Ingersoll-Rand Force 5 FH5 Installation guide

Form MHD56181
PARTS, OPERATION AND MAINTENANCE
SUPPLEMENT*
MODEL FH5
* This supplement should be used in conjunction with supporting documentation for the
hydraulic motor, disc brake, reduction gear assembly and controls as applicable.
Form MHD56181
Edition 1
April 1999
71350573
©
1999 Ingersoll-Rand Company
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, and maintenance information. Make
this manual available to all persons responsible for the operation,
installation and maintenance of these products.
WARNING
Do not use this winch for lifting, supporting, or transporting people or lifting or
supporting loads over people.
Always operate, inspect and maintain this winch in accordance with American National
Standards Institute Safety Code (ASME B30.7) and any other applicable safety codes and
regulations.
Refer all communications to the nearest Ingersoll-Rand Material Handling Office or
Distributor.

2MHD56181 - Edition 1
TABLE OF CONTENTS
Description Page No.
Safety Information
Danger, Caution, Warning and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safe Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications
Model Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Initial Operating Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Winch Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Winch Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drum Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubrication
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reduction Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Automatic Disc Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Seals and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drum Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection
Records and Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Winches Not in Regular Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection and Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–19
Maintenance
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic System General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning, Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts Information
Winch Drawings and Parts Lists Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts Drawings and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-32
Parts Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Return Goods Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Office Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

MHD56181 - Edition 1 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 product.
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
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.
DANGER
WWAARRNNIINNGG
CCAAUUTTIIOONN
NNOOTTIICCEE
are used to identify the level of potential hazard.
Safety Summary
WARNING
• Do not use this unit or attached equipment for lifting,
supporting, or transporting people or lifting or supporting
loads over people.
• The supporting structures and load-attaching devices used in
conjunction with these units must provide a safety factor of at
least three times the rated capacity of the unit. This is the
customer’s responsibility. If in doubt, consult a registered
structural engineer.
NOTICE
• Lifting and handling equipment is subject to different
regulations in each country. These regulations may not be
specified in this manual.
Ingersoll-Rand Material Handling winches are manufactured in
accordance with the latest ASME B30.7 standards.
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.
The Occupational Safety and Health Act of 1970 generally places
the burden of compliance with the owner/employer, 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 of the operator to exercise
caution, use common sense and be familiar with proper rigging
techniques. Refer to 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.

4MHD56181 - Edition 1
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 rule set 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, check 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 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 tipload the hook as this leads to spreading and
eventual failure of the hook.
10. Do not “side pull” or “yard”.
11. Make sure everyone is clear of the load path. 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 suspend a load for an extended period of time.
16. Do not leave a load suspended when the winch is unattended
or not in use.
17. Pay attention to the load at all times when operating the
winch.
18. After use, or when in a non-operational mode, the winch
should be secured against unauthorized and unwarranted use.
19. The operator must maintain an unobstructed view of the load
at all times.
20. Never use the winch wire rope as a sling.
WARNING LABELS
Each unit is shipped from the factory with the warning labels
shown. If the labels are not attached to your unit, order new labels
and install them. Refer to the parts list for the part number. Labels
are not shown actual size.

MHD56181 - Edition 1 5
SPECIFICATIONS
Model Code Explanation
Example: FH5-24MK1P FH5 - 24 M K 1 P
Series (Capacity)
FH5 =Hydraulic Powered Winch (5 metric ton / 11,000 lbs.)
Drum Flange Height or ManRider®:
- = Standard flange: 27 inch (660 mm) diameter
T = Tall flange: 35 inch (890 mm) diameter
MR = ManRider®(Refer to ManRider®Supplement Form #MHD56042)
TGL = Guideline
TPL = Podline
Drum Length (Distance between drum flanges):
12 = 12 inch (306 mm)
16 = 16 inch (406 mm)
24 = 24 inch (610 mm) Standard
30 = 30 inch (760 mm)
36 = 36 inch (915 mm) Tall Flange Winch only
Drum Brake:
A = Automatic Drum Brake
M = Manual Drum Brake
X = None
Disc Brake:
K = Automatic Disc Brake
X = None
Control: 1=Winch mounted lever throttle (Standard)
*2 = Customer provided
Options:
*7 = Drum Grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch)
** C = Low Temperature Components; specify -10° C (14° F) or -20° C (-4° F)
*D = Drum Divider Flange and additional wire rope anchor
G = Drum Guard
L = Drum Locking Pin
** M1 = Material Traceability (Typical material results)
** M2 = Material Traceability (Actual material results)
** M3 = Material Traceability (Actual material results for these parts in finished, as-delivered condition)
N = Type Approval – Specify:
A = American Bureau of Shipping (ABS); N = Det Norske Veritas (DNV); R = Lloyd’s Register of Shipping (LRS)
P = Marine 812 top coat
Q = Special paint; please specify
*S = Rotary Limit Switch
*U = Underwound
** W = Witness; please specify
X = Testing; please specify
Z = Sand Blast and Carbozinc Primer only
*-E = Compliance with European Machinery Directive (includes Emergency Stop and Overload Protection)
Notes: *Not covered in this manual. Contact the factory or your nearest Ingersoll-Rand distributor for information.
** Documentation, witness testing and material traceability available; must be requested at time of order. Specify options or
contact the factory or your nearest Ingersoll-Rand distributor for information.

6MHD56181 - Edition 1
Description of Operation
FH5 winches are hydraulic powered, planetary geared units
designed for lifting and pulling applications. FH5 winches are
supplied with either an automatic disc brake, a manual or
automatic externally mounted drum band brake, or a combination
of both.
The output from an externally mounted hydraulic motor is
transmitted through a coupling and shaft to the planetary reduction
gear assembly.
The FH5 winch disc brake assembly consists of friction plates
splined to a hub which in turn is connected to the drive shaft from
the motor. The brake friction plates are clamped to the drum shaft
through a spring applied piston.
The winch brake typically consists of a fail-safe disc brake and a
counterbalance valve. The brake is disengaged in the lowering
(payout) direction only. In the raise (haul-in) direction, the brake
remains engaged, and an internal sprag clutch provides fail-safe
load lifting, preventing momentary downward load drifting at the
instant the winch control valve (refer to manufacturer’s provided
information) is shifted to raise the load. The brake release oil
pressure is provided by fluid pressure ported from the winch
motor to the brake housing.
The counterbalance valve will prevent a runaway load condition.
Should the load try to drop faster than the winch is paying out,
overrunning the winch motor, the valve will sense a low pressure
condition at the motor inlet, and restrict fluid flow from the motor
outlet. This creates a fluid back-pressure on the winch motor,
causing the motor to quickly slow down, stopping the runaway
load.
The counterbalance valve should be preset to operate a minimum
of 130% of the maximum oil pressure induced by the rated winch
load.
The drum band brake operates by applying a friction force
between the drum brake and winch drum. The manual brake
requires an operator to engage and disengage the brake using a
lever located on top of the brake band. The automatic drum band
brake operation is similar to the disc brake with the following
exception: the automatic drum band brake fully disengages in both
the haul-in and payout directions.
General Specifications: Model
FH5 FH5T
Utility Rating 5:1
design factor Full Drum Line Pull @ 2700 psi (18620 kPa/
186 bar) 11,000 lbs 4,490 kgs 8,400 lbs 3810 kgs
Mid Drum Line Speed @ 40 gpm (151 l/min) 65 fpm 20 m/min 80 fpm 24 m/min
FH5-24MX1 Net Weight 1780 lbs 807 kg - - - - - -
FH5T-24MX1 Net Weight - - - - - - Contact Factory
Drum Barrel Diameter 15 inches 381 mm 15 inches 381 mm
Drum Flange Diameter 27.25 inches 692 mm 35.25 inches 895 mm
Motor Displacement 6.72 cu. in/rev 110 cu. cm/rev 6.72 cu. in/rev 110 cu. cm/rev
Maximum System Inlet pressure ** 3000 psi 207 bar 3000 psi 207 bar
Maximum System Flow at rated load ** 104 gpm 393 l/min 104 gpm 393 l/min
Hose size Refer to “INSTALLATION” section for recommended hose sizes
* Drum Wire
Rope
Storage Capacity
(feet / metres)
Drum Length (inches) Wire Rope Diameter
0.625 inch 16 mm
0.625 inch (16 mm) diameter
wire rope not recommended for
use on FH5T winches.
12 937 ft 247 m
16 1106 ft 335 m
24 (Standard) 1681 ft 509 m
30 2112 ft 640 m
0.75 inch 18 mm 0.75 inch 18 mm
12 515 ft 164 m 1174 ft 371 m
16 698 ft 222 m 1592 ft 503 m
24 (Standard) 1064 ft 338 m 2426 ft 766 m
30 1338 ft 425 m 3053 ft 963 m
36 (Tall flange only) - - - - - - 3679 ft 1160 m
0.875 inch 20 mm 0.875 inch 20 mm
12 374 ft 151 m 838 ft 310 m
16 509 ft 205 m 1139 ft 420 m
24 (Standard) 778 ft 312 m 1742 ft 641 m
30 979 ft 393 m 2194 ft 807 m
36 (Tall flange only) - - - - - - 2646 ft 973 m
*Wire rope storage capacity based on wire rope top layer located a minimum of 1/2 inch (13 mm) below drum flange as meets ASME
B30.7. The wire rope storage capacities listed may vary from figures stated elsewhere.
** Contact factory prior to operating winch with pressures and flow rates above the 5:1 utility rating.

MHD56181 - Edition 1 7
Traceability
Load bearing parts are documented to provide traceability. The
documentation includes chemical and physical properties of the
raw material, heat treating, hardening, tensile and charpy tests as
required for the part. Units with M2 or M3 in the model code
have traceable load-bearing components. Components with part
numbers ending in CH are charpy parts for use under extreme
cold conditions. Traceability requirements must be stated when
reordering these parts for continued certification.
INSTALLATION
Prior to installing the winch, carefully inspect it for possible
shipping damage.
Winches are supplied fully lubricated from the factory. Before
operation check oil levels and adjust as necessary. Use the proper
type of oil as recommended in the “LUBRICATION” section.
CAUTION
• 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
Refer to Dwg. MHP0133 on page 7 and Table 1 on page 7.
Care must be taken when moving, positioning or mounting the
winch. In most cases, lifting lugs have been provided to assist in
handling the winch. If the lug locations are improper for your
specific installation, great care should be taken to ensure that the
winch, when lifted, will be properly balanced. Determine the
weight of your winch by referring to the “SPECIFICATIONS”
section. Lift the winch 3 to 4 inches (75 to 100 mm) off the
ground.
Verify winch is balanced and secure before continuing lift.
Mount the winch so the axis of the drum is horizontal. If the winch
is to be mounted in an inverted position it may be necessary to
reposition the motor parts.
1. 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 uprights and side
rails resulting in winch damage.
2. Make sure the mounting surface is flat to within 0.005 inch
(0.127 mm) per inch of drum length. Shim if necessary.
3. Mounting bolts must be 3/4 inch (18 mm) Grade 8 or better.
Use self-locking nuts or nuts with lockwashers.
4. Tighten 3/4 inch (18 mm) mounting bolts evenly and torque
to 380 ft lbs (515 Nm) for dry thread fasteners. If the
fasteners are plated, lubricated or a thread locking compound
is used, torque to 280 ft lbs (380 Nm).
5. 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, for every inch (25 mm) of drum length,
be at least 1.6 feet (0.5 metre) from the drum. Refer to Dwg.
MHP1811 on page 8 and Table 2 on page 8.
6. Do not weld to any part of the winch.
Winch Bolt Hole Mounting Dimensions
(Dwg. MHP0133)
on page 7
Table 1 Winch Bolt Hole Mounting Dimensions
Dimension Drum Length (inches)
12 16 24 30 36*
‘A’ FH5 inch 31.25 - - -
mm 794
‘A’ FH5T inch 34.25
mm 870
‘B’ (with
Drum Brake) inch 7.5 9 10.5 10 11.5
mm 190 229 267 254 292
‘B’ (without
Drum Brake) inch 6 6.25 9 12 14
mm 152 159 229 305 356
‘C’inch 13/16
mm 20
Bolt Hole Qty
each Side Rail 45
*36 inch drum length applies to FH5T (tall flange) only.

8MHD56181 - Edition 1
(Dwg. MHP1811)
Notes:
1. Maintain a minimum of 3 tight wraps of wire rope on drum at
all times.
2. Ensure wire rope does not exceed top layer requirement.
Refer to “SPECIFICATIONS” section for drum capacity.
Wire Rope
CAUTION
• Maintain at least 3 tight wraps of wire rope on the drum at
all times.
• Install the wire rope to come off the drum for overwind
operation. Refer to Dwg. MHP1755 on page 8.
(Dwg. MHP1755)
NOTICE
• Some applications may require underwind operation.
Consult the factory prior to use.
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 that
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
should be 6 X 19 or 6 X 37 IWRC right lay to permit correct
installation of wire rope anchor. Refer to Table 3 on page 8 for
minimum and maximum recommended wire rope diameters.
Smaller wire rope sizes may be acceptable on custom designed
drums.
Installing Wire Rope
Refer to Dwg. MHP0166 on page 8.
1. Cut wire rope to length in accordance with the wire rope
manufacturer’s instructions.
2. Feed the end of the wire rope into the anchor hole in the
drum and pull through approximately one foot (305 mm) of
wire rope.
(Dwg. MHP0166)
3. Wrap the wire rope with wire a distance from the end equal to
the wedge length plus one inch (25 mm).
4. Slide the sleeve over the end of the wire rope so the larger
diameter of the taper bore is nearest the end of the wire rope.
5. Spread the end strands of the wire rope and insert the split
wedge until it is below the end of the wire rope.
Table 2 Lead Sheave Minimum Distance
Drum Length
(inches) ‘A’ Minimum Distance *
feet metres
12 19.2 5.85
16 25.6 7.8
24 38.4 11.7
30 48 14.6
36 57.6 17.5
* ‘A’ = 1.6 feet (0.5 metre) per inch of drum length.
Table 3 Minimum and Maximum Wire Rope Size
Model Minimum Maximum
inch mm inch mm
FH5 5/8 16 7/8 22
FH5T 3/4 18
Note: Maximum wire rope diameter is limited by the size of the
wire rope anchor hole. Refer to the parts list for correct wire rope
anchor part numbers.

MHD56181 - Edition 1 9
6. Pull the sleeve over the wire rope end until tight. Check that
the wire rope strands stay in the slots located on the split
wedge.
7. Pull the wire rope anchor into position in the drum anchor
pocket.
CAUTION
• Make sure the first wrap of wire rope is tight and lays flush
against the drum flange.
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.
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. Always maintain at least three full, tight wraps of wire rope
on the drum.
Hydraulic System
Hydraulic Hoses
In order to maintain maximum efficiency of the winch, select the
size of hydraulic lines according to the maximum volume of oil to
be used. Refer to Table 4 on page 9. If the hydraulic lines used are
too small, they may cause excessive back pressure, generating
heat and causing inefficiency within the hydraulic system.
The sizes in Table 4 are to be used as a guide only. If trouble is
experienced due to the use of long hoses, it may be necessary to
use hoses which are one size larger.
Table 4 Hydraulic Hose Recommendations
Hydraulic Fluid
The most frequent cause of malfunction or failure of hydraulic
equipment is the presence of contaminants in the hydraulic fluid.
Reduce contaminants by using clean hydraulic fluid, and changing
the fluid before it deteriorates. When the hydraulic fluid is
changed, also clean out the hydraulic reservoir. At a minimum, the
required oil cleanliness level is ISO 18/13 or better.
Periodic checks which may be performed by the operator to test
hydraulic fluid cleanliness include:
1. Check for a major change in color or noticeable thickening,
which are signs of severe deterioration and indicate the need
to change the fluid.
2. Check oil for foaming and aeration which may indicate low
oil level in the hydraulic tank, leaks, faulty hydraulic line
connections or moisture build-up in the oil.
ISO VG 30, 46 and 68 oils will give good results under normal
temperature conditions. The use of an oil having a high viscosity
index will minimize cold-start trouble and reduce the length of
warm-up periods. A high viscosity index will minimize changes
in viscosity with corresponding changes in temperature.
CAUTION
• Do not substitute synthetic fluids unless it has been
determined that winch, motor and hydraulic system seals are
compatible.
Use a premium anti-wear (AW) hydraulic fluid in the hydraulic
system. The following specifications are intended to serve as a
general guide in selecting suitable oils.
Oil Flow *
@ 3000 psig max Pressure Lines (inside diameter)
gpm l/min inch mm
10-30 27-114 1 26
31-60 115-227 1.25 32
61-90 228-303 1.5 38
90-120 304-454 1.75 45
* Based on 17 fps (5.2 mps) oil velocity.
Table 5 Recommended Hydraulic Oil
Temperature Recommended Hydraulic
Oil
Fahrenheit Celsius
above 32° F 0° C ISO VG 46
(SSU 230-240 @ 100° F)
0° to 32° F -17.7° to 0° C ISO VG 32
(SSU 160-165 @ 100° F)
below 0° F below -17.7° C
Consult local oil company
representative for oil having a
maximum viscosity of 7,400
SSU’s at the minimum
temperature encountered.

10 MHD56181 - Edition 1
Filters
Filters should be equipped with dirty filter indicators, which
should be checked daily. Replace filters if indicators show filter is
dirty. It is also recommended that filters be changed if hydraulic
oil is changed or a major component (pump, valve, motor, etc.) is
repaired or replaced.
When the winch is installed with its own hydraulic system or
when there is no filter in the existing circuit, a partial flow micro-
filter should be installed between the control valve and the
reservoir. This filter should be rated at Beta 200=6µm. Filters
must include an integral 50 psi (345 kPa/3.45 bar) bypass check
valve which will open when the filter element is filled to 80%
capacity.
Refer to ‘Filter Maintenance’ in the “MAINTENANCE” section
for servicing information.
Hydraulic Connections
When repairing or servicing any hydraulic lines or fittings in the
system, always flush each line and connection of all foreign
contaminants before making the final connection. Always cap or
plug open connections or lines. Verify port connections match
motor and installation information provided.
(Dwg. MHP1804)
Pump
Ensure the pump used with the winch motor is capable of
producing pressure and volume as specified for the winch.
Control Valve
The control valve used to operate the winch must be a four-way,
spring return to neutral, open center valve having a motor spool
directing all work port flow to the reservoir (return lines) when
the valve spool is in the neutral position. This control valve
should have good metering characteristics in order to provide
smooth winch control. A built-in relief valve, suitable for
maximum operating pressure and flow, should also be installed in
the control valve and/or hydraulic system.
Motor
For optimum performance and maximum durability of parts,
ensure hydraulic supply does not exceed recommended pressures
and flows. When feasible the motor should be installed as near as
possible to the pump. Motor case drain lines must be ported to the
reservoir and must not exceed 30 psi (207 kPa/2 bar).
(Dwg. MHP1759)
Disc Brake
Disc brake is shipped with petroleum based cooling oil installed.
Prior to operation, confirm oil level is to manufacturer’s
recommendations.
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. Make sure the hydraulic motor and case drain line is filled
with the recommended hydraulic fluid. Internal motor
leakage at low operating pressures may not be sufficient to
provide start-up lubrication.
2. Verify oil levels are in accordance with recommendations in
“LUBRICATION” section. Ensure all installation steps have
been followed.
3. When first operating the winch it is recommended that the
winch be driven slowly in both directions for a few minutes.
For winches that have been in storage for a period of more than
one month the following start-up procedure is required.
1. Give the winch an inspection conforming to the requirements
of “Winches Not in Regular Use” in the “INSPECTION”
section.
2. Operate the winch for 10 seconds in both directions to prime
all lines.
3. The winch is now ready for normal use.