Product Maintenance

Information

Air Powered
Man Rider Winch
TM

MR150K Series

(Dwg. MHP3377)

Save These Instructions

Form MHD56492
Edition 1
September 2015
R
47512571001
© 2015 Ingersoll-Rand
Only allow Ingersoll Rand trained technicians to perform maintenance on this product. For additional information contact Ingersoll Rand factory or nearest Distributor.
Manuals can be downloaded from http://www.ingersollrandproducts.com.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate all
warranties.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
These are the “original instructions”. Other languages are a translation of the “original instructions”.

Table 1: Product Information Manuals

Part/Document
Publication Part/Document Number Publication
Number
Product Safety Manual (Man Rider) MHD56251 Product Parts Information Manual MHD56489
Product Instruction Manual MHD56490

INSPECTION
Frequent inspections should be performed on equipment in regular service. Refer
to Product Information Manual.

Refer to Table 2 ‘Inspection Classifications’ on page 2 for suggested winch

inspection classifications for Periodic Inspection intervals. Select conditions most
appropriate 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

1. Siderails and Uprights: Check for deformed, cracked or corroded main Table 3: Wire Rope
components. Replace damaged parts. Number Broken Wires Number Broken Wires
2. Fasteners: Check retainer rings, capscrews, nuts and other fasteners on winch, Rope Construction in rope over a length in rope over a length
including mounting bolts. Replace if missing or damaged and tighten if loose. Type 6x nominal diameter 30x nominal diameter
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 6 x 19S-IWRC Single- 3 6
the following: layer rope
a. Build-up of dirt and corrosion. Clean with steam or a stiff wire brush to 6 x 37M-IWRC Single-
remove dirt and corrosion if necessary. 10 19
layer rope
b. Loose or damaged end connection. Replace if loose or damaged. 5. All Components: Inspect for wear, damage, distortion, deformation and
c. Check wire rope anchor is secure in drum. cleanliness. If external evidence indicates damage, disassemble as required to
d. Verify wire rope diameter. Measure the diameter of the wire rope from conduct a detailed inspection. Inspect gears, shafts, bearings, sheaves, springs
crown-to-crown throughout the life of the wire rope. Recording of the actual and covers. Replace worn or damaged parts. Clean, lubricate and reassemble.
diameter should only be done with the wire rope under equivalent loading 6. Brakes: Individually test brakes installed to ensure proper operation. Brakes
and in the same operating section as accomplished during previous must hold a 125% rated load at mid drum without slipping. If indicated by poor
inspections. If the actual diameter of the wire rope has decreased more than operation or visual damage, disassemble and repair brake(s). Check all brake
1/64 inch (0.4 mm) a thorough examination of the wire rope should be surfaces for wear, deformation or foreign deposits. Clean and replace
conducted by an experienced inspector to determine the suitability of the components as necessary. Adjustments can be made to the band brake to
wire rope to remain in service. Refer to Dwg. MHP0056 on page 2. compensate for normal brake lining wear. Refer to
ʽAdjustmentsʽon page 7. If brake band cannot be adjusted to hold rated load,
A replace the brake band assembly. Adjustments cannot be made to the disc brake.
The disc brake must be repaired as described in “MAINTENANCE”
sectionID# Maintenance does not exist in this book!.
7. Foundation or Supporting Structure: Check for distortion, wear and continued
ability to support winch and rated load. Ensure winch is firmly mounted and that
fasteners are in good condition and tight.
B 8. Control Valve: Check control valve operation. Ensure control valve handle
moves freely in both directions without sticking and automatically returns to
neutral when released. Ensure locking button moves freely and locks control
handle in neutral when not depressed.
9. Limit Switches: Operate winch in both directions to activate limit switches. Limit
switches should engage (stop winch operation) at established settings (+ / - 2 ft
[+ / - 0.6 m]). Reset limit switch by operating winch in opposite direction. Refer
to ‘Limit Switch Adjustment’ procedure in Product Instruction Manual.
10. Emergency Stop Valve: During winch operation verify the emergency stop
C valve operation. Valve must stop winch operation quickly. Valve must reset
properly. Refer to ‘Emergency Stop Valve’ in the “OPERATION” section in Product
Instruction Manual for procedures.
11. Overload Device: Ensure overload device is properly set to stop the winch when
loads exceed 150% (+/- 25%) of winch rated capacity. If winch does not shut
down, contact your distributor or the factory for repair information.
12. Slack Line Detector: Inspect rollers for wear and grooves or ridges. Replace
worn or grooved rollers. Check arms move freely and activate sensor valve.
Ensure rollers rotate freely. Check sensor valve plunger operation. If damaged
D or stiff, replace sensor valve.
13. Press Roller: Inspect rollers for wear and grooves. Ensure rollers freely rotate.
(Dwg. MHP0056) Replace rollers if worn or grooved. Replace bearings if rotation is rough or stiff.
14. Emergency Lowering Device: Provide auxiliary supply air to emergency
e. Inspect rope for broken strands/wires: When broken wires are evident close lowering power entry port and activate valve. Verify winch operation.
to, or within, the termination, even if few in number, are indicative of high 15. Drum Guard: Verify fasteners are tight and in good condition. Ensure guard is
stresses at this position and can be caused by incorrect fitting of the in good condition and panels are correctly positioned.
termination. The cause of this deterioration shall be investigated and, where 16. Operator Orientation Guard: Verify fasteners are tight and in good condition.
possible, the termination shall be remade, shortening the rope if sufficient Ensure guard is in good condition and panels are correctly positioned.
length remains for further use, otherwise the rope shall be discarded. One 17. Labels and Tags: Check for presence and legibility of labels. Replace if damaged
valley break may indicate internal rope deterioration, requiring closer or missing.
inspection of this section of rope. When two or more valley breaks are found
in one lay length, the rope should be considered for discard. If a complete
strand fracture occurs, the rope shall be immediately discarded. Where
broken wires are very close together, constituting a localized grouping of
such breaks, the rope shall be discarded. If the grouping of such breaks
occurs in a length less than 6d or is concentrated in any one strand, it may
be necessary to discard the rope even if the number of wire breaks is smaller
than the maximum number, refer to table on page 2

2 Form MHD56492 Edition 1

n Records and Reports n Maintenance Intervals
Inspection records, listing all points requiring periodic inspection should be Refer to Table 4 ‘Maintenance Interval Chart’ on page 4 for recommended
maintained for all load bearing equipment. Written reports, based on severity of maintenance schedule.
service, should be made on the condition of critical parts as a method of
documenting periodic inspections. These reports should be dated, signed by the NOTICE
person who performed the inspection, and kept on file where they are readily
available for review. • Perform an annual winch load test for all applications.

Form MHD56492 Edition 1 3

Table 4: Maintenance Interval Chart
Normal Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 45 days or 125 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.
1 year or 2 years or 3 years or 4 years or 5 years or 6 years or 8 years or
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs 8,000 hrs
Inspect Motor X X X X
Inspect Automatic Band Brake * X X X X X X X

Inspect Disc Brake X X

Inspect Gearbox X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
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
Press Roller X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X
Heavy Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 80 hours
Grease Fittings Lubricate grease fittings every 90 days or 250 hours
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
1 year or 2 years or 3 years or 4 years or 5 years or 6 years or 7 years or 7,000
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs hrs
Inspect Motor X X X
Inspect Automatic Band Brake * X X X X X X X
Inspect Disc Brake X X
Inspect Gearbox X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
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
Press Roller X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X
Severe Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 80 hours
Grease Fittings Lubricate grease fittings every 90 days or 250 hours
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
1 year or 2 years or 3 years or 4 years or 5 years or 6 years or 8 years or
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs 8,000 hrs
Inspect Motor X X X X X
Inspect Automatic 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
Inspect Control Valve X X X X X X
Inspect Drum, Housings and Main Frames X X X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X X X
Limit Switches X X X X X X X
Press Roller X X X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X

Note: Hours are for actual winch drum rotation.

4 Form MHD56492 Edition 1

* Do not disassemble air cylinder unless brake operation or visual inspection indicates a requirement.

Recommend complete general overhaul.

INSPECTION REPORT

Ingersoll Rand MR150K Series Air Winches

Model Number: Date:

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection:
(_____ Months _____ Years)
2. Discrepancy(s) noted during Frequent Inspection Operating Environment:
Normal ____ Heavy____ Severe ____
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________
Refer to the Product Instruction Manual and Product Parts Information Manual and “INSPECTION” section for general inspection criteria. Also, refer to appropriate National
Standards and Codes of practice. If in doubt about an existing condition, contact the nearest Ingersoll Rand Distributor or the factory for technical assistance.
CONDITION CORRECTIVE ACTION
COMPONENT NOTES
Pass Fail Repair Replace
Uprights and Siderails
Drum Band Brake (125% Load Test)
Disc Brake (125% Load Test)
Drum Band Brake (Visual Inspection)
Disc Brake (Visual Inspection)
Motor
Controls
Limit Switches
Air System
Fasteners ---
Emergency Stop Valve
Overload Device ---
Reduction Gears
Labels and Tags ---
Shafts
Drum Guard
Wire Rope Wedge ---
Emergency Lowering Device ---
Slack Line Device ---
Press Roller
Wire Rope ---
Other Components (list in NOTES
section)
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 set overload device or comply with standards and regulations
set forth in areas outside the USA.
This form can be photo copied and used as an inspection record.

Form MHD56492 Edition 1 5

 TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by personnel
instructed 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 REMEDY

Winch 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. Inspect brake piston seals and replace if seals appear to be leaking.
Drum brake does not release. Refer to “Adjustments” in “MAINTENANCE” section on page 7.
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 at
winch inlet and purge with clean, dry air or nitrogen.
Load continues to move when winch is Brake is slipping. Check brake friction discs and automatic band drum brake wear.
stopped. 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.
Lower limit switch activated. Raise load and check limit switch settings.
Winch hauls-in but does not payout.
Slack line detector activated. Determine cause of slack line and correct the problem.
Winch does not lift load or does not lift Motor may be damaged. Remove and disassemble motor as described in on page 7. Examine all parts and
rated capacity. Winch does not lift load. replace any that are worn or damaged.
Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements listed
in the “SPECIFICATIONS” section in Product Instruction Manual. Clean air line filter.
Brake is not releasing. Check brake release pilot hole is not restricted. Check seals on cylinder piston are
not 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 winch Motor may be damaged. Disassemble, inspect and clean motor. Replace any broken or damaged parts.
does not operate. Insufficient air supply. Ensure air pressure at winch inlet is at least 70 to 100 psig (5 to 7 bar) 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.
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
ID# Maintenance does not exist in this book!. Inspect all parts and replace all worn
or damaged parts.
Brake(s) not releasing. Refer to brake sections below.
Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements. Refer
to “SPECIFICATIONS” section in Product Instruction 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 at
winch inlet and purge with clean, dry air or nitrogen.
Motor may be damaged. Disassemble, inspect and clean motor. Replace any broken or damaged parts.
Throttle or pendant lever moves but winch
Insufficient air supply. Ensure air pressure at winch inlet is at least 70 to 100 psig (5 to 7 bar) at rated volume.
does not operate.
Clean air line filter.
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.
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
release brake, 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 discs
do not move, disassemble and inspect disc brake as described in
ID# Maintenance does not exist in this book!.

6 Form MHD56492 Edition 1

 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

this winch.
• Shut off air system and depressurize air lines before performing any
maintenance. A
• Do not use Trichloroethylene to clean parts.
• Use of other than genuine Ingersoll Rand parts may result in safety hazards, Securing
decreased performance and increased maintenance and may invalidate all Screw
warranties.
• After performing any maintenance on the winch, test winch to 125% of its Adjustment
rated line pull at mid drum before returning to service. (Testing to more B
than 125% of rated line pull may be required to comply with standards and Screw
regulations set forth in areas outside the USA.)
(Dwg. MHP2683)
NOTICE 1. Connect winch to an air supply.
2. Release securing screw and adjusting screw in order to increase or decrease the
• Refer to Product Instruction and Safety Manuals for specific information. SWL (increase SWL by tightening the adjusting screw). Adjustment must be
made for an overload of 125% maximum of SWL.
3. Tighten securing screw.
n General 4. Check winch operation at rated load. If necessary, repeat adjustment.

The correct disassembly (to prevent loss or damage of good parts), repair, assembly, n Automatic Band Drum Brake
testing and adjusting are critical to proper winch operation. Maintenance
procedures are technical in nature and require training and experience to Refer to Dwg. MHP2880 on page 7.
accomplish correctly. In addition, repair and testing require specialized equipment
that is not typically found at the products mounting site. 1. Loosen locknut ‘B’.
2. Tighten nut ‘A’ until the adjustment dimension 0.43 to 0.51 inch (11 to 13 mm)
Proper use, inspections and maintenance increase the life and usefulness of your is achieved.
Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and 3. Tighten locknut ‘B’.
all machined threads with applicable lubricants. Use of anti-seize compound and/ 4. Check brake operation.
or thread lubricant on capscrew and nut threaded areas prevents corrosion and
allows for easy disassembly of components.

It is extremely important that anyone involved with maintaining the product be

familiar with the servicing procedures of these products and be physically capable
of conducting 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
0.43-0.51 inch
11-13 mm

industry standards.

Ingersoll Rand cannot know of or provide all the procedures by which product
operations or repairs may be conducted and the hazards and/or results of each
method. If operation or maintenance procedures not specifically recommended by
the manufacturer are conducted, make sure that product safety is not endangered
by the actions taken. If not sure 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
specified elsewhere.

n Maintenance Intervals
Refer to Table 4 ‘Maintenance Interval Chart’ on page 4 for recommended
maintenance schedule.

n Adjustments
n Limit Switches
Refer to “Limit Switches” section in Product Instruction manual. Nut ‘A’ Locknut ‘B’
n Overload Device (Dwg. MHP2880)

WARNING
n Disc Brake
No brake adjustment is required. Refer to Dwg. MHP2849 on page 8, A. Piston;
• Overload is factory set and sealed with red paint and should not be adjusted B. Friction Plate; C. Drive Plate; D. Reaction Plate; E. 0.047 inch minimum (1.2 mm
without consulting an Ingersoll Rand trained technician. minimum).

1. Remove motor as described in ‘Motor Removal’ section on page 8.

2. Remove the reaction plate (57), splined hub (53), friction plates (55) and (58),
and drive plates (56).
3. Inspect the friction plates (55) and (58) for wear. If friction plate thickness is
uneven or is less than 0.047 in (1.2 mm), replace all friction plates.

No further disassembly is required, if only the brake friction discs are being inspected.
Ensure friction and drive plates are assembled in the correct order. Refer to ‘Disc
Brake Assembly’ on page 9.

Form MHD56492 Edition 1 7

 8. Store motor in a clean area until needed. If repair is required refer to specific
disassembly sections.

n Drum Guard Removal

Refer to Dwg. MHP3312.
E
1. Remove capscrews (8) and lockwashers (64)that secure the drum guards (7 and
0.047 inch minimum 9) and bottom panels (406) to endframes.
(1.2 mm minimum) 2. Remove drum guard (216), left panel (217) and right panel (218).

n Automatic Band Drum Brake Disassembly

Refer to Dwg. MHP3298.

1. Disconnect and tag the air lines.

A Piston Friction 2. Loosen nut (151) until brake band (111) is slack on drum.
B Plate 3. Remove one cotter pin (113) from each pin (112) and tap out pins (112) from
brake band ends.
Drive 4. Remove brake band (111) and adjustment screw (149). Remove capscrews (156)
C Plate
and lockwashers (64) that secure housing (147) to side rail (68). DO NOT
D disassemble brake cylinder assembly. Contact an Ingersoll Rand trained service
technician for cylinder disassembly and repair.
Reaction
Plate n Limit Switch Disassembly
(Dwg. MHP2849)
Refer to Dwg. MHP3372.
NOTICE
CAUTION
• Original brake disc thickness is 0.059 in (1.5 mm)
• It is not recommended to disassemble limit switch. Contact factory if repair
is required.
n Disassembly 1. Remove and tag hose connections if not already done.
2. Remove nuts (262) from rods (263). Remove cover (505), gasket (490) and
n General Disassembly Instructions housing (486) from limit switch adapter (450).
3. Remove capscrews (499) and pull spindle switch assembly (501) from limit switch
The following instructions provide necessary information to disassemble, inspect, adapter (450).
repair, and assemble product. Parts drawings are provided in Product Parts 4. Store limit switch assembly in a clean, dry area until winch reassembly.
Information Manual.
If a product is being completely disassembled for any reason, follow the order of n Press Roller Disassembly
topics as they are presented. It is recommended that all maintenance work on
product be performed in a clean dust-free work area. Refer to Dwgs. MHP3313.
In the process of disassembling product, observe the following:
1. Compress ends of springs (167) and (169) to disengage from spacer (66) and pin
1. Never disassemble product any further than is necessary to accomplish needed on press roller arm (163).
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 CAUTION
break the seal.
3. Do not heat a part with a flame to free it for removal, unless part being heated • Use care when releasing springs (167) and (169) from press roller. Springs
is already worn or damaged beyond repair and no additional damage will occur are under tension.
to other parts.
2. Remove capscrews (183) and lockwashers (73). Remove press roller assembly
In general, products are designed to permit easy disassembly and assembly. The from spacer (66).
use of heat or excessive force should not be required. 3. Remove capscrews (161) and washers (162) from both sides of roller arm (181).
Remove frames (176) and springs (169).
4. Keep work area as clean as practical, to prevent dirt and other foreign matter 4. Remove capscrews (161) and washers (162) from both sides of roller arm (181).
from getting into bearings or other moving parts. Remove press rollers (184).
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. n Slack Line Device Disassembly
6. When grasping a part in a vise, always use leather-covered or copper-covered
vise jaws to protect the surface of part and help prevent distortion. This is Refer to Dwgs. MHP3296.
particularly true of threaded members, machined surfaces and housings.
7. Do not remove any part which is a press fit in or on a subassembly unless removal 1. Remove and tag hose connections if not already done.
of that part is necessary for repairs or replacement. 2. Remove locknuts (301) and washers (307) from shoulder screws (310).
8. When removing ball bearings from shafts, it is best to use a bearing puller. When 3. Remove spacers (308) and lift off slack wire arm assembly.
removing bearings from housings, drive out bearing with a sleeve slightly 4. Tap shoulder screws (310) from uprights (62) and remove bearings (309).
smaller than outside diameter of bearing. The end of sleeve or pipe which 5. Remove capscrews (302) and lockwashers (73) from axle (304).
contacts bearing must be square. Protect bearings from dirt by keeping them 6. Remove locknuts (301) and lockwashers (73) from roller axle (305). Separate arms
wrapped in clean cloths. (303), rollers (306) and axles (304) and (305).
7. Remove capscrews (324) and lockwashers (2) from protector (323).
n External Components Removal 8. Remove protector (323) and sensor valve (327) from upright (62).

Refer to component disassembly sections for further repair. n Winch Base and Drum Disassembly
1. Shut off and bleed down main air supply to winch. Refer to Dwgs. MHP3312on page 8 to remove motor assembly from the winch.
2. Disconnect and tag all external air lines.
3. Remove inboard and outboard guarding. 1. Remove external components. Refer to ‘External Components Removal’ section
4. Remove tube guarding. on page 8.
5. Remove water separator, regulator, filter, and lubricator assembly. 2. Stand winch in a vertical position with motor end up.
6. Remove press roller assembly from spacer. Refer to press roller disassembly. 3. Remove capscrews (86), and washers (125) that secure motor, reduction gear
7. Remove drum guards. Refer to drum guard disassembly. and brake assembly to drum end cover (76). Set assembly to one side for further
8. Remove slack wire rope device from spacer. Refer to press roller disassembly. disassembly if needed.
9. Remove limit switch assembly. Refer to limit switch disassembly. 4. Remove capscrews (65) and (67), nuts (63) and lockwashers (64) to remove
spacers (66) and lifting lugs (69).
n Powerhead Removal (Controls, Motor, Disc Brake, and Reducer) 5. Remove capscrews (67), nuts (63) and lockwashers (64) to remove siderails (68).
6. Remove upright (62) and tube (70).
Refer to Dwg. MHP3312 and MHP3375. 7. Remove capscrews (50) and lockwashers (73). Separate drum end cover
assembly from upright (62).
1. Shut off and bleed down main air supply to winch. 8. Remove bearing (76) and oil seal (77) from drum (60) if not removed with drum
2. Remove tube guarding. If applicable remove operator orientation guarding. end cover (78).
3. Disconnect and tag air lines. 9. Carefully turn drum over so limit switch end is up.
4. Stand winch in a vertical position, with the motor end up. Ensure winch is 10. Remove upright (62) from drum (60).
properly supported. 11. Remove capscrews (50) and lockwashers (73) from drum end cover (78).
5. Remove four capscrews (86) and washers (2) that secure motor and control valve 12. Remove drum end cover (78) from upright (62).
assembly to endframes (62). 13. Remove bearing (76) and oil seal (77) from drum (60) if not removed with drum
6. Carefully pull motor assembly from winch. end cover (78).
7. Clean capscrews (86) and threaded holes with Loctite® 7063 or equivalent so
they are free of Loctite® residue.

8 Form MHD56492 Edition 1

n Disc Brake Disassembly 1. To separate control valve (100) from motor assembly, remove capscrews (137)
and (168) with lockwashers (2).
2. Remove capscrews (118) and lockwashers (2) from stop plate (119). Remove stop
Refer to Dwg. MHP3376. plate.
3. Partially remove capscrew (126) just far enough to allow emergency stop
1. Make sure the disc brake has been pulled from the motor and reducer assembly. housing assembly to be removed. Place emergency stop housing assembly to
2. Remove capscrews (25) (black) allowing brake and reducer assembly to be one side for later disassembly.
removed together. 4. Remove spools (142) from valve housing (135).
3. Use the two threaded puller holes in the piston (51) to remove piston (51) and 5. Completely remove capscrew (126) and lockwasher (125).
brake reaction plate (57) from brake housing (41). 6. Remove lever assembly, coupling (124) and spring (116).
4. Remove drive plates (56), friction plates (55) and (58), spacer (54) and splined 7. Do not disassemble handle unless repairs are needed. To disassemble handle,
hub (53). Note position for later assembly. tap out pin (120) and unscrew cap (121). Remove handle spool (123) and spring
5. Remove ‘O’ ring (16) and ‘O’ ring (52) from piston (51) and discard. (130).
8. Remove retainer (140), spindle shaft (131) and gear (138).
n Reduction Gear Disassembly 9. Remove retainer (140), spindle shaft (131) and gear cam (139).
10. Remove pins (132) from spindle shafts (115).
Refer to Dwg. MHP3376. 11. Remove bushings (133) and bushings (141).

1. Remove disc brake assembly refer to on page 9 Emergency Stop:

2. Remove fill plug (14) and drain oil from reduction gear into a suitable container. Refer to Dwg. MHP3307.
3. Remove capscrews (24) and (25) to separate reduction gear assembly from brake
housing (41). 1. Remove emergency stop valve (164) from end cover (172).
4. Remove capscrews (22) and washers (23) that secure reduction gear end cover 2. Remove and discard ‘O’ rings (175).
(15). 3. Unscrew and remove valve (165) with ‘O’ ring (171), ‘O’ ring (166) and protector
5. Remove retainer ring (12) from gear shaft (20). (170).
4. Remove retainer rings (178).
5. Remove springs (177) and balls (84).
CAUTION 6. Unscrew check valve (83) and remove ball (84).
7. Remove and discard ‘O’ rings (166).
• It may be necessary to use a small amount of air pressure in fill hole of
reduction gear end cover (15) to separate from housing (27).
n 2 Function Emergency Stop Pendant Disassembly (optional)
6. Remove and discard ‘O’ ring (16) on reduction gear end cover (15).
7. It is not necessary to remove bearing (39) from reduction gear end cover (15) Refer to Dwg. MHP3039.
unless damaged. Replace as necessary.
8. Remove bearing (13) and oil seal (17). Replace seal and bearing if necessary. 1. Disconnect hoses from pendant assembly (600).
9. Remove bearing (21) and ring gear (19). 2. Remove fittings (152).
10. Support end cover (15) and tap out shaft (20). 3. Remove lifting eye (617), if necessary.
11. Remove retainer ring (36) from sun gear (34). 4. Tap out pin (618) to remove the levers (619).
12. Support reducer housing (27) and gently tap out sun gear (34). 5. Unscrew and remove check valve (83) and ball (84).
13. Tap out gear shafts (33) and remove planet gears (31), spacers (30), needle 6. Remove setscrew (173) to remove the valve assemblies (165).
bearings (28) and bearing rings (29). 7. Remove protector (170), ‘O’ rings (166) and (171) from the valve (165).
14. Remove retainer ring (49). 8. Remove plugs (623) to remove the springs (177) and balls (84).
15. Remove sun gear (34). 9. Remove emergency stop button (164).
16. Remove retainer ring (36) and bearing (35). 10. Remove retainer ring (621) and exhaust washer (615) from handle (622).
17. Remove and discard gasket (26) and ‘O’ ring (16) from brake housing (41).
18. Remove and replace bearing (38) if necessary.
n Cleaning, Inspection and Repair
n Motor Disassembly
Refer to Product Parts Information Manual for item numbers referenced in the
Refer to Dwg. MHP3375. “Cleaning, Inspection and Repair” section.

1. Remove motor assembly as described in ‘Motor and Reduction Gear Removal’ n Cleaning
on page 8.
2. Remove control valve assembly (100) from motor assembly. Clean all winch component parts in solvent (except drum brake bands and disc brake
3. Remove capscrews (103) and emergency stop end cover (185). friction plates). The use of a stiff bristle brush will facilitate removal of accumulated
4. Remove and discard gasket (101). dirt and sediments on housings, frame and drum. If bushings have been removed it
5. Remove capscrews (107) and remove motor cover (97) from motor housing (87). may be necessary to carefully remove old Loctite® from bushing bores. Dry each part
6. Remove and discard ‘O’ rings (90). using low pressure, filtered compressed air. Clean drum brake band using a wire
7. Remove valves (105) and springs (96) from motor cover (97). brush or emery cloth. Do not wash drum brake band in solvent. If drum brake band
8. Remove ‘O’ rings (94) only if necessary. ‘O’ rings will need to be cut for removal. lining is oil soaked, it must be replaced.
NOTICE n Inspection
• The two bearings (91) located in the motor housing (87) are bonded with
Loctite® 603 or equivalent. Remove idle gear (104) and drive gear (92) only All disassembled parts should be inspected to determine their fitness for continued
if replacement is necessary; use a bearing punch (IR pn: 96441232) or use. Pay particular attention to the following:
standard drift punch and a hammer. Refer to Dwg. MHP2644
on page 10. Inspect gears for
- worn, cracked or broken teeth. Replace if necessary.
9. To remove both bonded bearings (91) from motor housing (87), it is necessary Inspect bushings for
to use a bearing punch and hammer. Two or three strikes are enough. • - wear, scoring or galling. Replace if necessary.
10. If replacement is necessary, remove bearings (91) from drive gear (92) and idle Inspect shafts for
gear (104) (use a suitable bearing extractor). • - ridges caused by wear. Replace if necessary.
11. Remove check valve (83) and ball (84) from motor housing (87). • - scoring or galling.
Inspect all threaded items for
Emergency Stop End Cover: • - damaged threads. Replace if necessary.
Inspect drum band brake lining for
• - oil, grease and glazing. If drum band brake lining is oil-soaked, excessively
1. Remove and discard ‘O’ rings (90). greasy or overly glazed, replace brake band. Remove small glazed areas of
2. Remove setscrew (180). band brake lining by sanding lightly with a fine grit emery cloth.
3. Remove ball (84). • - thickness of drum band brake lining. If drum brake band lining is less than
4. Remove valve seat (186). 0.062 in. (2 mm) thick anywhere along the edges, replace brake band
5. Remove seal (189) and axle (188). assembly.
6. Remove and discard ‘O’ rings (187).
7. Remove spring (193). Inspect motor housing gear bores for
8. Unscrew clamping screw (102). • - wear or scoring. For any large scratches or uneven/excessive wear patterns,
9. Unscrew regulating screw (192) and remove and discard ‘O’ ring (191). replace motor housing.
10. Remove valve seat (205). Inspect motor gears (92) and (104) for
11. Remove spring (213). • - ridges or excessive grooving on outside diameter of gears.
12. Remove capscrews (214). • - contact between gears and gear housing.
13. Separate caps (202) and (211), washers (208) and (206), sleeve (209) and Inspect slack wire device for
diaphragm (212). • - wear, grooves or scoring of rollers. Replace if any of these conditions exist.
14. Remove seals (203) and (210). • - smooth rotation. Rollers must operate without binding and without
15. Pull stop nut (194) and separate plunger (198) with diaphragm (196) from base excessive side-to-side play.
plate (199). Inspect bearings for
16. Unscrew nut (194) and remove plunger (198) and washer (195). • - loss of grease and evidence of grit, dirt or other contaminants. All motor
17. Remove and discard ‘O’ ring (197) . bearings are factory lubricated and sealed. If dry or contaminated, replace
18. Install a screw (dia. M5) in threaded hole on base plate (199) and pull it from the bearing.
motor cover (97). • - damage. Inspect roller bearings (needle). At any indication of damage or
contamination, replace bearings.
Inspect disc brake for
n Control Valve Disassembly • - wear. Replace brake discs if grooving pattern is no longer visible or if discs
are cracked or chipped.
Refer to Dwg. MHP3307. - thickness of disc. If less than 0.047 in (1.2 mm), replace.

Form MHD56492 Edition 1 9

n Repair 15. Install motor cover (97) on motor housing and secure with capscrews (107).
16. Lubricate ‘O’ rings (85) on valves (94) and (105). One ‘O’ ring is mounted in a
special groove. Ensure a good assembly.
Actual repairs are limited to the removal of small burrs and other minor surface 17. Install springs (96) and valve assemblies (94) and (104) in motor cover (97).
imperfections from gears, shafts, housings and machined surfaces. Use a fine stone 18. Lubricate and install ‘O’ rings (166) on check valve (83). Install ball (84) and check
or emery cloth for this work. valve assembly in motor housing (87).
19. Check to ensure motor gears turn smoothly in both directions.
1. Worn or damaged parts must be replaced. Refer to applicable parts listing for
specific replacement parts information.
2. Inspect all remaining parts for evidence of damage. Replace or repair any part
which is in questionable condition. The cost of the part is often minor in
comparison with the cost of redoing the 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.

n Assembly
Refer to the Product Parts Information Manual for drawings unless specified
elsewhere.

General instructions:

• - use new gaskets and seals.

• - replace worn parts.
• - assemble parts using match marks applied during disassembly. Compare
replacement parts with originals to identify installation alignments.

n Control Valve Assembly

Refer to Dwg. MHP3307.

1. Install bushings (133) and (141) in valve housing (135).

2. Install pins (132) in spindle shafts (115), so they extend an equal amount on both
sides.
3. Install retainer (140), spindle shaft (115), key (136) and gear cam (139) in valve
housing.
4. Install retainer (140), spindle shaft (131), key (136) and gear (138) in valve
housing. Ensure keys are vertically aligned and gear teeth are meshed.
5. If handle was disassembled, install spring (130) and handle spool (123) in lever
shaft (128). Align hole in handle spool (123) with slot in lever shaft (128) and
install pin (120) so it extends an equal amount on both sides. Install ʽOʽ ring
(122) on cap (121) and screw cap (121) into lever shaft (128).
6. Vertical Wire Rope Take-off Angle:
a. Install pin (134) in the top pin hole in valve housing (134).
b. Install lever assembly in coupling (124). Install spring (116) and coupling/
handle assembly on lower spindle shaft (115). Align notch in coupling with
pin in spindle shaft. Spring (116) ends will point up.
c. Install capscrew (126) and lockwasher (125) through coupling (124) and
lower hole in lever shaft (128).

or
7. Horizontal Wire Rope Take-off Angle:
a. Install pin (134) in the lower pin hole in valve housing (134).
b. Install lever assembly in coupling (124). Install spring (116) and coupling/
handle assembly on top spindle shaft (115). Align notch in coupling with pin
in spindle shaft. Spring (116) ends will point down.
c. Install capscrew (126) and lockwasher (125) through coupling (124) and top
hole in lever shaft (128).
8. Install spools (142) in valve housing (135).
9. Install emergency stop housing assembly to valve housing (135). Install shoulder (Dwg. MHP2644)
screw (127). Tighten capscrews (126) and (127) to secure emergency stop
housing. Motor Emergency Stop End Cover:
10. Install capscrews (118), lockwashers (2) and stop plate (119) on valve housing Refer to Dwg. MHP3375.
(135).
11. Check operation of control valve to ensure smooth movement and ability to 1. Lubricate and install ‘O’ ring (201) and seal (189) on base plate (199).
spring return and lock in neutral. 2. Lubricate and install ‘O’ ring (197) to plunger (198).
3. Install diaphragm (196) and washer (195) with stop nut (194) on plunger (198)
n Motor Assembly and insert into base plate (199). Ensure plunger assembly moves freely in bore
of base plate.
Refer to Dwg. MHP3375. 4. Insert base plate (199) with plunger into motor cover (97).
5. Lubricate and install ‘O’ rings (204) on valve seat (205).
1. Clean the grease from bearings (91). 6. Place washer (206), diaphragm (212), cap (211), seal (203), sleeve (209) and
2. Clean interior and exterior diameter of bearings with Loctite® 7063 or equivalent. washers (206) and (208) onto capscrew (214) and insert into valve seat (205).
3. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of Apply a thin film of Loctite® 243 or equivalent to capscrew threads. Do not over
bearing (91). Refer to Dwg. MHP2644 on page 10, A. Use a continuous thin tighten capscrew.
film of Loctite® 603 or equivalent to bond one bearing on each gear. Apply where 7. Place seal (210) and cap (202) on capscrew (62). Place spring (213) on cap (202).
arrows indicate; B. Do not bond bearings on this side of gears; C. Use of 8. Install valve seat assembly into emergency stop end cover (185).
continuous thin film Loctite® 603 or equivalent; D. Note: Wait 10 minutes with 9. Lubricate and install ‘O’ ring (191) on regulating screw (192); insert into
the housing in this position, to ensure proper bond; E. Install splined hub (75) emergency stop end cover (185) avoiding damage to the ‘O’ ring. Secure with
and rotate to ensure a proper bond. screw (102). Install screw (102) with Loctite® 243 or equivalent.
4. Apply a continuous thin film of Loctite® 603 or equivalent on bearing diameter 10. Lubricate and install spring (193).
on drive gear (92) and install bearing (91). 11. Install ‘O’ rings (187) to valve seat (186).
5. Install a second bearing (91), not bonded, on drive gear (92). 12. Insert axle (188) into valve seat (186) then install seals (189) on each end of axle
6. Apply a continuous thin film of Loctite® 603 or equivalent on interior diameter (188).
of bearing (91). 13. Insert valve seat (186) into emergency stop end cover (185).
7. Apply a continuous thin film of Loctite® 603 or equivalent on bearing diameter 14. Insert ball (84) into emergency stop end cover (185).
on idle gear (104) and install bearing (91). 15. Install gasket (101) on motor cover (97).
8. Install a second bearing (91), not bonded, on idle gear (104). 16. Install emergency stop end cover (185) on motor cover (97) and secure with
9. Apply a continuous thin film of Loctite® 603 or equivalent on bore for bearings capscrews (103).
in the motor housing (87). 17. Insert plug (182) if removed during disassembly.
10. Install drive gear (92) and idle gear (104) into motor housing, ensure the drive 18. Install setscrew (180) in emergency stop end cover (185).
gear and idle gear are completely inside motor housing and leave the motor 19. Install ‘O’ rings (90) on emergency stop end cover (185).
housing in a position as shown in Dwg. MHP2644 on page 10, for 10 minutes. 20. Install control valve assembly.
11. Turn the gears with coupling and a tool. Check bearings do not rotate on bonded 21. If pendant adapter plate (605) or (613) was removed from motor cover (83), refer
diameters and gears rotate freely. to pendant assemblies for installation.
12. Install pins (88) in motor cover (97).
13. Install exhaust washer (99) with a drop of Loctite® 601 or equivalent on motor
cover.
14. Install ‘O’ rings (90) on motor cover (97).

10 Form MHD56492 Edition 1

n Reduction Gear Assembly n Automatic Band Drum Brake Assembly
Refer to Dwg. MHP2807. Refer to Dwg. MHP3298. It is recommended that any brake cylinder service work be
conducted by an Ingersoll Rand trained technician.
1. Install oil seal (17) in the bore of the reduction gear end cover (15) so seal lip is
toward the planet assembly side. 1. Install ‘O’ ring (145) on the piston (146).
2. Lubricate and install ‘O’ ring (16) on outside diameter of reduction gear end cover 2. Install oil seal (114), ring (143) and ‘O’ ring (145) in the cover (117).
(15). Install plug (14). 3. Install piston (146) and spring (144) in the housing (147).
3. Press bearings (13) and (39) into the reduction gear end cover (15). Install retainer 4. Install cover (117) and close brake cylinder assembly with capscrews (302) and
ring (12) on the gear shaft (20). lockwashers (73). Before closing the brake cylinder, fill the spring housing with
4. Press gear shaft (20) into reduction gear end cover (15). about 1 oz. (25 ml) of SP 150 type oil.
5. Install ring gear (19) and bearing (21) on gear shaft (20) and secure in position
with retainer ring (94). Install assembly in reducer housing (27). Brake Band:
6. Press bearing (35) onto the sun gear (34) and locate with retainer ring (36). Install
sun gear (34) with bearing (35) in the planet gear support (32) and secure with 1. Thread nut (148) onto adjustment screw (149), then install adjustment screw
retainer ring (49). (149) in brake cylinder assembly.
7. Install two bearings (28) with a spacer (30) between in the bore of each planetary 2. Install the brake cylinder assembly with capscrews (156) and lockwashers (64)
gear (31). on the siderail (68).
8. Install bearing rings (29) in each bearing (28). 3. Install band brake (111) on drum (60). Anchor brake band ends to adjustment
9. Position each assembled planetary gear in the planet gear support (32) with the screw (149) and piston (146) with pins (112) and cotter pins (113). Bend ends of
timing mark as shown on drawing Dwg. MHP1406 on page 11, A. Planet Gear cotter pins apart.
Support; B. Timing Marks; C. Planet Gear. Carefully install gear shafts (33) 4. Install locknut (151) and washer (150) on adjustment screw (149).
5. Adjust brake band assembly. Refer to ‘Adjustments’ section on page 7.
CAUTION
n Limit Switches Assembly
• For assembly of planet gears, each planet gear must be positioned with the
timing mark as shown on Dwg. MHP1406. Refer to Dwg. MHP3372.

1. Install limit switch adapter (450) on drum end cover (78). Secure with capscrews
(98) and lockwashers (73).
2. Install spindle switch assembly (501) on limit switch adapter (450). Secure with
A capscrews (499).
3. Install one gasket (490) on each end of housing (486).
4. Thread one nut (73) and washer (73) on each rod (502). Install four rods in limit
switch adapter (450) and tighten nut (73). Ensure full thread engagement of rod
in limit switch adapter.
5. Install housing (486) and housing cover (505). Position housing with cap
assembly (498) hole on top. Align housing cover holes with rods.
6. Install nuts (504) on rods (502) to secure housing and housing cover.

n Slack Line Device Assembly

B Refer to Dwg. MHP3296.
C
1. Assemble valve support (325) to sensor valve (327) with capscrews (318).
2. Assemble protector (322) to valve support (325) with capscrews (22) and washers
(23).
(Dwg. MHP1406) 3. Assemble protector (323) and valve support (325) to upright (62) with capscrews
10. Install planetary gear assembly in the reducer housing (27). (324) and lockwashers (2).
11. Install ball bearing (38) on the planet gear support (32). Check planet gears, sun 4. Install bearings (309) on the shoulder screws (310).
gear and ring gear teeth mesh smoothly. 5. Assemble arms (303), rollers (306) and axles (304) and (305). Install nuts (301)
12. Place the reduction gear assembly in a vertical position with the planetary gear and lockwashers (73) on roller axle (305) to secure.
end up. 6. Install capscrews (302) and lockwashers (73) on axle (304).
13. Fill the gear assembly to within 1 in. (25 mm) of the top with clean oil. Refer to 7. Install spacers (308) and slack wire arm assembly. Tap shoulder screws (310) into
“LUBRICATION” section in Product Instruction Manual. uprights (62).
14. Install new gasket (20) on reducer housing (27). 8. Install nuts (301) and washers (307) on shoulder screws (310).
15. Apply Loctite® 243 to capscrews. Refer to “TORQUE CHART” on page 13. 9. Reconnect hoses.

n Disc Brake Assembly n Press Roller Assembly

Refer to Dwg. MHP3376. Refer to Dwgs. MHP3313.

1. Lubricate and install ‘O’ rings (16) and (52) on piston (51). 1. Install press rollers (184) between roller arms (181) and secure with capscrews
2. Install new gasket (26) on reducer housing (27) if not done during reduction gear (161) and washers (162).
assembly. 2. Install frames (176) and springs (169) on roller arms (181). Secure with capscrews
3. Assemble brake housing (41) to reducer assembly and secure with capscrew (24). (161) and washers (162).
4. Ensure plug (14) is removed, then press piston assembly into brake housing (41). 3. Install press roller assembly in spacer (404). Secure with capscrews (183) and
Puller screw holes must face out. lockwashers (73).
5. Install spacer (54) and splined hub (53). Start with friction plate (55) followed by 4. Compress ends of springs (167) and (169) to engage with spacer (66) and pin on
drive plate (56), friction plate with springs (58), drive plate (56), friction plate (55), press roller arm (163).
drive plate (56) and finishing with friction plate with springs (58).
6. Install plug (14). n Water Separator, Regulator, Filter, and Lubricator Assembly

n Winch Base and Drum Assembly Refer to Dwg. MHP3385.

Horizontal Take-off Angle:
Refer to Dwgs. MHP3312.
1.
1. Install oil seal (77) and rear bearing (76) on drum end cover (78). Oil seal lip must Install FRL assembly (400) to bracket (401) with capscrews (402), washers (404)
be toward the bearing. and locknut (403).
2. Install drum end cover assembly on upright (62) and secure with capscrews (50) 2. Install bracket (401) to spacer (66) on press roller side of winch.
and lockwashers (73). 3. install hose connections and three way shut-off valve (407).
3. Position the upright on several block of wood with the rear bearing (76) up.
4. Check that plate (72) is securely installed in the drum with countersunk screws Vertical Take-off Angle:
(71).
5. Lubricate the outside diameter of oil seal (77) and install drum assembly on rear 1. Install FLR assembly (400) to spacer (66), opposite press roller side, with bracket
bearing. (418) and secure with capscrews (420) and washers (419).
6. Install oil seal (77) and front bearing (76) on drum end cover (78). Oil seal lip must 2. Install hose connections and three way shut-off valve (407).
be toward the bearing.
7. Install drum end cover assembly on front upright (62) and secure with capscrews NOTICE
(50) and lockwashers (73).
8. Lubricate the outside diameter of oil seal (77) and install front upright assembly
on drum (60).
9. Rotate uprights so they are aligned and install spacers (66) and siderails (68) with • Run winch in both directions with no load to ensure proper connections
capscrews (65) and (67), nuts (63) and washers (64). Longer capscrews (65) are and no air leaks.
required to attach lifting lugs (69). Mount lifting lugs diagonally opposite.
10. Check pin (79) is installed in drum end cover (78).
11. Install motor reducer assembly. Ensure gear shaft (20) meshes with splined bore
in drum and secure with capscrews (86) and lockwashers (125).
12. Return winch to a horizontal position.
13. Install remaining external assemblies.

Form MHD56492 Edition 1 11

n Drum Guard Assembly
Refer to Dwg. MHP3312.

NOTICE

• Install drum guard for proper take-off angle, refer to data (name) plate for
model.

1. Install drum guard (216) and both side panel guards and secure with capscrew
(161).

n 2 Function Emergency Stop Pendant Assembly (optional)

Refer to Dwg. MHP2818.

1. Install ‘O’ rings (166) and protector (170) on valves (165). Install valve assemblies
in handle (514)
2. Install levers (503) in pendant handle (514) with pin (502). Stake pin in pendant
handle at both ends to secure.
3. Install screws (504) in levers.
4. Install screws (173) in handle.
5. Install balls (84) and springs (177) in handle (514). Secure in position with plugs
(518).
6. On pendants with emergency stop, install emergency stop button (164).
7. On pendants without emergency stop button, install plug (507).
8. Install exhaust washer (41) and secure in handle with retainer ring (512).

Adjustment:

1. a. Connect the inlet of the pendant to 100 psi (7 bar) air supply.
b. Connect a manometer at the outlet of the lever to be adjusted.
c. Apply a small amount of Loctite® No. 243 on the adjustment screw (521).
d. Tighten the adjustment setscrew to obtain a pressure of 15 psi (1 bar) without
actioning the lever.
e. Release the adjustment setscrew by a half turn (pressure must fall to zero).
f. Push the lever. Check that pressure reaches 93 +/-7 psi (6.5 +/- 0.5 bar). Check
that there is no leak at the exhaust.
g. Release the lever; exhaust must occur and result in rapid pressure reduction.
h. Repeat operations ‘f’ and ‘g’ 2 to 3 times.
i. Disconnect the manometer. Check to ensure that there are no leaks when
the lever is not activated.
j. Repeat the operations from ‘b’ to ‘i’ with each lever.

n Testing
n Operational Tests
Prior to initial use, winches shall be tested to ensure proper operation.

1. Check guards are installed and secure.

2. Check all winch mounting bolts are secure.
3. Operate winch in both directions with no load.
4. Check operation of brakes and emergency stop.
5. Check operation of limit switches, slack line device, press roller and other safety
devices when provided.

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

NOTICE

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

12 Form MHD56492 Edition 1

 TORQUE CHART
Standard Coarse Thread Torque
SAE Grade 5 SAE Grade 8
Size
Dry Lubricated PTFE Dry Lubricated PTFE
1/4-20 8-10 6-7 4 12-14 9-10 5-6
5/16-18 17-20 13-15 8-9 25-28 18-21 11-13
3/8-16 31-35 23-26 14-16 44-49 33-37 20-22
7/16-14 49-56 37-42 22-25 70-79 52-59 31-36
1/2-13 75-85 57-64 34-38 106-121 80-90 48-54
9/16-12 109-123 82-92 49-55 154-174 115-130 69-78
5/8-11 150-170 113-128 68-77 212-240 159-180 95-108
3/4-10 267-302 200-227 120-136 376-426 282-320 169-192
7/8-9 429-487 322-365 193-219 606-687 455-515 273-309
1-8 644-729 483-547 290-328 909-1030 681-772 409-463
1 1/8-7 794-900 596-675 357-405 1288-1460 966-1095 580-657
1 1/4-7 1121-1270 840-952 504-571 1817-2059 1363-1545 818-927
Standard Fine Thread Torque
SAE Grade 5 SAE Grade 8
Size
Dry Lubricated PTFE Dry Lubricated PTFE
1/4-20 10-11 7-8 4-5 14-15 10-12 6-7
5/16-24 19-22 14-16 9-10 27-31 20-23 12-14
3/8-24 35-40 26-30 16-18 49-56 37-42 22-25
7/16-20 55-63 41-47 25-28 78-88 58-66 35-40
1/2-20 85-96 64-72 38-43 120-136 90-102 54-61
9/16-18 121-137 91-103 55-62 171-194 128-146 77-87
5/8-18 170-193 127-144 76-87 240-272 180-204 108-122
3/4-16 297-337 223-253 134-152 420-476 315-357 189-214
7/8-14 474-537 355-403 213-242 669-758 502-568 301-341
1-12 704-798 528-599 317-359 995-1127 746-845 448-507
1 1/8-12 1023-1159 767-869 460-572 1444-1637 1083-1227 650-736
1 1/4-12 1425-1615 1069-1211 641-727 2012-2280 1509-1710 905-1026
Metric Coarse Thread Torque
Class 8.8 / 9.8 Class 10.9
Size
Dry Lubricated PTFE Dry Lubricated PTFE
M6x1 9-10 6-7 4 11-12 8-9 5-6
M8x1.25 21-23 16-18 9-11 26-30 20-22 12-13
M10x1.5 41-47 31-35 19-21 53-60 39-45 24-27
M12x1.75 71-81 54-61 32-36 91-103 68-77 41-46
M14x2 115-130 86-98 52-59 147-166 110-125 66-75
M16x2 165-187 124-140 74-84 227-257 170-193 102-116
M20x2.5 321-364 241-273 144-164 443-502 332-376 199-226
M22x2.5 439-497 329-373 197-224 605-686 454-514 272-309
M24x3 556-630 417-473 250-284 767-869 575-652 345-391
M30x3.5 1103-1250 827-938 496-563 1521-1724 1141-1293 685-776
Metric Fine Thread Torque
Class 8.8 / 9.8 Class 10.9
Size
Dry Lubricated PTFE Dry Lubricated PTFE
M8x1 22-25 17-19 10-11 28-32 21-24 13-14
M10x1.25 44-49 33-37 20-22 56-63 42-47 25-28
M12x1.25 78-89 59-67 35-40 100-113 75-85 45-51
M14x1.5 125-141 93-106 56-64 159-180 119-135 72-81
M16x1.5 176-200 132-150 79-90 243-276 183-207 110-124
M18x1.5 257-291 193-219 116-131 355-402 266-302 160-181
M20x1.5 358-406 268-304 161-183 494-559 370-420 222-252
M22x1.5 484-548 363-411 218-247 667-756 500-567 300-340
M24x2 609-690 456-517 274-310 839-951 630-713 378-428
M30x2 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 and
copper-based anti-seize coated fasteners.
PTFE: 2% minimum PTFE 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.

Form MHD56492 Edition 1 13

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