaged, illegible or become lost, contact your nearest distributor or the factory for free replacement.
•Use only approved rigging methods
-Do not make unauthorized modifications.
-Alterations are not permitted to the winch without factory approval.
•Use guards to avoid possible hazards
-Install guards to prevent personnel from contacting any moving parts.
•Ensure an accessible shut off valve has been installed in the air supply line and make others aware of its location
-Always install an emergency shut off switch or valve and instruct all personnel in its location and purpose.
nBefore Operating Winch
•Inspect winch, wire rope and rigging prior to every shift
-These inspections are to identify equipment problems that must be repaired prior to winch use.
-Perform all steps in “Frequent Inspection” procedure described in Product Information Manual supplied with the winch.
-Additionally perform “Periodic Inspection” procedure described in Product Maintenance Manual at recommended frequency based on use conditions.
•Ensure all winch components and attachments are functioning and properly adjusted
-Run winch slowly in each direction with no load and check operation of each attachment or option prior to application use.
•Ensure winch anchors and supporting structure are secure and in good condition
-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.
-Foundation or supporting structure - Check for distortion, wear, rigidity and continued ability to support winch and rated load. Ensure winch is firmly mounted and that fasteners are in good condition and tight.
•Ensure winch supply cables and hoses are in good condition and connections are tight
-Failure of electric cables or their disconnection while power is supplied can result in electrocution.
-Failure of air or hydraulic hoses or their disconnection while pressurized can result in hazardous situations including the whipping of hoses.
-Keep clear of whipping hoses. Shut off the compressed air or hydraulic pressure before approaching the whipping hose.
•Do not operate if malfunctioning or damage is found
-Notify supervisory or maintenance personnel of any malfunction or damage.
-Trained and authorized personnel must determine if repairs are required prior to operating winch.
-Winch should never be operated with damaged wire rope, controls or guards.
•Use caution when operating in extremely cold temperatures
-Extremely cold temperatures can affect performance of some materials. Operate winch with no load to lubricate parts and warm winch prior to applying a load.
-Ensure lubricants or hydraulic oil is suitable for operating temperatures.
-Optional low temperature winches are available. Refer to model number on data (name) plate and winch model code for approved operating temperature ranges.
nWhen Operating Winch
•Do not lift people or loads over people
-These winches are not designed for man lifting applications. Only use man rider rated winches for lifting people.
-Be aware of the location of all other personnel in the job area.
-Cordon off area and install warning signage around lift areas and along intended load paths.
-Never allow anyone to stand under a suspended load.
•Keep hands, clothing, jewelry, etc. away from wire rope, drum and other moving parts
-All moving parts create entanglement, pinching and other hazards.
-Use proper guards to ensure personnel are protected from moving parts.
-Shut off winch and power to the winch before touching any moving part or entering any hazardous area.
•Stop winch before touching wire rope
-Wire rope is an entanglement hazard. Never come in contact with a moving wire rope. It can catch on gloves, clothing, hands and other body parts and pull you into the winch, drum, guard, structure or other hazardous situations.
•Ensure wire rope spools evenly across drum width and each wrap is tight to drum and previous wrap
-Improper spooling can cause wire rope to bunch in one area of the drum.
-Bunched wire rope can build up in one area of the drum and then slide back down the built up wire rope to a smaller drum diameter. This can cause a load to drop.
-Bunched wire rope can build up in one area exceeding the drum flange diameter, climb over the flange and drop the load.
•Ensure tension is applied to wire rope when spooling
-Applying tension will help to facilitate tight spooling and level layers.
-If wire rope is slack when spooled onto the drum it will create gaps between wraps which will cause wire rope damage and erratic load movement.
-Refer to “WIRE ROPE SPOOLING” section on page 7.
•Be aware of load position at all times to avoid moving load into hazardous situations
-Operators must maintain visual contact with the load, drum and wire rope at all times.
-Monitor surrounding conditions to prevent load from contacting hazardous obstructions.
-Use spotters or
•Do not lift or pull load into support structure or winch
-Do not
-The use of limit switches or warning devices will help to prevent load contacting winch or structure.
-Continually monitor wire rope and load movement through all phases of operation.
•Do not run wire rope over sharp edges, use approved diameter sheaves
-Ensure wire rope has a direct path to the load or travels over a sheave or wire rope guide if a direct line cannot be established.
-Ensure sheave diameter is correctly sized for the wire rope in use. Refer to Table 1 on page 10.
-Running wire rope over sharp edges or undersized sheaves will cause premature wire rope failure.
•Ensure load does not exceed winch, wire rope and rigging ratings
-Refer to “SPECIFICATIONS” section in winch Product Information manual for maximum winch load rating.
-Check winch data (name) plate for maximum winch load rating.
-Exceeding the maximum rated winch load can cause winch or rigging failure allowing the load to drop.
-Operator must be aware of weight of load being moved.
•Keep everyone clear of load path
-Do not allow anyone to stand in the path of the load.
-Keep personnel clear of intended load path and the area behind the winch that is in line with the load path. Refer to Dwg. MHP2451 on page 11.
-Ensure there are no obstructions along intended load path that may restrict or affect load movement.
•Keep a minimum of three wraps of wire rope on drum at all times
-Wire rope anchors are not intended to retain the full load. Monitor wire rope payout to ensure 3 wraps are always on the drum.
-Less than 3 wraps may allow wire rope anchor to loosen.
•Immediately stop operation if load does not respond to winch control
-Check direction indicators on control match load direction.
-Ensure all controls function smoothly and do not stick or bind when operated.
-Keep controls dry and clean to avoid hand slippage resulting in loss of winch control.
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