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