Ingersoll-Rand BU7A Installation guide

Form P5710
PARTS, OPERATION AND MAINTENANCE MANUAL
for
MODEL BU7A AIR WINCH
(Dwg. MHP1233)
Form P5710
Edition 15
May 2001
03523115
© 2001 Ingersoll-Rand Company
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance
information. Make this manual available to all persons responsible for the
operation, installation and maintenance of these products.
Do not use this Air Winch for lifting, supporting, or transporting people or lifting or
supporting loads over people.
Always operate, inspect and maintain this Air Winch in accordance with American
National Standards Institute safety code (ASME B30.7) and any other applicable safety
codes and regulations.

2P5710 - Edition 15
TABLE OF CONTENTS
Description Page No.
Safety Information
Danger, Warning, Caution and Notice.................................................................................................................................................................3
Safety Summary...................................................................................................................................................................................................3
Safe Operating Instructions .................................................................................................................................................................................4
Warning Tags .......................................................................................................................................................................................................4
Specifications
Description...........................................................................................................................................................................................................5
Model Code Explanation .....................................................................................................................................................................................5
Performance Graphs ............................................................................................................................................................................................6
Installation
Mounting..............................................................................................................................................................................................................7
Wire Rope............................................................................................................................................................................................................7
Air Supply............................................................................................................................................................................................................8
Initial Operating Checks....................................................................................................................................................................................10
Operation
Winch Controls..................................................................................................................................................................................................11
Winch Brakes.....................................................................................................................................................................................................11
Free Spool Clutch ..............................................................................................................................................................................................12
Emergency Stop Device.....................................................................................................................................................................................12
Inspection
Records and Reports..........................................................................................................................................................................................13
Frequent Inspection............................................................................................................................................................................................13
Periodic Inspection ............................................................................................................................................................................................13
Winches Not in Regular Use..............................................................................................................................................................................14
Inspection and Maintenance Report ..................................................................................................................................................................15
Lubrication
Motor .................................................................................................................................................................................................................16
Gear Case...........................................................................................................................................................................................................16
Seals and Bearings.............................................................................................................................................................................................16
Wire Rope..........................................................................................................................................................................................................16
Troubleshooting
Troubleshooting.................................................................................................................................................................................................17
Maintenance
Maintenance Intervals........................................................................................................................................................................................18
Disassembly.......................................................................................................................................................................................................19
Cleaning, Inspection and Repair........................................................................................................................................................................21
Assembly ...........................................................................................................................................................................................................22
Testing................................................................................................................................................................................................................25
Parts Drawings and Parts List
Winch Assembly Parts Drawing........................................................................................................................................................................26
Winch Assembly Parts List................................................................................................................................................................................27
Kits, Special Tools and Accessories ..................................................................................................................................................................29
Automatic Brake Assembly Drawings and Parts List........................................................................................................................................30
Remote Pendant Throttle Handle Drawing and Parts List.................................................................................................................................38
Shuttle Valve Chest Assembly Drawing............................................................................................................................................................32
Shuttle Valve Chest Assembly Parts List...........................................................................................................................................................33
Remote Control Stop Valve Assembly Drawing ...............................................................................................................................................34
Drum Guard Assembly Drawing and Parts List................................................................................................................................................35
Stop Valve and Muffler Assembly Drawings and Parts Lists............................................................................................................................36
Label Locations Drawing and Parts List............................................................................................................................................................39
Construction Cage Drawing and Parts List........................................................................................................................................................40
Winch Upgrades.................................................................................................................................................................................................41
Additional Reference Material...........................................................................................................................................................................41
Parts Ordering Information................................................................................................................................................................................42
Warranty.............................................................................................................................................................................................................43

P5710 - Edition 15 3
SAFETY INFORMATION
This manual provides important information for all personnel
involved with the safe installation, operation and proper
maintenance of this product. Even if you feel you are familiar with
this or similar equipment, you should read this manual before
operating the winch.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures which, if
not followed, may result in a hazard. The following signal words
are used to identify the level of potential hazard.
Danger is used to indicate the presence
of a hazard which will cause severe
injury, death, or substantial property
damage if the warning is ignored.
Warning is used to indicate the presence
of a hazard which can cause severe
injury, death, or substantial property
damage if the warning is ignored.
Caution is used to indicate the presence
of a hazard which will or can cause
injury or property damage if the warning
is ignored.
Notice is used to notify people of
installation, operation, or maintenance
information which is important but not
hazard-related.
Safety Summary
• Do not use this winch for lifting, supporting, or transporting
people or lifting or supporting loads over people.
• The supporting structures and load-attaching devices used in
conjunction with this winch must provide an adequate safety
factor to handle the rated load, plus the weight of the winch
and attached equipment. This is the customer’s responsibility.
If in doubt, consult a registered structural engineer.
The National Safety Council, Accident Prevention Manual for
Industrial Operations, Eighth Edition and other recognized safety
sources make a common point: Employees who work near
suspended loads or assist in hooking on or arranging a load should
be instructed to keep out from under the load. From a safety
standpoint, one factor is paramount: conduct all lifting or pulling
operations in such a manner that if there were an equipment
failure, no personnel would be injured. This means keep out from
under a raised load and keep out of the line of force of any load.
Ingersoll-Rand winches are manufactured in accordance with the
latest ASME B30.7 standards.
The Occupational Safety and Health Act of 1970 generally places
the burden of compliance on the user, not the manufacturer. Many
OSHA requirements are not concerned or connected with the
manufactured product but are, rather, associated with the final
installation. It is the owner’s and user’s responsibility to determine
the suitability of a product for any particular use. It is
recommended that all applicable industry, trade association,
federal, state and local regulations be checked. Read all operating
instructions and warnings before operation.
Rigging: It is the responsibility ofthe operator to exercise caution,
use common sense and be familiar with proper rigging techniques.
See ASME B30.9 for rigging information, American National
Standards Institute, 1430 Broadway, New York, NY 10018.
This manual has been produced by Ingersoll-Rand to provide
dealers, mechanics, operators and company personnel with the
information required to install, operate, maintain and repair the
products described herein.
It is extremely important that mechanics and operators be familiar
with the servicing procedures of these products, or like or similar
products, and are physically capable of conducting the procedures.
These personnel shall have a general working knowledge that
includes:
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 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, it must be ensured that product safety is not
endangered by 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.

4P5710 - Edition 15
SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions have been
adapted in part from American National (Safety) Standard ASME
B30.7 and are intended to avoid unsafe operating practices which
might lead to injury or property damage.
Ingersoll-Rand recognizes that most companies who use winches
have a safety program in force at their facility. In the event that
some conflict exists between a ruleset forth in this publication and
a similar rule already set by an individual company, the more
stringent of the two should take precedence.
Safe Operating Instructions are provided to make an operator
aware of dangerous practices to avoid and are not necessarily
limited to the following list. Refer to specific sections in the
manual for additional safety information.
1. Only allow personnel trained in safety and operation of this
winch to operate and maintain this product.
2. Only operate a winch if you are physically fit to do so.
3. When a “DO NOT OPERATE” sign is placed on the winch,
or controls, do not operate the winch until the sign has been
removed by designated personnel.
4. Before each shift, the operator should inspect the winch for
wear and damage. Never use a winch that inspection
indicates is worn or damaged.
5. Never lift a load greater than the rated capacity of the winch.
Refer to “SPECIFICATIONS” section.
6. Keep hands, clothing, etc., clear of moving parts.
7. Never place your hand in the throat area of a hook or near
wire rope spooling onto or off of the winch drum.
8. Always rig loads properly and carefully.
9. Be certain the load is properly seated in the saddle of the
hook. Do not support a load on the tip of a hook.
10. Do not “side pull” or “yard”.
11. Make sure everyone is clear of the load path and there are no
objects in the way of the load. Do not lift a load over people.
12. Never use the winch for lifting or lowering people, and never
allow anyone to stand on a suspended load.
13. Ease the slack out of the wire rope when starting a lift or pull.
Do not jerk the load.
14. Do not swing a suspended load.
15. Never leave a suspended load unattended.
16. Pay attention to the load at all times when operating the
winch.
17. After use or when in a non-operational mode, the winch
should be secured against unauthorized and unwarranted use.
18. The operator must maintain an unobstructed view of the load
at all times.
19. Never use the winch wire rope as a sling.
20. Never operate a winch with twisted, kinked or damaged wire
rope.
21. Shut off air supply before leaving winch unattended.
22. Do not do anything you believe may be unsafe.
23. Never splice a sling chain by inserting a bolt between links.
24. Do not force a chain or hook into place by hammering. Do
not insert the point of the hook into a chain link.
25. Do not expose the sling chain to freezing temperatures, and
do not apply sudden loads to a cold chain.
WARNING TAGS
Each winch is shipped from the factory with the warning tags
shown. If tags are not attached to your winch, order new tags and
install them. Refer to parts list for part number. Tags are shown
smaller than actual size.
WARNING
?
Read the latest edition of ASME B30.7.
Comply with other federal, state and local rules.
P/N 71056410/A
for winches
Failure to follow these
warnings may result in
death, severe injury or
property damage:
Do not operate
this winch before
reading operation
and maintenance
manual.
Do not lift people or loads
over people.
Do not lift more than rated
load.
Do not allow less than three
wraps of wire rope to remain
on drum at all times.
Do not operate a damaged
or malfunctioning winch.
Do not remove or obscure
warning labels.

P5710 - Edition 15 5
SPECIFICATIONS
Description
The BU7A winch is powered by a radial piston air motor. The
output from the motor is transferred through the drum by the drive
shaft. The drive shaft rotates a series of connected spur gears
which form a reduction assembly. Output from the reduction
assembly drives the wire rope drum. Spur gears are not inherently
self-locking as other types of gears are, therefore the brake must
be applied whenever there is a load attached to the load line. The
winch is also equipped with a free spool feature.
• The free spool feature must only be used with a manual
brake. Use of a manual brake is the only way to maintain
control of the load line.
The free spool feature consists of a spring detented clutch jaw
connecting the final drive shaft and final spur gear in the reduction
assembly. When the clutch jaw is disconnected, the drum becomes
disconnected from the reduction gear assembly and motor and is
free to rotate in either direction.
(Dwg. MHP1286)
Model Code Explanation
Example: BU7APTAB BU7A PTAB
Series = BU7A
Options AB = Automatic Brake
RC = Remote Control
RCAB = Remote Control and Automatic Brake
PTAB =Remote Pendant Control and Automatic Brake
ZP = Zinc-plated
-E = Compliance with the European Machinery Directive
P = Marine 812 Finish
Z = Sandblast and Carbozinc Primer
E = Construction Cage
R = Natural Gas Operation*
* Not Covered in this manual.
Manual Brake Wire Rope
Drum
Motor Throttle Handle
Free Spool
Clutch
Gear Case

6P5710 - Edition 15
BU7A Performance Graph BU7APTAB Performance Graph
(Dwg. MHP2262) (Dwg. MHP2263)
1600
1400
1200
1000
800
600
200
006
Line Pull (Lbs)
12 18 24 30 36 42
Line Speed (ft/min)
48 54 60 66 72 78 84 90 96 102
30
20
40
50
Air Consumption (scfm)
60
70
400
1st wrap line pull
mid drum
full drum
1st wrap flow
mid drum
full drum
1400
1200
1000
800
600
400
200
006
Line Pull (Lbs)
12 18 24 30 36 42
Line Speed (ft/min)
48 54 60 66 72 78 84 90 96 102
30
20
40
50
Air Consumption (scfm)
60
70
1st wrap line pull
mid drum
full drum
1st wrap flow
mid drum
full drum
General Specifications Model
BU7A BU7APTAB
Air System Rated Operating Pressure 90 psig (6.3 bar)
Consumption Volume
(at rated pressure) 50 scfm 1.4 cu. m/min 50 scfm 1.4 cu. m/min
Rated Performance
(at rated pressure/volume)
Mid Drum Line Pull 1,000 lbs 454 kgs 1,000 lbs 454 kgs
Mid Drum Line Speed 43 fpm 13 m/min 37 fpm 11 m/min
Max Stall Pull - 1st Layer 1,950 lbs 886 kgs 1,950 lbs 886 kgs
Net Weight 75 lbs 34 kgs 108 lbs 49 kgs
Air Motor Pipe Inlet Size 1/2 inch 13 mm 1/2 inch 13 mm
Air System Hose Size 3/4 inch 19 mm 3/4 inch 19 mm
Wire Rope Anchor Hole Diameter 11/32 inch 8.7 mm 11/32 inch 8.7 mm
Drum Flange Diameter 8-1/2 inch (216 mm)
Drum Length (between flanges) 4-1/2 inch (114 mm)
Motor HP 1.6
Drum Wire Rope Storage
Capacity *
(feet/metres)
Wire Rope Diameter
1/4 inch ** 6 mm 5/16 inch 8 mm
158 ft 48 m 105 ft 32 m
Factors for determining STALL and LINE PULL at
various air pressure.
To obtain performances at operating pressures other than
90 psi, select the load or speed rating required from the
applicable performance graph and multiply that value by
the factor corresponding to the operating pressure from
the table.
Example: Model BU7A at 750 lbs with 70 psi and drum
half full.
To determine speed from curve:
50 fpm x 0.72 = 36 fpm.
AirPressure
(psi) Stall Factor Wire Rope Speed Factor
60 0.67 0.58
70 0.78 0.72
80 0.89 0.86
90 1.00 1.00
100 1.11 1.14
* Based on ASME B30.7 standards which require top layer to be at least 1/2 in. (13 mm) below drum flange diameter.
*Recommended drum working storage capacity is 80% of values shown.
** Recommended wire rope size.

P5710 - Edition 15 7
INSTALLATION
Prior to installing the winch, carefully inspect it for possible
shipping damage.
Winches are supplied from the factory drained of oil. Add oil prior
to winch operation. Check oil levels and adjust as necessary. Use
proper type of oil as recommended in “LUBRICATION” section.
• Owners and users are advised to examine specific, local or
other regulations, including American National Standards
Institute and/or OSHA Regulations which may apply to a
particular type of use of this product before installing or
putting winch to use.
Mounting
Mount winch with longitudinal center line horizontal and vent cap
(25) at top vertical center. The winch will not function properly if
the longitudinal center line is tilted more than 10° or if winch is
rotated so that vent cap is more than 20° off top vertical center.
For mounting on a vertical surface or for inverted mounting, the
motor case (28) can be rotated on the motor mounting bracket (79)
to any one of four different positions. This feature allows the
motor assembly to be positioned with the vent cap (25) on top. To
change the position of the motor assembly, drain the oil from the
motor case, unscrew the eight motor case capscrews (29) and
rotate the motor assembly to suit the mounting. Refer to Dwg.
MHP0548 on page 7. Ensure clear unrestricted access is always
available to control and brake levers.
Bolt Hole Dimensions
(Dwg. MHP0548)
1. Do not weld to any part of winch.
2. The winch mounting surface must be flat and of sufficient
strength to handle the rated load plus the weight of the winch
and attached equipment. An inadequate foundation may
cause distortion or twisting of the winch resulting in winch
damage.
3. Make sure mounting surface is flat to within 1/16 inch (2.0
mm). Shim if necessary.
4. Mounting bolts must be 1/2 inch - NC (14 mm) Grade 8 or
better. Use self-locking nuts or nuts with lockwashers.
5. Tighten mounting bolts evenly and torque to 110 ft lbs (15.2
kg m) for dry thread fasteners. If the fasteners are plated,
lubricated or a thread locking compound is used, torque to 80
ft lbs (11.0 kg m).
6. When a lead sheave is used, it must be aligned with the center
of the drum. The diameter of the lead sheave must be at least
18 times the diameter of the wire rope.
7. Maintain a fleet angle between the sheave and winch of no
more than 1-1/2°. The lead sheave must be on a center line
with the drum and be at least 7.2 feet (2.2 metres) from the
drum. Refer to Dwg. MHP0498, Note 3 on page 7.
Wire Rope and Fleet Angle Installation
(Dwg. MHP0498)
Notes:
1. Maintain a minimum of 3 tight wraps of wire rope on the
drum at all times.
2. For lifting applications, ensure top layer of wire rope is at
least 1/2 in. (13 mm) below edge of drum flange.
3. For correct fleet angle, maintain a minimum of 1.6 feet (0.5
metre) per inch of drum length. Example: for a 7 inch drum
length, locate the lead sheave at least 11.2 feet (3.5 metres)
from drum.
Wire Rope
• Maintain at least 3 tight wraps of wire rope on the drum at
all times. Refer to Dwg. MHP0498 Note 1 on page 7.
Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor for
assistance in selecting the appropriate type and size of wire rope
and, where necessary, a protective coating. Use a wire rope which
provides an adequate safety factor to handle the actual working
load and that meets all applicable industry, trade association,
federal, state and local regulations.
When considering wire rope requirements the actual working load
must include not only the static or dead load but also loads
resulting from acceleration, retardation and shock load.
Consideration must also be given to the size of the winch wire
rope drum, sheaves and method of reeving. Wire rope construction

8P5710 - Edition 15
must be 6 X 19 or 6 X 37 Extra Improved IWRC right lay to assist
spooling. Refer to Table 1 on page 8 for minimum and maximum
recommended wire rope diameters.
For winches used in lifting applications, ensure that the top layer
of the wire rope is a distance from the top of the drum flange that
is equal to at least twice the diameter of the wire rope. For
example: the top layer of a 8 mm wire rope must be at least 16 mm
below the drum flange edge. Refer to Dwg. MHP0498, Note 2 on
page 7.
As a general rule for lifting applications, a minimum of 5:1 wire
rope design factor is required with an 18:1 wire rope to drum
diameter ratio. For pulling applications, a 3:1 wire rope design
factor is required with a 15:1 wire rope to drum diameter ratio.
Safe Wire Rope Handling Procedures
1. Always use gloves when handling wire rope.
2. Never use wire rope which is frayed or kinked.
3. Never use wire rope as a sling.
4. Always ensure wire rope is correctly spooled and the first
layer is tight against the drum.
5. Always follow wire rope manufacturer’s recommendations
on use and maintenance of wire rope.
Installing Wire Rope
Refer to Dwg. MHP1288 on page 8.
1. Cut wire rope to length and fuse end to prevent fraying of
strands in accordance with the wire rope manufacturer’s
instructions.
2. Feed the fused end of the wire rope into the wire rope anchor
hole, past the two anchor screws, and position the end just
beneath the drum surface.
3. Apply the wire rope so that it winds over the top when the
drum is rotated in a direction that is clockwise when facing
the gear end of the winch. This is indicated by an arrow on
the gear case.
4. Secure by tightening both anchor screws. Make sure the
anchor screws are below the surface of the drum when
tightened.
(Dwg. MHP1288)
• Ensure the first wrap of wire rope is tight and lies flush
against the drum flange.
• The wire rope should be applied to the drum so that it
overwinds when the drum rotates in a clockwise direction
when facing the gear end of the winch. This is indicated by an
arrow on the gear case.
Wire Rope Spooling
To compensate for uneven spooling and the decrease in line pull
capacity as the drum fills up, use as short a wire rope as practical.
When rewinding apply tension to the end of the wire rope to
eliminate line slack. This helps achieve level winding and tight
spooling.
Rigging
Make sure all wire rope blocks, tackle and fasteners have a
sufficient safety margin to handle the required load under all
conditions. Do not allow wire rope to contact sharp edges or make
sharp bends which will cause damage to wire rope, use a sheave.
Refer to the wire rope manufacturer’s handbook for proper sizing,
use and care of wire rope.
Safe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not attach a welding electrode to winch or wire rope.
3. Never run the wire rope over a sharp edge. Use a correctly
sized sheave.
4. When a lead sheave is used, it must be aligned with the center
of the drum. Refer to Dwg. MHP0498 on page 7. The
diameter of the lead sheave must be at least 18 times the
diameter of the wire rope.
5. Always maintain at least three full, tight wraps of wire rope
on the drum.
Air Supply
The air supply must be clean, free from moisture and lubricated to
ensure optimum motor performance. Foreign particles, moisture
and lack of lubrication are the primary causes of premature motor
wear and breakdown. Using an air filter, lubricator and moisture
separator will improve overall winch performance and reduce
unscheduled downtime.
The air consumption is 50 scfm (1.4 cu.m/min.) at rated operating
pressure of 90 psig (6.3 bar/630 kPa) at the winch motor inlet. If
the air supply varies from what is recommended, winch
performance will change.
Table 1
Minimum and Maximum Wire Rope Sizes
Model Minimum Maximum
inch mm inch mm
BU7A 1/4 65/168
* Breaking Strength
RopeSize
(in.) lbs kgs Weight
per ft
(lbs)
Weight
per metre
(kgs)
1/4 (0.25) 6800 3084 0.11 0.15
5/16 (0.31) 10540 4781 0.18 0.25
* Based on extra improved plow steel wire rope with independent
wire rope core. ASME B30.7 requires a minimum of 3.5:1 design
factor with 15:1 wire rope diameter to drum diameter for most
applications (e.g. pulling/hauling and anchor handling). For
lifting and lowering, a 5:1 design factor with an 18:1 wire rope
diameter to drum diameter is required.

P5710 - Edition 15 9
Air Lines
The inside diameter of the winch air supply lines must not be less
than the size shown in Table 2 on page 9. Prior to making final
connections, all air supply lines should be purged with clean,
moisture free air or nitrogen before connecting to winch inlet.
Supply lines should be as short and straight as installation
conditions will permit. Long transmission lines and excessive use
of fittings, elbows, tees, globe valves etc. cause a reduction in
pressure due to restrictions and surface friction in the lines.
Remote Control (Optional Feature)
Refer to Dwg. MHP1241 on page 9 for hose connection positions.
(Dwg. MHP1241)
Air Line Lubricator
Refer to Dwg. MHP0191 on page 9.
Always use an air line lubricator with these motors. The lubricator
must have an inlet and outlet at least as large as the inlet on the
motor. Install the air line lubricator as close to the air inlet on the
motor as possible.
• Lubricator must be located no more than 10 ft. (3 m) from
the motor.
• Shut off air supply before filling air line lubricator.
The air line lubricator should be replenished daily and set to
provide 6 to 9 drops per minute of ISO VG 32 (10W) oil. A fine
mist will be exhausted from the throttle control valve when the air
line lubricator is functioning properly.
Air Line Filter
Refer to Dwg. MHP0191 on page 9.
It is recommended that an air line strainer/filter be installed as
close as practical to the motor air inlet port, but before the
lubricator, to prevent dirt from entering the motor. The
strainer/filter should provide 20 micron filtration and include a
moisture trap. Clean the strainer/filter periodically to maintain its
operating efficiency.
(Dwg. MHP0191)
Moisture in Air Lines
Moisture that reaches the air motor through air supply lines is a
primary factor in determining the length of time between service
overhauls. Moisture traps can help to eliminate moisture. Other
methods, such as an air receiver which collects moisture before it
reaches the motor, an aftercooler at the compressor that cools the
air to condense and collect moisture prior to distribution through
the supply lines are also helpful.
Motor
For optimum performance provide an air supply of 90 psig at 50
scfm (6.3 bar/630 kPa at 1.4 cu.m/min) for BU7A winches. The
air motor should be installed as near as possible to the compressor
or air receiver. Recommended pressures and volumes are
measured at the point of entry to the air motor.
Table 2
Minimum Allowable Air Supply Line Sizes
Model inch mm
BU7A 3/4 19
Haul-in
Green
Payout
Yellow
Supply
Red
Winch
Air Supply
Haul-in
Green
Supply
Red Payout
Yellow

10 P5710 - Edition 15
Initial Operating Checks
Winches are tested for proper operation prior to leaving the
factory. Before the winch is placed into service the following
initial operating checks should be performed.
1. Refer to the “LUBRICATION” section to ensure correct oil
level in air motor.
2. When first running the motor, inject some light oil into the
inlet connection to provide initial lubrication.
3. When first operating the winch it is recommended that the
motor be driven slowly in both directions for a few minutes.
Start-Up Procedures
For winches that have been in storage for a period of more than
one month, the following start-up procedure is required:
1. Refer to the “LUBRICATION” section to ensure correct oil
level in air motor.
2. Give the winch an inspection conforming to the requirements
listed in “Winches Not in Regular Use” in the
“INSPECTION” section.
3. Pour a small amount of ISO VG 32 (10W) oil in the motor
inlet port.
4. Operate the motor for 10 seconds in both directions to flush
out any impurities.
5. The winch is now ready for normal use.

P5710 - Edition 15 11
OPERATION
The four most important aspects of winch operation are:
1. Follow all safety instructions when operating the winch.
2. Allow only people trained in safety and operation of this
winch to operate this equipment.
3. Subject each winch to a regular inspection and maintenance
procedure.
4. Be aware of the winch capacity and weight of load at all
times.
• To avoid damage to the rigging, the structure supporting the
rigging and the winch, do not “two-block”* the end of the wire
rope.
* Two-blocking occurs when the winch wire rope is multi-reeved
using two separate sheave blocks which are allowed to come into
contact with each other during winch operation. When this occurs,
extreme forces are exerted on the wire rope and sheave blocks,
which may result in equipment and/or rigging failure.
• The winch is not designed or suitable for lifting, lowering or
moving persons. Never lift loads over people.
Operators must be physically competent and have no health
condition which might affect their ability to act. They must have
good hearing, vision and depth perception. The winch operator
must be carefully instructed in his duties and must understand the
operation of the winch, including a study of the manufacturer’s
literature. The operator must thoroughly understand proper
methods of hitching loads and must have a good attitude regarding
safety. It is the operator’s responsibility to refuse to operate the
winch under unsafe conditions.
Winch Controls
A spring loaded, motor mounted, manual throttle control valve is
supplied as a standard feature of this winch. Optional motor
throttle controls are available. Refer to the model code on the
winch nameplate and compare it to the “SPECIFICATIONS”
section of this manual to determine your configuration. The
throttle control provides operator control of the winch motor speed
and direction of drum rotation.
Winch Mounted Live Air Throttle (standard feature)
Refer to Dwg. MHP1239 on page 11.
The spring loaded manual control throttle mounts to the air motor.
When viewed from the air motor end move the control throttle
handle to the right (clockwise) to payout wire rope and to the left
(counterclockwise) to haul-in wire rope.
To ensure smooth operation of the winch sudden movements of
the control valve should be avoided.
(Dwg. MHP1239)
Remote Live Air Pendant Throttle (optional feature)
Refer to Dwg. MHP1319 on page 11.
Provides for remote winch control at distances of up to *15 feet
(4.5 metres) away from the winch. The pendant control throttle is
a two lever movable control station for winch operation. The
winch control valve, located on the winch motor, controls the
motor speed and direction of drum rotation. Direction of rotation
is determined by the pendant lever depressed.
* For distances greater than 15 feet (4.5 metres) contact Technical
Sales for control acceptability.
(Dwg. MHP1319)
Winch Brakes
Manual Drum Brake
The manual drum brake may be applied by pushing down on the
handle (55) and released by pulling up. If handle is pushed down
fully, it should lock in that position and prevent drum rotation until
released by the operator. The brake must be kept properly adjusted
to hold the required load. Refer to the “MAINTENANCE” section
for brake adjustment.
Automatic Drum Brake
The brake band is operated by a spring loaded air cylinder. When
control valve is actuated in any direction, air is applied to the
brake cylinder causing the brake rod to extend and release the

12 P5710 - Edition 15
brake band. When control valve is returned to neutral, there is no
air supply to the brake cylinder so the internal spring will retract
the brake rod causing the brake lever to lock the brake band in
position.
For winches equipped with an automatic brake, always ensure that
clutch jaw spacers (143) are installed.
Free Spool Clutch
• Do not engage clutch when motor is running or drum is
spinning, as this produces a severe strain on parts.
• Do not disengage clutch when winch is loaded. Be sure clutch
is fully engaged before operating winch.
A jaw type clutch connects the gearing and drum. The function of
the clutch is to disengage the rope drum from the motor so that the
wire rope can be unwound from the drum by hand without
working against the gearing and the compression of the motor. The
clutch is engaged or disengaged by the clutch lever (54) which is
located on the top of the gear case cover (76). When clutch is
engaged the lever is locked by a detent to prevent disengagement.
Detent is released by pressing down (toward base) on lever, after
which the end can be swung outward from the winch, disengaging
the clutch jaws. When clutch is in disengaged position it can be
engaged by moving end of lever toward winch. It may be
necessary to open the throttle a slight amount to position the jaws
for engagement.
• Do not use free spool clutch feature in combination with
automatic brake. Use of winches with free spool clutch and
automatic brake can result in severe injury, death or property
damage.
Emergency Stop Device
Refer to Dwgs. MHP1530 and MHP1546 on page 12.
The emergency stop device is located at the air inlet of the winch
on local control (winch mounted throttle) models and on the
pendant of remote control models. When the emergency stop is
activated, winch drum rotation ceases immediately.
1. To start winch operation, press the “ON” button.
2. To operate winch, press the “Haul-in” or “Payout” control
lever.
3. In the event of an emergency, all winch operation can be
stopped by pushing the emergency stop button. This will
prevent air from reaching the winch motor, thereby stopping
drum movement.
4. To restart the winch after the emergency stop has been
activated, press the “ON” button.
(Dwg. MHP1530)
(Dwg. MHP1546)
“EMERGENCY
STOP”
Button
“ON”
Button
Air
Inlet

P5710 - Edition 15 13
INSPECTION
Inspection information is based in part on American National
Standards Institute Safety Codes (ASME B30.7).
• All new, altered or modified equipment should be inspected
and tested by personnel instructed in safety, operation and
maintenance of this equipment to ensure safe operation at
rated specifications before placing equipment in service.
• Never use a winch that inspection indicates is damaged.
Frequent and periodic inspections should be performed on
equipment in regular service. Frequent inspections are visual
examinations performed by operators or personnel trained in
safety and operation of this equipment and include observations
made during routine winch operation. Periodic inspections are
thorough inspections conducted by personnel trained in the safety,
operation and maintenance of this equipment.
ASME B30.7 states inspection intervals depend upon the nature of
the critical components of the equipment and the severity of usage.
The inspection intervals recommended in this manual are based on
intermittent operation of the winch eight hours each day, five days
per week, in an environment relatively free of dust, moisture and
corrosive fumes. If the winch is operated almost continuously or
more than the eight hours each day, more frequent inspections will
be required.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages, allowing
corrective action to be taken before the condition becomes
dangerous.
Deficiencies revealed through inspection, or noted during
operation, must be reported to designated personnel instructed in
safety, operation and maintenance of this equipment. A
determination as to whether a condition constitutes a safety hazard
must be made, and the correction of noted safety hazards
accomplished and documented by written report before placing
the equipment in service.
Records and Reports
Inspection records, listing all points requiring periodic inspection
should be maintained for all load bearing equipment. Written
reports, based on severity of 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 person
who performed the inspection, and kept on file where they are
readily available for review.
Wire Rope Reports
Records should be maintained as part of a long-range wire rope
inspection program. Records should include the condition of wire
rope removed from service. Accurate records will establish a
relationship between visual observations noted during frequent
inspections and the actual condition of wire rope as determined by
periodic inspections.
Frequent Inspection
On equipment in continuous service, frequent inspection should
be made by operators at the beginning of each shift. In addition,
visual inspections should be conducted during regular operation
for indications of damage or evidence of malfunction.
1. WINCH. Prior to operation, visually inspect winch housing,
control, brake and drum for indications of damage. Any
discrepancies noted must be reviewed and inspected further
by authorized personnel instructed in the operation, safety
and maintenance of this winch.
2. WIRE ROPE. Visually inspect all wire rope which can be
expected to be in use during the day’s operations. Inspect for
wear and damage indicated by distortion of wire rope such as
kinking, “birdcaging,” core protrusion, main strand
displacement, corrosion, broken or cut strands. If damage is
evident, do not operate winch until the discrepancies have
been reviewed and inspected further by personnel
knowledgeable on wire rope safety and maintenance
procedures.
• The full extent of wire rope wear cannot be determined by
visual inspection. At any indication of wear or damage inspect
the wire rope in accordance with instructions in “Periodic
Inspection.”
3. WIRE ROPE REEVING. Check reeving and ensure wire
rope is properly secured to the drum. Do not operate the
winch unless the wire rope feeds onto the drum smoothly.
4. AIR SYSTEM. Visually inspect all connections, fittings,
hoses and components for indication of air leaks. Repair any
leaks or damaged components found.
5. BRAKE. During winch operation, test the brake. The brake
must be capable of supporting the load without slipping. The
automatic brake must release when the winch throttle is
operated. If the brake does not hold or does not release
properly, the brake must be adjusted or repaired.
6. LUBRICATION. Refer to “LUBRICATION” section for
recommended procedures.
7. MANUAL THROTTLE LEVER. Ensure operation of
manual throttle lever is smooth and winch is responsive to
lever movement. Lever must return to neutral when released.
If winch responds slowly or movement is unsatisfactory, do
not operate until all problems have been corrected.
8. PENDANT (optional feature). Ensure operation of pendant
levers is smooth and that the winch is responsive to pendant
control. Pendant levers must spring back to their starting
position when released.
9. MOTOR. Check oil level. Place a suitable container below
the motor and carefully open the level plug to remove any
accumulated water. Check oil level in motor and add oil as
necessary to maintain correct level. Ensure lubricated air
supply provides 6 to 9 drops of ISO VG 32 (10W) oil.
Operate motor slowly in both directions to verify operation.
Periodic Inspection
Periodic inspection intervals for winch use under various
conditions is listed below:
Disassembly may be required as a result of frequent inspection
findings or in order to properly inspect the individual components.
Disassembly steps are described in the “MAINTENANCE”
section. Maintain written records of periodic inspections to
provide an accumulative basis for continuing evaluation. Inspect
NORMAL HEAVY SEVERE
yearly semiannually quarterly

14 P5710 - Edition 15
all items listed in “Frequent Inspection.” Also inspect the
following:
1. FRAMES, CASES AND BRACKETS. Check for deformed,
cracked or corroded main components. Replace damaged
parts.
2. FASTENERS. Check retainer rings, split pins, 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 is anchored securely 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 actual diameter should only
be done with the wire rope under equivalent loading and
in the same operating section as accomplished during
previous inspections. If the actual diameter of the wire
rope has decreased more than 1/64 inch (0.4 mm) a
thorough examination of the wire rope should be
conducted by an experienced inspector to determine the
suitability of the wire rope to remain in service. Refer to
Dwg. MHP0056 on page 14.
(Dwg. MHP0056)
5. ALL COMPONENTS. Inspect for wear, damage, distortion,
deformation and cleanliness. If external evidence indicates
damage, disassemble as required to conduct a detailed
inspection. Inspect gears, shafts, bearings, sheaves, springs
and covers. Replace worn or damaged parts. Clean, lubricate
and reassemble.
6. BRAKE. Test brake to ensure proper operation. Brake must
hold a 125% rated load with full drum without slipping. If
indicated by poor operation or visual damage, disassemble
and repair brake. Check all brake surfaces for wear,
deformation or foreign deposits. If brake lining thickness is
less than minimum as described in the “MAINTENANCE”
section replace brakes. Clean and replace components as
necessary. Refer to the “MAINTENANCE” section for
adjustment information.
7. 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.
8. LABELS AND TAGS. Check for presence and legibility of
labels. Replace if damaged or missing.
9. DRUM GUARD (optional feature). Verify fasteners are tight
and in good condition. Ensure guard is in good condition.
10. EMERGENCY STOP VALVE (optional feature). During
winch operation verify the emergency shut-off valve
operation. Valve must stop winch operation quickly. Valve
must reset properly. Refer to “Emergency Stop Valve” in the
“OPERATION” section for procedures.
Winches Not in Regular Use
1. Equipment which has been idle for a period of one month or
more, but less than six months, shall be given an inspection
conforming to the requirements of “Frequent Inspection”
before being placed in service.
2. Equipment which has been idle for a period of over six
months shall be given a complete inspection conforming with
the requirements of “Periodic Inspection” before being place
in service.
3. Standby equipment shall be inspected at least semiannually
in accordance with the requirements of “Frequent
Inspection.” In abnormal operating conditions equipment
should be inspected at shorter intervals.

P5710 - Edition 15 15
This form may be copied and used as an inspection/maintenance record.
INSPECTION AND MAINTENANCE REPORT
Model BU7A Air Winch
Model Number: Date:
Serial Number: Inspected By:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection:
____Quarterly ____Semiannually ____Yearly Operating Environment:
2. Discrepancy(ies) noted during Frequent Inspection
3. Discrepancy(ies) noted during maintenance Normal____Heavy____Severe____
4. Other:_________________________________
Refer to the Parts, Operation and Maintenance Manual “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.
COMPONENT CONDITION CORRECTIVE
ACTION NOTES
Pass Fail Repair Replace
Case, Frame & Motor
Mounting Bracket
Drum Band Brake
(125% Load Test)
Drum Band Brake
(Visual Inspection)
Motor
Controls
Air System
Fasteners
Reduction Gears
Clutch
Labels and Tags ---
Shafts
Wire Rope --- ---
Guards
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

16 P5710 - Edition 15
LUBRICATION
To ensure continued satisfactory operation of the winch, all points
requiring lubrication must be serviced with the correct lubricant at
the proper time interval as indicated for each assembly.
The lubrication intervals recommended in this manual are based
on intermittent operation of the winch eight hours each day, five
days per week. If the winch is operated almost continuously or
more than the eight hours each day, more frequent lubrication will
be required. Also, the lubricant types and change intervals are
based on operation in an environment relatively free of dust,
moisture, and corrosive fumes. Use only those lubricants
recommended. Other lubricants may affect the performance of the
winch. Approval for the use of other lubricants must be obtained
from your Ingersoll-Rand distributor. Failure to observe this
precaution may result in damage to the winch and/or its associated
components.
Motor
Correct lubrication is one of the most important factors in
maintaining efficient winch operation. The motor is splash
lubricated by the oil in the motor housing and has no other means
of lubrication. It is therefore important to use only high quality,
Extreme Pressure (EP) rust and oxidation inhibiting gear oils or
non-detergent motor oils to ensure maximum performance and
minimum downtime for repairs. Refer to Table 3 on page 16.
Allow oil to settle before topping off. Oil capacity for the BU7A
winch motor is 1/2 pint (0.24 litres). Pour sufficient oil into the
vent cap opening to bring the oil in the motor case to the level of
the upper oil plug hole. Add oil slowly to prevent spilling.
The oil level in the motor should be checked daily or at the start of
each shift after accumulated water has been drained off.
When motors are operated in temperatures below freezing, wait
long enough at end of shift for water to separate from oil but not
long enough for it to freeze. Failure to drain the water when the
winch is to remain idle for a protracted period at low temperatures
may result in the oil splasher freezing fast. Drain water then refill
to the level plug. If desired, all the oil may be drained at the end of
the shift and the motor refilled with new oil.
Gear Case
Check grease in gear chamber weekly by removing lower grease
plug (75) in gear case cover (76). If grease is below this opening,
remove grease plug from top of gear case cover and add a
sufficient quantity of Ingersoll-Rand Heavy Gear Grease No. 70
to bring grease level in chamber up to the side opening.
Ingersoll-Rand Light Grease No. 28 or a soda- or mixed-base
grease of No. 2 consistency may be used as a substitute.
Seals and Bearings
If winch is disassembled, clean all parts thoroughly and coat
bearings and seals with clean grease. Refer to Table 4 on page 16.
Use sufficient grease to provide a good protective coat.
Wire Rope
Follow the wire rope manufacturer’s instructions. At a minimum,
observe the following guidelines.
1. Clean with a brush or steamto remove dirt, rock dust or other
foreign material on the surface of the wire rope.
• Do not use an acid-based solvent. Only use cleaning fluids
and lubricants specified by the wire rope manufacturer.
2. Apply a wire rope lubricant, LUBRI-LINK-GREEN® or ISO
VG 100 (30W) oil.
3. Brush, drip or spray lubricant weekly, or more frequently,
depending on severity of service.
Interval Lubrication Checks
Start of each shift Check flow and level of air line
lubricator (approximately 6 to 9 drops
per minute required at maximum
motor speed).
Check oil level in motor.
Monthly Inspect and clean or replace air line
filter.
Yearly Replace grease in gear case.
Drain and refill the oil in the winch
motor.
Table 3
Ambient
Temperature Recommended Oil Type
Below 32° F (0° C) ISO VG 32 (10W)
30° to 80° F (0° TO 26° C) ISO VG 68 (20W)
Above 80° F (26° C) ISO VG 100 (30W)
Table 4
Ambient
Temperature Recommended Grease Type
-20° to 50° F (-30° to 10° C) EP 1 multipurpose
lithium-based
30° to 120° F (-1° to 49° C) EP 2 multipurpose
lithium-based

P5710 - Edition 15 17
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. No air supply to winch. Check air supply line connections and hoses. Ensure air pressure at winch inlet is at least 90 psig (6.3 bar/630 kPa) at rated
volume.
Winch is overloaded. Reduce load to within rated capacity.
Drum brake is not released. Disengage manual drum brake or refer to “Automatic Drum
Brake” below.
Load continues to
move when winch is
stopped.
Drum brake is slipping. Check drum brake adjustment and brake band lining wear.
Winch does not lift or
pull load. Motor may be damaged. Remove and disassemble motor as described in the “MAINTENANCE” section. Examine all parts and replace any
that are worn or damaged.
Insufficient air supply. Verify air supply pressure and volume at winch inlet meets
requirements listed in the “SPECIFICATIONS” section. Clean
air line filter.
Winch is overloaded. Reduce load to within rated capacity.
Throttle (or pendant)
lever moves but winch
does not operate.
Motor may be damaged. Disassemble and clean the motor and replace any broken or
damaged parts.
Insufficient air supply. Ensure the air pressure at the winch inlet is at least 90 psig (6.3
bar/630 kPa) at rated volume. Clean air line filter.
Motor runs hot or
makes excessive noise
during operation.
Low oil level. Check oil level in the motor. Drain or add oil as required to
obtain the proper level.
Improper lubrication. Replace oil with type recommended in the “LUBRICATION”
section applicable to the operating environment. Set lubricator to
provide a minimum of 6 drops per minute. Check oil level in
lubricator.
Water in oil. Drain and refill with oil. Operate winch with no load slowly, in
both directions. If excessive noise is present 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” section. Inspect all parts and replace any
that are worn or damaged.
Air lines freeze. Water in air supply. Install or drain air system moisture traps, moisture collecting air
receivers and compressor aftercoolers. After corrective actions
have been taken, disconnect lines at winch inlet and purge with
clean, dry air or nitrogen prior to reattaching and operating
winch.
Automatic Drum Brake:
Brake cylinder will not
release. Drum brake out of adjustment. Adjust drum brake to maintain correct cylinder stroke.
Damaged cylinder seals. If air is noticed escaping from the cylinder breather when
attempting to release brake, replace or repair cylinder.
Dirty filter in air supply. Clean or replace filter.
Exhaust port plugged. Clear foreign material out of exhaust port. Air should exhaust
when control valve handle is in neutral.

18 P5710 - Edition 15
MAINTENANCE
•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 service personnel trained in safety and service on
this winch to perform maintenance.
•After performing any maintenance on the winch, test winch
to 125% of its rated capacity before returning to service.
•Turn off air system and depressurize air lines before
performing any maintenance.
Proper use, inspections and maintenance increase the life and
usefulness of your Ingersoll-Rand equipment. During assembly,
lubricate gears, nuts, capscrews and all machined threads with
applicable lubricants. Use of antiseize compound and/or thread
lubricant on capscrew and nut threaded areas prevents corrosion
and allows for easy disassembly of components.
Maintenance Intervals
The Maintenance Interval Chart below is based on intermittent
operation of equipment for eight hours each day, five days per
week. If the equipment is in operation for more than eight hours a
day or is operated in severe applications or environments, more
frequent maintenance should be performed.
•Before adjusting brake, remove any load from load line to
prevent injury or property damage.
Adjusting Manual Brake
Keep brake adjusted so that considerable pressure is required to
force lever past the high point. Never adjust the brake so tight that
lever cannot be moved to the locked position.
If brake does not hold rated load, disassemble and repair.
1. Lift up brake lever (55) to remove tension on brake band.
2. Remove brake lever screws, separate halves and set aside.
3. Spread brake band apart and measure thickness of metal band
and lining together. When brake band and lining together
measure less than 0.203 inches (5.2 mm) in any location, the
brake band assembly (61) must be replaced.
4. Rotate brake trunnion (56) half a turn clockwise when facing
the gear end of the winch.
5. Insert brake trunnion into brake lever and assemble with
screws. Place brake lever halves into brake band bracket.
6. Press lever down. This should be difficult until lever goes
“over center”and locks.
7. Actuate throttle lever in both directions. Drum should not
rotate.
8. If drum rotates, remove brake lever, tighten trunnion
clockwise another half turn and test again. Repeat until drum
does not rotate when lever is locked and throttle is activated.
Adjusting Automatic Brake
Refer to Dwg. MHP1210 on page 30.
If the brake assembly is removed or repaired, ensure that the
breather is installed and located at the top of the brake cylinder
during reassembly.
The automatic brake is spring actuated in the brake “ON”position
with no air. The brake cylinder must be energized to affect any
adjustments. The use of a brake-pressurizing tool is recommended
when adjusting the automatic brake. This tool consists of:3/8 NPT
pipe nipple, ball valve and a quick disconnect fitting (to connect to
shop air supply).
1. Remove screws (131) from brake lever, separate halves and
set aside.
2. Spread brake band apart and measure thickness of metal band
and lining together. When brake band and lining together
measure less than 0.203 inches (5.2 mm) in any location, the
brake band assembly (61) must be replaced.
3. Rotate brake trunnion (56) half a turn clockwise when facing
gear end of winch.
4. Place brake trunnion between brake lever halves and
assemble with screws.
5. Align lever with air cylinder clevis and insert brake pin.
Retain with cotter pin.
6. Attach test load to load line and lift load 6 to 9 inches (150 to
220 mm). When throttle lever is in neutral position
(centered), the load should not move.
7. Brake is correctly adjusted when 1/4 to 1/2 in. (13 to 19 mm)
of piston rod is exposed. Refer to Dwg. MHP1211 on page
19. If load does move, tighten trunnion a further half turn and
test again. Repeat until load does not move when throttle
lever is in neutral position.
Interval Maintenance Check
Start of each shift
(Operator or
Maintenance Personnel)
Make a thorough visual inspection
of winch for damage. Do not
operate winch if damaged.
Operate winch at low RPM in both
directions. Winch must operate
smoothly without sticking, binding
or abnormal noises. Check
operation of brake.
3 Months
(Maintenance Personnel)
Inspect brake linings. Clean or
replace parts as required. Adjust
brake as necessary.
Yearly
(Maintenance Personnel)
Inspect gearing, shafts and bearings
for wear and damage.
Repair or replace as necessary.
Check all supporting members,
including foundation, fasteners,
nuts, sheaves and rigging, etc. for
indications of damage or wear.
Repair or replace as necessary.

P5710 - Edition 15 19
(Dwg. MHP1211)
Motor
1. Drain and replace oil in motor and reduction gear after the
first 50 hours of initial winch operation. Thereafter, drain and
replace oil according to the intervals recommended.
2. Always inspect removed oil for evidence of internal damage
or contamination (metal shavings, dirt, water, etc.). If
indications of damage are noticed, investigate and correct
before returning winch to service.
3. After winch operation, allow oil to settle before topping off.
4. Always collect lubricants in suitable containers and dispose
of in an environmentally safe manner.
Gear Case Assembly
Check grease in gear case as recommended in “LUBRICATION”
section. If it is low, replenish it. Grease should be changed once a
year.
Disassembly
General Disassembly Instructions
The following instructions provide the necessary information to
disassemble, inspect, repair, and assemble the winch. Parts
drawings are provided in the parts section. In general, the winch is
designed to permit easy disassembly and assembly. The use of
heat or excessive force should not be required. If a winch is being
completely disassembled for any reason, follow the order of the
topics as they are presented. It is recommended that all
maintenance work on the winch be performed in a clean dust free
work area.
In the process of disassembling the winch, observe the following:
1. Never disassemble winch 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 the perimeter of a cover or housing with a soft
hammer, for example, is sufficient to break the seal.
3. Do not heat a part with a flame to free it for removal, unless
part being heated is already worn or damaged beyond repair
and no additional damage will occur to other parts.
4. Keep work area as clean as practical, to prevent dirt and other
foreign matter from getting into bearings or other moving
parts.
5. All seals, gaskets and ‘O’rings should be discardedonce they
have been removed. New seals, gaskets and ‘O’rings should
be used when assembling the winch.
6. When grasping a part in a vise, always use leather- or copper-
covered vise jaws to protect the surface of the part and help
prevent distortion. This is 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 the removal of that part is necessary for
repairs or replacement.
8. When removing ball bearings from shafts, it is best to use a
bearing puller. When removing bearings from housings, drive
out the bearing with a sleeve slightly smaller than the outside
diameter of bearing. The end of the sleeve which contacts the
bearing must be square. Protect bearings from dirt by keeping
them wrapped in clean cloths.
•Special attention should be given to the installation of needle
bearings. Direct pressure on the bearing itself may result in
distortion or fracture of its thin shell, resulting in premature
failure.
•Bearings should be pressed in with a bearing insertion tool
that is shaped to properly contact the bearing face.
•Do all pressing on the stamped face of the bearing.
The construction of the BU7A winch allows for the motor to be
removed, repaired and replaced without removing the gears.
Alternatively, gears can be removed and replaced without
disturbing the motor.
The following instructions cover the complete disassembly of the
winch. For sub-assemblies where it is obvious that no new parts
are required, do not disassemble. Even for complete
reconditioning, disassembly should proceed only far enough to
allow thorough inspection and replacement of worn or damaged
parts.
Brake Band Replacement
Refer to Dwg. MHP1207 on page 26.
For winches with automatic brake, remove cotter pin (134) and
brake lever pin (133). Then the following steps apply to all
winches:
1. Remove brake lever screws, separate handle and set aside.
2. Remove four capscrews (69) and lockwashers (71).
3. Pull gear case assembly away from drum.
4. Remove brake band assembly (61) from drum.
5. Remove retainer (58) from brake band pin (59). Push pin out
of brake band. Set aside brake adjusting screw (57) and
trunnion (56).
6. Refer to “INSTRUCTION SHEET”MHD56142 for “Brake
Lining Replacement Procedures”.
Control Valve Removal
Refer to Dwg. MHP1207 on page 26.
1. Unscrew the two valve chest cover capscrews (5) and remove
cover (7) with assembled parts from motor case (28).
2. Remove gasket (102).
3. Remove reverse valve nut (1) from reverse valve (10).
4. Pull throttle lever (2) and spring (3) from reverse valve.
5. Remove reverse valve (10), reverse valve seal (9) and ‘O’
ring (8) from valve chest cover.
6. Remove thrust washer (13).
Motor Disassembly
Refer to Dwg. MHP1207 on page 26.
1. Remove control valve as described in “Control Valve
Removal”.

20 P5710 - Edition 15
2. Using a 7/16 in. -14 thread bolt, remove rotary valve (15)
from rotary valve bushing (14).
3. Unscrew eight motor case capscrews (29) and remove motor
case (28) containing assembled motor from motor mounting
bracket (79).
4. Unscrew four cylinder capscrews (21) from any one of the
four cylinder heads (23) and remove the cylinder head,
cylinder sleeve (19) and gasket (24).
5. Rotate crank (44) until piston (17) is at top dead center. Push
piston wrist pin (18) out of piston, freeing piston from
connecting rod (39). Repeat until all four cylinders and
pistons have been removed freeing the crank (44) and
assembled parts.
6. Using two screw drivers, pry crank pin sleeve (36) from
crank and remove connecting rod rings (38), connecting rods
(39) and connecting rod bushing (37).
7. Remove crank bearing (78) (only if replacement is necessary)
by supporting inner ring of bearing and pressing on face of
motor pinion.
8. If pinion on crankshaft (44) is damaged or worn, it will be
necessary to replace entire crankshaft.
9. Unscrew four oil wall screws (35) and remove oil wall (33).
Removal of the oil wall is seldom necessary unless reverse
valve bushing (12) is to be removed.
10. Rotary valve bushing (14) and reverse valve bushing (12) are
press fits in the motor case and should never be removed
unless replacement is necessary. To remove, heat bushings to
450°F (232°C) to loosen Loctite®. Support the face of the
motor case that contacts the valve chest cover, and, with a
suitable arbor inserted into motor case and against the face of
the bushing, press bushing out while it is hot.
•Use an arbor that will clear the bushing keys (30) that project
into each bushing bore in motor case. Pressing bushings out in
the opposite direction or using an arbor that will not clear the
bushing keys will result in the keys being sheared off.
Rotary Valve Bushing Removal
Refer to Dwg. MHP1463 on page 20.
1. Fabricate one of the two punches shown in Dwg. MHP1461
on page 20, the first punch will clear the bushing key (30), the
second one has a slot to clear the bushing key. Press old
rotary valve bushing (14) out of motor housing (28).
2. Measure motor housing bore, if greater than 1.313 in. (33.35
mm) replace housing.
(Dwg. MHP1461)
(Dwg. MHP1463)
•Press rotary valve bushing out from inside motor housing
only. Bushing has a groove to clear bushing key (30).
•Support motor housing to prevent damage during pressing.
Reverse Valve Bushing Removal
Refer to Dwg. MHP1463 on page 20.
1. Fabricate one of the two punches shown in Dwg. MHP1461
on page 20, the first punch will clear the bushing key (30), the