Maintenance Product Information · Refer to the Product Information Manual and Product Parts...

ProductMaintenanceInformation

ModelFA10i

(Dwg. MHP2947)

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Form MHD56401Edition 2November 200745878600© 2007 Ingersoll Rand Company

Only allow Ingersoll Rand trained technicians to perform maintenance on this product. For additional information contact Ingersoll Rand Factory ornearest Distributor.For additional supporting documentation refer to Table 1 ‘Product Information Manuals’ on page 2.Manuals can be downloaded from www.winchandhoistsolutions.com.The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and may invalidate allwarranties.The original language of this manual is English.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 (Non-Man Rider) MHD56250 Product Parts Information Manual MHD56400

Product Safety Information Manual (Man Rider) MHD56251 Product Information Manual MHD56399

INSPECTION

Frequent inspections should be performed on equipment in regular service. Refer toProduct Information Manual.

n Periodic InspectionRefer to Table 2 ‘Inspection Classifications’ on page 2 for suggested winchinspection classifications for Periodic Inspection intervals. Select conditions mostappropriate to application.

Table 2: Inspection Classifications

Conditions Normal Heavy Severe

Typical Use (operating time) Infrequent Regular Continual/Constant

Load Range 60% of Capacity 75% of Times Used 80% of Capacity 75% of Times Used 100% of Capacity 75% of Times Used

Installation Protected/Enclosed/Dry Not Sheltered/Exterior Full Exposure

Atmosphere Clean/Non-Corrosive Dirty/Non-Corrosive/Freshwater Marine Dirty/Corrosive/Saltwater Marine

Climate Dry/Stable Temperature Wet/Moderate Temperature Fluctuations Wet/Severe Temperature Fluctuations

Maintain written records of periodic inspections to provide an accumulative basis forcontinuing evaluation. Inspect all items listed in the ‘Frequent Inspection’ section ofthe Product Information Manual. Also inspect the following at the suggested intervalsrecommended in Table 3 ‘Maintenance Interval Chart’ on page 3:1. Siderails and Uprights. Check for deformed, cracked or corroded main

components. Replace damaged parts.2. Fasteners. Check retainer rings, 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 the diameter of the wire rope from crown-

to-crown throughout the life of the wire rope. Recording of the actualdiameter should only be done with the wire rope under equivalent loadingand in the same operating section as accomplished during previousinspections. If the actual diameter of the wire rope has decreased more than1/64 inch (0.4 mm) a thorough examination of the wire rope should beconducted by an experienced inspector to determine the suitability of thewire rope to remain in service. Refer to Dwg. MHP0056 on page 2.

5. All Components. Inspect for wear, damage, distortion, deformation andcleanliness. If external evidence indicates damage, disassemble as required toconduct a detailed inspection. Inspect gears, shafts, bearings, sheaves, springsand covers. Replace worn or damaged parts. Clean, lubricate and reassemble.

6. Brakes. Individually test brakes installed to ensure proper operation. Brakes musthold a 125% rated load at mid drum without slipping. If indicated by pooroperation or visual damage, disassemble and repair brake(s). Check all brakesurfaces for wear, deformation or foreign deposits. Clean and replace componentsas necessary. Adjustments can be made to the band brake to compensate fornormal brake lining wear. Refer to ‘Adjustments ’ on page 6. If brake bandcannot be adjusted to hold rated load, replace the brake band assembly.Adjustments cannot be made to the disc brake. The disc brake must be repairedas described in “MAINTENANCE” on page 6.

7. Foundation or Supporting Structure. Check for distortion, wear and continuedability to support winch and rated load. Ensure winch is firmly mounted and thatfasteners are in good condition and tight.

8. Labels and Tags. Check for presence and legibility of labels. Replace if damagedor missing.

9. Limit Switches (optional feature). Operate winch in both directions to activatelimit switches. Limit switches should engage (stop winch operation) atestablished settings (+/- 2 feet [+/- 0.6 metres]). Reset limit switch by operatingwinch in opposite direction. Refer to ‘Limit Switch Adjustment’ procedure inProduct Information Manual.

10. Winch Guard (optional feature). Verify fasteners are tight and in goodcondition. Ensure guard is in good condition and panels are correctly positioned.

11. Emergency Stop Valve (optional feature). During winch operation verify theemergency stop valve operation. Valve must stop winch operation quickly. Valvemust reset properly. Refer to ‘Emergency Stop Valve’ in the “OPERATION” sectionin Product Information Manual for procedures.

12. Overload Device (optional feature). Ensure overload device is properly set tostop the winch when loads exceed 150% (+/- 25%) of winch rated capacity. Ifwinch does not shut down, contact your distributor or the factory for repairinformation.

(Dwg. MHP0056)

13. Press Roller (optional feature). Inspect rollers for wear and grooves. Ensurerollers freely rotate. Replace rollers if worn or grooved. Replace bearings ifrotation is rough or stiff.

n Records and ReportsInspection records, listing all points requiring periodic inspection should bemaintained for all load bearing equipment. Written reports, based on severity ofservice, should be made on the condition of critical parts as a method of documentingperiodic inspections. These reports should be dated, signed by the person whoperformed the inspection, and kept on file where they are readily available for review.

n Maintenance IntervalsRefer to ‘Periodic Inspection’ on page 2 and Table 2 ‘Inspection Classifications’ onpage 2 for maintenance interval guidance.

2 Form MHD56401 Edition 2

http://www.winchandhoistsolutions.com

Table 3: Maintenance Interval Chart

Normal ApplicationThe following work can be completed by owner maintenance personnel

System Air Filter Inspect system air filter every 45 days or 150 hours

Grease Fittings Lubricate grease fittings every 180 days or 500 hours

Gearbox Oil Level Check oil level in gearbox every 120 days or 340 hours

It is recommended that the following work be completed by an Ingersoll Rand trained service technician.

Standard Components 1 year or1,000 hrs

2 years or2,000 hrs

3 years or3,000 hrs

5 years or5,000 hrs

6 years or6,000 hrs

9 years or9,000 hrs

12 years or12,000 hrs

Inspect Motor X X X X

Inspect Manual Band Brake X X X X X X X

Inspect Disc Brake X X X

Inspect Gearbox X X X

Replace Winch Anchor Bolts X X X X

Rebuild Control Valve X X X X

Inspect Drum, Housings and Main Frames X X X

Optional Components

Emergency Shut-Off Valve X X X X X X X

Overload Device X X X X

Limit Switches X X X X X X X

Automatic Band Brake X X X X

Heavy ApplicationThe following work can be completed by owner maintenance personnel






2 years or2,000 hrs

3 years or3,000 hrs

5 years or5,000 hrs

6 years or6,000 hrs

8 years or8,000 hrs

10 years or10,000 hrs

Inspect Motor X X X


Inspect Disc Brake X X X


Replace Winch Anchor Bolts X X X

Rebuild Control Valve X X X

Inspect Drum, Housings and Main Frames X X X

Optional Components


Overload Device X X X X X



Severe ApplicationThe following work can be completed by owner maintenance personnel




Manual Band Brake Check band brake adjustment every 90 days or 250 hours



2 years or2,000 hrs

3 years or3,000 hrs

4 years or4,000 hrs

5 years or5,000 hrs

6 years or6,000 hrs

8 years or8,000 hrs

Inspect Motor X X X X


Inspect Disc Brake X X X X


Replace Winch Anchor Bolts X X X X

Rebuild Control Valve X X X X

Inspect Drum, Housings and Main Frames X X X X

Optional Components


Overload Device X X X X



Note: Hours are for actual winch drum rotation.

Recommend complete general overhaul.

Form MHD56401 Edition 2 3

INSPECTION REPORT

Ingersoll Rand Force 5 Infinity Series Models FA10i Air Winches

Model Number: Date:

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection:(_____ Months _____ Years) Operating Environment:

2. Discrepancy(s) noted during Frequent Inspection

Normal ____ Heavy____ Severe ____3. Discrepancy(s) noted during maintenance

4. Other: ___________________________

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

COMPONENTCONDITION CORRECTIVE ACTION

NOTESPass Fail Repair Replace

Uprights and Siderails

Drum Band Brake (125% Load Test)

Drum Locking Pin

Disc Brake (125% Load Test)

Drum Band Brake (Visual Inspection)

Disc Brake (Visual Inspection)

Motor

Limit Switches ---

Controls

Constant Tensioning System ---

Air System

Fasteners

Reduction Gears

Labels and Tags ---

Shafts

Winch Guard

Wire Rope Wedge ---

Emergency Stop Valve

Overload Device ---

Press Roller

Wire Rope ---

Drum Locking Pin ---

Other Components (list in NOTESsection)

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 areasoutside the USA.

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


TROUBLESHOOTING

This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by personnelinstructed 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 REMEDYWinch will not operate. Insufficient or 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 60 psig (3.4bar/340 kPa). Inspect brake piston seals and replace if seals appear to be leaking.

Shipping plugs may still be in place. Remove shipping plugs in valve and motor exhaust ports.

Drum brake does not release.Disengage manual band brake, or refer to ‘Automatic Band Brake (optional feature)’on page 6.

Emergency stop valve engaged. Reset emergency stop valve.Motor may be damaged. Disassemble and clean the motor and replace any broken or damaged parts.Air leak. Check hose and fitting connections. Inspect hose(s) for breaks. Tighten fittings and

repair or replace hoses as necessary.Overload device engaged. Reduce load to within rated capacity of winch. If overload device cannot be reset,

contact factory.Air lines freeze due to water in air supply. Install or drain air system moisture traps, moisture collecting air receivers and

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

Load continues to move when winch isstopped.

Brake is slipping. Check ‘Automatic Band Brake (optional feature)’ on page 6 and brake band liningwear. Check brake friction disc wear.

Winch is overloaded. Reduce load to within rated capacity.Winch motor controls sticking. Check pendant/throttle levers spring return to normal (neutral) position when

released.Winch does not lift load or does not liftrated capacity. Winch does not lift/pullload.

Motor may be damaged. Remove and disassemble motor as described in “MAINTENANCE” on page 6.Examine all parts and replace any that are worn or damaged.

Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements listedin the “SPECIFICATIONS” section in Product Information Manual. Clean air line filter.

Brake is not releasing. Check brake release pilot hole is not restricted. Check seals on cylinder piston arenot damaged. Brake will start to release at 50 psig (3.5 bar/350 kPa).

Winch is overloaded. Reduce load to within rated capacity.Oil leak from motor end of winch. Reduction assembly is leaking. Disassemble winch and inspect reduction assembly seals.Throttle or pendant lever moves but winchdoes not operate.

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 rated

volume. Clean air line filter.Air leak. Check hose and fitting connections. Inspect hose(s) for breaks. Tighten fittings and

repair or replace hoses as necessary.Motor does not run smoothly or makesexcessive noise during operation.

Damaged or broken piston or connecting rod. Disassemble and repair motor.

Motor runs hot or makes excessive noiseduring operation.

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 in Product Information

Manual. Set lubricator to provide 6 to 9 drops of oil per minute at maximum winchoperating capacity.

Water in oil. Drain and refill with recommended oil. Operate winch with no load slowly, in bothdirections. If noise still exists or motor overheats disassemble and repair motor.

Damaged or broken piston or connecting rod. Disassemble and repair motor.Winch runs slow. Improper hose or fitting sizes. Check fittings, connections and hoses for correct size and length. Replace parts that

may cause restricted air flow. Inspect air line filter.Motor may be damaged. Remove and disassemble motor as described in “MAINTENANCE” on page 6. Inspect

all parts and replace all worn or damaged parts.Brake(s) not releasing. Refer to brakes in “MAINTENANCE” on page 6.Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements. Refer

to “SPECIFICATIONS” section in Product Information Manual. Clean air line filter.Air lines freeze. Water in air supply. Install or drain air system moisture traps, moisture collecting air receivers and

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

Throttle lever hard to actuate, or lever doesnot spring return to neutral.

Reverse valve sticking in bushing. Remove and disassemble control valve. Clean control valve parts and check clearancebetween reverse valve and bushing.

Automatic Band Brake:Brake cylinder will not release. Band brake out of adjustment. Adjust band brake to maintain correct cylinder stroke.

Leaking cylinder seals. If air is noticed escaping from cylinder breather when attempting to release brake,replace or repair cylinder.

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

neutral. If no air escapes, replace dump valve.Automatic Disc Brake:Brake fails to release. Low air supply pressure. Ensure air pressure at inlet to disc brake is at least 60 psig (3.4 bar/340 kPa).

Leaking piston seals. Inspect brake breather. If air escapes from brake breather when attempting to releasebrake, replace brake seals.

No release pressure at brake port. Check for proper operation of winch controls.Sticking brake piston. Apply 60 psig (3.4 bar/340 kPa) to brake release port and check for brake disc

movement. (Brake discs can be viewed through brake breather hole.) If brake discsdo not move, disassemble and inspect disc brake as described in “MAINTENANCE”on page 6.


MAINTENANCE

WARNING

• Never perform maintenance on the winch while it is supporting a load.• Before performing maintenance, tag controls:

WARNING - DO NOT OPERATE, EQUIPMENT BEING REPAIRED.

• Only allow Ingersoll Rand trained Technicians to perform maintenance on thiswinch.

• After performing any maintenance on the winch, test winch to 125% of itsrated line pull at mid drum before returning to service. (Testing to more than125% of rated line pull may be required to comply with standards andregulations set forth in areas outside the USA.)

• Shut off air system and depressurize air lines before performing anymaintenance.

• Do not use Trichloroethylene to clean parts.• Use of other than genuine Ingersoll Rand parts may result in safety hazards,

decreased performance and increased maintenance and may invalidate allwarranties.

NOTICE

This Product Maintenance Manual is intended for use on both a utility or ManRider™ winch. Refer to Product Information and Safety Manuals for specificinformation.

n GeneralCorrect disassembly (to prevent loss or damage of good parts), repair, assembly,testing and adjusting are critical to proper winch operation. Maintenance proceduresare technical in nature and require training and experience to accomplish correctly.In addition, repair and testing require specialized equipment that is not typicallyfound at the winch-mounting site.

Proper use, inspections and maintenance increase the life and usefulness of yourIngersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and allmachined threads with applicable lubricants. Use of antiseize compound and/orthread lubricant on capscrew and nut threaded areas prevents corrosion and allowsfor easy disassembly of components.

It is extremely important that anyone involved with maintaining the winch be familiarwith the servicing procedures of these winches and be physically capable ofconducting the procedures. These personnel shall have skills that include:1. Proper and safe use and application of mechanics’ common hand tools as well as

special Ingersoll Rand or 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 productoperations or repairs may be conducted and the hazards and/or results of eachmethod. If operation or maintenance procedures not specifically recommended by themanufacturer are conducted, it must be ensured that product safety is not endangeredby 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.

NOTICE

• Refer to the Product Parts Information Manual for drawings unless specifiedelsewhere.

n Maintenance IntervalsRefer to Table 3 ‘Maintenance Interval Chart’ on page 3 for recommended maintenanceschedule.

n Adjustments

n Winch Guard

Refer to Dwg. MHP2946.Winch guard panels must be adjusted to suit wire rope departure angle. Adjust perprocedures in Product Information Manual.

n Disc Brake

Refer to Dwg. MHP2944.Disc brake adjustment is not required. If disc brake does not hold rated loaddisassemble and repair.If brake assembly is removed or disassembled ensure breather (23) is installed andlocated at top of brake housing during reassembly.

n Manual Band Brake (optional feature)

Refer to Dwg. MHP0627.1. Release wire rope tension on drum.2. Rotate handwheel (104) counterclockwise to release brake bands.

3. Loosen nut (120) and turn adjustment screw (127) to provide 1/16 to 1/8 inch(1.6 to 3.2 mm) gap between band lug and end of adjustment screw when brakeis applied.

4. When correct gap is obtained, tighten nut (120).5. Check brake band is partially lifted from drum diameter to reduce drag when brake

is not in use.

CAUTION

• When any part of brake lining thickness measures 0.062 inch (2 mm) or less,brake bands (128) must be replaced.

n Automatic Band Brake (optional feature)

Refer to Dwg. MHP2329.1. Remove cotter pin (57) at link stud (56).2. Apply air to brake cylinder (134) and remove pin (58) to disconnect link stud (56)

from brake band (59).3. Turn link stud (56) clockwise to increase cylinder rod extension. Turn link stud

(56) counterclockwise to decrease cylinder rod extension.4. Assemble link stud (56) to brake band (59) with pin (58) and cotter pin (57).

Release air to brake cylinder (134).5. Brake should hold rated load (refer to “INSPECTION” on page 2) when cylinder

(134) is retracted. Brake band should not drag on drum when cylinder usextended.

6. Install cotter pin (57). Bend ends of cotter pin to secure link stud to brake bandwhen adjustment is complete.

7. With brake “On” adjust screw (127) to just touch brake band (59).

n Pendant Operated Pilot Control Valve (optional feature)

Valve is set at factory. Refer to ‘Pendant Operated Pilot Control Valve Assembly’on page 13 for adjustment procedure.

n Overload Valve (optional feature)

Refer to Dwg. MHP2619 in Product Information Manual. A. Emergency Stop Button;B. Push Down to Stop Winch Movement; C. Overload Valve Reset Button; D. Twist RedButton to Reset; E. Overload Valve Adjustment Screw.

A 5/16 inch or 8 mm open-ended wrench is required.

Adjust overload valve by turning adjustment screw located at bottom of control valve.- Rotating adjustment screw (clockwise) will increase pressure required to

activate overload valve.

WARNING

• This adjustment can cause overload device to NOT activate before winch'ssafety limit is exceeded. This procedure should only be done by IngersollRand trained Technicians.

- Rotating adjustment screw (counterclockwise) will decrease pressure requiredto activate overload valve.

n Limit Switch

Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.

n Tensioning System

Refer to Dwg. MHP2028.The regulator is preset at 0 psig (0 bar/0 kPa) and therefore requires adjustment whenwinch is installed. To adjust for specific load applications, regulator pressure may beadjusted to increase or decrease tension setting.Regulator gauge and regulator are accessible through cover.

WARNING

• When adjusting regulator, ensure winch control lever is locked in neutralposition and tension selector lever is in the NORMAL position.

• Winch supply air is NOT shut off during regulator adjustments. To preventaccidental winch operation, allow only a single person, trained in operation,safety and maintenance of this product, to conduct regulator adjustments.

Regulator Adjustment Procedure:Refer to Dwg. MHP1865 in Product Information Manual.1. Attach test load of desired weight to load line, or connect load line to scale.

WARNING

• Ensure load line is connected to load and excessive slack is taken up beforeactivating auxiliary valve. When activated, auxiliary valve will automaticallyengage and winch will operate at full speed to set tension on load line.

2. Using winch control valve remove all slack from load line.


Setting with test load:Actuate auxiliary valve to TENSIONING position. Winch should operate, causing loadline to become taut. To increase tension, rotate regulator knob clockwise until loadbegins to rise. Rotate regulator knob counterclockwise a minimum of 1/4 turn, or untilload is balanced (does not raise or lower). Note pressure indicated on gauge for futuresetting reference.

Setting with scale:Actuate auxiliary valve to TENSIONING position. Winch should operate, causing loadline to become taut. To increase tension, rotate regulator knob clockwise until scaleindicates desired tension. Note pressure indicated on gauge for future settingreference.

n Disassembly

n General Disassembly Instructions

The following instructions provide necessary information to disassemble, inspect,repair, and assemble product. Parts drawings are provided in Product PartsInformation Manual.If a product is being completely disassembled for any reason, follow the order oftopics as they are presented. It is recommended that all maintenance work on productbe performed in a clean dust-free work area.In the process of disassembling product, observe the following:1. Never disassemble product any further than is necessary to accomplish needed

repair. A good part can be damaged during the course of disassembly.2. Never use excessive force when removing parts. Tapping gently around perimeter

of a cover or housing with a soft hammer, for example, is sufficient to break theseal.

3. Do not heat a part with a flame to free it for removal, unless part being heatedis already worn or damaged beyond repair and no additional damage will occurto other parts.

In general, products are designed to permit easy disassembly and assembly. The useof heat or excessive force should not be required.

4. Keep work area as clean as practical, to prevent dirt and other foreign matterfrom getting into bearings or other moving parts.

5. All seals, gaskets and ‘O’ rings should be discarded once they have been removed.New seals and ‘O’ rings should be used when assembling product.

6. When grasping a part in a vise, always use leather-covered or copper-covered visejaws to protect the surface of part and help prevent distortion. This is particularlytrue of threaded members, machined surfaces and housings.

7. Do not remove any part which is a press fit in or on a subassembly unless removalof that part is necessary for repairs or replacement.

8. When removing ball bearings from shafts, it is best to use a bearing puller. Whenremoving bearings from housings, drive out bearing with a sleeve slightly smallerthan outside diameter of bearing. The end of sleeve or pipe which contactsbearing must be square. Protect bearings from dirt by keeping them wrapped inclean cloths.

n Winch Disassembly

NOTICE

• Remove band brake if equipped. Refer to ‘Manual Band Brake (optionalfeature)’ on page 6 and ‘Automatic Band Brake (optional feature)’on page 6 for specific instructions.

Refer to Dwgs. MHP0875, MHP1007, MHP2944 and MHP2948.1. Remove wire rope from drum.2. Operate winch to position reduction gear drain plug at its lowest position.3. Relieve pressure in air lines by operating winch control several times after air

supply has been turned off.

WARNING

• Shut off, bleed down and disconnect air supply line before performing anydisassembly procedures.

• The weight of a winch with a 24 inch (610 mm) long drum and no wire ropeis 3550 lb. (1610 kg). Exercise caution when lifting and moving winch.

4. Disconnect and tag air lines.5. Remove winch from its mounting and take to a suitable work area before

beginning disassembly.6. Remove lower case pipe plug (218) on motor housing (217) and allow oil to drain

into a suitable container and dispose of in an environmentally safe manner.Loosen vent cap (210) to vent motor housing.

7. Drain oil from reduction gear assembly by removing one plug (406) whenpositioned at its lowest point and one plug (406) from its highest point to vent.Refer to Dwg. MHP0567 in Product Information Manual. If winch is equipped witha band brake, elevate the winch outboard end (opposite from motor end) toprevent draining oil from contaminating brake band lining.

8. For winches with a disc brake, remove pipe plug (24) in brake housing (21) todrain brake oil.

9. Remove band brake, winch guard and any other externally mounted winchattachments.

10. Refer to ‘Winch Guard Disassembly’ on page 7.a. Remove panels (805) and (807), one section at a time, by removing locknuts

(804) and crossbars (806).b. Remove capscrews (197) and washers (117) securing lifting lugs (194) to

uprights.c. Remove capscrews (408) and washers (306) securing guards (801), (802),

(803) and (810) to uprights (42) and (184).

WARNING

• Air motor weighs approximately 260 lb. (118 kg). Adequately support airmotor before removing motor mounting capscrews.

11. For winches with a disc brake, remove tubing and fittings from control valve tobrake housing (21).

12. Remove capscrews (4) and lockwashers (3) securing motor assembly to motoradapter (6). Using a hoist to support motor, pull motor straight away from winch.Refer to ‘Motor Disassembly’ on page 7 if motor disassembly is required.

Instructions 13 through 21 apply only to winches with a disc brake.

13. Alternately and evenly loosen eight capscrews (2) until brake spring compressionis relaxed. Remove capscrews (2) and motor adapter (6).

14. Remove brake reaction plate (8) and springs (9).15. Remove brake housing (21) and ‘O’ ring (15). If brake housing sticks, tap it with

a plastic mallet until parts separate.16. Remove seal sleeve (14). Remove ‘O’ ring (13) from inside seal sleeve (14).17. Pull out input shaft (7) with geared hub (19).18. Remove seven friction plates (16) and eight drive plates (17).19. Remove brake piston (10) from brake housing (21). Tap lightly with a plastic

mallet to separate parts if necessary.20. Remove seals (11) and (12) from brake piston (10).21. Remove retainer ring (38) from input shaft (7) and remove geared hub (19).22. Remove retainer ring (36) and bearing (37) from inside drum shaft (41). Tap with

a plastic mallet if necessary.23. If coupling (49) came out with input shaft (7) remove at this time. If not, reach

into drum shaft (41) and remove coupling (49). Remove retainer ring (45) frominside coupling (49).

24. Support drum (96).25. Remove capscrews (119) and lockwashers (117) which secure siderails (98) to

inboard upright (42). Drive out dowel pins (183).26. Remove inboard upright (42).27. Remove capscrews (39) from drum shaft (41). Drive out dowels (62). Pry drum

shaft (41) from upright (42).28. Remove ‘O’ ring (43).29. Remove capscrews (582) and lockwashers (306).30. Tap end cover (193) loose and remove.31. Remove capscrews (192) and bearing retainer (191).32. Remove remaining capscrews (119) and lockwashers (117) that attach siderails

(98) to outboard upright (184). Drive out remaining dowel pins (183) and removesiderails (98).

33. Pull outboard upright (184) away from drum (96).34. Remove bearing (188).35. Position drum (96) vertically (with reduction gear assembly facing up).36. Remove capscrews (63) holding adapter (52) onto drum.37. Install two 1/2 inch - 13 NC x 2 inch capscrews into threaded holes in outer bolt

pattern ring of adapter (52). Use these capscrews as jacking bolts to break seal.Attach suitable lifting eyes to these bolts and lift reduction gear assembly out ofdrum and place on a clean work surface.

38. Remove all plugs (406) from reduction gear.39. Remove capscrews (50) and nuts (48). Using a hammer and punch, tap spring

pins (40) into support (405). With a plastic mallet, tap adapter (52) until it isfree of support (405).

40. Replace plugs (406) and loosely tighten.

n Winch Guard Disassembly

Refer to Dwg. MHP2945.1. Remove capscrews (197) and washers (117) securing lifting lugs (194) to

uprights.2. Remove panels (805) and (807) one section at a time, by removing nuts (804)

and crossbars (806).3. Remove capscrews (408) and washers (306) that secure panels (801), (802), (803)

and (810) to winch uprights.4. Remove guards.

n Motor Disassembly

Refer to Dwg, MHP1007.1. Remove five capscrews (253) from exhaust flange (254).2. Remove rotary valve housing (247) by pulling it out of motor housing (217) as

an assembly with exhaust flange (254).

CAUTION

• Do not remove exhaust flange (254) until rotary valve (250) has beenremoved from rotary valve housing (247).

3. Remove rotary valve (250) by pulling it out from assembly through motor housingend of rotary valve housing (247).

4. Remove exhaust flange (254), capscrews (551), lockwashers (549) and controlvalve assembly (500).

5. Remove each cylinder (201) by removing four capscrews (200). Remove headgasket (209) and discard.

6. Remove mounting flange (216) by removing capscrews (4) and lockwashers (3),and then pulling mounting flange straight off.

7. Position one piston (204) at top of its stroke. In this position, wrist pin (203)can be removed. Remove one retainer ring (205) from either side of piston (204).Push wrist pin (203) out by hand from one side. If wrist pin is too tight it isacceptable to carefully heat piston to 200°F (93°C) or less and then push wristpin out.


NOTICE

• If piston, wrist pin, connecting rod or cylinder head are to be reassembled,number each set. Add radial alignment marks for each piston and cylinderhead to motor housing.

8. Remove remaining pistons as described in step 7 as required. To remove crankassembly, all pistons and cylinder heads must be removed.

9. Crank assembly (231) can now be removed, with oil slinger (230), by pullingstraight out from motor housing (217). Use care while guiding connecting rods(206) through inside of motor housing.

Crankshaft Disassembly:1. Remove cotter pin (236) and pin nut (237).2. Remove lock pin (235) by carefully driving it out of its location. Use care not to

damage threads.3. Pull crankshaft valve end (231) off the crankshaft.4. Remove connecting rod rings (234), bushing (233), sleeve (232) and connecting

rods (206). Record the five connecting rod (206) numbers and foot directions sothey can be reinstalled in the same order.

5. Oil slinger (230) does not have to be removed unless damaged. If removal isrequired, heating of the five screws (229) may be required to loosen Loctite®connection.

n Control Valve Disassembly

Refer to Dwg. MHP2696.

Handle Removal:Handle disassembly is not recommended.1. Carefully pry off plug (935).2. Remove capscrew (901) and tablock washer (909).

NOTICE

• Observe spring (937) connection during disassembly. This spring is undertension and is required to return handle to neutral position.

3. Carefully pull handle assembly (930) from reverse valve (943). Remove spring(937).

Reverse Valve Removal:1. Remove buttonhead screws (938), capscrews (925) and washers (924) from seal

bracket (939). Remove seal bracket from valve housing (917). Remove and discard‘O’ rings (941) and (942).

2. Remove capscrews (901) and washers (902) from exhaust flange (955). Removeflange from valve housing. Remove and discard ‘O’ ring (942).

3. Slide reverse valve (943) out exhaust flange side of housing until ball (916) isvisible on reverse valve. Allow ball (916) to drop out of bushing (944) and removeball.

4. Remove bushing (944) from exhaust flange side of housing.

NOTICE

• Dowel pin (945) allows the bushing (944) to be removed only from theexhaust flange side of housing. Ball (916) retains reverse valve (943) inbushing.

• Do not remove reverse valve (943), bushing (944), and ball (916) at thesame time; damage may occur to bushing.

• Take care to not allow ball (916) to drop into motor. If this occurs it may benecessary to disassemble motor to retrieve ball.

Piston Removal:1. Remove capscrews (901) and washers (902) from piston cover (919). Remove

cover and discard gasket (918).2. Remove capscrews (901) and washers (902) from poppet cover (903). Remove

cover and discard gasket (904).3. Remove the following items from housing poppet bore: poppet spring (905),

poppet cap (906) and poppet seal (907).4. From poppet side, push piston (922) out of valve housing (917). Remove ‘O’ rings

(921) and (923) and discard.

Pilot Valve Removal:

NOTICE

• For easier removal, it is recommended to use Ingersoll Rand pilot valve tool(920). This must be purchased separately.

If pilot valve is not damaged, it is not necessary to disassemble completely.1. Remove plug (912).2. Remove pilot valve assembly (910) as an assembly.3. Discard and replace pilot valve assembly (910) if necessary.

n Emergency Stop and Overload Control Valve Disassembly


Handle Removal:Follow disassembly instructions in ‘Control Valve Disassembly’ on page 8.

Reverse Valve Removal:1. Remove buttonhead screws (938), capscrews (925) and washers (924) from seal

bracket (939). Remove seal bracket from valve housing (917). Remove and discard‘O’ rings (941) and (942).

2. Remove capscrews (721), washers (902), exhaust flange (955) and exhaustadapter (723). Remove and discard ‘O’ rings (942) and (722).

3. Move reverse valve (943) out exhaust flange side of valve housing (917) until ball(916) is visible on reverse valve. Allow ball (916) to drop out of bushing (944)and remove ball.

4. Remove bushing (944) from exhaust flange side of housing.

NOTICE

• Dowel pin (945) allows the bushing (944) to be removed only from theexhaust flange side of housing. Ball (916) retains reverse valve (943) inbushing.

• Do not remove reverse valve (943), bushing (944) and ball (916) at the sametime; damage may occur to bushing.

• Take care to not allow ball (916) to drop into motor. If this occurs it may benecessary to disassemble motor to retrieve ball.

Piston Removal:Follow disassembly instructions in ‘Control Valve Disassembly’ on page 8.

Pilot Valve Removal:Follow disassembly instructions in ‘Control Valve Disassembly’ on page 8.

Emergency Stop Removal:1. Unscrew adapter (706) and E-Stop button (705) from valve housing.2. Remove plunger (707). Remove and discard ‘O’ rings (703).3. Pull spring (711) out of valve housing (917) and discard.

Overload Valve Removal:1. Unscrew cap (700). Remove and discard grommet (701).2. Pull out plunger (702), remove and discard ‘O’ rings (703).3. Remove capscrews (901) and washers (902) from cover (719) underneath valve

housing (917).

NOTICE

• Cover (719) retains spring (718). To remove capscrews (901) and washer(902), unscrew in a crisscross pattern.

4. Remove adjusting screw (720) and ‘O’ ring (716).5. Remove adjusting nut (717), plate (715), gasket (714), ‘O’ ring (713) and piston

(712) from valve housing (917). Discard gasket (714) and ‘O’ ring (713).

n Pendant Operated Pilot Control Valve Disassembly (optionalfeature)


CAUTION

• Do not disassemble control valve.• Contact an Ingersoll Rand Service Center for repair.

n Manual Band Brake Disassembly (optional feature)

Refer to Dwg. MHP0627.1. Remove nuts (102), lockwashers (103) and U-bolts (109).2. Remove nut (110), handwheel (104), bearing (111) and tube (112).3. Pull out brake screw (114). Catch spring (113) as brake screw clears.4. Remove capscrews (116) and lockwashers (117). Remove anchor (118) and plate

(122).5. Remove capscrews (119) and washers (117). Remove support (126).6. Slide brake band halves (128) off drum (96).7. Remove capscrews (124), washers (123) and nuts (115) and separate brake band

halves.

n Automatic Band Brake Disassembly (optional feature)

Refer to Dwg. MHP2329.1. Disconnect and remove hose, fittings and exhaust valve (71) from cylinder (134).2. Remove cotter pin (57) and pin (58) from link stud (56) and brake band (59).3. Remove cotter pin (44) and pin (46). Separate clevis (51) from lever arms (34)

and (61).4. Remove nuts (60), washers (32) and capscrews (25) from lever arms (34) and

(61).5. Remove spacers (35), bushings (54) and pivot nuts (55).6. Remove cotter pin (44) and pin (65) from bracket (74). Remove cylinder (134)

from bracket (74).7. Remove capscrews (67) and (116) and lockwashers (117). Remove anchor (118),

bracket (74) and plate (122).8. Remove capscrews (119) and washers (117). Remove support (126).9. Slide brake band halves (128) off drum (96).10. Remove capscrews (124), washers (123) and nuts (115) and separate brake band

halves.

CAUTION

• It is not recommended to disassemble cylinder (134) due to extremepressure of loaded spring. Contact factory for service.

n Reduction Gear Disassembly

NOTICE

• It is extremely important to maintain a clean work area when reduction gearassembly is disassembled.

• Disassembly is not recommended. If it is unavoidable, use the followingsteps.


Refer to Dwg. MHP0875.1. Place reduction gear assembly on a clean work bench. Have a couple of wooden

blocks available to prevent assembly from rolling around. There will also be asmall amount of oil remaining in housing so have some absorbent material readilyavailable.

2. Using a hammer and punch, drive spring pins (404) in, until they are completelyin input housing (424).

3. Remove capscrews (401) and, using a plastic mallet, tap seal support (400) untilloose and remove.

4. Remove oil seal (402) and ‘O’ ring (403).5. Remove capscrews (425).6. Using a plastic mallet, tap support (405) and ring gear (409) to separate.7. Remove ‘O’ ring (408) and bearing (407).8. Pull out planetary support (410) assembly.9. From planet gear side reach into planetary support hub and remove retainer ring

(420). Spacer (422) may be on shaft (445) or still in spacer (418). Remove at thistime.

10. Push spacer (418) out of planetary support and remove ‘O’ ring (419).

NOTICE

• Do not disassemble planetary gears from their housings unless required toreplace damaged parts. Disassembly directions 11 and 12 apply only toplanetary gears (415) housed in planetary support (410). For informationon other planetary assemblies (430 and 440) contact your Ingersoll Randdistributor or the factory.

11. Place planetary support (410) in a container. Holding the planet gear (415) withone hand, slowly push planet gear shaft (417) out of support. Carefully removeplanet gear. When thrust bearings (413) become free squeeze together withfingers. Once spring pins (412) are free they may fly out or roller bearings (414)might start to fall out. Remove planet gear assembly and carefully place incontainer.

12. Slide thrust bearings (413) off ends of planet gear (415) and push out all rollerbearings (414) into container.

13. Separate ring gear (409) from input housing (424) and remove ‘O’ ring (408).14. Remove spacer (423).15. Remove capscrews (439).16. Separate input housing (424) from ring gear (436) and remove ‘O’ ring (434).17. Remove retainer ring (427) from input housing (424) and pull out cylinder roller

bearing (426).18. Remove sun gear (429) and spacer (428). Separate the two.19. Remove planetary assembly (430).20. Remove sun gear (433) and spacer (422). Separate the two.21. Remove retainer ring (435) from sun gear (433).22. Tap out spring pins (437). Separate ring gear (436) from input housing (438) and

remove ‘O’ ring (434).23. Tap out spring pins (443). Remove capscrews (448) and separate input housing

(438) from ring gear (444) and end cover (446).24. Remove planetary assembly (440) and ‘O’ ring (442).25. Remove ‘O’ ring (442) and shaft (445).26. Remove capscrews (452) and separate front cover (450). Remove thrust plate

(449) and gasket (447).27. Remove adjusting screw (453).

n Press Roller Disassembly (optional feature)

Refer to Dwg. MHP2945.1. Compress the ends of springs (405) and (406) to disengage from siderail (98) and

pins (413) on press roller arm (407).2. Loosen collars (404).3. Remove capscrews (408) and washers (409) from both ends of shaft (403), and

carefully slide shaft (403) through hole in upright (42). Press roller assembly(400) will fall away from shaft (403).

4. It is not necessary to remove bushings (410) unless replacing.5. Remove springs (405) and (406) from press roller arm (407).6. Remove capscrews (408), washers (409) and rollers (401) from shaft (411).7. Remove shaft (411) and center roller (402) from press roller arm (407).

n Drum Locking Pin Disassembly (optional feature)

Refer to Dwg. MHP2675.1. Remove capscrews (305) and washers (306) to separate drum locking pin assembly

from winch upright (184).2. Unscrew drum lock pin (312) from shaft (304). Separate spring (310), drum lock

pin (312) and housing (308) from assembly.3. Remove nut (303) and capscrew (302) to separate handle (301) from shaft (304).4. Remove bushing (311) from winch upright (84) only if replacement is required.

n Two Function Pendant Disassembly (optional feature)

Refer to Dwg. MHP1677 or MHP2346.1. Remove fittings (348) and lifting eye (440).2. Unscrew plugs (444). Remove springs (445) and balls (446).3. Tap out pin (447) and remove levers (453).4. Remove setscrew (455) from pendant handle (454).5. Remove valve assemblies (452). Remove ‘O’ rings (443) and (449) and protectors

(451). Discard ‘O’ rings.6. Remove plug (470) or emergency stop valve (441) from pendant handle.7. Remove retainer ring (458) and exhaust washer (457).

n Limit Switch Disassembly (optional feature)


NOTICE

• It is not recommended to disassemble limit switch. Contact factory if repairis required.

1. Remove and tag hose connection if not already done.2. Remove capscrews (97) and washers (96) that secure limit switch assembly to

upright (84).3. Store limit switch assembly in a clean, dry area until winch reassembly.

n Cleaning, Inspection and Repair

n Cleaning

Clean all product component parts in solvent (except brake bands and disc brakefriction plates). The use of a stiff bristle brush will facilitate removal of accumulateddirt and sediments in the reduction assembly, on housings, frame and drum. Dry eachpart using low pressure, filtered compressed air. Clean brake band using a wire brushor emery cloth. Do not wash brake band in solvent. If brake band lining is oil soaked,it must be replaced.

n Inspection

All disassembled parts should be inspected to determine their fitness for continueduse. Pay particular attention to the following:1. Inspect all gears for worn, cracked, or broken teeth.2. Inspect all bushings for wear, scoring, or galling.3. Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent

on shafts, replace shaft. Inspect all surfaces on which oil seal lips seat.4. Inspect all bearings for play, distorted races, pitting and roller or ball wear or

damage. Inspect bearings for freedom of rotation.5. Inspect all threaded items and replace those having damaged threads.6. Inspect band brake lining for oil, grease and glazing. If band brake lining is oil-

soaked replace brake bands as a set. Remove glazed areas of band brake liningby sanding lightly with a fine grit emery cloth.

7. Measure thickness of band brake lining. If brake band linings are less than 0.062inch (2 mm) thick anywhere along edges replace brake bands as a set.

8. Inspect cylinder bores. Minor scratches in bore lining may be repaired by lightlyhoning to remove. Refer to tolerances listed below for acceptable clearances.Replace liner if deep scratches or gouges are apparent. Measure inside diameterof liner. If measurement is greater than 4.764 inches (121 mm) replace liner.‘Ring Gap’ may also be used to determine wear; place compression ring into liner,using a piston, push ring until approximately half way in liner and measure ‘Gap’— 0.003 inch (0.076 mm) is normal; replace rings, or liner, if ‘Gap’ exceeds 0.020inch (0.51 mm).

9. Inspect the drive plates for warpage or other damage, and replace damaged partsas necessary. Replace the input pinion shaft oil seal.

10. Measure the thickness of the brake friction disc. The brake friction disc must showan even wear pattern. If the brake friction disc is 0.076 inch (1.93 mm) or less,replace the disc.

n Repair

Actual repairs are limited to removal of small burrs and other minor surfaceimperfections from gears and shafts. Use a fine stone or emery cloth for this work.Do not use steel wool.1. Worn or damaged parts must be replaced. Refer to the applicable parts list in the

Product Parts Information Manual for specific replacement parts information.2. Inspect all remaining parts for evidence of damage. Replace or repair any part

which is in questionable condition. Cost of the part is often minor in comparisonwith cost of redoing job.

3. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings.4. Examine all gear teeth carefully, and remove nicks or burrs.5. Polish edges of all shaft shoulders to remove small nicks which may have been

caused during handling.6. Remove all nicks and burrs caused by lockwashers.7. Replace all gaskets, oil seals, and ‘O’ rings removed during product disassembly.

n Assembly

n General Instructions

• Use all new gaskets and seals.• Replace worn parts.• Assemble parts using matchmarks attached during disassembly. Compare

replacement parts with originals to identify installation alignments.• Lubricate all internal parts with rust and oxidation inhibiting lubricant, ISO

VG 100 (SAE 30W).• Apply a light coat of Loctite® 243 to all threaded components prior to

assembly, unless otherwise specified.

n Control Valve Assembly


Reverse Valve Assembly:1. Insert reverse valve (943) into bushing (944) with ball slot oriented UP,

approximately 2-1/2 inches (64 mm).2. Insert bushing (944) and reverse valve (943) into valve housing (917) from

exhaust flange side, ensuring that groove in bushing is aligned with dowel pin(945).

3. Apply grease to ball (916) and insert into reverse valve platform. With finger,push ball (916) in housing until ball hits end of reverse valve.


4. Holding ball (916) in position on reverse valve platform, rotate reverse valve fromneutral position to approximately 45 degrees in either direction. Ball will ‘walk’up side of reverse valve platform and move in ball hole in bushing (944).

NOTICE

• Do not rotate reverse valve past a 90 degree position; it may result in ball(916) falling into motor.

5. Slowly push reverse valve, while still in the 45 degree position, the rest of theway in housing until flush with surface. From other side of valve, rotate reversevalve back to neutral position. Ball should be seated in ball slot at that time.

6. Lubricate ‘O’ ring (942) and place into groove in exhaust flange (955).7. Secure exhaust flange (955) to valve housing (917) with capscrews (901) and

washers (902).8. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’ ring (942) and place in

groove in seal bracket.9. Place seal bracket over end of reverse valve. Using finger pressure, press until

seal is seated on reverse valve and seal bracket is seated on valve housing. Securewith washers (924), capscrews (925) and buttonhead screws (938).

Pilot Valve Assembly:

NOTICE

• For easier installation, it is recommended to use Ingersoll Rand pilot valvetool (920). This must be purchased separately.

1. Install pilot valve assembly (910).2. Apply thread sealant Loctite® 567 to pilot valve assembly (910) and place pilot

valve assembly into valve housing (917). Use a large flat-tipped screwdriver toengage slots in pilot seat to tighten until pilot assembly is 1/8 inch (3.175 mm)from housing bore.

3. Insert plug (912) and tighten.

Piston Assembly:1. Lubricate and install ‘O’ rings (921) and (923) on piston (922).2. Insert assembled piston into valve housing (917) from handle side.3. Secure gasket (918), piston cover (919) and washers (902) with capscrews (901).4. Place poppet seal (907) into poppet cap (906). Place this assembly into valve

housing and seat on piston (922).5. Place spring (905) over this assembly.6. Secure with gasket (904), poppet cover (903), washers (902) and capscrews

(901).

Handle Assembly:1. Place spring (937) over reverse valve handle end in seal bracket (939).

NOTICE

• Spring (937) will have to be 'cocked' over stud in bracket. This will ensurehandle returns to neutral.

2. Install handle assembly (930) over reverse valve end. Handle will have to be liftedslightly to allow pin to fit into slot in seal bracket (939).

3. Secure handle assembly (930) to reverse valve with tab lockwasher (909) andcapscrew (901). Refer to “TORQUE CHART” on page 15 for torque requirements.Washer (909) has small tab on side; engage with small hole in handle.

4. Bend tabs of washer (909) over flats of capscrew.5. Press plug (935) into handle assembly to cover capscrew. Check control handle

movement. Correct any discrepancies.

n Emergency Stop and Overload Control Valve Assembly


Reverse Valve Assembly:1. Insert reverse valve (943) into bushing (944) with ball slot oriented UP,

approximately 2-1/2 inches (64 mm).2. Insert bushing (944) and reverse valve (943) into valve housing (917) from

exhaust flange side, ensuring that groove in bushing is aligned with dowel pin(945).

3. Apply grease to ball (916) and insert into reverse valve platform. With finger,push ball (916) in housing until ball hits end of reverse valve.

4. Holding ball (916) in position on reverse valve platform, rotate reverse valve fromneutral position to approximately 45 degrees in either direction. Ball will ‘walk’up side of reverse valve platform and move in ball hole in bushing (944).

NOTICE

• Do not rotate reverse valve past a 90 degree position; it may result in ball(916) falling into motor.

5. Slowly push reverse valve, while still in the 45 degree position, the rest of theway in housing until flush with surface. From other side of valve, rotate reversevalve back to neutral position. Ball should be seated in ball slot at that time.

6. Lubricate ‘O’ rings (942) and (722), and place in grooves in exhaust adapter (723).7. Lubricate ‘O’ ring (942) and place in groove in exhaust flange (955).8. Secure exhaust adapter (723) with exhaust flange (955) to valve housing (917)

with capscrews (721) and washers (902).9. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’ ring (942) and place

into groove in seal bracket.10. Place seal bracket over end of reverse valve. Using finger pressure, press until

seal is seated on reverse valve and seal bracket is seated on valve housing. Securewith washers (924), capscrews (925) and buttonhead screws (938).

Pilot Valve Assembly:Follow assembly instructions in ‘Control Valve Assembly’ on page 9.

Piston Assembly:Follow assembly instructions in ‘Control Valve Assembly’ on page 9.

Handle Assembly:Follow assembly instructions in ‘Control Valve Assembly’ on page 9.

Emergency Stop Assembly:1. Insert spring (711) into valve housing (917).2. Place ‘O’ rings (703) on plunger (707).3. Insert plunger into valve housing.4. Screw adapter (706) and E-Stop button (705) into valve housing.5. Tighten adapter until snug; do not over tighten.

Overload Valve Assembly:1. Replace ‘O’ rings (703) on plunger (702).2. Insert plunger (702) with ‘O’ rings in valve housing (917).3. Replace grommet (701) in cap (700).4. Install and tighten cap (700) flush to valve housing.5. Replace piston (712) if it appears damaged or worn.6. Insert ‘O’ ring (713) on piston (712).7. Replace gasket (714).

NOTICE

• Cover (719) retains spring (718), adjustment nut (717) and plate (715).Insert capscrews (901) and washers (902) in a crisscross pattern untiltightened evenly.

8. Insert adjusting screw (720). Refer to “OPERATION” section ‘Overload Device’ inProduct Information Manual for adjustment.

9. Secure control valve assembly to intake manifold using capscrews (951) andwashers (949). Use new gaskets (946) between control valve and manifold.

10. Test control valve for proper operation. Lift slide handle and move handle all theway in one direction and release hand. Control handle should return and lock inthe neutral position. Repeat for other direction.

11. Connect brake line.12. Connect air supply line.

n Motor Assembly


Crankshaft Assembly:1. If removed, press crank bearing (228) on crank shaft assembly (231). Press only

on inner race of bearing.2. Place crank assembly (231) on a work bench with oil slinger (230) down and slide

sleeve (232) (with tang up) on crankpin.3. Slide bushing (233) over sleeve (232) and first connecting rod ring (234) with

chamfer up.4. Install connecting rods (206) in same order as removed, with all feet pointing in

same direction, using first connecting rod ring (234) to hold one side ofconnecting rod feet.

5. Slide second connecting rod ring (234) over other side of connecting rod feetwith chamfer on ring facing down (toward stem of connecting rod).

6. Slide crank shaft (231) (valve end) over crankpin while simultaneously aligningtang on sleeve (232) with slot in crank shaft.

7. Rotate and position crank shaft (valve end) relative to crankpin to allowinstallation of lock pin (235).

8. Tap lock pin (235) in place and install pin nut (237). Refer to “TORQUE CHART”on page 15 for torque requirements.

9. Install cotter pin (236).10. Install roll pin (240) and bearing (228) into valve end of crank shaft.11. Check that all connecting rods move freely around crank.

Motor Body Assembly:1. Position crank assembly (231) in motor housing (217) with bearing (228) seated

and connecting rods (206) centered in cylinder holes.2. Assemble throttle valve assembly (500), gaskets (546) and exhaust flange (254)

to rotary valve housing (247) using four capscrews (551) and lockwashers (549).3. Install bearing (252) on rotary valve (250) by pressing only on inner race of

bearing. With exhaust flange (254) down, install rotary valve (250) into rotaryvalve housing (247). Slide rotary valve out of rotary valve housing far enough toinstall seal ring (251) on crank shaft end of rotary valve (250). Slide rotary valveback into rotary valve housing (247).

4. Install ‘O’ ring (244) into motor housing (217).5. Install rotary valve housing gasket (243) onto rotary valve housing (247). With

exhaust flange down on bench, install motor housing (217) on to rotary valvehousing (247). Check for any evidence of damage to ‘O’ ring (244) when rotaryvalve housing is fully engaged. Install capscrews (253). Refer to “TORQUE CHART”on page 15 for torque requirements.

NOTICE

• Make certain that roll pin (240) and three lugs on rotary valve (250) line upwith corresponding hole and lugs on crank shaft.

• Do not allow rotary valve (250) to slide back in rotary valve housing (247).If rotary valve slides in too far, seal ring (251) will lock up in internal groovesof rotary valve housing (247) and restrict further assembly.

6. Rotate crank assembly to position one connecting rod (206) at the top of itsstroke. Install a piston (204) with its rings (202) and (207) to connecting rod(206) with wrist pin (203) and retainer rings (205). Refer to Dwg. MHP0224on page 11 for oil and compression ring installation. A. Piston Head; B.Compression Ring Groove; C. Ends of compression rings must be staggered toavoid alignment with wrist pin opening and ends of oil ring; D. Colored ends ofoil ring must butt together and must not overlap; E. Install one compression ringon either side of oil ring; F. Wrist pin opening.

7. Install a new cylinder head gasket (209) before installing cylinder (201).


8. Install cylinder (201) over piston (204) by compressing both piston rings (202)and (207). Secure cylinder head to motor housing (217) with four capscrews(200). Refer to “TORQUE CHART” on page 15 for torque requirements.

9. Repeat Steps 6 through 9 with remaining cylinders.10. Rotate motor by hand. Motor should rotate without binding.11. Press bearing (228) into motor side of mounting flange (216).12. Install mounting flange (216) and gasket (226) on large base side of motor

housing (217). Make sure notches on both parts are aligned. Temporarily secureparts with one capscrew (4), lockwasher (3) and a 1/2-NC nut.

13. Lightly lubricate ‘O’ ring (5) and install in groove on motor adapter (6).

NOTICE

• ‘O’ ring (5) listed in step 13 refers to part number 51459 as shown on winchassembly Dwg. MHP2948 in the Parts Information Manual. This part must beplaced between mounting flange (216) and motor adapter (6).

14. Install eye bolts (213) and vent cap assembly (210) in motor housing (217).15. Ensure oil drain and level plugs (218) are installed.

Piston Head

Wrist pin opening

Install one compression ring on either side of oil ring

Ends of compression rings must be staggered to avoid alignment with wrist pin opening and ends of oil ring

Colored ends of oil ringmust butt together,and must not overlap

Compression Ring Groove

A

B

C

D

E

F

(Dwg. MHP0224)

n Reduction Gear Assembly


NOTICE

• During assembly of components apply a light coat of Loctite® 242 to allthreaded fasteners. Clean all mating surfaces. ‘O’ rings can be held in placewith a coating of EP grease applied to groove.

• It is extremely important to maintain a clean work area when reduction gearassembly is reassembled. During reassembly clean each part thoroughly andlightly coat with appropriate lubricant as described in ‘RecommendedLubricants’ of “LUBRICATION” section in the Product Information Manual.

1. If removed, install planetary gears (415) into planetary support (410) as follows:a. Install a pair of spring pins (412) into holes in planetary support (410).b. Install and center roller spacer (416) in planet gear (415) bore.c. Place 40 roller bearings (414) in each side of planet gear (415), a light coat

of grease will help to hold them in place. Place a thrust bearing (413) oneach side of planetary gear assembly and squeeze.

d. Depress one spring pin (412) and slide planetary gear assembly over it.Depress other side and tip gear assembly into planetary support. Rotate gearassembly around spring pins until shaft hole aligns.

e. Push planet gear shaft (417) into place. Repeat for remaining two gearassemblies.

f. Ensure each planet gear (415) rotates freely, without sticking or binding.2. Fasten thrust plate (449) to front cover (450) with screws (453) and loosely

tighten.3. Place a new gasket (447) on end cover (446). Install capscrews (452) through

front cover (450), gasket (447) and into end cover (446) and tighten.4. Lubricate and install new ‘O’ ring (442) into groove on end cover (446). Apply a

bead of Loctite® 515 sealant to mating surface.5. Align ring gear (444) with spring pins (443) and press ring gear on end cover

(446). Apply a bead of Loctite® 515 sealant to mating surface.6. Lubricate and install new ‘O’ ring (442) into input housing (438).

7. Slide shaft (445) into planetary assembly (440). Insert this assembly into ringgear (444).

8. Align spring pins (443) with input housing (438) and press down.9. Insert capscrews (448) through end cover (446) and into input housing (438).

Refer to “TORQUE CHART” on page 15 for torque requirements.10. Lubricate and install new ‘O’ ring (434) into groove on input housing (438). Apply

a bead of Loctite® 515 sealant to mating surface.11. Align ring gear (436) with spring pins (437) and press down.12. Install retaining ring (435) onto sun gear (433) and slide down shaft (445) into

planetary assembly (440).13. Install spacer (422) into sun gear (433).14. Install planetary assembly (430) into ring gear (436).15. Slide sun gear (429) onto shaft (445) and into planetary assembly (430). Insert

spacer (428) into sun gear (429).16. Insert bearing (426) into input housing (424). Install retainer ring (427).17. Lubricate and install new ‘O’ ring (434) into groove on input housing (424). Apply

a bead of Loctite® 515 sealant to mating surface.18. Align spring pins (437) with input housing (424) and press down.19. Insert capscrews (439) through input housing (438) and into input housing

(424). Refer to “TORQUE CHART” on page 15 for torque requirements.20. Insert spacer (423) into input housing (424) with bevel facing housing.21. Lubricate and install new ‘O’ ring (419) onto outer groove on spacer (418). Insert

spacer (422) into center recess in spacer (418). Place this assembly into planetarysupport (410) from planet gear end.

22. Insert retainer ring (420) in planetary support to hold spacer assembly in place.23. Lubricate and install new ‘O’ ring (408) into groove in input housing (424). Apply

a bead of Loctite® 515 sealant to mating surface.24. Align ring gear (409) with spring pins (404) and push down.25. Insert planetary support assembly into ring gear (409).26. Lubricate and install new ‘O’ ring (408) into groove in support (405). Apply a bead

of Loctite® 515 sealant to mating surface.27. Align support (405) with spring pins (404) and push down.28. Insert capscrews (425) through input housing (424) into support (405). Refer to

“TORQUE CHART” on page 15 for torque requirements.29. Insert ball bearing (407) into support (405).30. Insert oil seal (402) into seal support (400) (lip facing out).31. Lubricate and install new ‘O’ ring (403) in groove in support (405). Apply a bead

of Loctite® 515 sealant to mating surface.32. Align bolt holes with seal support (400) and support (405).33. Insert capscrews (401) through seal support, into support and tighten.34. Turn adjusting screw (453) in until end play is eliminated, then back it out two

turns.

n Drum Assembly

Refer to Dwgs. MHP2948 and MHP0875.

NOTICE

• During assembly of components apply a light coat of Loctite® 242 to allthreaded fasteners.

• Clean all mating surfaces. ‘O’ rings can be held in place with a coating of EPgrease applied to groove.

1. Position drum (96) in vertical position, with reduction gear side facing up.2. Remove plugs (406) from reduction gear support (405). Apply a bead of Loctite®

515 sealant on reduction gear surface that mates with adapter (52).3. Place adapter (52) on reduction gear and align bolt holes. There is one place on

adapter with no hole. This should be positioned over one of plug (406) holes.This becomes the drain/fill location (other 3 plugs will be blocked). Installcapscrews (50) through adapter (52) and attach nuts (48). Refer to “TORQUECHART” on page 15 for torque requirements. With a hammer and punch, drivespring pins (404) into adapter (52) until about 1/16 inch (1.5 mm) below surface.

4. Apply a bead of Loctite® 515 sealant to surface of drum (96) where adapter (52)will mate.

5. Install two 1/2 inch - 13 NC x 2 inch capscrews with suitable lifting eyes intothreaded holes in outer bolt pattern ring of drum adapter (52). Lift reduction gearassembly into drum (96). Align bolt holes and install capscrews (63) throughadapter (52) and into drum (96). Refer to “TORQUE CHART” on page 15 fortorque requirements.

6. Place drum in horizontal position.

n Winch Assembly

Refer to Dwgs. MHP2948 and MHP2944.

NOTICE

• During assembly of components apply a light coat of Loctite® 242 to allthreaded fasteners.

• Clean all mating surfaces. ‘O’ rings can be held in place with a coating of EPgrease applied to groove.

1. Install bearing (188) in outboard upright (184).2. Install outboard upright (184) on drum end. Ensure assembly is kept centered on

journal during this step.3. Install bearing retainer (191). Secure with capscrews (192). Refer to “TORQUE

CHART” on page 15 for torque requirements.4. Apply a bead of Loctite® 515 sealant to mating surface of outboard upright (184)

and install end cover (193). Secure with capscrews (582) and washers (306). Referto “TORQUE CHART” on page 15 for torque requirements.

5. Lubricate and install ‘O’ ring (43) on drum shaft (41).6. Insert drum shaft (41) into inboard upright (42), aligning dowel pin holes.7. Install dowel pins (62) flush or slightly below surface of drum shaft (41).8. Install capscrews (39). Refer to “TORQUE CHART” on page 15 for torque

requirements.9. Install inboard upright (42) onto reduction gear input shaft. Ensure splines on

drum shaft (41) align with splines in reduction gear.10. Install siderails (98) to uprights (42) and (184) and loosely secure using

capscrews (119) and washers (117).


11. Tap dowel pins (183) into position until flush with siderails.12. Tighten capscrews (119) evenly. Refer to “TORQUE CHART” on page 15 for torque

requirements.13. Lightly coat input shaft (7) with Loctite® 609 and press bearing (37) onto input

shaft (7). Install retainer ring (38).14. Insert retainer ring (45) into middle of coupling (49). Place onto reduction gear

end of input shaft (7).15. Install input shaft assembly into drum shaft (41). Install retainer ring (36) in

bore of drum shaft (41).

Instructions 16 through 27 cover winches with a disc brake. For winches withouta disc brake skip to instruction 28.

16. Slide splined hub (19) onto input shaft (7), gear teeth side in first. Install retainerring (38).

17. Place seven friction plates (16) and eight drive plates (17) onto splined hub (19).Lubricate all plates with ISO VG 46 (SAE 10W) oil, starting with a drive plate (17),then friction plate (16) until all plates are used.

18. Locate brake port. This should be 45 degrees to the right of top center. There aretwo other ports which should be straight up and straight down (one becomes thedrain, the other becomes a vent).

19. Install pipe plug (24) into lower port in brake housing (21). Install reducerbushing (22) and breather (23) into top port on brake housing (21).

20. Slide brake housing (21) over brake plates. Apply a coating of ISO VG 100 (SAE3EP) oil to inside surface of brake housing (21).

21. Lubricate and install seals (11) and (12) in brake piston (10) grooves so lips faceeach other. Do not over stretch seals during this procedure. Refer to Dwg.MHP0139 on page 12, A. Seal Lip; B. Seal; C. Brake Piston.

22. Install brake piston assembly into brake housing (21), ensuring that lips of sealsare not pinched or rolled over. Gently tap into position using a plastic mallet untilseated. (Cover brake port during tapping; oil can spray out.)

23. Lubricate and install brake springs (9) into each brake piston hole.24. Lubricate and install ‘O’ ring (15) into top groove in brake housing (21).25. Tap reaction plate (8) into motor adapter (6).

Seal Lip

Seal

BrakePiston

A

BC

(Dwg. MHP0139)

26. Mount motor adapter (6) to brake housing (21) and drum shaft (41). There is apair of holes on the outer bolt hole pattern that are aligned with bolt holes onthe inner hole pattern. The smaller diameter holes on the outer pattern are themotor mounting holes. The larger diameter holes on the inner pattern are thebrake housing mounting holes. The matched/aligned holes must be in the 6o’clock position.

27. There are three methods to compress springs (9) and fasten capscrews (2).a. Use three— 1/2 inch - NC x 5 inch socket head capscrews and evenly space

them around motor adapter (6). Mark each position. Evenly tighten themdown (compressing springs). Install regular capscrews (2). Refer to “TORQUECHART” on page 15 for torque requirements.

b. Remove the three extra long capscrews and replace with capscrews (2). Referto “TORQUE CHART” on page 15 for torque requirements.

c. Press down brake piston (10) until capscrews (2) can engage threads. Referto “TORQUE CHART” on page 15 for torque requirements.

WARNING

The air motor weighs approximately 260 lb. (118 kg). Adequately support airmotor while installing motor mounting capscrews.

28. Install ‘O’ ring (13) into center of seal sleeve (14). Slide this assembly onto inputshaft (7). Ensure that bevel is facing motor. Apply a coating of grease over sleeveand exposed input shaft.

29. Apply a coating of grease to oil seal (227) and crank bearing (228) in motor.30. Lubricate and install ‘O’ ring (5) in groove in motor adapter (6).31. Slide motor over input shaft (7). Be careful not to damage oil seal. Motor might

have to be rotated around input shaft slightly to align splines.32. Remove 1/2 inch nut from mounting flange (216). Push motor until flush with

motor adapter (6). Insert capscrews (4) and lockwasher (3) through motor intomotor adapter (6). Refer to “TORQUE CHART” on page 15 for torquerequirements.

33. On winches with a disc brake install fitting (31) into brake housing port. Attachtee fitting (86) and dump valve (30) to fitting (31) followed by vented fitting(29). Connect air line assembly (28), (20) and (27) between vented fitting (29)and hose fitting (26) on control valve.

n Manual Band Brake Assembly (optional feature)

Refer to Dwg. MHP0627.1. Clamp top of brake bands (128) together with a C-clamp.2. Slide this assembly over drum (96).3. Install capscrews (124), washers (123) and nuts (115) through bottom blocks on

brake bands (128) and tighten.4. Remove C-clamp.5. Install brake screw (114) through lugs on top of brake bands (128), with spring

(113) located between lugs.6. Slide tube (112) onto brake screw (114) followed by bearing (111).7. Thread handwheel (104) onto brake screw (114) and loosely tighten.8. Thread nut (110) onto brake screw (114) until 1/4 inch (6.5 mm) of threads are

exposed.9. Place anchor (118) over rear lug on brake band (128). Rotate brake band (128)

until bolt holes in anchor align with holes in rear siderail (98).10. Install capscrews (116) and washers (117) through anchor (118), siderail (98)

and into plate (122) and tighten.11. Install adjustment screw (127) through nut (120) and into support (126). Expose

1/4 inch (6.5 mm) of threads.12. Install capscrews (119) and washers (117) through siderail (98) and into support

(126) and tighten.13. Tighten handwheel (104) all the way tight. Screw adjustment screw up or down

until there is 1/16 to 1/8 inch (1.6 to 3.2 mm) clearance between screw (127)and lug on brake band (128).

14. When handwheel is loosened, brake band (128) should NOT touch drum surface.If brake band does touch drum then decrease gap in 1/16 inch (1.5 mm)increments until band does not touch.

15. With handwheel (104) fully tightened, place capscrews (106) through washers(125) and bracket (108) into brake band (128). Loosely tighten.

16. Place U-bolt (109) over tube (112) and through bracket (108). Place lockwashers(103) and nuts (102) onto U-bolt (109) and loosely tighten.

17. Move bracket (108) up or down until tube (112) is level. Tighten all capscrewsand nuts. Refer to “TORQUE CHART” on page 15 for torque requirements.

n Automatic Band Brake Assembly (optional feature)

Refer to Dwg. MHP2329.1. Install brake band halves on drum (96).2. Install capscrews (124), washers (123) and nuts (115) through bottom blocks on

brake bands (128) and tighten.3. Place anchor (118) over rear lug on brake band (128). Rotate brake band (128)

until bolt holes in anchor align with holes in rear siderail (98).4. Install capscrews (116) with washers (117) through bracket (74), siderail (98)

and anchor (118) into plate (122) and tighten.5. Install adjustment screw (127) through nut (120) and into support (126). Expose

1/4 inch (6.5 mm) of threads.6. Install capscrews (119) and washers (117) through siderail (98) and into support

(126) and tighten.7. Install nut (130) and clevis (51) on cylinder (134).8. Press bushings (54) into lever arms (34) and (61).9. Install link stud (56) in pivot nut (55). Connect link stud to brake band lug with

pin (58) and cotter pins (57). Bend cotter pin ends apart. Position pivot nutbetween lever arms (34) and (61).

10. Install capscrews (25), washers (32), spacers (35) with nuts (60) onto lever arms(34) and (61).

11. Install cylinder (134) so it connects with bracket (74) and between lever arms.Use pins (46) and (65) and secure with cotter pins (44). Bend ends of cotter pinsapart to secure cylinder when adjustment is complete.

12. Install fitting (73), dump valve (71), fitting (70) and hose (68) to the cylinder(134).

13. Adjust automatic brake as described under ‘Adjustments’ in the “MAINTENANCE”section on page 6.

n Limit Switch Assembly (optional feature)

Refer to Dwg. MHP2677.1. Secure limit switch assembly to upright (184) with capscrews (97) and washers

(96).2. Install hose connections. Refer to label 71459929 on page 13.


(Dwg. 71459929)

n Pendant Operated Pilot Control Valve Assembly

Valve Shaft A

(Dwg. MHP1022)

Brake Release Valve Installation and Adjustment:Refer to Dwgs. MHP2969 in the Product Information Manual and MHP1027on page 13, A. Sleeve.

NOTICE

• Valve assembly (341) shaft body is longer on one side of middle groove thanthe other. Correct placement of valve assembly is with longer shaft sectionlocated toward bottom of valve body (339). The shorter section will protrudeup, through valve body.

• To adjust brake release valve, ensure sleeve (338) is loose on shaft (331).If not loose, back off (turn counterclockwise) setscrew (337).

1. Rotate sleeve (338) to place the longer edge on top. Refer to Dwg. MHP1027on page 13.

2. Using gentle hand pressure to prevent damage to valve assembly (341) shaftbody, press valve assembly down until ball is in firm contact with sleeve (338).

Sleeve A

(Dwg. MHP1027)

CAUTION

• Do not disassemble pilot cap assemblies. Valve cylinder and valve cap arepress fit together. Close fit tolerances cannot be maintained if disassembled.If repair is required, replacement of the pilot cap assembly is required.

Pendant Valve Adjustment:1. Lubricate threads and install capscrews (366) and (368), lockwashers (924),

gasket (340) and pilot cap assembly (367) to valve body (339). Tighten capscrew,but do not torque.

2. Reaching into exhaust port on valve body (339), grasp shaft (331) and check formovement in either direction. Any movement requires adjustment.

3. If there is shaft movement, remove pilot cap assembly and back out setscrews inpistons 1/4 turn. Repeat until there is no movement.

4. When adjustment is complete, tighten capscrews (366) and (368). Refer to“TORQUE CHART” on page 15 for torque requirements.

Adapter Installation:1. Place gasket (358) on mating face of adapter (369) and align holes with valve

body (339). Coat threads with Loctite® 242 and, from the bottom side of adapter,install capscrews (370) into valve body. Refer to “TORQUE CHART” on page 15for torque requirements.

n Two Function Pendant Assembly (optional feature)

Refer to Dwg. MHP1677 with emergency stop or MHP2346 without emergency stop.1. Install ‘O’ rings (443) and (449) along with protector (451) on valves (452).

Install valve assemblies in handle (454).2. Install levers (453) in pendant handle (454) with pin (447). Stake pin in pendant

handle at both ends to secure.3. Install screws (448) in levers.4. Install balls (446) and springs (445) in handle (454). Secure in position with

plugs (444).5. On pendants with emergency stop, install emergency stop button (441). On

pendants without emergency stop, install plug (470).6. Install exhaust washer (457) and secure in handle with retainer ring (458).7. Attach hoses to fittings located on top of pendant handle. Locate hoses to fittings

as shown in Dwg. MHP2398 in Product Information Manual.

n Brake Connection

Refer to Dwg. MHP2239.Winches without overload valve and/or emergency stop will use configuration 3. Discand automatic band brake will require a tee at disc brake port. Contact factory forreplacement.

Winches with an overload valve and/or emergency stop will use configuration 4 andwill require a tee at brake port.

n Winch Guard Assembly (optional feature)

Refer to Dwg. MHP2946.1. Secure frames (801), (802), (803) and (810) to uprights (42) and (184) with

capscrews (408) and washers (306).2. Secure lifting lugs (194) to uprights with capscrews (197) and washers (117).3. Install panels (805) and (807) one at a time, beginning with the lower (805)

panel.4. Install first crossbar (806) with nuts (804).5. Attach panel to crossbar (806).6. Hold second panel (805) in place and install second crossbar (806) by sliding

through (hooked) edges of the two panels.7. Secure crossbar (806) with nuts (804).8. Continue until all panels are in place.9. Tighten all fasteners and check winch guard is secure. Ensure wire rope does not

interfere with winch guard during winch operation.

n Drum Locking Pin Assembly (optional feature)

Refer to Dwg. MHP2675.1. Install new bushing (311) in winch upright (184) if replacement was required.2. Install shaft (304) in handle (301) and secure with nut (303) and capscrew (302).3. Install cover (307) on shaft (304) so capscrew holes are aligned with holes in

upright when handle (301) is in a horizontal position.4. Install housing (308), spring (310), and drum lock pin (312) on shaft (304).

Tighten drum lock pin (312) on thread of shaft (304). Apply a small amount ofLoctite® 242 to threads. Refer to “TORQUE CHART” on page 15 for torquerequirements.

5. Install drum locking pin assembly in upright and secure with capscrews (305) andwashers (306).

n Press Roller Assembly (optional feature)

Refer to Dwg. MHP2945.1. If bushings (410) have been removed, replace and install in uprights (42) and

(184), and in both ends of arm (407). Grease bushings (410) for ease ofinstallation.

2. Install center roller (402) in press roller arm (407) and install shaft (411) throughboth parts.

3. Install outside rollers (401) and secure with capscrews (408) and washers (409).Apply a small amount of Loctite® 242 to threads of capscrews.

4. Install springs (405) and (406) so that the shorter end of the springs is towardthe inner portion of the arm (407) where the pins (413) are located.

5. One person positions press roller so the top of arm (407) is curved up toward theunderside of the drum (96), and holds press roller in place while the other personcompletes installation.

6. Adjust both springs (405) and (406) so that the long end of springs is on theinside of siderail (98).


NOTICE

• Do not engage shorter end of spring behind pins of arm (407) until aftershaft (403) has been installed and secured, and press roller assemblyadjusted to center of drum.

7. Install shaft (403) through hole in leg of upright (42) only.8. Install one collar (404) on end of shaft (403) between upright and press roller

assembly. Do not tighten collar (404) until steps 11 and 12 have been completed.9. Install shaft (403) through press roller assembly (400).10. Install second collar (404) and slide shaft through hole in leg of upright (184).

Ensure that the long end of springs (405) and (406) are still between the siderail(98) and drum (96). Do not tighten collar (404) until steps 11 and 12 have beencompleted.

11. Secure shaft (403) to uprights using capscrews (408) and washers (409). Applya small amount of Loctite® 242 to threads of capscrews.

12. Adjust press roller assembly so that it is centered between the drum flanges, andtighten collars (404).

13. Use extreme caution and pry short end of one spring (405) so that it is positionedbehind the pin (413) of arm (407).

14. Repeat step 13 for spring (406).

NOTICE

• Use caution when installing springs (405) and (406); springs are undertension.

n Testing

n Operational Test

Prior to initial use, all new, altered or repaired winches shall be tested to ensureproper operation.

a. Check oil level in motor, reduction gear assembly and disc brake are correct.b. To initially ‘break in’ new or overhauled motors, operate without load, in both

directions, for 15 minutes at 100 - 200 RPM.

c. New Brake Band Lining Run-in Procedure: All new brake band linings requirea ‘run-in’ period.

d. Operate the winch without load in the payout direction while graduallyapplying the brake. Allow the brake to slip for approximately one minute.Winch motor may stall as brake band lining fully engages. Do not allow braketo overheat.

e. Check operation of brakes. Adjust if necessary as described in the“MAINTENANCE” section.

f. Check operation of limit switches, locking devices and all safety devices whenequipped.

g. Check foundation mounting fasteners are secure.h. Install winch guard.

n Load Test

Prior to initial use, all extensively repaired winches shall be load tested by or underthe direction of an Ingersoll Rand trained Technician and a written report furnishedconfirming the rating of winch. Test loads shall not be less than 100% of rated linepull and should not exceed 125% of rated line pull. To test winch at 125% of ratedload apply following load with wire rope on the first layer of the drum:

FA10i Winch 34,500 lb. (15,698 kg)

NOTICE

• Testing to more than 125% of rated line pull may be required to set overloaddevice or comply with standards and regulations set forth in areas outside ofthe USA.

n Limit Switches (optional feature)

Operate winch through three complete cycles to ensure consistent limit switchoperation within +/- 2 feet (0.6 m) of set points. Refer to 'Limit Switch Adjustment'procedure in Product Information Manual to establish set points.


TORQUE CHART

Standard Coarse Thread Torque

SizeSAE Grade 5 SAE Grade 8

Dry Lubricated PTFE Dry Lubricated PTFE1/4-20 8-10 6-7 4 12-14 9-10 5-65/16-18 17-20 13-15 8-9 25-28 18-21 11-133/8-16 31-35 23-26 14-16 44-49 33-37 20-227/16-14 49-56 37-42 22-25 70-79 52-59 31-361/2-13 75-85 57-64 34-38 106-121 80-90 48-549/16-12 109-123 82-92 49-55 154-174 115-130 69-785/8-11 150-170 113-128 68-77 212-240 159-180 95-1083/4-10 267-302 200-227 120-136 376-426 282-320 169-1927/8-9 429-487 322-365 193-219 606-687 455-515 273-3091-8 644-729 483-547 290-328 909-1030 681-772 409-463

1 1/8-7 794-900 596-675 357-405 1288-1460 966-1095 580-6571 1/4-7 1121-1270 840-952 504-571 1817-2059 1363-1545 818-927

Standard Fine Thread Torque

SizeSAE Grade 5 SAE Grade 8

Dry Lubricated PTFE Dry Lubricated PTFE1/4-20 10-11 7-8 4-5 14-15 10-12 6-75/16-24 19-22 14-16 9-10 27-31 20-23 12-143/8-24 35-40 26-30 16-18 49-56 37-42 22-257/16-20 55-63 41-47 25-28 78-88 58-66 35-401/2-20 85-96 64-72 38-43 120-136 90-102 54-619/16-18 121-137 91-103 55-62 171-194 128-146 77-875/8-18 170-193 127-144 76-87 240-272 180-204 108-1223/4-16 297-337 223-253 134-152 420-476 315-357 189-2147/8-14 474-537 355-403 213-242 669-758 502-568 301-3411-12 704-798 528-599 317-359 995-1127 746-845 448-507

1 1/8-12 1023-1159 767-869 460-572 1444-1637 1083-1227 650-7361 1/4-12 1425-1615 1069-1211 641-727 2012-2280 1509-1710 905-1026

Metric Coarse Thread Torque

SizeClass 8.8 / 9.8 Class 10.9

Dry Lubricated PTFE Dry Lubricated PTFEM6x1 9-10 6-7 4 11-12 8-9 5-6

M8x1.25 21-23 16-18 9-11 26-30 20-22 12-13M10x1.5 41-47 31-35 19-21 53-60 39-45 24-27M12x1.75 71-81 54-61 32-36 91-103 68-77 41-46

M14x2 115-130 86-98 52-59 147-166 110-125 66-75M16x2 165-187 124-140 74-84 227-257 170-193 102-116

M20x2.5 321-364 241-273 144-164 443-502 332-376 199-226M22x2.5 439-497 329-373 197-224 605-686 454-514 272-309M24x3 556-630 417-473 250-284 767-869 575-652 345-391

M30x3.5 1103-1250 827-938 496-563 1521-1724 1141-1293 685-776Metric Fine Thread Torque

SizeClass 8.8 / 9.8 Class 10.9

Dry Lubricated PTFE Dry Lubricated PTFEM8x1 22-25 17-19 10-11 28-32 21-24 13-14

M10x1.25 44-49 33-37 20-22 56-63 42-47 25-28M12x1.25 78-89 59-67 35-40 100-113 75-85 45-51M14x1.5 125-141 93-106 56-64 159-180 119-135 72-81M16x1.5 176-200 132-150 79-90 243-276 183-207 110-124M18x1.5 257-291 193-219 116-131 355-402 266-302 160-181M20x1.5 358-406 268-304 161-183 494-559 370-420 222-252M22x1.5 484-548 363-411 218-247 667-756 500-567 300-340M24x2 609-690 456-517 274-310 839-951 630-713 378-428M30x2 1227-1390 920-1043 552-626 1692-1918 1269-1438 761-863

Notes:1. Definitions:

DRY: Cadmium plate, zinc plate, and oiled fasteners.LUBRICATED: Molysulfide paste, carnaba wax, molysulfide grease andcopper-based anti-seize coated fasteners.PTFE: 2% minimum PTFE (teflon) coated fasteners.

2. All torque values foot-pounds unless noted.3. SAE grade 5 equivalent to ASTM A325 Type 2 and ASTM A449.4. SAE grade 8 equivalent to ASTM A354 Grade BD, ASTM A490 Type 1.5. If mixing fasteners use lowest torque value.6. Torque values 75 to 85% of fastener proof load ref.


Maintenance Product Information · Refer to the Product Information Manual and Product Parts...

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Transcript of Maintenance Product Information · Refer to the Product Information Manual and Product Parts...