Ingersoll-Rand FORCE 5i FA7i Setup guide

Product Maintenance
Information
FORCE 5i Air Winch
Models
FA7i, FA7Ti, FA7Ti-GL and FA7Ti-PL
MHP2919
6-02-07
(Dwg. MHP2919)
Save These Instructions
R
Form MHD56398
Edition 3
October 2013
45877164
©2013 Ingersoll-Rand

OnlyallowIngersoll Rand trainedtechnicianstoperformmaintenanceonthisproduct.ForadditionalinformationcontactIngersollRand factoryornearest
Distributor.
For additional supporting documentation refer to Table 1 ‘Product Information Manuals’ on page 2.
Manuals can be downloaded from http://www.ingersollrandproducts.com.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate all
warranties.
Original instructions are in English. Other languages are a translation of the original instructions.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
Table 1: Product Information Manuals
Publication Part/DocumentNumber Publication Part/Document
Number
Product Safety Information Manual (Non-Man Rider) MHD56250 Product Information Manual (Non-Man Rider) MHD56396
Product Safety Information Manual (Man Rider) MHD56251 Product Information Manual (Man Rider) Contact Factory
Product Parts Information Manual MHD56397
INSPECTION
Frequent inspections should be performed on equipment in regular service. Refer
to Product Information Manual. Some options may not apply to your product, refer
to data (name) plate for correct model and any applicable manuals.
nPeriodic Inspection
Refer to Table 2 ‘Inspection Classifications’ on page 3 for suggested winch
inspection classifications for Periodic Inspection intervals. Select conditions most
appropriate to application.
Maintain written records of periodic inspections to provide an accumulative basis
forcontinuingevaluation. Inspectallitems listedinthe ‘FrequentInspection’section
of the Product Information Manual. Also inspect the following at the suggested
intervals recommended in Table 3 ‘Maintenance Interval Chart’ on page 4:
1. Siderails and Uprights. Check for deformed, cracked or corroded main
components. Replace damaged parts.
2. Fasteners. Check retainer rings, capscrews, nuts and other fasteners on winch,
including mounting bolts. Replace if missing or damaged and tighten if loose.
3. Drum and Sheaves. Check for cracks, wear or damage. Replace if necessary.
4. Wire Rope. In addition to ‘Frequent Inspection’ requirements, also inspect for
the following:
a. Build-up of dirt and corrosion. Clean with steam or a stiff wire brush to
remove dirt and corrosion if necessary.
b. Loose or damaged end connection. Replace if loose or damaged.
c. Check wire rope anchor is secure in drum.
d. Verify wire rope diameter. Measure the diameter of the wire rope from
crown-to-crownthroughoutthe lifeofthe wirerope.Recording of theactual
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 2.
A
B
C
D
(Dwg. MHP0056)
5. AllComponents. Inspect forwear,damage, distortion,deformation,cracks, 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. Brakes. Individually test brakes installed to ensure proper operation. Brakes
must hold a 125%ratedload at mid drum without slipping. If indicated by poor
operation or visual damage, disassemble and repair brake(s). Check all brake
surfaces for wear, deformation or foreign deposits. Clean and replace
components as necessary. Adjustments can be made to the band brake to
compensate for normal brake lining wear. Refer to ‘Adjustments’ on page 7.
If band brake cannot be adjusted to hold rated load, replace the brake band
assembly. Adjustments cannot be made to the disc brake. The disc brake must
be repaired as described in “MAINTENANCE” on page 7.
WARNING
• Replace band brakes that are worn or have metal to metal contact. Worn
or improperly functioning brakes may cause excessive heat build-up or
cause sparks.
7. FoundationorSupportingStructure.Checkfordistortion,wearandcontinued
abilitytosupportwinch and rated load. Ensurewinchisfirmly mounted and that
fasteners are in good condition and tight.
8. Winch Guard. Verify fasteners are tight and in good condition. Ensure guard is
in good condition and panels are correctly positioned.
9. LimitSwitches.Operate winchinbothdirectionstoactivatelimitswitches.Limit
switches should engage (stop winch operation) at established settings (+/- 2
feet[+/- 0.6metres]).Reset limitswitch byoperatingwinchinopposite direction.
Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.
10. Emergency Stop Valve. During winch operation verify the emergency stop
valve operation. Valve must stop winch operation quickly. Valve must reset
properly.Referto ‘Emergency StopValve’in the “OPERATION”sectionin Product
Information Manual for procedures.
11. OverloadDevice.Ensureoverload deviceis properlysettostopthe winchwhen
loads exceed 150% (+/- 25%) of winch rated capacity. If winch does not shut
down, contact your distributor or the factory for repair information.
12. Press Roller. Inspect rollers for wear and grooves. Ensure rollers freely rotate.
Replace rollers if worn or grooved. Replace bearings if rotation is rough or stiff.
13. Labelsand Tags.Checkfor presence andlegibilityof labels. Replaceifdamaged
or missing.
2Form MHD56398 Edition 3

Table 2: Inspection Classifications
Conditions Normal Heavy Severe
Typical Use (operating time) Infrequent Regular Continual/Constant
Load Range 60% of Capacity 75% of Times Used 80% of Capacity 75% of Times Used 100% of Capacity 75% of Times Used
Installation Protected/Enclosed/Dry Not Sheltered/Exterior Full Exposure
Atmosphere Clean/Non-Corrosive Dirty/Non-Corrosive/Freshwater Marine Dirty/Corrosive/Saltwater Marine
Climate Dry/Stable Temperature Wet/Moderate Temperature Fluctuations Wet/Severe Temperature Fluctuations
nRecords 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.
nMaintenance Intervals
Refer to Table 3 ‘Maintenance Interval Chart’ on page 4for recommended
maintenance schedule.
Form MHD56398 Edition 3 3

Table 3: Maintenance Interval Chart
Normal Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 45 days or 150 hours
Grease Fittings Lubricate grease fittings every 180 days or 500 hours
Gearbox Oil Level Check oil level in gearbox every 120 days or 340 hours
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
Standard Components 1 year or
1,000 hrs 2 years or 2,000 hrs 3 years or 3,000 hrs 5 years or 5,000 hrs 6 years or 6,000 hrs 9 years or 9,000 hrs 12 years or 12,000 hrs
Inspect Motor X X X X
Inspect Manual Band Brake X X X X X X X
Inspect Disc Brake X X X
Inspect Gearbox X X X
Replace Winch Anchor Bolts X X X X
Rebuild Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X
Optional Components
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Automatic Band Brake X X X X
Heavy Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 100 hours
Grease Fittings Lubricate grease fittings every 90 days or 250 hours
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
Standard Components 1 year or
1,000 hrs 2 years or 2,000 hrs 3 years or 3,000 hrs 5 years or 5,000 hrs 6 years or 6,000 hrs 8 years or 8,000 hrs 10 years or 10,000 hrs
Inspect Motor X X X
Inspect Manual Band Brake X X X X X X X
Inspect Disc Brake X X X
Inspect Gearbox X X X
Replace Winch Anchor Bolts X X X
Rebuild Control Valve X X X
Inspect Drum, Housings and Main Frames X X X
Optional Components
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X X
Limit Switches X X X X X X X
Automatic Band Brake X X X X
Severe Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 100 hours
Grease Fittings Lubricate grease fittings every 90 days or 250 hours
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours
Manual Band Brake Check band brake adjustment every 90 days or 250 hours
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
Standard Components 1 year or
1,000 hrs 2 years or 2,000 hrs 3 years or 3,000 hrs 4 years or 4,000 hrs 5 years or 5,000 hrs 6 years or 6,000 hrs 8 years or 8,000 hrs
Inspect Motor X X X X
Inspect Manual Band Brake X X X X X X X
Inspect Disc Brake X X X X
Inspect Gearbox X X X
Replace Winch Anchor Bolts X X X X
Rebuild Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Optional Components
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Automatic Band Brake X X X X
Note: Hours are for actual winch drum rotation.
Recommend complete general overhaul.
4 Form MHD56398 Edition 3

INSPECTION REPORT
Ingersoll Rand Force 5 Infinity Series FA7i and FA7Ti Air Winches
Model Number: Date:
Serial Number: Inspected by:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection:
(_____ Months _____ Years) Operating Environment:
2. Discrepancy(s) noted during Frequent Inspection
Normal ____ Heavy____ Severe ____
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________
Refer to the Product Information Manual and Product Parts Information Manual and “INSPECTION” section for general inspection criteria. Also, refer to appropriate 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
Uprights and Siderails
Drum Band Brake (125% Load Test)
Drum Locking Pin
Disc Brake (125% Load Test)
DrumBandBrake (Visual Inspection)
Disc Brake (Visual Inspection)
Motor
Limit Switches ---
Controls
Constant Tensioning System ---
Air System
Fasteners
Reduction Gears
Labels and Tags ---
Shafts
Winch Guard
Wire Rope Wedge ---
Emergency Stop Valve
Overload Device ---
Press Roller
Wire Rope ---
Drum Locking Pin ---
Other Components (list in NOTES
section)
TESTING Pass Fail NOTES
Operational (No Load)
Operational (10% Load)
Operational (Maximum Test Load*)
* Maximum test load is 125% of rated line pull. Testing to more than 125% of rated load may be required to comply with standards and regulations set forth in areas
outside the USA.
This form may be photo copied and used as an inspection record.
Form MHD56398 Edition 3 5

TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by personnel
instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common winch symptoms, probable causes and remedies.
SYMPTOM CAUSE REMEDY
Winch will not operate. Insufficient or no air supply to winch. Check air supply line connections and hoses.
Winch is overloaded. Reduce load to within rated capacity.
Disc brake does not release. Pressurize disc brake release port and check for leakage. Replace brake piston seals
if leakage is found. Ensure air pressure at inlet to disc brake is at least 45 psig (3.1
bar/310 kPa). Inspect brake piston seals and replace if seals appear to be leaking.
Shipping plugs may still be in place. Remove shipping plugs in valve and motor exhaust ports.
Drum brake does not release. Disengage manual band brake, or refer to on page 7.
Emergency stop valve engaged. Reset emergency stop valve.
Motor may be damaged. Disassemble and clean the motor and replace any broken or damaged parts.
Air leak. Check hose and fitting connections. Inspect hose(s) for breaks. Tighten fittings and
repair or replace hoses as necessary.
Overload device engaged. Reduce load to within rated capacity of winch. If overload device cannot be reset,
contact factory.
Air lines freeze due to water in air supply. Install or drain air system moisture traps, moisture collecting air receivers and
compressor aftercoolers. After corrective action has been taken, disconnect lines at
winch inlet and purge with clean, dry air or nitrogen.
Load continues to move when winch is
stopped. Brake is slipping. Checkbrake bandliningwear.Checkbrakefrictiondiscwear.Refer to“Adjustments” on page 7.
Winch is overloaded. Reduce load to within rated capacity.
Winch motor controls sticking. Check pendant/throttle levers spring return to normal (neutral) position when
released.
Winch does not lift load or does not lift
rated capacity. Winch does not lift/pull
load.
Motor may be damaged. Remove and disassemble motor as described in “MAINTENANCE” on page 7.
Examine all parts and replace any that are worn or damaged.
Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements listed
in the “SPECIFICATIONS” section in Product Information Manual. Clean air line filter.
Brake is not releasing. Check brake release pilot hole is not restricted. Check seals on cylinder piston are
not damaged. Brake will start to release at 45 psig (3.1 bar/310 kPa).
Winch is overloaded. Reduce load to within rated capacity.
Oil leak from motor end of winch. Reduction assembly is leaking. Disassemble winch and inspect reduction assembly seals.
Throttle or pendant lever moves but winch
does not operate. Motor may be damaged. Disassemble and clean motor and replace any broken or damaged parts.
Insufficient air supply. Ensureairpressure at winchinletis at least90psig (6.3 bar/630 kPa)atrated volume.
Clean air line filter.
Air leak. Check hose and fitting connections. Inspect hose(s) for breaks. Tighten fittings and
repair or replace hoses as necessary.
Motor does not run smoothly or makes
excessive noise during operation. Damaged or broken piston or connecting rod. Disassemble and repair motor.
Motor runs hot or makes excessive noise
during operation. Low oil level. Check oil level in motor. Add oil as required to obtain proper level.
Improper lubrication. Replace oil with type recommended in “LUBRICATION” section in Product
Information Manual. Set lubricator to provide 6 to 9 drops of oil per minute at
maximum winch operating capacity.
Water in oil. Drain and refill with recommended oil. Operate winch with no load slowly, in both
directions. If noise still exists or motor overheats disassemble and repair motor.
Damaged or broken piston or connecting
rod. Disassemble and repair motor.
Winch runs slow. Improper hose or fitting sizes. Check fittings, connections and hoses for correct size and length. Replace parts that
may cause restricted air flow. Inspect air line filter.
Motor may be damaged. Remove and disassemble motor as described in “MAINTENANCE” on page 7.
Inspect all parts and replace all worn or damaged parts.
Brake(s) not releasing. Refer to brakes in “MAINTENANCE” on page 7.
Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements. Refer
to “SPECIFICATIONS” section in Product Information Manual. Clean air line filter.
Air lines freeze. Water in air supply. Install or drain air system moisture traps, moisture collecting air receivers and
compressor aftercoolers. After corrective action has been taken, disconnect lines at
winch inlet and purge with clean, dry air or nitrogen.
Throttle lever hard to actuate, or lever does
not spring return to neutral. Reverse valve sticking in bushing. Remove and disassemble control valve. Clean control valve parts and check clearance between reverse valve and bushing.
Automatic Band Brake:
Brake cylinder will not release. Band brake out of adjustment. Adjust band brake to maintain correct cylinder stroke.
Leaking cylinder seals. If air is noticed escaping from cylinder breather when attempting to release brake,
replace or repair cylinder.
Dirty filter in air supply. Clean or replace filter.
Faulty dump valve. Check dump valve exhaust port. Air should exhaust when control valve handle is in
neutral. If no air escapes, replace dump valve.
Automatic Disc Brake:
Brake fails to release. Low air supply pressure. Ensure air pressure at inlet to disc brake is at least 45 psig (3.1 bar/310 kPa).
Leaking piston seals. Inspect brake breather. If air escapes from brake breather when attempting to
release brake, replace brake seals.
No release pressure at brake port. Check for proper operation of winch controls.
Sticking brake piston. Apply 45 psig (3.1 bar/310 kPa) to brake release port and check for brake disc
movement. (Brake discs can be viewed through brake breather hole.) If brake discs
do not move, disassemble and inspect disc brake as described in
“MAINTENANCE” on page 7.
6 Form MHD56398 Edition 3

MAINTENANCE
WARNING
• Never perform maintenance on the winch while it is supporting a load.
• Before performing maintenance, tag controls:
WARNING - DO NOT OPERATE, EQUIPMENT BEING REPAIRED.
• Only allow Ingersoll Rand trained Technicians to perform maintenance on
this winch.
• Shut off air system and depressurize air lines before performing any
maintenance.
• Do not use Trichloroethylene to clean parts.
•UseofotherthangenuineIngersollRand partsmayresultinsafetyhazards,
decreased performance and increased maintenance and will invalidate all
warranties.
•After performing any maintenance on the winch, test winch to 125% of its
rated line pull at mid drum before returning to service. (Testing to more
than125%ofratedlinepullmay be required to comply with standards and
regulations set forth in areas outside the USA.)
NOTICE
•Some options are not available for a Man Rider winch, refer to data (name)
plate.
nGeneral
Correct disassembly (to prevent loss or damage of good parts), repair, assembly,
testing and adjusting are critical to proper winch operation. Maintenance
procedures are technical in nature and require training and experience to
accomplish correctly. In addition, repair and testing require specialized equipment
that is not typically found at the products mounting site.
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 anti-seize compound and/
or thread lubricant on capscrew and nut threaded areas prevents corrosion and
allows for easy disassembly of components.
It is extremely important that anyone involved with maintaining the product be
familiar with the servicing procedures of these products and be physically capable
of conducting the procedures. These personnel shall have skills that include:
1. Proper and safe use and application of mechanics’ common hand tools as well
as special Ingersoll Rand or recommended tools.
2. Safety procedures, precautions and work habits established by accepted
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.
NOTICE
• Refer to the Product Parts Information Manual for drawings unless
specified elsewhere.
nMaintenance Intervals
Refer to Table 3 ‘Maintenance Interval Chart’ on page 4 for recommended
maintenance schedule.
nAdjustments
nWinch Guard
Refer to Dwg. MHP2921.
Winch guard panels must be adjusted to suit wire rope departure angle. Adjust per
procedures in Product Information Manual.
nDisc Brake (optional feature)
Refer to Dwg. MHP2924.
Disc brake adjustment is not required. If disc brake does not hold rated load
disassemble and repair.
If brake assembly is removed or disassembled ensure breather (29) is installed and
located at top of brake housing during reassembly.
nManual Band Brake
Refer to Dwg. MHP2923.
1. Release wire rope tension on drum.
2. Raise brake lever (104) to free brake bands (131) and (132).
3. Remove cotter pin (102) and pin (133).
4. Rotate link stud (103) clockwise to increase brake torque.
5. Install pin (133) and check adjustment.
6. Brake should be adjusted until brake lever over center position can be attained
with 50 to 100 lb. (23 to 45 kg) force on brake lever (104).
7. Install cotter pin (102) when adjustment is completed. Bend ends of cotter pin
over.
CAUTION
• When any part of brake lining measures 0.062 inch (2 mm) or less, brake
bands (131) and (132) or linings must be replaced.
nAutomatic Band Brake (optional feature)
Refer to Dwg. MHP2923.
1. Remove cotter pin (102) at adjustment clevis (107).
2. Apply air to brake cylinder (110) and remove pin (106) to disconnect clevis from
brake lever (105).
3. Turn adjustment clevis (107) clockwise to increase cylinder rod extension. Turn
clevis counterclockwise to decrease cylinder rod extension.
4. Assemble clevis (107) to brake lever (105) with pin (106). Release air to brake
cylinder (110).
5. Measure cylinder rod extension. Length should be 1 to 1-1/2 inches (25 to 37
mm). Readjust if necessary.
6. Install cotter pin (102) to secure clevis to brake lever when adjustment is
complete. Bend ends of cotter pin over.
7. With brake “On” adjust screw (127) to just touch arm (124).
nPendant Operated Pilot Control Valve
Valve is set at factory. Refer to “Pendant Operated Pilot Control Valve
Assembly”on page 14 for adjustment procedure.
nOverload Valve
Refer to Dwg. MHP2619 in Product Information Manual. A. Emergency Stop Button;
B. Push Down to Stop Winch Movement; C. Overload Valve Reset Button; D. Twist
Red Button to Reset; E. Overload Valve Adjustment Screw.
A 5/16 inch or 8 mm open-ended wrench is required.
Adjust overload valve by turning adjustment screw located at bottom of control
valve.
-Rotating adjustment screw (clockwise) will increase pressure required to
activate overload valve.
WARNING
•This adjustment can cause overload device to NOT activate before winch's
safety limit is exceeded. This procedure should only be done by Ingersoll
Rand trained Technicians.
-Rotating adjustment screw (counterclockwise) will decrease pressure
required to activate overload valve.
nLimit Switch
Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.
nTensioning System
Refer to Dwg. MHP2028.
The regulator is preset at 0 psig (0 bar/0 kPa) and therefore requires adjustment
when winch is installed. To adjust for specific load applications, regulator pressure
may be adjusted to increase or decrease tension setting.
Regulator gauge and regulator are accessible through cover.
WARNING
• When adjusting regulator, ensure winch control lever is locked in neutral
position and tension selector lever is in the NORMAL position.
•Winch supply air is NOT shut off during regulator adjustments. To prevent
accidental winch operation, allow only a single person, trained in
operation, safety and maintenance of this product, to conduct regulator
adjustments.
Regulator Adjustment Procedure:
Refer to Dwg. MHP1865 in Product Information Manual.
1. Attach test load of desired weight to load line, or connect load line to scale.
WARNING
•Ensure load line is connected to load and excessive slack is taken up before
activating auxiliary valve. When activated, auxiliary valve will
automatically engage and winch will operate at fullspeed to set tension on
load line.
2. Using winch control valve remove all slack from load line.
Form MHD56398 Edition 3 7

Setting with test load:
Actuate auxiliary valve to TENSIONING position. Winch should operate, causing load
line to become taut. To increase tension, rotate regulator knob clockwise until load
beginsto rise.Rotateregulatorknobcounterclockwiseaminimumof1/4 turn,or until
load is balanced (does not raise or lower). Note pressure indicated on gauge for
future setting reference.
Setting with scale:
Actuate auxiliary valve to TENSIONING position. Winch should operate, causing load
line to become taut. To increase tension, rotate regulator knob clockwise until scale
indicates desired tension. Note pressure indicated on gauge for future setting
reference.
nGuideline System - Regulator Adjustment
Refer to Dwg. MHP2940.
The regulator (794) on bracket (791) is factory preset at approximately 50 psig (3.5
bar/349 kPa) to maintain tension of 4500 lbs (2045 kg) on load line. To change this
preset for specific load applications, regulator pressure may be adjusted to increase
or decrease tension setting.
WARNING
• When adjusting regulator, ensure winch control lever is locked in neutral
position and guideline selector lever is in the NORMAL position.
• Winch supply air is NOT turned off during regulator adjustments. To
prevent accidental winch operation, allow only a single person, trained in
operation, safety and maintenance of this product, to conduct regulator
adjustments.
Regulator Adjustment Procedure:
1. Remove valve handle ball (770).
2. Remove cover (766).
3. Loosen jam nut on regulator (794). Refer to Dwg. MHP1175 on page 7, A.
Regulator; B. Jam Nut; C. Adjustment Screw.
WARNING
• Ensure slack load line is taken up by operating winch control valve with
selector in NORMAL position. If selector lever is placed in GUIDELINE
position the winch will immediately attempt to establish line tension
causing line to ‘snap’ resulting in injury or damage to property.
Regulator (794) Adjustment:
A
B
C
Regulator
Adjustment
Screw Jam Nut
(Dwg. MHP1175)
4. Place selector lever into GUIDELINE position.
5. Observingpressure gauge(32), rotateregulator adjustmentscrew.RefertoDwg.
MHP1175 on page 8.
NOTICE
•Clockwiseturnsincreaseregulatorpressure resultinginincreased loadline
tension. Counterclockwise turns decrease regulator pressure resulting in
decreased load line tension.
6. Increase or decrease pressure setting in 5 psig (0.35bar/34 kPa) increments.
Allow winch to adjust to setting before proceeding. Repeat adjustment until
required tension is established.
CAUTION
•Continuous overhauling at regulator pressures equal to or greater than 70
psig (4.8 bar/483 kPa) may cause winch damage.
nDisassembly
nGeneral Disassembly Instructions
The following instructions provide necessary information to disassemble, inspect,
repair, and assemble product. Parts drawings are provided in Product Parts
Information Manual.
If a product is being completely disassembled for any reason, follow the order of
topics as they are presented. It is recommended that all maintenance work on
product be performed in a clean dust-free work area.
In the process of disassembling product, observe the following:
1. Never disassemble product any further than is necessary to accomplish needed
repair. A good part can be damaged during the course of disassembly.
2. Never use excessive force when removing parts. Tapping gently around
perimeter of a cover or housing with a soft hammer, for example, is sufficient to
break 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.
In general, products are designed to permit easy disassembly and assembly. The
use of heat or excessive force should not be required.
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 discarded once they have been
removed. New seals and ‘O’ rings should be used when assembling product.
6. When grasping a part in a vise, always use leather-covered or copper-covered
vise jaws to protect the surface of part and help prevent distortion. This is
particularly true of threaded members, machined surfaces and housings.
7. Donotremoveanypart whichisapressfit inoron asubassembly unlessremoval
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 bearing with a sleeve slightly
smaller than outside diameter of bearing. The end of sleeve or pipe which
contacts bearing must be square. Protect bearings from dirt by keeping them
wrapped in clean cloths.
nWinch Disassembly
Refer to Dwgs. MHP2693, MHP2937 and MHP2923.
1. Remove wire rope from drum.
2. Operate winch to position reduction gear drain plug at its lowest position.
3. Relieve pressure in air lines by operating winch control several times after air
supply has been turned off.
WARNING
•Shut off, bleed down and disconnect the air supply line before performing
any disassembly procedures.
4. Disconnect and tag air lines.
5. Remove winch from its mounting and take to a suitable work area before
beginning disassembly.
6. Remove lower case drain plug (225) on motor housing (217) and allow oil to
drain into a suitable container. Loosen vent cap (210) to vent motor housing.
7. Drain oil from reduction gear assembly by removing one plug (58) when
positioned at its lowest point, and one plug (58) from its highest point to vent.
Refer to Dwg. MHP0140 in Product Information Manual. If winch is equipped
with a band brake, elevate winch outboard end (opposite from motor end) to
prevent draining oil from contaminating brake band lining.
8. For winches with a disc brake, remove pipe plug (24) in brake housing (21) to
drain brake oil.
9. Remove band brake, winch guard and any other externally mounted winch
attachments.
10. Refer to ‘Winch Guard Disassembly’ on page 9.
a. Remove panels (805) and (807), one section at a time, by removing locknuts
(804) and crossbars (806).
b. Remove capscrews (182) and washers (48) securing lifting lugs (183) to
uprights.
c. Remove capscrews (809) and washers (96) securing guards (802), (801) and
(810) to uprights (42) and (184).
WARNING
• The air motor weighs approximately 260 lb. (118 kg). Adequately support
air motor before removing motor mounting capscrews.
11. Remove capscrews (4) and lockwashers (3) securing motor assembly to motor
adapter(6).Using a hoisttosupport motor,pullmotor straight awayfromwinch.
Reference the ‘Motor Disassembly’ on page 9 if motor disassembly is required.
Instructions 12 through 18 apply only to winches with a disc brake.
12. Alternately and evenly loosen eight capscrews (179) until brake spring
compression is relaxed. Remove capscrews and motor adapter (6).
13. Remove brake housing (21). If brake housing sticks, tap it with a soft-faced
hammer until parts separate.
14. Note position of all brake parts for reassembly.
15. Remove five friction plates (16) and six drive plates (17).
16. Remove springs (9) from brake piston (10).
17. Remove brake piston (10) from brake housing (21). Tap lightly with a plastic
mallet to separate parts, if necessary.
18. Remove seals (11) and (12) from brake piston (10).
19. Loosen capscrew in collar (13) and slide collar from drive shaft (35) with gear
(19).
20. Remove retainer ring (36) from bore of drum shaft (41).
21. Pull shaft and bearing assembly from drum shaft (41).
22. Support drum (96) and remove capscrews (39) from drum shaft (41). Pry drum
shaft (41) from inboard upright (42).
23. Remove capscrews (180) and lockwashers (178) that secure siderails (98) to
inboard upright (42). Drive out dowel pins (181).
24. Remove inboard upright (42).
25. Remove capscrews (196), lockwashers (306) and end cover (193) from outboard
upright (184).
26. Remove capscrews (192) and bearing retainer (191) from drum (96).
27. Remove drum and reduction gear assembly.
8Form MHD56398 Edition 3

28. Remove remaining capscrews (180) and lockwashers (178) that attach siderails
(98) to outboard upright (184). Drive out dowel pins (181).
29. Remove bearing (188) from outboard upright (184).
30. Remove capscrews (45) and lockwashers (46) securing gear carrier (52) to drum
(96).
31. Install two 3/4 inch - 10 NC x 3 inch long capscrews into threaded holes in outer
bolt pattern ring of gear carrier (52). Use these capscrews to break seal. Remove
reduction gear assembly from drum (96).
32. Remove dowel pins (181) from gear carrier (52).
To disassemble reduction gear refer to
‘Reduction Gear Disassembly - Standard’ on page 10.
nWinch Guard Disassembly
Refer to Dwg. MHP2921.
1. Remove capscrews (182) and washers (46) securing lifting lugs (183) to uprights.
2. Removepanels(805) onesectionat atime,by removing nuts(804)and crossbars
(806).
3. Remove capscrews (809) and washers (96) that secure panels (801), (802) and
(810) to winch uprights.
4. Remove panels.
nMotor Disassembly
Refer to Dwgs. MHP2693 and MHP2696.
1. Remove pipe plugs (225) to drain oil from motor.
2. Remove four capscrews (951) and washers (949) that secure control valve (900)
to rotary valve housing (247).
3. Remove control valve assembly and gaskets (946).
4. Remove five capscrews (93) from exhaust flange (253).
5. Remove rotary valve housing (247) by pulling it out of motor housing (217) as
an assembly with exhaust flange (253).
CAUTION
• Do not remove the exhaust flange (253) until rotary valve (250) has been
removed from rotary valve housing (247).
6. Remove rotary valve (250) by pulling it out from assembly through the motor
housing end of rotary valve housing (247).
7. Supportmotorassemblyand remove ten capscrews(4)andlockwashers (3). Pull
motor assembly away from winch.
8. Remove each cylinder head (201) by removing four capscrews (200). Remove
head gasket (209).
9. Pull cylinder liner (208) straight out.
10. Positionpiston(204) at topofits stroke. Inthisposition, with cylinderlinerpulled
out, wrist pin (203) can be removed. Remove one retainer ring (205) on wrist pin
(203) from either side of piston (204). Push wrist pin (203) out by hand from one
side.If wristpinistootight,itis acceptableto carefullyheatpistonto200°F(93°C)
or less and then push wrist pin out.
NOTICE
•If piston, wrist pin, connecting rod or cylinder liner are to be reassembled,
number each set. Also add radial alignment marks for each piston and
cylinder liner to motor housing.
11. Remove remaining cylinder liners and pistons as described above. To remove
crank assembly, all pistons and cylinder liners must be removed.
12. Crank assembly (231) can now be removed with oil slinger (230) by pulling
straight out from motor housing (217). Use care while guiding connecting rods
(206) through inside of motor housing.
Crankshaft Disassembly:
1. Remove bearing (228) and roll pin (240) from crank assembly (231).
2. Remove cotter pin (236) and pin nut (237) from lock pin (235).
3. Remove lock pin (235) by carefully driving it out of its location. Use care not to
damage pin threads.
4. Pull crankshaft valve end off crank assembly (231).
5. Remove connecting rod rings (234), connecting rod bushing (233), sleeve (232)
and connecting rods (206). Record five connecting rod (206) numbers and foot
directions so they can be reinstalled in same order.
6. Oil slinger (230) does not have to be removed unless damaged. If removal is
required, heating of five buttonhead screws (229) may be necessary to loosen
Loctite® connection.
nControl Valve Disassembly
Refer to Dwg. MHP2696.
Handle Removal:
Handle disassembly is not recommended.
1. Carefully pry off plug (935).
2. Remove capscrew (901) and tablock washer (909).
NOTICE
• Observe spring (937) connection during disassembly. This spring is under
tension and is required to return handle to neutral position.
3. Carefully pull handle assembly (930) from reverse valve (943). Remove spring
(937).
Reverse Valve Removal:
1. Remove buttonhead screws (938), capscrews (925) and washers (924) from seal
bracket (939). Remove seal bracket from valve housing (917). Remove and
discard ‘O’ rings (941) and (942).
2. Remove capscrews (901) and washers (902) from exhaust flange (955). Remove
flange from valve housing. Remove and discard ‘O’ ring (942).
3. Slide reverse valve (943) out exhaust flange side of housing until ball (916) is
visibleonreverse valve.Allowball (916)todrop outofbushing (944)andremove
ball.
4. Remove bushing (944) from exhaust flange side of housing.
NOTICE
• Dowel pin (945) allows the bushing (944) to be removed only from the
exhaust flange side of housing. Ball (916) retains reverse valve (943) in
bushing.
•Donotremovereversevalve(943),bushing(944),andball(916)atthesame
time; damage may occur to bushing.
•Take care to not allow ball (916) to drop into motor. If this occurs it may be
necessary to disassemble motor to retrieve ball.
Piston Removal:
1. Remove capscrews (901) and washers (902) from piston cover (919). Remove
cover and discard gasket (918).
2. Remove capscrews (901) and washers (902) from poppet cover (903). Remove
cover and discard gasket (904).
3. Remove the following items from housing poppet bore: poppet spring (905),
poppet cap (906) and poppet seal (907).
4. Frompoppetside, push piston(922)out of valvehousing(917). Remove ‘O’rings
(921) and (923) and discard.
Pilot Valve Removal:
NOTICE
•Foreasierremoval, itisrecommended touseIngersoll Randpilotvalve tool
(920). This must be purchased separately.
If pilot valve is not damaged, it is not necessary to disassemble completely.
1. Remove plug (912).
2. Remove pilot valve assembly (910) as an assembly.
3. Discard and replace pilot valve assembly (910) if necessary.
nEmergency Stop and Overload Control Valve Disassembly
Refer to Dwg. MHP2697.
Handle Removal:
Follow disassembly instructions in ‘Control Valve Disassembly’ on page 9.
Reverse Valve Removal:
1. Remove buttonhead screws (938), capscrews (925) and washers (924) from seal
bracket (939). Remove seal bracket from valve housing (917). Remove and
discard ‘O’ rings (941) and (942).
2. Remove capscrews (721), washers (902), exhaust flange (955) and exhaust
adapter (723). Remove and discard ‘O’ rings (942) and (722).
3. Move reverse valve (943) out exhaust flange side of valve housing (917) until ball
(916) is visible on reverse valve. Allow ball (916) to drop out of bushing (944) and
remove ball.
4. Remove bushing (944) from exhaust flange side of housing.
NOTICE
• Dowel pin (945) allows the bushing (944) to be removed only from the
exhaust flange side of housing. Ball (916) retains reverse valve (943) in
bushing.
•Donotremove reversevalve(943), bushing(944)and ball(916)at thesame
time; damage may occur to bushing.
•Take care to not allow ball (916) to drop into motor. If this occurs it may be
necessary to disassemble motor to retrieve ball.
Piston Removal:
Follow disassembly instructions in ‘Control Valve Disassembly’ on page 9.
Pilot Valve Removal:
Follow disassembly instructions in ‘Control Valve Disassembly’ on page 9.
Emergency Stop Removal:
1. Unscrew adapter (706) and E-Stop button (705) from valve housing.
2. Remove plunger (707). Remove and discard ‘O’ rings (703).
3. Pull spring (711) out of valve housing (917) and discard.
Overload Valve Removal:
1. Unscrew cap (700). Remove and discard grommet (701).
2. Pull out plunger (702), remove and discard ‘O’ rings (703).
3. Remove capscrews (901) and washers (902) from cover (719) underneath valve
housing (917).
NOTICE
• Cover (719) retains spring (718). To remove capscrews (901) and washer
(902), unscrew in a crisscross pattern.
4. Remove adjusting screw (720) and ‘O’ ring (716).
5. Remove adjusting nut (717), plate (715), gasket (714), ‘O’ ring (713) and piston
(712) from valve housing (917). Discard gasket (714) and ‘O’ ring (713).
nPendant Operated Pilot Control Valve Disassembly
Refer to Dwg. MHP2969.
CAUTION
• Do not disassemble end caps of control valve. Valve caps are press fit
together and have a close fit tolerance,
Form MHD56398 Edition 3 9

1. Removecapscrews(951)and washers (96) thatsecurevalve to motor onadapter
(369).Capscrewsand washers (96)cannotbe removed untiladapteris separated
from valve body (339). Separate valve as an assembly from winch motor rotary
valve housing (247).
2. Remove capscrews (370) and separate adapter (369) from valve body. Remove
and discard gasket (358).
3. Remove retainer ring (362). Pull poppet assembly (357) along with poppet seat
(361) and valve piston (364) from valve body (339).
4. Reach into valve body and remove spring (356) and exhaust poppet (354).
5. Remove retainer ring (365) and separate valve piston (364) and poppet seat
(361).
6. Remove and discard ‘O’ rings (360), (713) and (363).
7. Push shaft (331) to front of valve body to cause pin (335) to push seat restrictor
(333) out of valve body.
8. Removeanddiscard ‘O’ ring (334).Supportshaft (331) onbothsidesof pins (335)
and push pins out.
9. Insert allen wrench into open hole in sleeve (338) and back out setscrew (337) a
couple of turns to loosen sleeve on shaft (331). Remove sleeve.
10. To remove valve assemblies (341) or pins (347), remove capscrew (381), washer
(344) and spring clip (343). From the exhaust port, using a soft material probe,
push valve assembly or pin up through top of valve body until it can be grasped
from the top. Pull out valve assembly or pin.
nManual or Automatic Band Brake Disassembly
Refer to Dwg. MHP2923.
1. Automatic Brake:
a. Disconnect and remove hose, fittings and dump valve (112) from cylinder
(110).
b. Remove cotter pin (102) and pin (133) from link stud (103) and brake band
(131).
c. Remove cotter pin (102) and pin (106). Separate clevis (107) from brake lever
(105).
d. Remove cotter pin (102) and pin (134). Remove cylinder (110) from bracket
(118).
2. Manual Brake:
a. Removecotter pin(102) andpin (133)fromhandle(104)thenremovehandle
(104) from brake band (132).
3. Remove capscrews (116), lockwashers (117) and stop plate (126). Ensure pivot
bracket (122) is no longer secured to siderail.
4. Use a hoist to raise winch approximately 6 inches (15 cm). Separate brake band
halvesand rotatebrakeband assemblyslowly untilitcan beremoved fromdrum
(96).
5. Remove cotter pins (102) and pins (101) so brake band halves can be removed
from arm (124). Lower winch when brake band assembly has been removed.
nReduction Gear Disassembly - Standard
NOTICE
•Itisimportanttomaintain acleanwork areawhenreduction gearassembly
is disassembled.
• Disassembly is not recommended. If it is unavoidable, use the following
steps.
Refer to Dwg. MHP2918.
1. Place reduction gear assembly on a clean work bench with cover (94) up.
2. Remove capscrews (95) and pry off cover (94).
3. Remove pinion (91), ring gear (92), spacer (90), planet assembly (88) and sun
gear (87).
4. Remove and discard ‘O’ rings (55) from ring gear.
5. Remove four pins (93) from between cover (94) and spacer (90) and store in a
safe place.
6. If required, remove thrust plate (86) from sun gear (87).
7. Remove ring gear (85), retainer ring (78) and intermediate planet assembly (84).
8. Remove and discard ‘O’ rings (55) from ring gear.
9. Remove four pins (89) from between spacer (90) and input housing (82) and
store in a safe place.
10. Turn remaining assembly over. Input housing (82) should face down.
11. Remove five capscrews (53) and oil seal support (54).
12. Remove and discard ‘O’ ring (55) and oil seal (58).
13. Remove output housing (57).
14. Remove bearing (59), thrust plate (62) and spacers (64) and (65).
15. Remove ring gear (67). Remove and discard two ‘O’ rings (63).
16. Remove three pins (66) from between output housing (57) and input housing
(82) and store in a safe place.
17. Remove and discard ‘O’ ring (61) from planetary support (69).
18. Remove planetary gear assembly (69). Remove retainer ring (76) and sun gear
(77) from assembly.
19. Remove bearing spacer (79) and bearing (81) from input housing (82).
NOTICE
•Donotdisassembleplanetarygearsfromtheir housings unless required to
replace damaged parts. For information on planetary assemblies (69), (84)
and (88), contact your Ingersoll Rand distributor or the factory.
nReduction Gear Disassembly - Guideline (optional feature)
Refer to Dwg. MHP1708.
CAUTION
•Itisimportanttomaintain acleanwork areawhenreduction gearassembly
is disassembled.
1. Place reduction gear assembly on a clean work bench with cover (94) up.
2. Remove capscrews (95) and pry off cover (94).
NOTICE
•There are four pins (93) aligning cover, ring gear and input housing. These
do not require removal, and may remain in any of these components.
3. Remove thrust plate (473) and pinion shaft (474).
4. Pull planetary assembly (84) out of ring gear (85). Separate ring gear and discard
‘O’ rings (55).
5. Remove sun gear (77). Remove thrust bearing (65) from sun gear.
6. Remove capscrews (50) and nuts (83).
7. Separate input housing (82).
NOTICE
• There are three pins (66) aligning input housing, ring gear and output
housing. These do not require removal, and may remain in any of these
components.
8. Remove bearing spacer (79) and bearing (81) from input housing.
9. Remove planetary support assembly. For disassembly, refer to
‘Planetary Support Disassembly:’ on page 10.
10. Separate ring gear (67) and discard ‘O’ rings (63).
11. Remove bearing (59).
12. Remove capscrews (53) and oil seal support (54). Remove and discard oil seal
(58) and ‘O’ ring (55).
Planetary Support Disassembly:
1. Pull thrust plate (64) from center of planetary support assembly.
2. Remove retainer ring (76). Remove ‘O’ ring (61) and thrust plate (62) from
support. Discard ‘O’ ring.
NOTICE
• Planetary support is machined as a set. Matchmark both halves to ensure
correct alignment during assembly.
• Do not disassemble planetary support or gears unless required to replace
damaged parts.
3. Separate planetary support (69) into individual parts.
4. Removeplanetgear shaft(68) withplanetarygear assembly.Placeon cleanshop
towel.
5. Slide thrust bearing (75) off shaft (68). Push shaft out of planetary gear.
6. Use shaft to push bearings (73) and spacer (72) out of planetary gear (74).
nPress Roller Disassembly
Refer to Dwgs. MHP2935 and MHP2938.
1. Compress the ends of the springs (405) and (406) to disengage from siderail (98)
and pins (413) on press roller arm (407).
CAUTION
• Use care when releasing springs (405) and (406) from press roller. Springs
are under tension.
2. Loosen collars (404).
NOTICE
• Ensure press roller assembly is adequately supported before removing
shaft (403).
3. Remove capscrews (408) and washers (409) from both ends of shaft (403), and
carefullyslideshaft (403)throughhole inupright(42). Pressrollerassembly (400)
and collar (404) will fall away from shaft (403).
4. It is not necessary to remove bushings (410) unless replacing.
5. Remove springs (405) and (406) from press roller arm (407).
6. Removecapscrews (408),washers(409)androllers(402)from endsof pressroller
arm (407).
nDrum Locking Pin Disassembly (optional feature)
Refer to Dwg. MHP2675.
1. Remove capscrews (305) and washers (306) to separate drum locking pin
assembly from winch upright (184).
2. Unscrew drum lock pin (312) from shaft (304). Separate spring (310), drum lock
pin (312) and housing (308) from assembly.
3. Remove nut (303) and capscrew (302) to separate handle (301) from shaft (304).
4. Remove bushing (311) from winch upright (84) only if replacement is required.
nTwo Function Pendant Disassembly (optional feature)
Refer to Dwg. MHP1677 or MHP2346.
1. Remove fittings (348) and lifting eye (440).
2. Unscrew plugs (444). Remove springs (445) and balls (446).
3. Tap out pin (447) and remove levers (453).
4. Remove setscrew (455) from pendant handle (454).
5. Remove valve assemblies (452). Remove ‘O’ rings (443) and (449) and protectors
(451). Discard ‘O’ rings.
6. Remove plug (470) or emergency stop valve (441) from pendant handle.
7. Remove retainer ring (458) and exhaust washer (457).
nLimit Switch Disassembly
Refer to Dwg. MHP2677.
10 Form MHD56398 Edition 3

NOTICE
•Itisnotrecommendedto disassemble limit switch. Contact factoryifrepair
is required.
1. Remove and tag hose connection if not already done.
2. Remove capscrews (97) and washers (96) that secure limit switch assembly to
upright (84).
3. Store limit switch assembly in a clean, dry area until winch reassembly.
nCleaning, Inspection and Repair
nCleaning
Clean all product component parts in solvent (except brake bands and disc brake
friction plates). The use of a stiff bristle brush will facilitate removal of accumulated
dirt and sediments in the reduction assembly, on housings, frame and drum. Dry
each part using low pressure, filtered compressed air. Clean brake band using a wire
brush or emery cloth. Do not wash brake band in solvent. If brake band lining is oil
soaked, it must be replaced.
nInspection
All disassembled parts should be inspected to determine their fitness for continued
use. Pay particular attention to the following:
1. Inspect all gears for worn, cracked, or broken teeth.
2. Inspect all bushings for wear, scoring, or galling.
3. Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent
on shafts, replace shaft. Inspect all surfaces on which oil seal lips seat.
4. Inspect all bearings for play, distorted races, pitting and roller or ball wear or
damage. Inspect bearings for freedom of rotation.
5. Inspect all threaded items and replace those having damaged threads.
6. Inspect band brake lining for oil, grease and glazing. If band brake lining is oil-
soaked replace brake bands as a set. Remove glazed areas of band brake lining
by sanding lightly with a fine grit emery cloth.
7. Measure thickness of band brake lining. If brake band linings are less than 0.062
inch (2 mm) thick anywhere along edges replace brake bands as a set.
8. Inspect cylinder bores. Minor scratches in bore lining may be repaired by lightly
honing to remove. Refer to tolerances listed below for acceptable clearances.
Replace liner if deep scratches or gouges are apparent. Measure inside diameter
ofliner.If measurementisgreater than 4.764inches(121 mm)replaceliner. ‘Ring
Gap’ may also be used to determine wear; place compression ring into liner,
using a piston, push ring until approximately half way in liner and measure ‘Gap’
— 0.003 inch (0.076 mm) is normal; replace rings, or liner, if ‘Gap’ exceeds 0.020
inch (0.51 mm).
9. Inspect the drive plates for warpage or other damage, and replace damaged
parts as necessary. Replace the input pinion shaft oil seal.
10. Measure the thickness of the brake friction disc. The brake friction disc must
show an even wear pattern. If the brake friction disc is 0.076 inch (1.93 mm) or
less, replace the disc.
nRepair
Actual repairs are limited to removal of small burrs and other minor surface
imperfections from gears and shafts. Use a fine stone or emery cloth for this work.
Do not use steel wool.
1. Worn or damaged parts must be replaced. Refer to the applicable parts list in
the Product Parts Information Manual for specific replacement parts
information.
2. Inspect all remaining parts for evidence of damage. Replace or repair any part
which is in questionable condition. Cost of the part is often minor in comparison
with cost of redoing job.
3. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings.
4. Examine all gear teeth carefully, and remove nicks or burrs.
5. Polish edges of all shaft shoulders to remove small nicks which may have been
caused during handling.
6. Remove all nicks and burrs caused by lockwashers.
7. Replace all gaskets, oil seals, and ‘O’ rings removed during product disassembly.
nAssembly
nGeneral Instructions
•Use all new gaskets and seals.
•Replace worn parts.
•Assemble parts using matchmarks attached during disassembly. Compare
replacement parts with originals to identify installation alignments.
•Lubricateallinternalparts with rustandoxidationinhibiting lubricant, ISO
VG 100 (SAE 30W).
•Apply a light coat of Loctite® 243 to all threaded components prior to
assembly, unless otherwise specified.
nControl Valve Assembly
Refer to Dwg. MHP2696.
Reverse Valve Assembly:
1. Insert reverse valve (943) into bushing (944) with ball slot oriented UP,
approximately 2-1/2 inches (64 mm).
2. Insert bushing (944) and reverse valve (943) into valve housing (917) from
exhaust flange side, ensuring that groove in bushing is aligned with dowel pin
(945).
3. Apply grease to ball (916) and insert into reverse valve platform. With finger,
push ball (916) in housing until ball hits end of reverse valve.
4. Holdingball (916)in positionon reversevalve platform,rotatereversevalvefrom
neutral position to approximately 45 degrees in either direction. Ball will ‘walk’
up side of reverse valve platform and move in ball hole in bushing (944).
NOTICE
• Do not rotate reverse valve past a 90 degree position; it may result in ball
(916) falling into motor.
5. Slowly push reverse valve, while still in the 45 degree position, the rest of the
way in housing until flush with surface. From other side of valve, rotate reverse
valve back to neutral position. Ball should be seated in ball slot at that time.
6. Lubricate ‘O’ ring (942) and place into groove in exhaust flange (955).
7. Secure exhaust flange (955) to valve housing (917) with capscrews (901) and
washers (902).
8. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’ ring (942) and place in
groove in seal bracket.
9. Place seal bracket over end of reverse valve. Using finger pressure, press until
sealis seatedon reversevalve andseal bracketis seatedon valvehousing. Secure
with washers (924), capscrews (925) and buttonhead screws (938).
Pilot Valve Assembly:
NOTICE
•For easier installation, it is recommended to use Ingersoll Rand pilot valve
tool (920). This must be purchased separately.
1. Install pilot valve assembly (910).
2. Apply thread sealant Loctite® 567 to pilot valve assembly (910) and place pilot
valve assembly into valve housing (917). Use a large flat-tipped screwdriver to
engage slots in pilot seat to tighten until pilot assembly is 1/8 inch (3.175 mm)
from housing bore.
3. Insert plug (912) and tighten.
Piston Assembly:
1. Lubricate and install ‘O’ rings (921) and (923) on piston (922).
2. Insert assembled piston into valve housing (917) from handle side.
3. Secure gasket (918), piston cover (919) and washers (902) with capscrews (901).
4. Place poppet seal (907) into poppet cap (906). Place this assembly into valve
housing and seat on piston (922).
5. Place spring (905) over this assembly.
6. Securewith gasket(904),poppetcover(903),washers(902) andcapscrews (901).
Handle Assembly:
1. Place spring (937) over reverse valve handle end in seal bracket (939).
NOTICE
• Spring (937) will have to be 'cocked' over stud in bracket. This will ensure
handle returns to neutral.
2. Installhandleassembly (930)over reversevalveend. Handlewillhave tobelifted
slightly to allow pin to fit into slot in seal bracket (939).
3. Secure handle assembly (930) to reverse valve with tab lockwasher (909) and
capscrew (901). Refer to “TORQUE CHART” on page 16 for torque requirements.
Washer (909) has small tab on side; engage with small hole in handle.
4. Bend tabs of washer (909) over flats of capscrew.
5. Press plug (935) into handle assembly to cover capscrew. Check control handle
movement. Correct any discrepancies.
nEmergency Stop and Overload Control Valve Assembly
Refer to Dwg. MHP2697.
Reverse Valve Assembly:
1. Insert reverse valve (943) into bushing (944) with ball slot oriented UP,
approximately 2-1/2 inches (64 mm).
2. Insert bushing (944) and reverse valve (943) into valve housing (917) from
exhaust flange side, ensuring that groove in bushing is aligned with dowel pin
(945).
3. Apply grease to ball (916) and insert into reverse valve platform. With finger,
push ball (916) in housing until ball hits end of reverse valve.
4. Holdingball (916)in positionon reversevalve platform,rotatereversevalvefrom
neutral position to approximately 45 degrees in either direction. Ball will ‘walk’
up side of reverse valve platform and move in ball hole in bushing (944).
NOTICE
• Do not rotate reverse valve past a 90 degree position; it may result in ball
(916) falling into motor.
5. Slowly push reverse valve, while still in the 45 degree position, the rest of the
way in housing until flush with surface. From other side of valve, rotate reverse
valve back to neutral position. Ball should be seated in ball slot at that time.
6. Lubricate‘O’rings (942) and(722),and place ingroovesin exhaust adapter(723).
7. Lubricate ‘O’ ring (942) and place in groove in exhaust flange (955).
8. Secure exhaust adapter (723) with exhaust flange (955) to valve housing (917)
with capscrews (721) and washers (902).
9. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’ ring (942) and place into
groove in seal bracket.
10. Place seal bracket over end of reverse valve. Using finger pressure, press until
sealis seatedon reversevalve andseal bracketis seatedon valvehousing. Secure
with washers (924), capscrews (925) and buttonhead screws (938).
Pilot Valve Assembly:
Follow assembly instructions in ‘Control Valve Assembly’ on page 11.
Piston Assembly:
Follow assembly instructions in ‘Control Valve Assembly’ on page 11.
Handle Assembly:
Follow assembly instructions in ‘Control Valve Assembly’ on page 11.
Form MHD56398 Edition 3 11

Emergency Stop Assembly:
1. Insert spring (711) into valve housing (917).
2. Place ‘O’ rings (703) on plunger (707).
3. Insert plunger into valve housing.
4. Screw adapter (706) and E-Stop button (705) into valve housing.
5. Tighten adapter until snug; do not over tighten.
Overload Valve Assembly:
1. Replace ‘O’ rings (703) on plunger (702).
2. Insert plunger (702) with ‘O’ rings in valve housing (917).
3. Replace grommet (701) in cap (700).
4. Install and tighten cap (700) flush to valve housing.
5. Replace piston (712) if it appears damaged or worn.
6. Insert ‘O’ ring (713) on piston (712).
7. Replace gasket (714).
NOTICE
• Cover (719) retains spring (718), adjustment nut (717) and plate (715).
Insert capscrews (901) and washers (902) in a crisscross pattern until
tightened evenly.
8. Insert adjusting screw (720). Refer to “OPERATION” section ‘Overload Device’ in
Product Information Manual for adjustment.
9. Secure control valve assembly to intake manifold using capscrews (951) and
washers (949). Use new gaskets (946) between control valve and manifold.
10. Test control valve for proper operation. Lift slide handle and move handle all the
way in one direction and release hand. Control handle should return and lock in
the neutral position. Repeat for other direction.
11. Connect brake line.
12. Connect air supply line.
nMotor Assembly
Refer to Dwg. MHP2693.
Crankshaft Assembly:
1. If removed, press crank bearing (228) on crank assembly (231). Apply pressure
only on inner race of bearing.
2. Place crank assembly on a work bench with oil slinger (230) down and slide the
sleeve (232), with tang up, on crank pin.
3. Slide connecting rod bushing (233) over sleeve (232) and first connecting rod
ring (234) with chamfer up.
4. Install connecting rods (206) in same order as removed, with all feet pointing in
same direction, using first connecting rod ring (234) to hold one side of
connecting rod feet.
5. Slide second connecting rod ring over other side of connecting rod feet with
chamfer on ring facing down (toward stem of connecting rod).
6. Slide crankshaft (valve end) over crank pin while simultaneously aligning tang
on sleeve (232) with slot in crankshaft.
7. Rotate and position crankshaft (valve end) relative to crank pin to allow
installation of lock pin (235).
8. Tap lock pin (235) into place and install pin nut (237). Refer to
“TORQUE CHART” on page 16 for torque requirements.
9. Install cotter pin (236) and bend ends over.
10. Install roll pin (240) and bearing (228) into valve end of crankshaft.
11. Check that all connecting rods move freely around crank.
Motor Body Assembly:
1. Position crank assembly (231) into motor housing (217). Ensure bearing (228) is
seated and connecting rods (206) are centered in cylinder holes.
NOTICE
•Make certain roll pin (240) and three lugs on rotary valve (250) line up with
corresponding hole and lugs on crankshaft.
•Donotallowrotaryvalvetoslidebackinrotaryvalvehousing(247).Ifrotary
valveslidesintoofar,sealring(251)willlockupininternalgroovesofrotary
valve housing (247) and restrict further assembly.
2. Rotate crank assembly until one connecting rod (206) is at the top of its stroke.
Install a piston (204) with its rings (202) and (207) to connecting rod with wrist
pin (203) and retainer rings (205). Refer to Dwg. MHP0224 on page 12 for oil
and compression ring installation. A. Piston Head; B. Compression Ring Groove;
C. Ends of compression rings must be staggered to avoid alignment with wrist
pin opening and ends of oil ring; D. Colored ends of oil ring must butt together,
and must not overlap; E. Install one compression ring on either side of oil ring;
F. Wrist Pin Opening.
3. Install a new cylinder head gasket (209) before installing cylinder liner (208).
4. Install cylinder liner over the piston by compressing both piston rings with a
single band ring compressor.
5. Install cylinder head (201) over cylinder and secure cylinder head to motor
housing with four capscrews (200). Refer to “TORQUE CHART” on page 16 for
torque requirements.
6. Repeat steps 2 through 5 with remaining cylinders.
7. Rotate motor by hand. Motor should rotate without binding.
8. Install mounting flange (216) and gasket (226) on front of motor housing. Make
sure notches on both parts are aligned.
9. Lightly lubricate ‘O’ ring (70) and install in groove on motor adapter (71).
NOTICE
• ‘O’ ring and motor adaptor, items (70) and (71) in step 9, refer to part
numbers 51459 and 14227 as shown on winch assembly Dwgs. MHP0950
andMHP0649.‘O’ring(70)mustbeplaced between mounting flange (216)
and motor adapter (71).
10. Temporarily install capscrews (4) and nuts finger tight to retain mounting flange
(216).
11. Install eye bolts (213), vent cap assembly (210) and pipe plug (214) in motor
housing.
12. Ensure oil drain and pipe plugs (225) are installed.
Rotary Valve Assembly:
1. Assemble throttle control valve (900) and gasket (946) to rotary valve housing
(247) using four capscrews (951) and lockwashers (949).
2. Tighten capscrews (951). Refer to “TORQUE CHART” on page 16 for torque
requirements. Throttle handle should move fully left and right without sticking
or binding, and should center (by spring force) automatically when released.
3. Install two seal rings (251) on each end of rotary valve (250). Place bearing (252)
onto the rear of rotary valve (250) and press into position. Press only on bearing
inner race. With rotary valve housing (247) exhaust flange down, install rotary
valve into housing.
4. Install ‘O’ ring (244) into motor housing (217).
5. Install rotary valve housing gasket (243) onto rotary valve housing. With exhaust
flange down on bench, install motor housing (217) onto rotary valve housing.
Check for any evidence of damage to ‘O’ ring when rotary valve housing is fully
engaged. Install and tighten capscrews (93). Refer to
“TORQUE CHART” on page 16 for torque requirements.
Piston Head
Wrist pin
opening
Install one wiper ring on
either side of oil ring
Ends of wiper rings must be
staggered to avoid alignment
with wrist pin opening and
ends of oil ring
Colored ends of oil ring
must butt together, and
must not overlap
Compression Ring Groove
(Dwg. MHP0224)
nReduction Gear Assembly - Standard
NOTICE
• It is important to maintain a clean work area when reduction assemblies
arereassembled.Duringreassemblycleaneachpartthoroughlyandlightly
coat with ‘Recommended Lubricants’ in the “LUBRICATION” section in the
Product Information manual.
Refer to Dwg. MHP2918.
1. Install bearing (81) and bearing spacer (79) in input housing (82).
2. Installsungear (77) inplanetarygear assembly (69).Installretainer rings (76)and
(78).
3. Install planetary gear assembly (69) in input housing (82).
4. Install new ‘O’ ring (61) on thrust plate (62).
5. Install three pins (66) in input housing (82). Install two new ‘O’ rings (63) on ring
gear (67). Align pin holes and install on input housing.
6. Install spacers (64) and (65) in sun gear (77).
7. Install thrust plate (62).
8. Install bearing (59) and oil seal (58) on planetary support (69).
9. Align pin holes and install output housing (57).
10. Install new ‘O’ ring (55) and oil seal support (54). Secure with five capscrews (53).
Apply Loctite® 242 to capscrew threads. Refer to
“TORQUE CHART” on page 16 for torque requirements.
11. Place a bead of Loctite® 515 sealant on output housing (57) mating surface to
drum adapter (52) to provide seal between parts. Sealant should be applied
inside of capscrew pattern.
12. Align holes in output housing (57) with drum adapter (52) and install eighteen
capscrews (50). Apply Loctite® 242 to capscrew threads. Capscrews must
protrude through holes in input housing (82). Install nuts (83) on capscrews.
Refer to “TORQUE CHART” on page 16 for torque requirements.
13. Position assembly with drum adapter down.
14. Align gears and install planetary assembly (84) onto sun gear (77).
15. Install two new ‘O’ rings (55) and four pins (89) on ring gear (85). Position pins
with an equal amount extending from each side of ring gear. Align pins with
input housing (82) holes and install.
16. Install thrust plate (86) in sun gear (87) and install sun gear into planetary
assembly (84).
17. Install planetary assembly (88) on pinion (91).
18. Install pinion (91) on sun gear (87).
19. Align pin holes and install spacer (90) on ring gear (85).
20. Install two new ‘O’ rings (55) and four pins (93) on ring gear (92). Position pins
with an equal amount extending from each side of ring gear. Align pins with
spacer (90) holes and install.
12 Form MHD56398 Edition 3

21. Align pin holes and install cover (94). Apply Loctite® 242 to eight capscrew (95)
threads and install. Refer to “TORQUE CHART” on page 16 for torque
requirements.
22. Ensure four plugs (56) are threaded fully into input housing (82) and that fit is
tight.
23. Place a bead of Loctite® 515 sealant on drum (96) mating surface with drum
adapter (52) to provide a seal between the two. Sealant placement should be
outside of capscrew pattern.
24. Align holes in drum adapter (52) with drum (96). Install two pins (181). Apply
Loctite® 242 to twelve capscrew (45) threads and, with twelve lockwashers (46),
install. Refer to “TORQUE CHART” on page 16 for torque requirements.
nDrum Assembly
Refer to Dwg. MHP2937.
1. Stand drum (96) in upright position. Align splines and carefully lower inboard
upright and drum shaft assembly onto drum (96).
2. Using a ‘C’ clamp, secure inboard flange assembly to drum flange and set
complete assembly in a horizontal position.
3. Clean surface, pack bearing (188) with grease and install outboard upright (184).
4. Install outboard upright (184) on drum end. Ensure assembly is kept centered
on journal during this step.
5. Install bearing retainer (191). Secure by installing two capscrews (192). Lightly
coat capscrew threads with Loctite® 242. Refer to
“TORQUE CHART” on page 16 for torque requirements.
6. Apply a light coat of Loctite® 515 sealant to mating surface of outboard upright
(184) and install end cover (193). Secure using four capscrews (196) and
lockwashers (306). Lightly coat capscrew threads with Loctite® 242. Refer to
“TORQUE CHART” on page 16 for torque requirements.
7. Installsiderails (98)touprights (42)and (184)andlooselysecureusing capscrews
(180) and lockwashers (178).
8. Tap dowel pins (181) into position until flush with siderails.
9. Tighten eight capscrews (180) evenly. Refer to “TORQUE CHART” on page 16
for torque requirements.
10. Mount winch to foundation as described in the ‘INSTALLATION’ section in the
Product Information Manual.
11. Ifliftinglugs(183) have been removed,attachwithcapscrews (182) and washers
(46) to upright(s) (42) and (184).
nWinch Assembly
Refer to Dwgs. MHP2693 and MHP2937.
1. Clean both mating surfaces on inboard upright (42) and install drum shaft (41)
through bore aligning dowel pin holes.
2. Install dowel pins (40) flush or slightly below surface of drum shaft (41).
3. Install eight capscrews (39). Lightly coat capscrew threads with Loctite® 242.
Refer to “TORQUE CHART” on page 16 for torque requirements.
4. Press bearing (37) onto drive shaft (35). Lightly coat inner bearing race bore with
Loctite® 609. Install retainer ring (38).
5. Install shaft and bearing into drum shaft (41) so smaller splined end enters first.
Install retainer ring (36) in bore of drum shaft (41).
Instructions 6 through 17 cover winches with a disc brake. For winches
without a disc brake skip to instruction 18.
6. Installgear (19)so splinedsideonoutsidediametergoesonfirst.Installcapscrew
incollar (13)andplaceonshaft (35).Maintain pressureoncollartokeep itagainst
gear and tighten capscrew in collar.
7. Lubricate and install ‘O’ ring (33) on hub of drum shaft (41).
8. Install brake housing (21) on drum shaft (41) being careful not to damage ‘O’
ring (33).
9. Position brake housing so brake port is in the 2 o'clock position (as viewed from
the motor end). Install drain plug (24) in brake housing at the 6 o'clock position.
10. Install reducer fitting (22) and breather (29) in top of brake housing (21).
11. Lubricate friction plates (16) with a light motor oil. Refer to ‘Recommended
Lubricants’ in Product Information Manual. Install friction plates (16) and drive
plates (17) in brake housing (21). Begin with a drive plate then alternate with
friction plates between drive plates. Ensure splined teeth mesh. Do not force
plates into place during installation.
12. Lubricate and install seals (11) and (12) in brake piston (10) grooves so seal lips
face each other. Do not overstretch seals during this procedure. Refer to Dwg.
MHP0139 on page 13, A. Seal Lip; B. Seal; C. Brake Piston.
13. Installbrake pistonassemblyinbrakehousingsosteppedsideentersfirst.Gently
tap into position using a soft mallet until seated.
14. Install one brake spring (9) in each brake spring hole.
15. Lubricate and install ‘O’ ring (47) in groove on brake housing (21).
NOTICE
• ‘O’ ring, item (47) listed in step 15, refers to part number 51458 as shown
on Dwg. MHP2937. This part must be placed between brake housing (21)
and motor adapter (6).
Brake Seal Installation
Seal Lip
Seal
Brake
Piston
A
B
C
(Dwg. MHP0139)
16. Install brake reaction plate (8) in motor adapter (6).
17. Two threaded holes in motor adapter (6) are centered between mounting bolt
holes. Install motor adapter with these two holes in the 6 o'clock position.
18. Secure motor adapter with eight capscrews (1) using Loctite® 242. Refer to
“TORQUE CHART” on page 16 for torque requirements. On winches with a disc
brake, install capscrews evenly to compress brake springs. Do not allow plate to
become cocked. Evenly hand tighten all capscrews before applying final torque.
19. On disc brake equipped winches, install shaft (7) on end of drive shaft (35). On
winches without disc brake, secure motor adapter (6) with capscrews (1). Refer
to “TORQUE CHART” on page 16 for torque requirements.
20. Lubricate and install ‘O’ ring (5) in groove on motor adapter (6).
21. Ensure seal adapter (15) and oil seal (2) are installed in bore of motor assembly.
Seal lip must face into motor assembly.
WARNING
• The air motor weighs approximately 260 lb. (118 kg). Adequately support
air motor while installing motor mounting capscrews.
22. Place gasket (226) on mounting flange (216) and align holes.
23. If motor assembly is being mounted with winch in a vertical position, install one
short bolt and nut to keep motor mounting flange (216) from dropping off.
Lower motor assembly carefully onto drive shaft (35). Position throttle assembly
at the top. Be careful not to damage oil seal (2). When correctly positioned,
remove bolt and nut and lower motor assembly the remaining distance.
24. Install the motor assembly to motor mounting plate using capscrews (4) and
lockwashers (3). Lightly coat capscrew threads with Loctite® 242. Refer to
“TORQUE CHART” on page 16 for torque requirements.
25. On winches with a disc brake, install nipple fitting (31), tee fitting (34) and gauge
(32).Installdumpvalve(26)and nipplefitting.Install elbowfitting(956)incontrol
valveassembly(900) or (908).Installvented fitting (27)betweendump valve (26)
and hose or tubing assembly.
nManual and Automatic Band Brake Assembly
Refer to Dwg. MHP2923.
1. Install pivot bracket (122) on the end of arm (124) with pin (121) and cotter pins
(102). Recessed side of the threaded hole must be toward the band side.
2. Install connecting link (125) on the arm (124) and secure in position with pin
(101) and cotter pins (102). Assemble connecting link (125) so curved surface
matches contour of the brake band.
3. Install halves of brake band (128) to the connecting link (125) and secure with
pins (101) and cotter pins (102).
4. Lift the winch assembly, with a suitable hoist, approximately 6 inches (15 cm) off
the floor or work bench.
5. Position the brake band sub-assembly around the brake diameter on the drum
(96) so the arm (124) lays at the bottom. When positioned, lower the winch.
6. Mount pivot bracket (122) on the inside surface of the siderail (98) and secure in
position with capscrews (116) and lockwashers (117).
7. Screw link stud (103) into brake lever (104) and install the brake lever (104) in
the lug on the end of the brake band (128). Lubricate the pivot points being
careful not to get grease on the brake band lining.
8. Pull the halves of the brake band together and install pin (133) through the lug
on band (128) and the adjusting screw (103) of the handle assembly.
9. Install stop plate (126) on the inside of the siderail with capscrews (116) and
lockwashers (117). Install adjusting screw (127) and locknut (120) through the
siderail and stop plate (126) until it contacts the arm (124).
10. Adjust brake as described in 'Adjustments' in the “MAINTENANCE” section.
CAUTION
• Bend ends of all cotter pins (102) apart to secure.
Automatic Band Brake Actuator Assembly:
11. Install bracket (118) on siderail (98) with capscrews (116) and lockwashers (117).
12. Screw nut (108) and clevis (107) onto cylinder rod.
13. Screw link stud (103) into brake lever (105). Attach brake lever (105) to brake
band (128) with pin (133) and cotter pins (102).
14. Install cylinder (110) so it connects with bracket (118) and brake lever (105). Use
pins (106) and (134) and cotter pins (102) to secure in position.
15. Install dump valve (112), fittings and hose (115) to the cylinder (110).
Form MHD56398 Edition 3 13

16. Adjust automatic brake as described in 'Adjustments' in the “MAINTENANCE”
section.
nLimit Switch Assembly
Refer to Dwg. MHP2677.
1. Secure limit switch assembly to upright (184) with capscrews (97) and washers
(96).
2. Install hose connections. Refer to label 71459929 on page 14.
(Dwg. 71459929)
nPendant Operated Pilot Control Valve Assembly
Valve Shaft A
(Dwg. MHP1022)
Brake Release Valve Installation and Adjustment:
Refer to Dwgs. MHP2969 in the Product Information Manual and MHP1027
on page 14, A. Sleeve.
NOTICE
• Valve assembly (341) shaft body is longer on one side of middle groove
than the other. Correct placement of valve assembly is with longer shaft
sectionlocatedtowardbottom of valve body(339).Theshorter section will
protrude up, through valve body.
•To adjust brake release valve, ensure sleeve (338) is loose on shaft (331). If
not loose, back off (turn counterclockwise) setscrew (337).
1. Rotate sleeve (338) to place the longer edge on top. Refer to Dwg. MHP1027
on page 14.
2. Using gentle hand pressure to prevent damage to valve assembly (341) shaft
body, press valve assembly down until ball is in firm contact with sleeve (338).
Sleeve A
(Dwg. MHP1027)
CAUTION
• Do not disassemble pilot cap assemblies. Valve cylinder and valve cap are
press fit together. Close fit tolerances cannot be maintained if
disassembled. If repair is required, replacement of the pilot cap assembly
is required.
Pendant Valve Adjustment:
1. Lubricate threads and install capscrews (366) and (368), lockwashers (924),
gasket (340) and pilot cap assembly (367) to valve body (339). Tighten capscrew,
but do not torque.
2. Reaching into exhaust port on valve body (339), grasp shaft (331) and check for
movement in either direction. Any movement requires adjustment.
3. If there is shaft movement, remove pilot cap assembly and back out setscrews
in pistons 1/4 turn. Repeat until there is no movement.
4. When adjustment is complete, tighten capscrews (366) and (368). Refer to
“TORQUE CHART” on page 16 for torque requirements.
Adapter Installation:
1. Place gasket (358) on mating face of adapter (369) and align holes with valve
body (339). Coat threads with Loctite® 242 and, from the bottom side of adapter,
install capscrews (370) into valve body. Refer to
“TORQUE CHART” on page 16 for torque requirements.
nTwo Function Pendant Assembly (optional feature)
RefertoDwg.MHP1677 with emergency stoporMHP2346 without emergency stop.
1. Install ‘O’ rings (443) and (449) along with protector (451) on valves (452). Install
valve assemblies in handle (454).
2. Install levers (453) in pendant handle (454) with pin (447). Stake pin in pendant
handle at both ends to secure.
3. Install screws (448) in levers.
4. Install balls (446) and springs (445) in handle (454). Secure in position with plugs
(444).
5. On pendants with emergency stop, install emergency stop button (441). On
pendants without emergency stop, install plug (470).
6. Install exhaust washer (457) and secure in handle with retainer ring (458).
7. Attachhosestofittingslocatedontopofpendanthandle.Locatehosestofittings
as shown in Dwg. MHP2398 in Product Information Manual.
nWinch Guard Assembly
Refer to Dwg. MHP2921.
1. Secure frames (802), (801) and (810) to uprights (42) and (184) with capscrews
(809) and washers (96).
2. Secure lifting lugs (183) to uprights with capscrews (182) and washers (46).
3. Installpanels(805) and(807)one ata time, beginningwith eithertheupper (807)
or lower (805) panel.
4. Install first crossbar (806) with nuts (804).
5. Attach panel to crossbar (806).
6. Hold second panel (805) in place and install second crossbar (806) by sliding
through (hooked) edges of the two panels.
7. Secure crossbar (806) with nuts (804).
8. Continue until all panels are in place.
9. Tighten all fasteners and check winch guard is secure. Ensure wire rope does not
interfere with winch guard during winch operation.
nDrum Locking Pin Assembly (optional feature)
Refer to Dwg. MHP2675.
1. Install new bushing (311) in winch upright (184) if replacement was required.
2. Install shaft (304) in handle (301) and secure with nut (303) and capscrew (302).
3. Install cover (307) on shaft (304) so capscrew holes are aligned with holes in
upright when handle (301) is in a horizontal position.
4. Installhousing (308),spring(310),anddrumlockpin (312)on shaft(304). Tighten
drum lock pin (312) on thread of shaft (304). Apply a small amount of Loctite®
242 to threads. Refer to “TORQUE CHART” on page 16 for torque requirements.
5. Install drum locking pin assembly in upright and secure with capscrews (305)
and washers (306).
nPress Roller Assembly
Refer to Dwgs. MHP2935 and MHP2938.
Two people are recommended when installing press roller assembly.
1. If bushings (410) have been removed, replace and install in uprights (42) and
(184),andinbothendsofarm(407).Greasebushings(410)foreaseofinstallation.
14 Form MHD56398 Edition 3

2. Install rollers (402) on smaller ends of press roller arm (407) and secure with
capscrews (408) and washers (409). Apply a small amount of Loctite® 242 to
threads of capscrews.
3. Install springs (405) and (406) so that the shorter end of springs are toward the
inner portion of the arm (407) where the pins (413) are located.
4. One person positions press roller so the top of arm (407) is curved up toward the
undersideofthe drum (96),andholds press rollerinplace while theotherperson
completes installation.
5. Adjust both springs (405) and (406) so that the long end of springs are on the
inside of siderail (98).
NOTICE
• Do not engage shorter end of spring behind pins of arm (407) until after
shaft (403) has been installed and secured, and press roller assembly
adjusted to center of drum.
6. Install shaft (403) through hole in leg of upright (42) only.
7. Install one collar (404) on end of shaft (403) between upright and press roller
assembly.Donot tightencollar (404)untilsteps 10and11 havebeen completed.
8. Install shaft (403) through press roller assembly (400).
9. Install second collar (404) and slide shaft through hole in leg of upright (184).
Ensure that the long end of springs (405) and (406) are still between the siderail
(98) and drum (96). Do not tighten collar (404) until steps 10 and 11 have been
completed.
10. Secure shaft (403) to uprights using capscrews (408) and washers (409). Apply a
small amount of Loctite® 242 to threads of capscrews.
11. Adjustpressroller assembly so thatitis centered between thedrumflanges, and
tighten collars (404).
12. Useextremecaution and pry shortendof one spring (405)sothat it is positioned
behind the pin (413) of arm (407).
13. Repeat step 12 for spring (406).
CAUTION
• Use caution when installing springs (405) and (406); springs are under
tension.
nTesting
nOperational Test
Prior to initial use, all new, altered or repaired winches shall be tested to ensure
proper operation.
a. Check oil level in motor, reduction gear assembly and disc brake are correct.
b. To initially ‘break in’ new or overhauled motors, operate without load, in
both directions, for 15 minutes at 100 - 200 RPM.
c. NewBrakeBand Lining Run-in Procedure:Allnew brake bandliningsrequire
a ‘run-in’ period.
d. Operate the winch without load in the payout direction while gradually
applying the brake. Allow the brake to slip for approximately one minute.
Winchmotor maystallas brakeband liningfullyengages.Donot allowbrake
to overheat.
e. Check operation of brakes. Adjust if necessary as described in the
“MAINTENANCE” section.
f. Check operation of limit switches, locking devices and all safety devices
when equipped.
g. Check foundation mounting fasteners are secure.
h. Install winch guard.
nLoad Test
Prior to initial use, all extensively repaired winches shall be load tested by or under
the direction of an IngersollRandtrained Technician and a written report furnished
confirming the rating of winch. Test loads shall not be less than 100% of rated line
pull and should not exceed 125% of rated line pull. To test winch at 125% of rated
load apply following load with wire rope on the first layer of the drum:
FA2.5A Winch 6,250 lb. (2,835 kg)
FA5A Winch 12,500 lb. (5,670 kg)
NOTICE
•Testingtomorethan125%ofratedlinepullmayberequiredtosetoverload
device or comply with standards and regulations set forth in areas outside
of the USA.
nLimit Switches
Operate winch through three complete cycles to ensure consistent limit switch
operation within +/- 2 feet (0.6 m) of set points. Refer to 'Limit Switch Adjustment'
procedure in Product Information Manual to establish set points.
Form MHD56398 Edition 3 15

TORQUE CHART
Standard Coarse Thread Torque
Size SAE Grade 5 SAE Grade 8
Dry Lubricated PTFE Dry Lubricated PTFE
1/4-20 8-10 6-7 4 12-14 9-10 5-6
5/16-18 17-20 13-15 8-9 25-28 18-21 11-13
3/8-16 31-35 23-26 14-16 44-49 33-37 20-22
7/16-14 49-56 37-42 22-25 70-79 52-59 31-36
1/2-13 75-85 57-64 34-38 106-121 80-90 48-54
9/16-12 109-123 82-92 49-55 154-174 115-130 69-78
5/8-11 150-170 113-128 68-77 212-240 159-180 95-108
3/4-10 267-302 200-227 120-136 376-426 282-320 169-192
7/8-9 429-487 322-365 193-219 606-687 455-515 273-309
1-8 644-729 483-547 290-328 909-1030 681-772 409-463
1 1/8-7 794-900 596-675 357-405 1288-1460 966-1095 580-657
1 1/4-7 1121-1270 840-952 504-571 1817-2059 1363-1545 818-927
Standard Fine Thread Torque
Size SAE Grade 5 SAE Grade 8
Dry Lubricated PTFE Dry Lubricated PTFE
1/4-20 10-11 7-8 4-5 14-15 10-12 6-7
5/16-24 19-22 14-16 9-10 27-31 20-23 12-14
3/8-24 35-40 26-30 16-18 49-56 37-42 22-25
7/16-20 55-63 41-47 25-28 78-88 58-66 35-40
1/2-20 85-96 64-72 38-43 120-136 90-102 54-61
9/16-18 121-137 91-103 55-62 171-194 128-146 77-87
5/8-18 170-193 127-144 76-87 240-272 180-204 108-122
3/4-16 297-337 223-253 134-152 420-476 315-357 189-214
7/8-14 474-537 355-403 213-242 669-758 502-568 301-341
1-12 704-798 528-599 317-359 995-1127 746-845 448-507
1 1/8-12 1023-1159 767-869 460-572 1444-1637 1083-1227 650-736
1 1/4-12 1425-1615 1069-1211 641-727 2012-2280 1509-1710 905-1026
Metric Coarse Thread Torque
Size Class 8.8 / 9.8 Class 10.9
Dry Lubricated PTFE Dry Lubricated PTFE
M6x1 9-10 6-7 4 11-12 8-9 5-6
M8x1.25 21-23 16-18 9-11 26-30 20-22 12-13
M10x1.5 41-47 31-35 19-21 53-60 39-45 24-27
M12x1.75 71-81 54-61 32-36 91-103 68-77 41-46
M14x2 115-130 86-98 52-59 147-166 110-125 66-75
M16x2 165-187 124-140 74-84 227-257 170-193 102-116
M20x2.5 321-364 241-273 144-164 443-502 332-376 199-226
M22x2.5 439-497 329-373 197-224 605-686 454-514 272-309
M24x3 556-630 417-473 250-284 767-869 575-652 345-391
M30x3.5 1103-1250 827-938 496-563 1521-1724 1141-1293 685-776
Metric Fine Thread Torque
Size Class 8.8 / 9.8 Class 10.9
Dry Lubricated PTFE Dry Lubricated PTFE
M8x1 22-25 17-19 10-11 28-32 21-24 13-14
M10x1.25 44-49 33-37 20-22 56-63 42-47 25-28
M12x1.25 78-89 59-67 35-40 100-113 75-85 45-51
M14x1.5 125-141 93-106 56-64 159-180 119-135 72-81
M16x1.5 176-200 132-150 79-90 243-276 183-207 110-124
M18x1.5 257-291 193-219 116-131 355-402 266-302 160-181
M20x1.5 358-406 268-304 161-183 494-559 370-420 222-252
M22x1.5 484-548 363-411 218-247 667-756 500-567 300-340
M24x2 609-690 456-517 274-310 839-951 630-713 378-428
M30x2 1227-1390 920-1043 552-626 1692-1918 1269-1438 761-863
Notes:
1. Definitions:
DRY: Cadmium plate, zinc plate, and oiled fasteners.
LUBRICATED: Molysulfide paste, carnaba wax, molysulfide grease and
copper-based anti-seize coated fasteners.
PTFE: 2% minimum PTFE coated fasteners.
2. All torque values foot-pounds unless noted.
3. SAE grade 5 equivalent to ASTM A325 Type 2 and ASTM A449.
4. SAE grade 8 equivalent to ASTM A354 Grade BD, ASTM A490 Type 1.
5. If mixing fasteners use lowest torque value.
6. Torque values 75 to 85% of fastener proof load ref.
16 Form MHD56398 Edition 3

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