1. Procedures and Practices Air Hoist Air Hose
Morgan City Rentals
Procedures and Practices
Air Hoist
Air Hose

2. Main Service Areas of the Hoist
Throttle Handle
Forward / Reverse
Brake Handle
Throttle Valve
Brake Adjustment Screw
Motor End Fill Plug
Gear End Fill Plug
Motor End Drain Plug
Gear End Drain Plug
Skid Mounting Bolts

3. Practices and Procedures These practices and procedures have been prepared to provide the end user with basic operating practices. This program does not include all safe working practices required in specific lifting situations. The information is based on quality control procedures set by Morgan City Rentals and should be performed by trained and experienced personnel.
Always maintain and operate winch in accordance with ANSI B30.9 safety code
Allow qualified, through training, personnel to operate winch
Subject winch to regular inspection and maintenance
Operator must understand proper methods of hitching loads
Operator should have a knowledge of attitude regarding safety
Operator should not operate under unsafe conditions
Winches are not to be used for lifting or lowering personnel

4. Hoist Inspection Procedures
Adhered to, recorded by, and directed by a qualified person
Inspections done at the beginning of each shift or job
Items to be checked should included:
Lubrication
Brakes
Wire Rope and Hooks or End Connections
Hoses, Connections, Brake Handle, Throttle Handle
Mounts (motor, bolts, and skid)
Anchor screws are NOT designed or intended
to hold any load/ weight

5. Air Hoist Inspection Frequencies
Two classifications of Inspections
Frequently - Periodically
Frequently inspections are made by a qualified person to determine the degree of exposure to wear, deterioration, or malfunction within respected intervals.
Normal Service – monthly
Heavy Service – weekly to monthly
Severe Service – daily to weekly
Periodically inspections are made to record external conditions to provide the basis for a continuing evaluation.
Normal Service – equipment in place - yearly
Heavy Service – equipment in place - yearly
Severe Service – equipment in place - quarterly

6. Hoist Maintenance Procedures
Lubrication
Check oil daily and maintain proper levels
Secure drain plugs and vent cap
Drain oil regularly and replace
Water will accumulate and cause blow-by
Hose and Connections
Use proper air hose connections and hose safety clamp -1” crowfoot with safety clamp
Smaller hose and fittings will reduce efficiency of the winch
For top performance operate winch at 90 psig (6.2 bar/620 kPa) air pressure
Gear Lubrication
Should be done every 60 – 90 days
Inspect gear end for sufficient signs of lubrication
Add No. 1 grade gear grease to the grease plug
Mounting
Mount drum so that the axis of drum is horizontal and vent cap is not more than 15 degrees off of top vertical
Check mounting bolts and base plate before executing a lift

7. Air Hoist Pre Lift Operational Test
All test should be done by
trained qualified person
Visually inspect hoist before lift and prepare a JSA with consideration to the following items:
Operator Qualifications
Cargo weights
Lifting, lowering, swing, and lift path
Containment and spill potential
Weight capacity limitations of hoist
Weather and site conditions
Operation of clutches, brakes, and paws
Locking safety devices
Wire rope is correctly rated for hoist
Sheaves, and application
Wire rope anchor screw on drum
Stability and anchor points of hoist
Read all warning information on hoist
BU7A 1K Hoist
K5UL 6 K Hoist
22 K IR Hoist

8. Air Hoist Safe Operating Instructions
Before Each Daily Use of the Hoist
Start each use of hoist as if it is the first task of the job. Never assume that the hoist is ready for use before YOU do your INSPECTION
Review the troubleshooting guide on common winch symptoms , probable causes and remedies
Check all air hoses connections and do a pre-start inspection on the power source (air compressor)
Make sure air supply is clean and free from moisture
Check air hoist position and mounting to surface before use
Conduct a detail inspection all components (brake lining and handle) and moving parts on hoist before using hoist.
Make sure at least 3 wraps of wire are on the drum before use and never have less than three wraps at all times
Inspect wire and verify wire rope diameter to match load
Make sure PPE is worn during operations
CAUTION –
Never perform maintenance while the hoist is under a load. Disconnect all air lines and tag before maintenance. Air exhaust from the motor can cause debris to fly.

9. Air Hoist Safe Operating Instructions
Never lift a load of unknown weight or weight greater than winch capacity
Never use winch rope as a sling
Always stand clear of load and never carry load over people
Insure clutch is fully engaged and do not disengage clutch with load
Do not “side pull” or “yard” hoist
Do not operate with kinked, twisted, or damaged wire
Make sure wire winds properly on drum
Standard Formula is 20 times winch diameter for self winding
Ease slack out of wire when starting a lift. Do not jerk or yank the load
Be sure no objects are in the way of load
Always test winch to MAX capacity with dead pull to check rigging and winch mount tie downs
Avoid shock loads
Any product will break if abused, misused, overused, or not maintained properly
Shut off air supply when winch is left unattended
Be certain that load is seated in the saddle of the hook
Do not divert attention away from a suspended load
Do not use winch as a ground for welding or attach a welding electrode to winch or sling
Do not leave load suspended for an extended period of time-never unattended
Always check brake and lubrication before lift
Never - ever do anything you believe to be unsafe
Do not swing a suspended load
If communication is lost with the operator “All Stop”
If unsure of directions given, “ All Stop”
Operator can “STOP” lift at anytime if he feels that it is unsafe
Attachments must have the same working load as wire and hoist (clips, hooks, shackles)

10. Air Hoist Safe Operating Instructions
When paying out ensure wire is:
Is smoothly paying out and drum is not over running the wire rope, causing a slack wire rope condition
Wire is seated in all sheaves and sheaves are rotating with wire rope
Not making any unusual noises (snapping or popping)
Not damaged or worn
Kept under tension to prevent loose wraps
Properly ensure in anchor screws and no less than three wraps on the drum
When hauling-in ensure that wire rope is:
Tightly wound on drum – use tension to keep wraps tight
Spool onto drum evenly with no overlapping
Wire is seated in all sheaves and sheaves are rotating with wire rope

11. Air Hoist Information Chart
For top performance and maximum durability, operate this winch at 90 psi (6.2 bar/620 kPa) of air pressure

12. Morgan City Rentals Air Hoist
6,250 lbs. Man-Rider Air Hoist
Model FA525 MR
22,000 lbs. Air Hoist
Model FA10140
Make sure the right hoist is selected for the JOB!

13. Morgan City Rentals 28 K Air Hoist Capacities
AW4A-40
28,000 lbs.

14. Air Hoist Models Wire Capacities

15. Air Hoist Models Wire Capacities
Never exceed working load limit
Keep out from under a raised load
Avoid Shock Loads
Inspect hoist regularly
Service regularly

16. Wire Rope Spooling Criteria
When reeling wire rope from one reel to another, it is preferable for the rope to travel from top to top
Hoist should be spooled with the recommended wire rope size. Ensure tension is applied to wire rope when spooling onto drum (approximately 10% of working load is recommended.
Cutting and seizing wire rope – should be properly seized on both sides of the cut, if not wire will unravel. Use proper PPE when working with wire
Do not install wire that has been overloaded or stretched
Make sure wire is properly attached to the drum with the set screws. Wire rope anchors are not intended to retain the full load. Ensure three wraps of wire are always on the drum. Less than three wraps will allow rope anchors to loosen.
Keep tension on the wire while spooling on drum and guide each wire close to the preceding wrap
After installation, allow wire to run through a cycle of operation at low speed

17. ANSI ASME B 30.9 Safety Code Section 9-2.1: Construction
Wire Rope Material
The wire rope slings covered by this Chapter shall be as specified in Tables 4 through 11 based upon nominal wire rope strength as shown in Federal Specification RR-W-410 and Military Specification MIL-W (except for fatigue requirements which are not applicable to sling usage). Grades, types, sizes, and constructions other than those specified in Tables 4 through 11 may be used. When such slings are used, the sling manufacturer shall be consulted for specific data.
Minimum Sling Length
(a) Slings made of rope with 6 x 19 and 6 x 37 classification, and cable laid slings shall have a minimum clear length of rope 10 times the rope diameter between splices, sleeves, or end fittings.
(b) Braided slings shall have a minimum clear length of rope 40 times the component (individual) rope diameter between the loops or end fittings.
(c) Grommets and endless slings shall have a minimum circumferential length of 96 times the body diameter of the grommet or endless sling.
All swaged-socket and poured-socket assemblies shall be proof tested to the wire rope or fitting manufacturers recommendations but in no case greater than 50% of the component wire ropes' or structural strands' nominal strength. All other assemblies shall be proof tested when specified by the purchaser. The proof load for swaged-socket and poured-socket assemblies shall be a minimum of two times the vertical hitch rated load but shall not exceed 2.5 times the vertical hitch rated load.
The proof load for single leg hand tucked slings shall be a minimum of the vertical hitch rated load and shall not exceed 1.25 times the vertical hitch rated load.
The proof load for mechanical splice single leg slings and endless slings shall be two times the vertical hitch rated load.
The proof load for multiple leg bridle slings shall be applied to the individual legs and shall be either 1.25, for hand tucked splice, or 2, for mechanical splice, times the vertical
hitch rated load of a single leg sling of the same size, grade, and construction of rope. Any master link to which multiple leg slings are connected shall be proof loaded to two times the force applied by the combined legs.

18. ANSI ASME B 30.9 Safety Code Section 9-2.5: Sling Identification
Marking Requirements. Each sling shall be marked to show:
(a) name or trademark of manufacturer,
(b) rated load for the type of hitch(es), and the angle upon which it is based,
(c) diameter or size
Sling identification shall be done by the sling manufacturer.
Maintenance of Sling Identification.
Sling identification should be maintained by the user so as to be legible during the life of the sling.  
Section 9-2.6: Effects of Environment
Fiber core wire rope slings of all grades shall not be exposed to temperatures in excess of 180 °F (82°C).
When wire rope slings of any grade are to be used at temperatures above 400°F (204°C) or below -60 °F ( -51°C), the sling manufacturer should be consulted.
The strength of slings can be affected by chemically active environments as sling materials may be susceptible to damage from caustic or acid substances or fumes; strongly oxidizing environments attack all common sling materials. The sling manufacturer should therefore be consulted before slings are used in chemically active environments.
Section 9-2.7: End Attachments
All load bearing components welded prior to or after assembly in the sling shall be proof tested.
Welding of handles or any other accessories to end attachments, except covers to thimbles, shall be performed prior to the assembly of the sling.
Knots. Eyes in wire rope slings shall not be formed using knots.
Wire Rope Clips and Hooks
Wire rope clips shall not be used to fabricate wire rope slings except where the application of slings prevents the use of prefabricated slings or where the specific application is designed by a qualified person.
Slings made with wire rope clips should not be used as a choker hitch.
Wire rope clips shall be drop-forged steel of the single saddle (U-bolt) or double saddle type clip. Malleable cast iron clips shall not be used. For spacing, number of clips, and torque values, refer to the clip manufacturer's recommendation.

19. Air Hose - Safe Practices
All hose assemblies should be viewed as potential hazards. This document is designed to inform and educate anyone who manufactures, specifies, supplies, purchases, assembles, uses, maintains or tests any hose assemblies or its component parts. The proper selection and maintenance of hose, couplings, attachment devices and accessories are imperative.
It is the end users responsibility to identify to the distributor the application and any special conditions that the hose assembly must meet. It is the distributors responsibility to supply the proper assembly for the intended application. Accidents and down time may occur if hose assemblies are not properly selected for the specific application.
The performance and safety of the assembly is affected by the quality of the individual components. The use of the acronym
S.T.A.M.P.E.D. (Size, Temperature, Application, Media, Pressure, Ends) will help in the proper selection of the hose assembly components.
Failure to use these procedures can result in serious injury and destruction of property and equipment.     
When fabricating and specifying hose assemblies ask the following questions:
Size: What is the I.D. (Inside Diameter) of the hose? What is the O.D. (Outside Diameter) of both ends of the hose? What is the overall length of the assembly required?
Temperature: What is the temperature range of the media (product) that is flowing through the hose assembly? What is the temperature range of the environment that surrounds the outside of the hose assembly?
Application: How is the hose assembly actually being used? Is it a pressure application? Is it a vacuum (suction) application? Is it a gravity flow application? Are there any special requirements that the hose assembly is expected to perform? Is the hose being used in a horizontal or vertical position? Are there any pulsations or vibrations acting on the hose assembly?
Media: What is the media/material that is flowing through the hose assembly? Being specific is critical. Check for: Abrasive materials, chemical compatibility, etc.
Pressure: What is the maximum pressure including surges (or, maximum vacuum) that this hose assembly will be subjected to? Always rate the maximum working pressure of your hose assembly by the lowest rated component in the system.
Ends: What couplings have been requested by the user? Are they the proper fittings for the application and hose selected?
Hose assemblies must be inspected prior to each use. Worn out fittings, attachment devices, hose and accessory items must be replaced. Retaining devices (safety devices) such as clips, cables or chains must be used. Clamps must be checked regularly to the specified torque found in the Dixon literature. Under no circumstance should any coupling be disconnected while under pressure unless the coupling is specifically designed to do so. Disconnecting couplings under pressure could result in serious injury or death, and destruction to property and equipment.

20. Air Hose Safe Practices
Before attempting to disconnect the hose from the air line, the air should be cut off. Store hose coils off the floor promptly after use. A safety-check valve installed in the air line at the manifold will stop the air supply automatically if a line break occurs. A short chain fastened to the hose and to the tool housing can keep the hose from thrashing about if a coupling breaks
Check to be sure the air hose is in good condition. Air hoses are designed to withstand pressure, but they become weakened at points where they have been bent, where they are attached to the shutoff valve and to the nozzle, and where they have been kinked. These weak points may swell like a balloon and burst, throwing pieces of hose in every direction.
Always coiling the hose without kinks -- and hanging it over a broad support, not over a hook, nail, or angle iron when it is not in use.
Air hoses
An air hose presents the same tripping or stumbling hazard as cords on electric tools. Persons or materials accidentally hitting the hose may unbalance the operator or cause the tool to fall from an overhead place;
Air hoses should be protected from trucks and pedestrians by runways or planks laid on either side of the hose;
Do not disconnect an air hose from the tool being used, and use that air hose for cleaning purposes;
Air should be cut off before attempting to disconnect the air hose from the line. Air pressure in the hose should also be cleared before disconnecting;
Eye protection is required when operating air power tools. (See OP-G-1.3.2);
Safety-check valves are recommended to automatically shut off air supply if a crack or leak occurs.

21. Air Hoists operating
in the Gulf of Mexico