Ingersoll-Rand Man Rider LS2-150RLP-L E Series Setup guide

Product Maintenance
Information
Air Powered Man Rider™ Winch
Models
LS2–150RLP-L-( )-E LS2–150RLP-PHXXM-( )-E
(Lever Control) (Remote Control)
Save These Instructions
R
Form MHD56305
Edition 4
October 2013
71455570
©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 Manual (Man Rider) MHD56251 Product Parts Information Manual MHD56306
Product Instructions Manual MHD56293
INSPECTION
Frequent inspections should be performed on equipment in regular service. Refer
to Product Information Manual.
nPeriodic Inspection
Refer to Table 2 ‘Inspection Classifications’ on page 2 for suggested winch
inspection classifications for Periodic Inspection intervals. Select conditions most
appropriate to application.
Table 2: Inspection Classifications
Conditions Normal Heavy Severe
Typical Use (operating time) Infrequent Regular Continual/Constant
Load Range 60% of Capacity 75% of Times Used 80% of Capacity 75% of Times Used 100% of Capacity 75% of Times Used
Installation Protected/Enclosed/Dry Not Sheltered/Exterior Full Exposure
Atmosphere Clean/Non-Corrosive Dirty/Non-Corrosive/Freshwater Marine Dirty/Corrosive/Saltwater Marine
Climate Dry/Stable Temperature Wet/Moderate Temperature Fluctuations Wet/Severe Temperature Fluctuations
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 4 ‘Maintenance Interval Chart’ on page 3:
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)
e. Inspect rope for broken strands/wires: When broken wires are evident close
to, or within, the termination, even if few in number, are indicative of high
stresses at this position and can be caused by incorrect fitting of the
termination.Thecauseof this deterioration shall beinvestigatedand,where
possible, the termination shall be remade, shortening the rope if sufficient
length remains for further use, otherwise the rope shall be discarded. One
valley break may indicate internal rope deterioration, requiring closer
inspection of this section of rope. When two or more valley breaks are found
in one lay length, the rope should be considered for discard. If a complete
strand fracture occurs, the rope shall be immediately discarded. Where
broken wires are very close together, constituting a localized grouping of
such breaks, the rope shall be discarded. If the grouping of such breaks
occurs in a length less than 6d or is concentrated in any one strand, it may
be necessary to discard the rope even if the number of wire breaks is smaller
than the maximum number, refer to table on page 2
Table 3: Wire Rope
Rope Construction
Type
Number Broken Wires
in rope over a length
6x nominal diameter
Number Broken Wires
in rope over a length
30x nominal diameter
6 x 19S-IWRC Single-
layer rope 3 6
6 x 37M-IWRC Single-
layer rope 10 19
5. All Components. Inspect for wear, damage, distortion, deformation and
cleanliness. If external evidence indicates damage, disassemble as required to
conduct a detailed inspection. Inspect gears, shafts, bearings, sheaves, springs
and covers. Replace worn or damaged parts. Clean, lubricate and reassemble.
6. 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
ʽAdjustmentsʽon page 7. If brake band cannot be adjusted to hold rated load,
replacethebrakebandassembly.Adjustmentscannotbemadeto thediscbrake.
The disc brake must be repaired as described in “MAINTENANCE”
sectionon page 7.
7. FoundationorSupportingStructure.Checkfordistortion,wearandcontinued
abilitytosupportwinch and rated load. Ensurewinchisfirmly mounted and that
fasteners are in good condition and tight.
8. Control Valve. Check control valve operation. Ensure control valve handle
moves freely in both directions without sticking and automatically returns to
neutral when released. Ensure locking button moves freely and locks control
handle in neutral when not depressed.
9. 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.
2Form MHD56305 Edition 4

12. Slack Line Detector. Inspect rollers for wear and grooves or ridges. Replace
worn or grooved rollers. Check arms move freely and activate sensor valve.
Ensure rollers rotate freely. Check sensor valve plunger operation. If damaged
or stiff, replace sensor valve.
13. 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.
14. Emergency Lowering Device. Provide auxiliary supply air to emergency
lowering power entry port and activate valve. Verify winch operation.
15. Drum Guard. Verify fasteners are tight and in good condition. Ensure guard is
in good condition and panels are correctly positioned.
16. Labelsand Tags.Checkfor presence andlegibilityof labels. Replaceifdamaged
or missing.
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 4 ‘Maintenance Interval Chart’ on page 3 for recommended
maintenance schedule.
NOTICE
• Perform an annual winch load test for all applications.
Table 4: Maintenance Interval Chart
Normal Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 45 days or 125 hours
Grease Fittings Lubricate grease fittings every 180 days or 500 hours
Gearbox Oil Level Check oil level in gearbox every 120 days or 340 hours
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
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 Automatic Band Brake * X X X X X X X
Inspect Disc Brake X X
Inspect Gearbox X X
Inspect Output Shaft X X X X X X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Press Roller X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X
Note: Hours are for actual winch drum rotation.
* Do not disassemble air cylinder unless brake operation or visual inspection indicates a requirement.
Recommend complete general overhaul.
Form MHD56305 Edition 4 3

Table 5: Maintenance Interval Chart
Heavy Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 80 hours
Grease Fittings Lubricate grease fittings every 90 days or 250 hours
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
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 7 years or 7,000 hrs
Inspect Motor X X X
Inspect Automatic Band Brake * X X X X X X X
Inspect Disc Brake X X
Inspect Gearbox X X
Inspect Output Shaft X X X X X X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Press Roller X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X
Severe Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 80 hours
Grease Fittings Lubricate grease fittings every 90 days or 250 hours
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
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 X
Inspect Automatic Band Brake * X X X X X X X
Inspect Disc Brake X X X
Inspect Gearbox X X X
Inspect Output Shaft X X X X X X X
Replace Winch Anchor Bolts X X X
Inspect Control Valve X X X X X X
Inspect Drum, Housings and Main Frames X X X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X X X
Limit Switches X X X X X X X
Press Roller X X X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X
Note: Hours are for actual winch drum rotation.
* Do not disassemble air cylinder unless brake operation or visual inspection indicates a requirement.
Recommend complete general overhaul.
4 Form MHD56305 Edition 4

INSPECTION REPORT
Ingersoll Rand L2–150RLP Series Air Winches
Model Number: Date:
Serial Number: Inspected by:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection:
(_____ Months _____ Years) Operating Environment:
Normal ____ Heavy____ Severe ____
2. Discrepancy(s) noted during Frequent Inspection
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)
Disc Brake (125% Load Test)
DrumBandBrake (Visual Inspection)
Disc Brake (Visual Inspection)
Motor
Controls
Limit Switches
Air System
Fasteners ---
Emergency Stop Valve
Overload Device ---
Reduction Gears
Labels and Tags ---
Output Shaft
Shafts
Drum Guard
Wire Rope Wedge ---
Emergency Air supply Tank or
System ---
Slack Line Devise ---
Press Roller
Wire Rope ---
Other Components (list in NOTES
section)
TESTING Pass Fail NOTES
Operational (No Load)
Operational (10% Load)
Operational (Maximum Test Load*)
*Maximumtestloadis 125% of rated linepull.Testingto more than 125%ofratedload may be required tosetoverloaddevice or comply withstandardsandregulations
set forth in areas outside the USA.
This form may be photo copied and used as an inspection record.
Form MHD56305 Edition 4 5

TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by personnel
instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common winch symptoms, probable causes and remedies.
SYMPTOM CAUSE REMEDY
Winch will not operate. Insufficient or no air supply to winch. Check air supply line connections and hoses.
Winch is overloaded. Reduce load to within rated capacity.
Disc brake does not release. Inspect brake piston seals and replace if seals appear to be leaking.
Drum brake does not release. Refer to ʽAdjustmentsʽ in “MAINTENANCE” section on page 7.
Emergency stop valve engaged. Reset emergency stop valve.
Motor may be damaged. Disassemble and clean the motor and replace any broken or damaged parts.
Air leak. Check hose and fitting connections. Inspect hose(s) for breaks. Tighten fittings and
repair or replace hoses as necessary.
Overload device engaged. Reduce load to within rated capacity of winch. If overload device cannot be reset,
contact factory.
Air lines freeze due to water in air supply. Install or drain air system moisture traps, moisture collecting air receivers and
compressor aftercoolers. After corrective action has been taken, disconnect lines at
winch inlet and purge with clean, dry air or nitrogen.
Load continues to move when winch is
stopped. Brake is slipping. Check brake friction discs and automatic band drum brake wear.
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 hauls-in but does not payout. Lower limit switch activated. Raise load and check limit switch settings.
Slack line detector activated. Determine cause of slack line and rectify problem.
Winch does not lift load or does not lift
rated capacity. Winch does not lift load. Motor may be damaged. Remove and disassemble motor as described in ‘’ 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 50 psig (3.5 bar/350 kPa).
Winch is overloaded. Reduce load to within rated capacity.
Oil leak from motor end of winch. Reduction assembly is leaking. Disassemble winch and inspect reduction assembly seals.
Throttle or pendant lever moves but winch
does not operate. Motor may be damaged. Disassemble, inspect and clean motor. 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.
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 ‘’ on page 7. Inspect all parts and
replace all worn or damaged parts.
Brake(s) not releasing. Refer to brake sections below.
Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements. Refer
to “SPECIFICATIONS” section in Product 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 or pendant lever moves but winch
does not operate.
Motor may be damaged. Disassemble, inspect and clean motor. 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.
Automatic Band Brake:
Brake cylinder will not release. Band brake out of adjustment. Adjust band brake to maintain correct cylinder stroke.
Leaking cylinder seals. If air is noticed escaping from cylinder breather when attempting to release brake,
replace or repair cylinder.
Dirty filter in air supply. Clean or replace filter.
Automatic Disc Brake:
Brake fails to release. Low air supply pressure. Ensure air pressure at inlet to disc brake is at least 60 psig (3.4 bar/340 kPa).
Leaking piston seals. Inspect brake breather. If air escapes from brake breather when attempting to
release brake, replace brake seals.
No release pressure at brake port. Check for proper operation of winch controls.
Sticking brake piston. Apply 60 psig (3.4 bar/340 kPa) to brake release port and check for brake disc
movement. (Brake discs can be viewed through brake breather hole.) If brake discs
do not move, disassemble and inspect disc brake as described in ‘’ on page 7.
6 Form MHD56305 Edition 4

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 may 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
• Refer to Product Information and Safety Manuals for specific information.
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.
Drawing No. from Parts Manual
MHD56306 Page No.
MHP2728 4
MHP2729 10
MHP2730 16
MHP2731 13
MHP2732 14
MHP2807 6
MHP2811 12
MHP2812 8
MHP2817 4
MHP2818 18
MHP3100 20
nMaintenance Intervals
Refer to Table 4 ‘Maintenance Interval Chart’ on page 3 for recommended
maintenance schedule.
nAdjustments
nLimit Switches
Refer to ʽLimit Switchesʽ section in Product Information Manual.
nDisc Brake
No brake adjustment is required. Refer to Dwg. MHP2849 on page 7, A. Piston;
B. Friction Plate; C. Drive Plate; D. Reaction Plate; E. 0.047 inch minimum (1.2 mm
minimum).
1. Remove motor as described in ‘Motor Removal’ section on page 8.
2. Remove the reaction plate (57), splined hub (53), friction plates (55) and (58),
and drive plates (56).
3. Inspect the friction plates (55) and (58) for wear. If friction plate thickness is
uneven or is less than 0.047 in (1.2 mm), replace all friction plates.
Nofurtherdisassemblyisrequired,ifonlythebrake frictiondiscsarebeinginspected.
Ensure friction and drive plates are assembled in the correct order. Refer to ‘Disc
Brake Assembly’ on page 9.
Piston Friction
Plate
0.047 inch minimum
(1.2 mm minimum)
Drive
Plate
Reaction
Plate
A
B
C
D
E
(Dwg. MHP2849)
NOTICE
• Original brake disc thickness is 0.059 in (1.5 mm)
nOverload Device
WARNING
•Overloadisfactorysetandsealedwithredpaintandshouldnotbeadjusted
without consulting an Ingersoll Rand trained technician.
Securing
Screw
Adjustment
Screw
A
B
(Dwg. MHP2683)
1. Connect winch to an air supply.
2. Release securing screw and adjusting screw in order to increase or decrease the
SWL (increase SWL by tightening the adjusting screw). Adjustment must be
made for an overload of 135% maximum of SWL.
3. Tighten securing screw.
4. Check winch operation at rated load. If necessary, repeat adjustment.
Form MHD56305 Edition 4 7

nAutomatic Band Drum Brake
Refer to Dwg. MHP2880 on page 8.
1. Loosen locknut ‘B’.
2. Tighten nut ‘A’ until the adjustment dimension 0.43 to 0.51 inch (11 to 13 mm)
is achieved.
3. Tighten locknut ‘B’.
4. Check brake operation.
11-13 mm
Nut ‘A’ Locknut ‘B’
0.43-0.51 inch
(Dwg. MHP2880)
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.
nExternal Components Removal
Refer to component disassembly sections for further repair.
1. Disconnect and tag all external air lines.
2. Remove filter, regulator and lubricator (FRL) assembly from spacer (66).
3. Remove drum guards. Refer to drum guard disassembly.
4. Remove press roller assembly from spacer. Refer to press roller disassembly.
5. Remove slack wire rope device from spacer. Refer to press roller disassembly.
6. Remove limit switch assembly. Refer to limit switch disassembly.
nMotor and Reduction Gear Removal
Refer to Dwg. MHP2812 and MHP2728.
1. Shut off and bleed down main air supply to winch.
2. Disconnect and tag air lines.
3. Stand winch in a vertical position, with the motor end up. Ensure winch is
properly supported.
4. Remove four capscrews (86) and washers (125) that secure motor and control
valve assembly to upright (62).
5. Carefully pull motor assembly from winch.
6. Clean capscrews (86) and threaded holes with Loctite® 7063 or equivalent so
they are free of Loctite® residue.
7. Store motor in a clean area until needed. If repair is required refer to specific
disassembly sections.
nDrum Guard Disassembly
Refer to Dwg. MHP2817.
1. Remove capscrews (171).
2. Remove drum guard (216), left panel (217) and right panel (218).
nAutomatic Band Drum Brake Disassembly
Refer to Dwg. MHP2811.
1. Disconnect and tag the air lines.
2. Loosen nut (151) until brake band (111) is slack on drum.
3. Remove one cotter pin (113) from each pin (112) and tap out pins (112) from
brake band ends.
4. Remove brake band (111) and adjustment screw (149). Remove capscrews (156)
and lockwashers (64) that secure housing (147) to side rail (68). DO NOT
disassemblebrakecylinder assembly. ContactanIngersollRand trainedservice
technician for cylinder disassembly and repair.
nLimit Switch Disassembly
Refer to Dwg. MHP2730.
CAUTION
•Itisnotrecommendedto disassemble limit switch. Contact factoryifrepair
is required.
1. Remove and tag hose connections if not already done.
2. Remove nuts (504) from rods (502). Remove cover (505), gasket (490) and
housing (486) from limit switch adapter (450).
3. Removecapscrews(499)andpullspindleswitchassembly(501)fromlimitswitch
adapter (450).
4. Store limit switch assembly in a clean, dry area until winch reassembly.
nPress Roller Disassembly
Refer to Dwgs. MHP2728 and MHP2731.
1. Compress ends of springs (167) and (169) to disengage from spacer (66) and pin
on press roller arm (163).
CAUTION
• Use care when releasing springs (167) and (169) from press roller. Springs
are under tension.
2. Remove capscrews (183) and lockwashers (73). Remove press roller assembly
from spacer (66).
3. Remove capscrews (161) and washers (162) from both sides of roller arm (181).
Remove frames (176) and springs (169).
4. Remove capscrews (161) and washers (162) from both sides of roller arm (181).
Remove press rollers (184).
nSlack Line Device Disassembly
Refer to Dwgs. MHP2732.
1. Remove and tag hose connections if not already done.
2. Remove locknuts (301) and washers (307) from shoulder screws (310).
3. Remove spacers (308) and lift off slack wire arm assembly.
4. Tap shoulder screws (310) from uprights (62) and remove bearings (309).
5. Remove capscrews (302) and lockwashers (73) from axle (304).
6. Removelocknuts(301)andlockwashers(73)from rolleraxle(305).Separatearms
(303), rollers (306) and axles (304) and (305).
7. Remove capscrews (324) and lockwashers (2) from protector (323).
8. Remove protector (323) and sensor valve (327) from upright (62).
nWinch Base and Drum Disassembly
Refer to Dwgs. MHP2728, MHP2807 and MHP2812. Refer to ‘Motor and Reduction
Gear Removal’ section on page 8 to remove motor assembly from the winch.
1. Remove external components. Refer to ‘External Components Removal’ section
on page 8.
2. Stand winch in a vertical position with motor end up.
3. Remove capscrews (86), and washers (125) that secure motor, reduction gear
and brake assembly to drum end cover (76). Set assembly to one side for further
disassembly if needed.
4. Remove capscrews (65) and (67), nuts (63) and lockwashers (64) to remove
spacers (66) and lifting lugs (69).
5. Remove capscrews (67), nuts (63) and lockwashers (64) to remove siderails (68).
6. Remove upright (62) and tube (70).
8Form MHD56305 Edition 4

7. Remove capscrews (50) and lockwashers (73). Separate drum end cover
assembly from upright (62).
8. Remove bearing (76) and oil seal (77) from drum (60) if not removed with drum
end cover (78).
9. Carefully turn drum over so limit switch end is up.
10. Remove upright (62) from drum (60).
11. Remove capscrews (50) and lockwashers (73) from drum end cover (78).
12. Remove drum end cover (78) from upright (62).
13. Remove bearing (76) and oil seal (77) from drum (60) if not removed with drum
end cover (78).
nDisc Brake Disassembly
Refer to Dwg. MHP2807.
1. Remove capscrews (25) (black) allowing brake and reducer assembly to be
removed together.
2. Use the two threaded puller holes in the piston (51) to remove piston (51) and
brake reaction plate (57) from brake housing (41).
3. Remove drive plates (56), friction plates (55) and (58), spacer (54) and splined
hub (53). Note position for later assembly.
4. Remove ‘O’ ring (16) and ‘O’ ring (52) from piston (51) and discard.
nReduction Gear Disassembly
Refer to Dwg. MHP2807.
1. Remove disc brake assembly refer to on page 9
2. Remove fill plug (14) and drain oil from reduction gear into a suitable container.
3. Removecapscrews (24)and(25) toseparate reductiongearassembly frombrake
housing (41).
4. Remove capscrews (22) and washers (23) that secure reduction gear end cover
(15).
5. Remove retainer ring (12) from gear shaft (20).
CAUTION
• It may be necessary to use a small amount of air pressure in fill hole of
reduction gear end cover (15) to separate from housing (27).
6. Remove and discard ‘O’ ring (16) on reduction gear end cover (15).
7. It is not necessary to remove bearing (39) from reduction gear end cover (15)
unless damaged. Replace as necessary.
8. Remove bearing (13) and oil seal (17). Replace seal and bearing if necessary.
9. Remove bearing (21) and ring gear (19).
10. Support end cover (15) and tap out shaft (20).
11. Remove retainer ring (36) from sun gear (34).
12. Support reducer housing (27) and gently tap out sun gear (34).
13. Tap out gear shafts (33) and remove planet gears (31), spacers (30), needle
bearings (28) and bearing rings (29).
14. Remove retainer ring (49).
15. Remove sun gear (34).
16. Remove retainer ring (36) and bearing (35).
17. Remove and discard gasket (26) and ‘O’ ring (16) from brake housing (41).
18. Remove and replace bearing (38) if necessary.
nMotor Disassembly
Refer to Dwg. MHP2812.
1. Remove motor assembly as described in ‘Motor and Reduction Gear Removal’
on page 8.
2. Remove control valve assembly (100) from motor assembly.
3. Remove capscrews (103) and emergency stop end cover (185).
4. Remove and discard gasket (101).
5. Remove capscrews (107) and remove motor cover (97) from motor housing (87).
6. Remove and discard ‘O’ rings (90).
7. Remove valves (105) and springs (96) from motor cover (97).
8. Remove ‘O’ rings (94) only if necessary. ‘O’ rings will need to be cut for removal.
NOTICE
• The two bearings (91) located in the motor housing (87) are bonded with
Loctite® 603 or equivalent. Remove idle gear (104) and drive gear (92) only
if replacement is necessary; use a bearing punch (IR pn: 96441232) or
standard drift punch and a hammer. Refer to Dwg. MHP2644
on page 11.
9. To remove both bonded bearings (91) from motor housing (87), it is necessary
to use a bearing punch and hammer. Two or three strikes are enough.
10. If replacement is necessary, remove bearings (91) from drive gear (92) and idle
gear (104) (use a suitable bearing extractor).
11. Remove check valve (83) and ball (84) from motor housing (87).
Emergency Stop End Cover:
1. Remove and discard ‘O’ rings (90).
2. Remove setscrew (180).
3. Remove ball (84).
4. Remove valve seat (186).
5. Remove seal (189) and axle (188).
6. Remove and discard ‘O’ rings (187).
7. Remove spring (193).
8. Unscrew clamping screw (102).
9. Unscrew regulating screw (192) and remove and discard ‘O’ ring (191).
10. Remove valve seat (205).
11. Remove spring (213).
12. Remove capscrews (214).
13. Separate caps (202) and (211), washers (208) and (206), sleeve (209) and
diaphragm (212).
14. Remove seals (203) and (210).
15. Pull stop nut (194) and separate plunger (198) with diaphragm (196) from base
plate (199).
16. Unscrew nut (194) and remove plunger (198) and washer (195).
17. Remove and discard ‘O’ ring (197) .
18. Install a screw (dia. M5) in threaded hole on base plate (199) and pull it from
motor cover (97).
nControl Valve Disassembly
Refer to Dwg. MHP2729.
1. To separate control valve (100) from motor assembly, remove capscrews (137)
and (168) with lockwashers (2).
2. Removecapscrews(118)andlockwashers (2)fromstopplate(119). Removestop
plate.
3. Partially remove capscrew (126) just far enough to allow emergency stop
housing assembly to be removed. Place emergency stop housing assembly to
one side for later disassembly.
4. Remove spools (142) from valve housing (135).
5. Completely remove capscrew (126) and lockwasher (125).
6. Remove lever assembly, coupling (124) and spring (116).
7. Do not disassemble handle unless repairs are needed. To disassemble handle,
tap out pin (120) and unscrew cap (121). Remove handle spool (123) and spring
(130).
8. Remove retainer (140), spindle shaft (131) and gear (138).
9. Remove retainer (140), spindle shaft (131) and gear cam (139).
10. Remove pins (132) from spindle shafts (115).
11. Remove bushings (133) and bushings (141).
Emergency Stop:
Refer to Dwg. MHP2729.
1. Remove emergency stop valve (164) from end cover (172).
2. Remove and discard ‘O’ rings (175).
3. Unscrew and remove valve (165) with ‘O’ ring (171), ‘O’ ring (166) and protector
(170).
4. Remove retainer rings (178).
5. Remove springs (177) and balls (84).
6. Unscrew check valve (83) and remove ball (84).
7. Remove and discard ‘O’ rings (166).
n2 Function Emergency Stop Pendant Disassembly (optional)
Refer to Dwg. MHP2818.
1. Disconnect hoses from pendant assembly (600).
2. Remove fittings (152).
3. Remove lifting eye (617), if necessary.
4. Tap out pin (618) to remove the levers (619).
5. Unscrew and remove check valve (83) and ball (84).
6. Remove setscrew (173) to remove the valve assemblies (165).
7. Remove protector (170), ‘O’ rings (166) and (171) from the valve (165).
8. Remove plugs (623) to remove the springs (177) and balls (84).
9. Remove emergency stop button (164).
10. Remove retainer ring (621) and exhaust washer (615) from handle (622).
nCleaning, Inspection and Repair
Refer to Product Parts Information Manual for item numbers referenced in the
“Cleaning, Inspection and Repair” section.
nCleaning
Cleanall winchcomponent partsin solvent(except drumbrake bandsand discbrake
friction plates). The use of a stiff bristle brush will facilitate removal of accumulated
dirt and sediments on housings, frame and drum. If bushings have been removed it
maybenecessaryto carefully removeoldLoctite®from bushing bores.Dryeachpart
using low pressure, filtered compressed air. Clean drum brake band using a wire
brush or emery cloth. Do not wash drum brake band in solvent. If drum 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:
Inspect gears for
- worn, cracked or broken teeth. Replace if necessary.
Inspect bushings for
•-wear, scoring or galling. Replace if necessary.
Inspect shafts for
•-ridges caused by wear. Replace if necessary.
•-scoring or galling.
Inspect all threaded items for
•-damaged threads. Replace if necessary.
Inspect drum band brake lining for
•-oil, grease and glazing. If drum band brake lining is oil-soaked, excessively
greasy or overly glazed, replace brake band. Remove small glazed areas of
band brake lining by sanding lightly with a fine grit emery cloth.
•-thickness of drum band brake lining. If drum brake band lining is less than
0.062 in. (2 mm) thick anywhere along the edges, replace brake band
assembly.
Inspect motor housing gear bores for
•-wear or scoring. For any large scratches or uneven/excessive wear patterns,
replace motor housing.
Inspect motor gears (92) and (104) for
•-ridges or excessive grooving on outside diameter of gears.
•-contact between gears and gear housing.
Inspect press roller and slack wire device for
•-wear, grooves or scoring of rollers. Replace if any of these conditions exist.
•-smooth rotation. Rollers must operate without binding and without
excessive side-to-side play.
Form MHD56305 Edition 4 9

Inspect bearings for
•-loss of grease and evidence of grit, dirt or other contaminants. All motor
bearings are factory lubricated and sealed. If dry or contaminated, replace
the bearing.
•-damage. Inspect roller bearings (needle). At any indication of damage or
contamination, replace bearings.
Inspect disc brake for
•-wear. Replace brake discs if grooving pattern is no longer visible or if discs
are cracked or chipped.
-thickness of disc. If less than 0.047 in (1.2 mm), replace.
nRepair
Actual repairs are limited to the removal of small burrs and other minor surface
imperfections from gears, shafts, housings and machined surfaces. Use a fine stone
or emery cloth for this work.
1. Worn or damaged parts must be replaced. Refer to applicable parts listing for
specific replacement parts information.
2. Inspect all remaining parts for evidence of damage. Replace or repair any part
which is in questionable condition. The cost of the part is often minor in
comparison with the cost of redoing the job.
3. Smooth out all nicks, burrs or galled spots on shafts, bores, pins or bushings.
4. Examine all gear teeth carefully and remove nicks or burrs.
5. Polish edges of all shaft shoulders to remove small nicks which may have been
caused during handling.
6. Remove all nicks and burrs caused by lockwashers.
nAssembly
Refer to the Product Parts Information Manual for drawings unless specified
elsewhere.
General instructions:
•-use new gaskets and seals.
•-replace worn parts.
•-assemble parts using match marks applied during disassembly. Compare
replacement parts with originals to identify installation alignments.
nControl Valve Assembly
Refer to Dwg. MHP2729.
1. Install bushings (133) and (141) in valve housing (135).
2. Install pins (132) in spindle shafts (115), so they extend an equal amount on both
sides.
3. Install retainer (140), spindle shaft (115), key (136) and gear cam (139) in valve
housing.
4. Install retainer (140), spindle shaft (131), key (136) and gear (138) in valve
housing. Ensure keys are vertically aligned and gear teeth are meshed.
5. If handle was disassembled, install spring (130) and handle spool (123) in lever
shaft (128). Align hole in handle spool (123) with slot in lever shaft (128) and
install pin (120) so it extends an equal amount on both sides. Install ʽOʽ ring
(122) on cap (121) and screw cap (121) into lever shaft (128).
6. Vertical Wire Rope Take-off Angle:
a. Install pin (134) in the top pin hole in valve housing (134).
b. Install lever assembly in coupling (124). Install spring (116) and coupling/
handle assembly on lower spindle shaft (115). Align notch in coupling with
pin in spindle shaft. Spring (116) ends will point up. Refer to Dwg. MHP2998
on page 10
c. Install capscrew (126) and lockwasher (125) through coupling (124) and
lower hole in lever shaft (128).
or
7. Horizontal Wire Rope Take-off Angle:
a. Install pin (134) in the lower pin hole in valve housing (134).
b. Install lever assembly in coupling (124). Install spring (116) and coupling/
handle assembly on top spindle shaft (115). Align notch in coupling with pin
in spindle shaft. Spring (116) ends will point down. Refer to Dwg. MHP2998
on page 10.
c. Install capscrew (126) and lockwasher (125) through coupling (124) and top
hole in lever shaft (128).
8. Install spools (142) in valve housing (135).
9. Installemergencystop housingassembly to valvehousing (135).Installshoulder
screw (127). Tighten capscrews (126) and (127) to secure emergency stop
housing.
10. Install capscrews (118), lockwashers (2) and stop plate (119) on valve housing
(135).
11. Check operation of control valve to ensure smooth movement and ability to
spring return and lock in neutral.
Vertical
(Standard)
Note: position
of coupling,
shoulder screw
and spring.
Horizontal
Note: position
of coupling,
shoulder screw
and spring.
(Dwg. MHP2998)
nMotor Assembly
Refer to Dwg. MHP2812.
1. Clean the grease from bearings (91).
2. Cleaninterior andexterior diameterof bearingswith Loctite®7063 orequivalent.
3. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of
bearing (91). Refer to Dwg. MHP2644 on page 11, A. Use a continuous thin
filmof Loctite®603orequivalenttobondone bearingon eachgear. Applywhere
arrows indicate; B. Do not bond bearings on this side of gears; C. Use of
continuous thin film Loctite® 603 or equivalent; D. Note: Wait 10 minutes with
the housing in this position, to ensure proper bond; E. Install splined hub (75)
and rotate to ensure a proper bond.
4. Apply a continuous thin film of Loctite® 603 or equivalent on bearing diameter
on drive gear (92) and install bearing (91).
5. Install a second bearing (91), not bonded, on drive gear (92).
6. Apply a continuous thin film of Loctite® 603 or equivalent on interior diameter
of bearing (91).
7. Apply a continuous thin film of Loctite® 603 or equivalent on bearing diameter
on idle gear (104) and install bearing (91).
8. Install a second bearing (91), not bonded, on idle gear (104).
9. Apply a continuous thin film of Loctite® 603 or equivalent on bore for bearings
in the motor housing (87).
10. Install drive gear (92) and idle gear (104) into motor housing, ensure the drive
gear and idle gear are completely inside motor housing and leave the motor
housing in a position as shown in Dwg. MHP2644 on page 11, for 10 minutes.
11. Turnthe gearswithcouplinganda tool.Check bearingsdonotrotateon bonded
diameters and gears rotate freely.
12. Install pins (88) in motor cover (97).
13. Install exhaust washer (99) with a drop of Loctite® 601 or equivalent on motor
cover.
14. Install ‘O’ rings (90) on motor cover (97).
15. Install motor cover (97) on motor housing and secure with capscrews (107).
16. Lubricate ‘O’ rings (85) on valves (94) and (105). One ‘O’ ring is mounted in a
special groove. Ensure a good assembly.
17. Install springs (96) and valve assemblies (94) and (104) in motor cover (97).
18. Lubricate and install ‘O’ rings (166) on check valve (83). Install ball (84) and check
valve assembly in motor housing (87).
19. Check to ensure motor gears turn smoothly in both directions.
10 Form MHD56305 Edition 4

(Dwg. MHP2644)
Motor Emergency Stop End Cover:
Refer to Dwg. MHP2812.
1. Lubricate and install ‘O’ ring (201) and seal (189) on base plate (199).
2. Lubricate and install ‘O’ ring (197) to plunger (198).
3. Install diaphragm (196) and washer (195) with stop nut (194) on plunger (198)
and insert into base plate (199). Ensure plunger assembly moves freely in bore
of base plate.
4. Insert base plate (199) with plunger into motor cover (97).
5. Lubricate and install ‘O’ rings (204) on valve seat (205).
6. Place washer (206), diaphragm (212), cap (211), seal (203), sleeve (209) and
washers (206) and (208) onto capscrew (214) and insert into valve seat (205).
Apply a thin film of Loctite® 243 or equivalent to capscrew threads. Do not over
tighten capscrew.
7. Place seal (210) and cap (202) on capscrew (62). Place spring (213) on cap (202).
8. Install valve seat assembly into emergency stop end cover (185).
9. Lubricate and install ‘O’ ring (191) on regulating screw (192); insert into
emergency stop end cover (185) avoiding damage to the ‘O’ ring. Secure with
screw (102). Install screw (102) with Loctite® 243 or equivalent.
10. Lubricate and install spring (193).
11. Install ‘O’ rings (187) to valve seat (186).
12. Insert axle (188) into valve seat (186) then install seals (189) on each end of axle
(188).
13. Insert valve seat (186) into emergency stop end cover (185).
14. Insert ball (84) into emergency stop end cover (185).
15. Install gasket (101) on motor cover (97).
16. Install emergency stop end cover (185) on motor cover (97) and secure with
capscrews (103).
17. Insert plug (182) if removed during disassembly.
18. Install setscrew (180) in emergency stop end cover (185).
19. Install ‘O’ rings (90) on emergency stop end cover (185).
20. Install control valve assembly.
21. If pendant adapter plate (605) or (613) was removed from motor cover (83), refer
to pendant assemblies for installation.
nReduction Gear Assembly
Refer to Dwg. MHP2807.
1. Install oil seal (17) in the bore of the reduction gear end cover (15) so seal lip is
toward the planet assembly side.
2. Lubricateandinstall‘O’ring(16)onoutsidediameterofreductiongearendcover
(15). Install plug (14).
3. Pressbearings(13)and(39) intothereductiongearend cover(15).Installretainer
ring (12) on the gear shaft (20).
4. Press gear shaft (20) into reduction gear end cover (15).
5. Install ring gear (19) and bearing (21) on gear shaft (20) and secure in position
with retainer ring (94). Install assembly in reducer housing (27).
6. Pressbearing(35)onto the sun gear(34)andlocate with retainer ring (36).Install
sun gear (34) with bearing (35) in the planet gear support (32) and secure with
retainer ring (49).
7. Installtwobearings (28) with aspacer(30) between in theboreof each planetary
gear (31).
8. Install bearing rings (29) in each bearing (28).
9. Position each assembled planetary gear in the planet gear support (32) with the
timing mark as shown on drawing Dwg. MHP1406 on page 11, A. Planet Gear
Support; B. Timing Marks; C. Planet Gear. Carefully install gear shafts (33)
CAUTION
•Forassemblyofplanet gears, each planetgearmustbe positioned with the
timing mark as shown on Dwg. MHP1406.
B
A
C
(Dwg. MHP1406)
10. Install planetary gear assembly in the reducer housing (27).
11. Install ball bearing (38) on the planet gear support (32). Check planet gears, sun
gear and ring gear teeth mesh smoothly.
12. Place the reduction gear assembly in a vertical position with the planetary gear
end up.
13. Fill the gear assembly to within 1 in. (25 mm) of the top with clean oil. Refer to
“LUBRICATION” section in Product Information Manual.
14. Install new gasket (20) on reducer housing (27).
15. Apply Loctite® 243 to capscrews. Refer to “TORQUE CHART” on page 13.
nDisc Brake Assembly
Refer to Dwg. MHP2807.
1. Lubricate and install ‘O’ rings (16) and (52) on piston (51).
2. Installnewgasket (26)onreducer housing (27)ifnot doneduringreduction gear
assembly.
3. Assemblebrakehousing(41)to reducerassemblyandsecurewith capscrew(24).
4. Ensure plug (14) is removed, then press piston assembly into brake housing (41).
Puller screw holes must face out.
5. Install spacer (54) and splined hub (53). Start with friction plate (55) followed by
driveplate(56), friction platewithsprings (58), drive plate(56),friction plate (55),
drive plate (56) and finishing with friction plate with springs (58).
6. Install plug (14).
nWinch Base and Drum Assembly
Refer to Dwgs. MHP2728, MHP2807 and MHP2812.
1. Install oil seal (77) and rear bearing (76) on drum end cover (78). Oil seal lip must
be toward the bearing.
2. Install drum end cover assembly on upright (62) and secure with capscrews (50)
and lockwashers (73).
3. Position the upright on several block of wood with the rear bearing (76) up.
4. Check that plate (72) is securely installed in the drum with countersunk screws
(71).
5. Lubricate the outside diameter of oil seal (77) and install drum assembly on rear
bearing.
6. Installoilseal(77) and front bearing (76)ondrumend cover (78). Oil seallipmust
be toward the bearing.
7. Installdrumend coverassemblyon frontupright(62) and securewith capscrews
(50) and lockwashers (73).
8. Lubricate the outside diameter of oil seal (77) and install front upright assembly
on drum (60).
9. Rotateuprightsso they are alignedandinstall spacers (66) andsiderails(68) with
capscrews (65) and (67), nuts (63) and washers (64). Longer capscrews (65) are
required to attach lifting lugs (69). Mount lifting lugs diagonally opposite.
10. Check pin (79) is installed in drum end cover (78).
11. Install motor reducer assembly. Ensure gear shaft (20) meshes with splined bore
in drum and secure with capscrews (86) and lockwashers (125).
12. Return winch to a horizontal position.
13. Install remaining external assemblies.
nAutomatic Band Drum Brake Assembly
Refer to Dwg. MHP2811. It is recommended that any brake cylinder service work be
conducted by an Ingersoll Rand trained technician.
1. Install ‘O’ ring (145) on the piston (146).
2. Install oil seal (114), ring (143) and ‘O’ ring (145) in the cover (117).
3. Install piston (146) and spring (144) in the housing (147).
Form MHD56305 Edition 4 11

4. Install cover (117) and close brake cylinder assembly with capscrews (302) and
lockwashers (73). Before closing the brake cylinder, fill the spring housing with
about 1 oz. (25 ml) of SP 150 type oil.
Brake Band:
1. Thread nut (148) onto adjustment screw (149), then install adjustment screw
(149) in brake cylinder assembly.
2. Install the brake cylinder assembly with capscrews (156) and lockwashers (64)
on the siderail (68).
3. Install band brake (111) on drum (60). Anchor brake band ends to adjustment
screw (149) and piston (146) with pins (112) and cotter pins (113). Bend ends of
cotter pins apart.
4. Install locknut (151) and washer (150) on adjustment screw (149).
5. Adjust brake band assembly. Refer to ‘Adjustments’ section on page 7.
nLimit Switches Assembly
Refer to Dwg. MHP2730.
1. Install limit switch adapter (450) on drum end cover (78). Secure with capscrews
(98) and lockwashers (73).
2. Install spindle switch assembly (501) on limit switch adapter (450). Secure with
capscrews (499).
3. Install one gasket (490) on each end of housing (486).
4. Thread one nut (73) and washer (73) on each rod (502). Install four rods in limit
switch adapter (450) and tighten nut (73). Ensure full thread engagement of rod
in limit switch adapter.
5. Install housing (486) and housing cover (505). Position housing with cap
assembly (498) hole on top. Align housing cover holes with rods.
6. Install nuts (504) on rods (502) to secure housing and housing cover.
nSlack Line Device Assembly
Refer to Dwg. MHP2732.
1. Assemble valve support (325) to sensor valve (327) with capscrews (318).
2. Assembleprotector(322)tovalvesupport(325)withcapscrews(22)andwashers
(23).
3. Assembleprotector(323) and valvesupport(325) to upright(62)with capscrews
(324) and lockwashers (2).
4. Install bearings (309) on the shoulder screws (310).
5. Assemble arms (303), rollers (306) and axles (304) and (305). Install nuts (301)
and lockwashers (73) on roller axle (305) to secure.
6. Install capscrews (302) and lockwashers (73) on axle (304).
7. Install spacers (308) and slack wire arm assembly. Tap shoulder screws (310) into
uprights (62).
8. Install nuts (301) and washers (307) on shoulder screws (310).
9. Reconnect hoses.
nPress Roller Assembly
Refer to Dwgs. MHP2728 and MHP2731.
1. Install press rollers (184) between roller arms (181) and secure with capscrews
(161) and washers (162).
2. Install frames (176) and springs (169) on roller arms (181). Secure with capscrews
(161) and washers (162).
3. Install press roller assembly in spacer (404). Secure with capscrews (183) and
lockwashers (73).
4. Compress ends of springs (167) and (169) to engage with spacer (66) and pin on
press roller arm (163).
nFilter, Lubricator and Regulator Assembly
Refer to Dwg. MHP3100.
Horizontal Take-off Angle:
1. Install FRL assembly (400) to bracket (401) with capscrews (402), washers (404)
and locknut (403).
2. Install bracket (401) to spacer (66) on press roller side of winch.
3. install hose connections and three way shut-off valve (407).
Vertical Take-off Angle:
1. Install FLR assembly (400) to spacer (66), opposite press roller side, with bracket
(418) and secure with capscrews (420) and washers (419).
2. Install hose connections and three way shut-off valve (407).
NOTICE
• Run winch in both directions with no load to ensure proper connections
and no air leaks.
nDrum Guard Assembly
Refer to Dwg. MHP2817.
NOTICE
•Install drum guard for proper take-off angle, refer to data (name) plate for
model.
1. Install drum guard (216) and both side panel guards and secure with capscrew
(161).
n2 Function Emergency Stop Pendant Assembly (optional)
Refer to Dwg. MHP2818.
1. Install ‘O’ rings (166) and protector (170) on valves (165). Install valve assemblies
in handle (514)
2. Install levers (503) in pendant handle (514) with pin (502). Stake pin in pendant
handle at both ends to secure.
3. Install screws (504) in levers.
4. Install screws (173) in handle.
5. Install balls (84) and springs (177) in handle (514). Secure in position with plugs
(518).
6. On pendants with emergency stop, install emergency stop button (164).
7. On pendants without emergency stop button, install plug (507).
8. Install exhaust washer (41) and secure in handle with retainer ring (512).
Adjustment:
1. a. Connect the inlet of the pendant to 100 psi (7 bar) air supply.
b. Connect a manometer at the outlet of the lever to be adjusted.
c. Apply a small amount of Loctite® No. 243 on the adjustment screw (521).
d. Tightentheadjustmentsetscrewtoobtainapressureof15psi(1bar)without
actioning the lever.
e. Release the adjustment setscrew by a half turn (pressure must fall to zero).
f. Pushthe lever.Checkthat pressurereaches 93+/-7psi (6.5+/- 0.5bar).Check
that there is no leak at the exhaust.
g. Release the lever; exhaust must occur and result in rapid pressure reduction.
h. Repeat operations ‘f’ and ‘g’ 2 to 3 times.
i. Disconnect the manometer. Check to ensure that there are no leaks when
the lever is not activated.
j. Repeat the operations from ‘b’ to ‘i’ with each lever.
nTesting
nOperational Tests
Prior to initial use, winches shall be tested to ensure proper operation.
1. Check guards are installed and secure.
2. Check all winch mounting bolts are secure.
3. Operate winch in both directions with no load.
4. Check operation of brakes and emergency stop.
5. Check operation of limit switches, slack line device, press roller and other safety
devices when provided.
nLoad Test
Prior to initial use, all new, extensively repaired, or altered winches shall be load
tested by or under the direction of an Ingersoll Rand trained technician and a
written report furnished confirming the rating of the winch. Test loads shall not be
less than 100% of rated line pull and should not exceed 125% of rated line pull. To
test winch at 125% of rated load, apply following load with wire rope on the first
layer of the drum:
NOTICE
• Testing to more than 125% of rated line pull may be required to comply
with standards and regulations set forth in areas outside of the USA.
12 Form MHD56305 Edition 4

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.
Form MHD56305 Edition 4 13

SERVICE NOTES
14 Form MHD56305 Edition 4

SERVICE NOTES
Form MHD56305 Edition 4 15

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