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Winch, Racking Board (EUAB) Product Information Manual

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0% found this document useful (0 votes)
188 views12 pages

Winch, Racking Board (EUAB) Product Information Manual

Uploaded by

Tony
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Product Information

EU AND EUL AIR WINCHES

(Dwg. MHP1234)

Save These Instructions

Form MHD56383
Edition 1
November 2010
43809441
© 2010 Ingersoll-Rand Company
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 MHD56250 Product Maintenance Information Manual MHD56464
Product Parts Information Manual MHD56384

PRODUCT DESCRIPTION
The EU and EUL winches are powered by a radial piston air motor. The output from
the motor is transferred to the drum by the motor shaft. The motor shaft rotates a
series of connected spur gears which form a reduction assembly. Output from the
reduction assembly drives the wire rope drum. Spur gears are not inherently self-
locking as other types of gears are, therefore the brake must be applied whenever
there is a load supported by the load line.

2 Form MHD56383 Edition 1


SPECIFICATIONS
Model Code Explanation
Example: EUAB/PT - P EU AB/PT - P

Model:
EU = 2,000 lbs (908 kg) Winch with standard drum length
EUL = 2,000 lbs (908 kg) Winch with long drum length
Options:
AB = Automatic drum band brake
RC = Remote full flow control
RCAB = Remote full flow control and automatic band brake
PTAB = Remote full flow pendant and automatic band brake
AB/PT = Remote pilot pendant and automatic band brake
AB/PLT = Remote pilot lever throttle and automatic band brake
E = Construction cage
G = Drum guard
J = Air line accessories
L = Extended warranty†
P = Marine 812 Finish†
P1 = Marine 812–X Finish†
W = Client witness of load test†

(1) Remote full flow throttles are provided with 6 feet (2 metres) of hose. Specify hose lengths greater than 6 feet. For lengths greater than 20
feet (6 metres) with the Remote Full Flow Throttle, or 66 feet (20 metres) with the Remote Pilot Lever and Remote Pilot Pendant Throttles
contact your Ingersoll Rand distributor or the factory for control acceptability. Metric lengths are provided for reference only, order lengths
in feet. (Used with Auto Band Brake only.)
(2) RC without AB is for pulling applications only. Do not use for lifting or lowering, as the operator may be too far away to operate a manual
brake.
(3) Free spool clutches are standard on classic winches. A disengaging clutch, however, will not be supplied on units ordered with automatic
brakes (AB).

† Not covered in this manual

Form MHD56383 Edition 1 3


Table 2: Specifications
Rated Operating Pressure 90 psig (6.3 bar)
Air System Consumption Volume
65 scfm 1.8 cu.m/min
(at rated Pressure)
Mid Drum Line Pull 2,000 lbs 907 kgs
Rated Performance
Mid Drum Line Speed 55 fpm 17 m/min
(at rated pressure/volume)
Max Stall Pull - 1st Layer 4,500 lbs 2,041 kgs
Net Weight 310 lbs 141 kgs
Air Motor Pipe Inlet Size 3/4 inch NPT
Air System Hose Size 1 inch 25 mm
Rope Anchor Hole Diameter 9/16 inch 14 mm
Drum Barrel Diameter 6 inches 152.4 mm
Drum Flange Diameter 12.25 inches 311.2 mm
Motor HP 4.4
Drum Length Wire Rope Diameter
Drum Wire Rope Storage Capacity *
in. mm 5/16 in.** 8 mm** 3/8 in. 10 mm 7/16 in. 11 mm
(feet/metres)
4-13/16 97 357 ft 109 m 226 ft 69 m 133 ft 40 m
Recommended safe working load (lbs) ****
Rope Size Breaking strength *** Wt/ft Pulling Lift/Lower
(in.) (lbs) 3.5:1 5.0:1
lbs kg lbs kg lbs kg
5/16 (0.31) 9,160 3,419 0.18 2,617 1,187 1,832 831
7/16 (0.44) 17,780 6,636 0.35 4,500 2,045 3,556 1,613

* Recommended drum working storage capacity is 80% of values shown.


** Recommended wire rope size.
*** Based on improved plow steel wire rope with independent wire rope core.
ASME B30.7 requires a minimum 3.5:1 design factor with 15:1 wire rope pitch diameter to drum diameter for most applications (e.g. pulling/hauling and anchor
****
handling). For lifting and lowering, a 5:1 design factor with an 18:1 wire rope pitch diameter to drum diameter is required.

INSTALLATION
Prior to installing the product, carefully inspect it for possible shipping damage. n EUL Model – Bolt Hole Dimensions
Products are supplied fully lubricated from the factory. Check oil levels and adjust as
necessary before operating product. Refer to “LUBRICATION” on page 7 for
recommended oils and lubrication intervals. Refer to Dwg. MHP2411 on page 9, A. Base Center Line.

CAUTION
n Wire Rope
• Owners and users are advised to examine specific, local or other regulations,
including American Society of Mechanical Engineers (ASME) and/or OSHA CAUTION
Regulations which may apply to a particular type of use of this product before
installing or putting product to use. • 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.
NOTICE • Do not attach a welding electrode to winch or wire rope.
• Install wire rope to come off drum for overwind operation (normal
application).
• Prior to installation refer to Product Safety Information Manual for all
sections of installation.
n Wire Rope Selection

n Mounting 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.
Mount winch with longitudinal center line horizontal and vent cap at top vertical Use a wire rope which provides an adequate safety factor to handle the actual working
center. The winch will not function properly if the longitudinal center line is tilted load and meets all applicable industry, trade association, federal, state and local
more than 10˚ or if winch is rotated so that vent cap is more than 20˚ off top vertical regulations.
center.
When considering wire rope requirements the actual working load must include not
For mounting on a vertical surface or for inverted mounting, the motor case can be only the static or dead load but also loads resulting from acceleration, retardation
rotated on the motor mounting bracket to any one of four different positions. This and shock load. Consideration must also be given to the size of the winch wire rope
feature allows the motor assembly to be positioned with the vent cap on top. To drum, sheaves and method of reeving. Maximum wire rope diameter is limited by the
change the position of the motor assembly, drain the oil from the motor case, unscrew wire rope anchor. It is recommended that wire rope construction be 6 X 19 or 6 X 37
the eight motor case capscrews and rotate the motor assembly to suit the mounting. IWRC right lay. Refer to Table 3 ‘Minimum and Maximum Wire Rope Size’
Ensure clear unrestricted access is always available to control and brake levers. on page 4 for recommended size.

1. Do not weld to any part of winch. Table 3: Minimum and Maximum Wire Rope Size
2. The winch mounting surface must be flat and of sufficient strength to handle the
rated load plus the weight of the winch and attached equipment. An inadequate Minimum Maximum
foundation may cause distortion or twisting of the winch resulting in winch Model
damage. inch mm inch mm
3. Make sure mounting surface is flat to within 1/16 inch (2.0 mm). Shim if EU
necessary. 5/16 8 7/16 11
4. Mounting bolts must be Grade 8 or better. Use self-locking nuts or nuts with EUL
lockwashers.
5. Tighten mounting bolts evenly and torque to specification in torque chart. Refer For winches used in lifting applications, ensure that the top layer of the wire rope
to ‘Torque Chart’ in Product Maintenance Manual. is a distance from the top of the drum flange that is equal to at least twice the
6. Maintain a fleet angle between sheave and winch of no more than 1-1/2°. The diameter of the wire rope. For example: the top layer of a 8 mm wire rope must be at
lead sheave must be on a center line with drum and, for every inch (25 mm) of least 16 mm below the drum flange edge.
drum length, be at least 1.6 feet (0.5 metre) from the drum. Refer to Product
Safety Information Manual.
n Installing Wire Rope
n EU Model – Bolt Hole Dimensions Refer to Dwg. MHP1334 on page 9, A. Wire Rope; B. Setscrew.
1. Cut wire rope to length and fuse end to prevent fraying of strands in accordance
Refer to Dwg. MHP1238 on page 9, A. Base Center Line. with the wire rope manufacturer’s instructions.
2. Feed the fused end of the wire rope into the wire rope anchor hole, past the two
anchor screws, and position the end just beneath the drum surface.

4 Form MHD56383 Edition 1


3. Apply the wire rope so that it winds over the top when the drum is rotated in a
direction that is counterclockwise when facing the motor end of the winch. This NOTICE
is indicated by instruction plate on the gear case.
4. Secure by tightening anchor screws. • When air filter is used ensure it allows air to pass through at products rated
scfm. Refer to “SPECIFICATIONS” on page 3.
CAUTION
n Air Pressure Regulator
• Make sure first wrap of wire rope is tight and lies flush against the drum
flange. If an air pressure regulator is used, install between lubricator and filter.
• The wire rope should be applied to the drum so that it overwinds when the
drum rotates in a clockwise direction when facing the drum end of the winch.
This is indicated by an arrow on the gear case. n Moisture in Air Lines
Moisture that reaches the air motor through air supply lines is a primary factor in
n Safe Wire Rope Handling Procedure 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
- Always use gloves when handling wire rope. before it reaches motor, or an aftercooler at compressor that cools air to condense
- Never use wire rope that is frayed or kinked. and collect moisture prior to distribution through supply lines, are also helpful.
- Never use wire rope as a sling.
- Always ensure wire rope is correctly spooled and the first layer is tight against
drum. n Mufflers
- Always follow wire rope manufacturer’s recommendation on use and
maintenance of wire rope. Ensure mufflers are installed in winch exhaust manifold and control valve exhaust
port. Check mufflers periodically to ensure they are functioning correctly.
n Wire Rope Spooling
n Shut Off Valve
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 Refer to the Product Safety Information Manual for information.
end of the wire rope to eliminate line slack. This helps achieve level winding and
tight spooling.
n Drum Guard
n Rigging
Use of a drum guard is recommended on all winches. Refer to the Product Parts
Make sure all wire rope blocks, tackle and fasteners have a sufficient safety margin Information Manual.
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 Install drum guard and remove the minimum amount of mesh from the guard to
to wire rope manufacturer’s instructions for proper sizing, use and care of wire rope. provide clearance for wire rope travel.

n Safe Installation Procedures WARNING


1. Do not use wire rope as a ground (earth) for welding. • Do not allow wire rope to come into contact with drum guard during winch
2. Do not attach a welding electrode to winch or wire rope. operation. Wire rope could become worn and damaged. Adjust opening in
3. Never run wire rope over a sharp edge. Use a correctly sized sheave. guard to clear wire rope travel angle.
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 the diameter of wire rope. Refer to Dwg.
MHP2449 in Product Safety Information Manual. n Motor
5. Always maintain at least three full, tight wraps of wire rope on drum.
For optimum performance and maximum durability of parts, provide recommended air
supply as measured at motor inlet. Refer to Table 2 ‘Specifications’ on page 4. The air
n Air Supply motor should be installed as near as possible to compressor or air receiver.

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 n Natural Gas Operation (optional feature)
causes of premature motor wear and breakdown. Using an air filter, lubricator and
moisture separator will improve overall product performance and reduce unscheduled
downtime. Refer to Dwg. MHP0191 on page 9, A. Air Out; B. Lubricator; C. WARNING
Regulator; D. Air In; E. Filter.

Refer to Table 2 ‘Specifications’ on page 4 for motor air consumption and rated • Ensure all fittings and connections are tight. Inspect all connections with
operating pressure. If air supply varies from what is recommended, product suitable leak detection equipment.
performance will change. • At first notice of any unusual odors or noticeable leaks, cease winch
operation until source is identified and corrected.
Install air line lubricator, filter and regulator as close as possible to air inlet on motor. • Natural gas exhaust must be piped away from the winch.
Lubricator must be located no more than 10 ft (3 m) from motor.
The winch may be run using natural gas. However, motor and valve modifications are
n Air Lines required for this usage. Refer to Product Parts Information manual for additional
information. Use of natural gas will reduce motor life. Natural gas exhausting from
Inside diameter of air supply lines must not be less than size specified in Table 2 the winch must be piped away.
‘Specifications’ on page 4. Before making final connections, all air supply lines should
be purged with clean, moisture free air or nitrogen before connecting to main air
inlet. Supply lines should be as short and straight as installation conditions will n Initial Winch Operating Checks
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 Winches are tested for proper operation prior to leaving the factory. Before the winch
lines. is placed into service the following initial operating checks should be performed.

n Air Line Lubricator 1. When first running the motor inject a small amount of light oil into the inlet
connection to provide initial lubrication.
Always use an air line lubricator with these motors. The lubricator must have an inlet 2. Check oil level in motor and gear case grease are correct. Top off levels as required
and outlet at least as large as inlet on motor. before operation as described in “LUBRICATION” section on page 7.
3. Operate winch in both directions with no load for one to two minutes.
CAUTION 4. New brake band Lining Run-in Procedure: All new brake band linings require a
‘run-in’ period. Operate the winch without load in the payout direction while
gradually applying the brake. Allow the brake to slip for approximately one
• Lubricator must be located no more than 10 ft (3 m) from motor. minute. Winch motor may stall as drum brake band lining fully engages. Do not
• Shut off air supply before filling air line lubricator. allow brake to overheat.
5. Check operation of brakes. Adjust if necessary as described in “MAINTENANCE”
The air line lubricator should be replenished daily and set to provide 6 to 9 drops per section in the Product Maintenance Information Manual.
minute of ISO VG 32 (SAE 10W) oil. A fine mist will be exhausted from control valve 6. Check operation of limit switches, locking mechanisms and all safety devices
when air line lubricator is functioning properly. when equipped.
7. Check foundation mounting fasteners are secure.
n Air Line Filter 8. Install drum guard when provided.

It is recommended that an air line strainer/filter be installed before the lubricator to For winches that have been in storage, the following start-up procedures are required:
prevent dirt from entering the motor. The strainer/filter should provide 20 micron
filtration and include a moisture trap. Clean the strainer/filter periodically to 1. Give the winch an inspection conforming to requirements of
maintain its operating efficiency. ‘Winches Not in Regular Use’ on page 7.
2. Pour a small amount of ISO VG 32 (SAE 10W) oil in motor inlet port.
3. Operate motor for 15 seconds in both directions to flush out any impurities.
4. The winch is now ready for normal use.

Form MHD56383 Edition 1 5


OPERATION
It is recommended that the user and owner check all appropriate and applicable * For distances greater than 66 feet (20 metres) contact Technical Sales for control
regulations before placing this product into use. Refer to Product Safety Information acceptability.
Manual before operating product.
The four most important aspects of product operation are:

1. Follow all safety instructions when operating the product.


n Winch Brakes
2. Allow only people trained in safety and operation of this winch to operate this
equipment. n Manual Drum Brake (standard)
3. Subject each product to a regular inspection and maintenance procedure.
4. Be aware of product capacity and weight of load at all times. To apply the manual drum brake, rotate the brake lever clockwise. Rotate brake lever
counterclockwise to release. The brake must be kept properly adjusted to hold the
WARNING required load.

• Do not lift loads over people. n Automatic Drum Band Brake (optional feature)
The automatic drum band brake is a spring applied, air released brake which utilizes
NOTICE an air actuated, spring loaded cylinder, that automatically disengages brake when
motor is operated. Air pressure in cylinder overcomes spring pressure to release brake.
• Refer to Product Parts Information Manual for drawings unless specified When control valve is placed in neutral position, air in cylinder is vented and spring
elsewhere. automatically engages brake to prevent drum rotation.

The cylinder brake screw coupling must be kept properly adjusted to hold required
load.
n Winch Controls
The spring loaded, motor mounted, live air manual throttle control valve is supplied NOTICE
as a standard feature on this winch. Optional remote throttle controls are available.
Reference model code on the winch data (name) plate and compare it to • Extended exposure to corrosive atmospheres can cause the band brake lining
“SPECIFICATIONS” on page 3, to determine your configuration. The throttle controls to adhere to the drum. It is recommended when winch is not in operation
provide operator control of motor speed and direction of drum rotation. and in a no load condition that the band brake be left in a released position.

n Winch Mounted Air Throttle (standard) For winches equipped with an automatic brake, always ensure that clutch jaw spacers
are installed.
Refer to MHP3122 on page 9, A. Payout; B. Neutral; C. Haul-in.
The winch control throttle valve is spring loaded, full flow air and mounts to valve
chest on motor. n Free Spool Clutch
When viewed from the air motor end move the control throttle handle to the left
(counterclockwise) to payout wire rope and to the right (clockwise) to haul-in wire WARNING
rope.
• Do not engage clutch when motor is running or drum is spinning, as this
Avoid sudden movements of handle to ensure smooth operation of winch. When produces a severe strain on parts.
released, handle will return to neutral/center position. • Do not disengage clutch when winch is loaded. Be sure clutch is fully engaged
before operating winch.
n Remote Full Flow Air Throttle (optional feature) A jaw type clutch connects the gearing and drum. The function of the clutch is to
disengage the wire rope drum from the motor so that the wire rope can be unwound
Refer to Dwg. MHP3138 on page 10, A. Payout; B. Neutral; C. Haul-in. from the drum by hand without working against the gearing and the compression of
Provides for remote mounting of winch control at a fixed location of up to *15 feet the motor. The clutch is engaged or disengaged by the clutch lever which is located
(4.5 metres) away from the winch. When viewed from the air exhaust end move control on the top of the gear case cover. When clutch is engaged the lever is locked by a
handle to the left (counterclockwise) to payout wire rope and to the right (clockwise) detent to prevent disengagement. Detent is released by pressing down (toward base)
to haul-in wire rope. on lever, after which the end can be swung outward from the winch, disengaging the
clutch jaws. When clutch is in disengaged position it can be engaged by moving end
* For distances greater than 15 feet (4.5 metres) contact Technical Sales for control of lever toward winch. It may be necessary to open the throttle a slight amount to
acceptability. position the jaws for engagement.

n Remote Pilot Pendant Throttle (optional feature) WARNING


Refer to Dwg. MHP2233 on page 10, A. Haul-in; B. Payout. • Do not use free spool clutch feature in combination with automatic brake.
Provides for remote winch control at distances of up to 66 feet* (20 metres) away Use of winches with free spool clutch and automatic brake can result in
from winch. The pilot pendant control throttle is a two function movable control severe injury, death or property damage.
station for winch operation. Pilot pressure from pendant control activates winch
control valve. The winch control valve, located on winch motor, controls motor speed
and direction of drum rotation. Direction of drum rotation is determined by the
pendant lever/button depressed.

INSPECTION
Inspection information is based in part on American Society of Mechanical Engineers
Safety Codes (ASME B30.7).
n Wire Rope Reports
WARNING Records should be maintained as part of a long-term wire rope inspection program.
Records should include the condition of wire rope removed from service. Accurate
• All new or repaired equipment should be inspected and tested by records will establish a relationship between visual observations noted during
Ingersoll Rand trained Technicians to ensure safe operation at rated frequent inspections and the actual condition of wire rope as determined by periodic
specifications before placing equipment in service. inspections.
• Never use a winch that inspection indicates is damaged.
Frequent and periodic inspections should be performed on equipment in regular n Frequent Inspection
service. Frequent inspections are visual examinations performed by operators or
Ingersoll Rand trained Inspectors and include observations made during routine On equipment in regular service, frequent inspections should be made by operators
equipment operation. Periodic inspections are thorough inspections conducted by at the beginning of each shift. In addition, visual and audible inspections should be
Ingersoll Rand trained Technicians. ASME B30.7 states inspection intervals depend conducted during regular operation for indications of damage or evidence of
upon the nature of the critical components of the equipment and the severity of malfunction (such as abnormal noises).
usage. Refer to “Inspection Classifications” chart and “Maintenance Intervals” chart
in Product Maintenance Information Manual for recommended maintenance intervals. Disassembly may be required as a result of frequent inspection findings or in order
Careful inspection on a regular basis will reveal potentially dangerous conditions to properly inspect the individual components. Disassembly steps are described in the
while still in the early stages, allowing corrective action to be taken before the Product Maintenance Information Manual.
condition becomes dangerous.
1. Surrounding Area. Visually check for winch oil leaks. Do not operate winch if
Deficiencies revealed through inspection, or noted during operation, must be reported leaking oil is found. Ensure surrounding area has no slippery surfaces and is
to designated personnel to ensure corrective action is taken. obstruction free.
2. Hoses and Fittings. Visually inspect for damage, air leaks and loose connections.
A determination as to whether a condition constitutes a safety hazard(s) must be Repair all leaks or damage and tighten loose connections prior to starting daily
decided, and the correction of noted safety hazard(s) accomplished and documented tasks.
by written report before placing the equipment in service.

6 Form MHD56383 Edition 1


3. Muffler. Visually check for restrictions or external damage. Clear restrictions or 13. Lubrication. Refer to “LUBRICATION” on page 7 for recommended procedures
replace if damaged. and lubricants.
4. Manual Shut-Off Valve. Test shut-off valve to ensure proper operation and free 14. Labels and Tags: Check for presence and legibility of labels. Refer to Product
movement. Parts Information Manual for correct labels and placement. Replace if damaged
5. Guards. Verify wire rope does not contact guard during winch operation and that or missing.
guards are secure and undamaged.
6. Winch. Visually inspect winch housings, control(s), external brake 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
n Winches Not in Regular Use
Technician.
7. Winch Operation. Power winch in both directions. Winch must operate smoothly 1. Equipment which has been idle for a period of one month or more, but less than
without sticking, binding or abnormal noises and have minimal vibration. six months, shall be given an inspection conforming to the requirements of
8. Pendant (optional feature). Ensure operation of pendant levers is smooth and ‘Frequent Inspection’ on page 6 before being placed in service.
2. Equipment which has been idle for a period of over six months shall be given a
winch is responsive to pendant control. Pendant levers must spring return to the complete inspection conforming with the requirements of ‘Periodic Inspection’
neutral position when released. before being placed in service. Refer to Product Maintenance Information Manual.
9. Manual Throttle Lever. Ensure operation of manual throttle lever is smooth and 3. Standby equipment shall be inspected at least semi-annually in accordance with
winch is responsive to lever movement. Lever must return to neutral. If winch the requirements of ‘Frequent Inspection’ on page 6.
responds slowly or controls stick, do not operate winch until all problems have 4. All oils must be drained and replaced with new, and all grease cavities shall be
been corrected. packed to the prescribed limit. Refer to “LUBRICATION” section on page 7.
Product must be operated for at least 15 seconds in both directions with well
NOTICE lubricated, dry air.
• The full extent of wire rope wear cannot be determined by visual inspection.
At any indication of wear inspect wire rope in accordance with instructions
in “Periodic Inspection.” Refer to Product Maintenance Information Manual. n Storing the Winch
10. Wire Rope. Visually inspect all wire rope expected to be in use during the day’s 1. Always store the winch in a no load condition.
operations. Inspect for wear and damage indicated by distortion of wire rope such 2. Wipe off all dirt and water.
as kinking, “birdcaging,” core protrusion, main strand displacement, corrosion, 3. To prevent rust buildup from internal condensation, open lubricator to allow more
broken or cut strands. If damage is evident, do not operate winch until the oil into winch and operate with no load. If winch is being stored from air source
discrepancies have been reviewed and inspected further by personnel place small amount of 20 weight oil at air inlet port.
knowledgeable on wire rope safety and maintenance procedures. 4. Oil the wire rope.
11. Wire Rope Spooling. Visually check reeving and ensure wire rope feeds on and 5. Place in a dry location.
off the drum smoothly. Verify spooling direction (overwind or underwind) is 6. Before returning winch to service, follow instructions for ‘Winches Not in Regular
correct for winch and application. Use’ in the “INSPECTION” section on page 6.
12. Brake(s). Lift and lower the load a short distance to test brake(s). Brake(s) must 7. Mufflers and Breathers. All mufflers and breathers must be removed and replaced
hold load without slipping. Automatic brake must release when winch control with threaded plugs to prevent dust and moisture from entering motor and valve
throttle is operated. If brake(s) do not hold load or do not release properly, they assemblies.
must be adjusted or repaired. 8. Drum Brake. Product equipped with a manual band brake must be stored with
the brake in its disengaged position.
WARNING
• Worn or improperly functioning brakes may cause excessive heat buildup and
sparks.

LUBRICATION
To ensure continued satisfactory operation of the winch, all points requiring
lubrication must be serviced with the correct lubricant at the proper time interval as
indicated for each assembly. n Recommended Lubricants
Refer to ‘Maintenance Interval’ chart in Product Maintenance Information Manual for Table 5: Ingersoll Rand Lubricants
recommended lubrication intervals. Use only those lubricants recommended. Other
lubricants may affect product performance. Approval for use of other lubricants must Where Used Size Part Number
be obtained from your Ingersoll Rand distributor. Failure to observe this precaution Wire Rope 16 oz Lubri-Link-Green®
may result in damage to winch and/or its associated components.
Bearings and Gear Case 1 lb 70 1 LB
Table 4: Lubrication Intervals Air Line Lubricator 1 Qt 29665
Component Interval
Table 6: Air Motor Recommended Lubricant Grade
Check Air Line Lubricator
Daily Temperature Grade Type
Check Motor Oil Level
Below 32° F (0° C) ISO VG 32 (SAE 10W)
Check Gear Case Grease Weekly
Change Motor Oil 32° to 80° F (0° to 27° C) ISO VG 68 (SAE 20W)
1 year or 1000 hours of winch operation
Change Gearbox Grease Above 80° F (27° C) ISO VG 100 (SAE 30W) *
* Units shipped from factory with this lubricant.

n General Lubrication Table 7: Recommended Grease Grade


Correct lubrication is one of the most important factors in maintaining efficient Temperature Grade Type
product operation.
-20° to 50° F (-30° to 10° C) EP 1 multipurpose lithium based grease
1. The recommended grade of oil must be used at all times. Use of unsuitable oil 30° to 120° F (-1° to 49° C) EP 2 multipurpose lithium based grease
may result in excessive temperature rise, loss of efficiency and possible damage
to lubricated components. Refer to ‘Recommended Lubricants’ section
on page 7. Note: Units are shipped from factory with EP 2 grease.
2. It is recommend that the first oil change be done after approximately 50 hours
of initial operation. Thereafter, drain and replace oil according to Table 4 n Motor
‘Lubrication Intervals’ on page 7.
3. Always inspect removed oil for evidence of internal damage or contamination
(metal shavings, dirt, water, etc.). If indications of damage are noted, investigate CAUTION
and correct before returning winch to service.
4. After product operation, allow oil to settle before topping off. • Do not use synthetic or detergent lubricants in air motor. Synthetic lubricants
5. Always collect lubricants in suitable containers and dispose of in an will result in oil blowing by piston rings.
environmentally safe manner.
The motor is splash lubricated by oil in motor housing and has no other means of
WARNING lubrication. It is therefore important to use only good quality, non-detergent motor
oil to ensure maximum performance and minimum downtime for repairs. Refer to
• Pneumatic products use oil to prevent excessive heat buildup and to prevent ‘Recommended Lubricants’ on page 7.
wear that could cause sparks. Oil levels must be properly maintained.
Add oil through filler opening until oil flows from level plug hole. Add oil slowly to
prevent spilling. Refer to Table 8 ‘Motor Oil Capacity’ on page 8.

Form MHD56383 Edition 1 7


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 the end of shift for water to separate from oil
but not long enough for it to freeze. Drain water then refill to level plug, located on
side of motor housing. If desired, all oil may be drained at end of shift and motor
refilled with new oil.

Table 8: Motor Oil Capacity


Capacity
pints litres
3 1.44

n Gear Case
Check grease in gear chamber weekly by removing lower grease plug in gear case
cover. If grease is below this opening, remove grease plug from top of gear case cover
and add a sufficient quantity to bring grease level in chamber up to the side opening.

n Seals and Bearings


If product is disassembled, clean all parts thoroughly and coat bearings and seals
with clean grease. Refer to ‘Recommended Lubricants’ section on page 7. Use
sufficient grease to provide a good protective coat. Lubricate grease fittings monthly
with 2 or 3 pumps of a grease gun.

n Wire Rope
Follow the 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 the surface of the wire rope.

CAUTION
• Do NOT use an acid-based solvent. Only use cleaning fluids specified by the
wire rope manufacturer.
2. Apply a wire rope lubricant, Ingersoll Rand LUBRI-LINK-GREEN® or ISO VG 100
(SAE 30W) grade oil.
3. Brush, drip or spray lubricant weekly, or more frequently, depending on severity
of service.

n Natural Gas Lubrication


CAUTION
• Use of other than PAG Synthetic oils can cause premature seal failure, which
could cause damage to the motor. Refer to caution label part number
71470744.

8 Form MHD56383 Edition 1


PRODUCT INFORMATION GRAPHICS
EU Model - Bolt Hole Dimensions
A
A Base Air Out
Center C
Line Regulator
D=13/16 in.
45-1/4° (20 mm) x 4 holes

R=5-5/8 in. Air In


(143 mm) 1-1/4 in. (32 mm)
7 Tap 1-3/8 in.
(35 mm) deep
B
Lubricator E
R=6-1/2 in.
(165 mm) Filter

1 in. (25 mm) (Dwg. MHP0191)

(Dwg. MHP1238)
B C
EUL Model - Bolt Hole Dimensions
Neutral Haul-In
A
A Payout
Base Center
Line
D=0.8125 in.
4 in. (102 mm) (21 mm)
8 holes
3.75 in.
(95 mm)

7.094 in.
(180 mm)

9.160 in. 3.977 in.


(233 mm) (101 mm)

4.5 in. (114 mm)

(Dwg. MHP2411)

A (Dwg. MHP3122)
Wire Rope

Setscrews
B

(Dwg. MHP1334)

Form MHD56383 Edition 1 9


PRODUCT INFORMATION GRAPHICS (CONTINUED)

(Dwg. MHP2233)

C B
Haul-In Neutral
A
Payout

(Dwg. MHP3138)

10 Form MHD56383 Edition 1


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

If any Product proves defective within its original one-year warranty period, it should Fulcrum series electric winch, product code 405-002: 2 year warranty.
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 Winch and Hoist Solutions Extended Warranty This option provides a price for
IR has determined to have been misused or abused, improperly maintained by the extending the Ingersoll Rand Winch and Hoist Solutions Warranty from the standard
user, or where the malfunction or defect can be attributed to the use of non-genuine one (1) year to two (2) years from the date of purchase. All other provisions of the
IR repair parts. standard warranty to remain in effect.

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

Form MHD56383 Edition 1 11


www.ingersollrandproducts.com

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