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PARTS, OPERATION AND MAINTENANCE MANUAL
THIRD GENERATION
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance infor-
mation. Make this manual available to all persons responsible for the
operation, installation and maintenance of these products.
These instructions apply only to winches designed by Ingersoll-Rand that are identified for
personnel lifting by a permanent nameplate attached to the winch at the factory.
Always operate, inspect and maintain this winch in accordance with American National
Standards Institute Safety Code (ASME B30.7) and any other applicable safety codes and
regulations.
Refer all communications to the nearest Ingersoll-Rand Material Handling Office or
Distributor.
Form MHD56115
Edition 1
October 1997
71300248
© 1997 Ingersoll-Rand Company
MODEL FA5A-MR
ManRider
1
Form MHD56115
®
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Summarization of Contents
SAFETY INFORMATION
Danger, Warning, Caution and Notice
Explanation of hazard signal words (Danger, Warning, Caution, Notice) and their meanings.
Safety Summary
Key safety points for supporting structures and load-attaching devices, customer responsibilities.
GENERAL INFORMATION
Man-Rider® Winch Approvals and Limitations
Details on type approvals, regulatory bodies, and conditions for personnel lifting use.
SAFE WINCH OPERATING INSTRUCTIONS
Man-Rider Operating Instructions
Specific safety guidelines for personnel lifting operations, including operator duties and system checks.
General Operating Instructions
General safe practices to avoid injury during winch operation, covering load limits and moving parts.
SPECIFICATIONS
Model Code Explanation
Breakdown of model number designations and their meanings for configuration options.
OPERATION
Initial Winch Operating Checks
Pre-operation checks before putting the winch into service, including lubrication and functional tests.
Winch Controls
Descriptions of throttle and pendant control operations for motor speed and direction.
INSPECTION
Frequent Inspection
Daily visual checks for winch components, wire rope, air system, and brakes.
Periodic Inspection
In-depth inspections conducted at regular intervals, covering all major components and structure.
LUBRICATION
Reduction Gear and Disc Brake Lubrication
Procedures for lubricating the reduction gear and disc brake, including oil types and intervals.
MAINTENANCE
Adjustments
Procedures for adjusting winch brake systems, including manual and automatic drum band brakes.
DISASSEMBLY
Motor Disassembly
Specific steps for disassembling the air motor, including cylinder heads, pistons, and crankshaft.
Disc Brake Disassembly
Steps for taking apart the disc brake assembly, including springs, plates, and sprag clutch.
ASSEMBLY
Motor Assembly
Step-by-step instructions for reassembling the motor, including pistons, liners, and crank assembly.
Winch Assembly
Instructions for reassembling the main winch components, including uprights, drum, and brakes.
TESTING
Operational Test
Procedures for testing the winch before initial use, covering oil levels and brake operation.
Load Test
Guidelines for performing a load test on the winch, specifying test loads and conditions.
PARTS ORDERING INFORMATION
Return Goods Policy
Guidelines for returning products for warranty or service, including authorization requirements.
WARRANTY
HOIST AND WINCH LIMITED WARRANTY
Terms and conditions of the product warranty, covering defects and limitations.
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