MODEL FA10i

Product
Maintenance
Information
Model
FA10i
(Dwg. MHP2947)
Save These Instructions
Form MHD56401
Edition 2
November 2007
45878600
© 2007 Ingersoll Rand Company
Only allow Ingersoll Rand trained technicians to perform maintenance on this product. For additional information contact Ingersoll Rand Factory or
nearest Distributor.
For additional supporting documentation refer to Table 1 ‘Product Information Manuals’ on page 2.
Manuals can be downloaded from www.winchandhoistsolutions.com.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and may invalidate all
warranties.
The original language of this manual is English.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
Table 1: Product Information Manuals

Publication Part/Document Number Publication Part/Document Number
Product Safety Information Manual (Non-Man Rider) MHD56250 Product Parts Information Manual MHD56400
Product Safety Information Manual (Man Rider) MHD56251 Product Information Manual MHD56399
INSPECTION
Frequent inspections should be performed on equipment in regular service. Refer to
Product Information Manual.
n Periodic 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 for 11. Emergency Stop Valve (optional feature). During winch operation verify the
continuing evaluation. Inspect all items listed in the ‘Frequent Inspection’ section of emergency stop valve operation. Valve must stop winch operation quickly. Valve
the Product Information Manual. Also inspect the following at the suggested intervals must reset properly. Refer to ‘Emergency Stop Valve’ in the “OPERATION” section
recommended in Table 3 ‘Maintenance Interval Chart’ on page 3: in Product Information Manual for procedures.
1. Siderails and Uprights. Check for deformed, cracked or corroded main 12. Overload Device (optional feature). Ensure overload device is properly set to
components. Replace damaged parts. stop the winch when loads exceed 150% (+/- 25%) of winch rated capacity. If
2. Fasteners. Check retainer rings, capscrews, nuts and other fasteners on winch, winch does not shut down, contact your distributor or the factory for repair
including mounting bolts. Replace if missing or damaged and tighten if loose. information.
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-crown throughout the life of the wire rope. Recording of the actual
diameter should only be done with the wire rope under equivalent loading
and in the same operating section as accomplished during previous
inspections. If the actual diameter of the wire rope has decreased more than
1/64 inch (0.4 mm) a thorough examination of the wire rope should be
conducted by an experienced inspector to determine the suitability of the
wire rope to remain in service. Refer to Dwg. MHP0056 on page 2.
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% rated load at mid drum without slipping. If indicated by poor (Dwg. MHP0056)
operation or visual damage, disassemble and repair brake(s). Check all brake 13. Press Roller (optional feature). Inspect rollers for wear and grooves. Ensure
surfaces for wear, deformation or foreign deposits. Clean and replace components rollers freely rotate. Replace rollers if worn or grooved. Replace bearings if
as necessary. Adjustments can be made to the band brake to compensate for rotation is rough or stiff.
normal brake lining wear. Refer to ‘Adjustments ’ on page 6. If brake band
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 n Records and Reports
as described in “MAINTENANCE” on page 6.
7. Foundation or Supporting Structure. Check for distortion, wear and continued
ability to support winch and rated load. Ensure winch is firmly mounted and that Inspection records, listing all points requiring periodic inspection should be
fasteners are in good condition and tight. maintained for all load bearing equipment. Written reports, based on severity of
8. Labels and Tags. Check for presence and legibility of labels. Replace if damaged service, should be made on the condition of critical parts as a method of documenting
or missing. periodic inspections. These reports should be dated, signed by the person who
9. Limit Switches (optional feature). Operate winch in both directions to activate performed the inspection, and kept on file where they are readily available for review.
limit switches. Limit switches should engage (stop winch operation) at
established settings (+/- 2 feet [+/- 0.6 metres]). Reset limit switch by operating
winch in opposite direction. Refer to ‘Limit Switch Adjustment’ procedure in n Maintenance Intervals
Product Information Manual.
10. Winch Guard (optional feature). Verify fasteners are tight and in good Refer to ‘Periodic Inspection’ on page 2 and Table 2 ‘Inspection Classifications’ on
condition. Ensure guard is in good condition and panels are correctly positioned. page 2 for maintenance interval guidance.
2 Form MHD56401 Edition 2

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.
1 year or 2 years or 3 years or 5 years or 6 years or 9 years or 12 years or
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 5,000 hrs 6,000 hrs 9,000 hrs 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
Standard Components
Inspect Motor X X X
Inspect Disc Brake 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
Overload Device X X X X X
Severe Application
Manual Band Brake Check band brake adjustment every 90 days or 250 hours
Standard Components
Inspect Motor X X X X
Inspect Disc Brake X 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
Overload Device X X X X
Note: Hours are for actual winch drum rotation.
Recommend complete general overhaul.
Form MHD56401 Edition 2 3

INSPECTION REPORT
Ingersoll Rand Force 5 Infinity Series Models FA10i Air Winches

Model Number: Date:
Serial Number: Inspected by:
Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection:
Operating Environment:
(_____ Months _____ Years)
2. Discrepancy(s) noted during Frequent Inspection
3. Discrepancy(s) noted during maintenance Normal ____ Heavy____ Severe ____
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.
CONDITION CORRECTIVE ACTION
COMPONENT NOTES
Pass Fail Repair Replace
Uprights and Siderails
Drum Band Brake (125% Load Test)
Drum Locking Pin
Disc Brake (125% Load Test)
Drum Band Brake (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.

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 60 psig (3.4
bar/340 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.
Disengage manual band brake, or refer to ‘Automatic Band Brake (optional feature)’
Drum brake does not release.
on page 6.
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 Brake is slipping. Check ‘Automatic Band Brake (optional feature)’ on page 6 and brake band lining
stopped. wear. Check brake friction disc wear.
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 Motor may be damaged. Remove and disassemble motor as described in “MAINTENANCE” on page 6.
rated capacity. Winch does not lift/pull Examine all parts and replace any that are worn or damaged.
load. 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).
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 Motor may be damaged. Disassemble and clean motor and replace any broken or damaged parts.
does not operate. Insufficient air supply. Ensure air pressure at winch inlet is at least 90 psig (6.3 bar/630 kPa) at rated
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 Damaged or broken piston or connecting rod. Disassemble and repair motor.
excessive noise during operation.
Motor runs hot or makes excessive noise Low oil level. Check oil level in motor. Add oil as required to obtain proper level.
during operation. 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 6. Inspect
all parts and replace all worn or damaged parts.
Brake(s) not releasing. Refer to brakes in “MAINTENANCE” on page 6.
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 Reverse valve sticking in bushing. Remove and disassemble control valve. Clean control valve parts and check clearance
not spring return to neutral. 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 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 “MAINTENANCE”
on page 6.

MAINTENANCE
3. Loosen nut (120) and turn adjustment screw (127) to provide 1/16 to 1/8 inch
WARNING (1.6 to 3.2 mm) gap between band lug and end of adjustment screw when brake
is applied.
• Never perform maintenance on the winch while it is supporting a load. 4. When correct gap is obtained, tighten nut (120).
• Before performing maintenance, tag controls: 5. Check brake band is partially lifted from drum diameter to reduce drag when brake
is not in use.
WARNING - DO NOT OPERATE, EQUIPMENT BEING REPAIRED.
CAUTION
• Only allow Ingersoll Rand trained Technicians to perform maintenance on this • When any part of brake lining thickness measures 0.062 inch (2 mm) or less,
winch. brake bands (128) must be replaced.
• 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 than
125% of rated line pull may be required to comply with standards and n Automatic Band Brake (optional feature)
regulations set forth in areas outside the USA.)
• Shut off air system and depressurize air lines before performing any Refer to Dwg. MHP2329.
maintenance. 1. Remove cotter pin (57) at link stud (56).
• Do not use Trichloroethylene to clean parts. 2. Apply air to brake cylinder (134) and remove pin (58) to disconnect link stud (56)
• Use of other than genuine Ingersoll Rand parts may result in safety hazards, from brake band (59).
decreased performance and increased maintenance and may invalidate all 3. Turn link stud (56) clockwise to increase cylinder rod extension. Turn link stud
warranties. (56) counterclockwise to decrease cylinder rod extension.
4. Assemble link stud (56) to brake band (59) with pin (58) and cotter pin (57).
Release air to brake cylinder (134).
NOTICE 5. Brake should hold rated load (refer to “INSPECTION” on page 2) when cylinder
(134) is retracted. Brake band should not drag on drum when cylinder us
This Product Maintenance Manual is intended for use on both a utility or Man extended.
Rider™ winch. Refer to Product Information and Safety Manuals for specific 6. Install cotter pin (57). Bend ends of cotter pin to secure link stud to brake band
information. when adjustment is complete.
7. With brake “On” adjust screw (127) to just touch brake band (59).
n General n Pendant Operated Pilot Control Valve (optional feature)
Correct disassembly (to prevent loss or damage of good parts), repair, assembly, Valve is set at factory. Refer to ‘Pendant Operated Pilot Control Valve Assembly’
testing and adjusting are critical to proper winch operation. Maintenance procedures on page 13 for adjustment procedure.
are technical in nature and require training and experience to accomplish correctly.
In addition, repair and testing require specialized equipment that is not typically n Overload Valve (optional feature)
found at the winch-mounting site.
Refer to Dwg. MHP2619 in Product Information Manual. A. Emergency Stop Button;
Proper use, inspections and maintenance increase the life and usefulness of your B. Push Down to Stop Winch Movement; C. Overload Valve Reset Button; D. Twist Red
Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and all Button to Reset; E. Overload Valve Adjustment Screw.
machined threads with applicable lubricants. Use of antiseize compound and/or
thread lubricant on capscrew and nut threaded areas prevents corrosion and allows A 5/16 inch or 8 mm open-ended wrench is required.
for easy disassembly of components.
Adjust overload valve by turning adjustment screw located at bottom of control valve.
It is extremely important that anyone involved with maintaining the winch be familiar - Rotating adjustment screw (clockwise) will increase pressure required to
with the servicing procedures of these winches and be physically capable of activate overload valve.
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. WARNING
2. Safety procedures, precautions and work habits established by accepted industry
standards. • This adjustment can cause overload device to NOT activate before winch's
safety limit is exceeded. This procedure should only be done by Ingersoll
Ingersoll Rand cannot know of or provide all the procedures by which product Rand trained Technicians.
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 - Rotating adjustment screw (counterclockwise) will decrease pressure required
manufacturer are conducted, it must be ensured that product safety is not endangered to activate overload valve.
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. n Limit Switch
Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.
NOTICE
• Refer to the Product Parts Information Manual for drawings unless specified
n Tensioning System
elsewhere.
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
n Maintenance Intervals adjusted to increase or decrease tension setting.
Regulator gauge and regulator are accessible through cover.
Refer to Table 3 ‘Maintenance Interval Chart’ on page 3 for recommended maintenance
schedule.
WARNING
• When adjusting regulator, ensure winch control lever is locked in neutral
n Adjustments position and tension selector lever is in the NORMAL position.
• Winch supply air is NOT shut off during regulator adjustments. To prevent
n Winch Guard accidental winch operation, allow only a single person, trained in operation,
safety and maintenance of this product, to conduct regulator adjustments.
Winch guard panels must be adjusted to suit wire rope departure angle. Adjust per Regulator Adjustment Procedure:
procedures in Product Information Manual. Refer to Dwg. MHP1865 in Product Information Manual.
1. Attach test load of desired weight to load line, or connect load line to scale.
n Disc Brake
WARNING
Disc brake adjustment is not required. If disc brake does not hold rated load • Ensure load line is connected to load and excessive slack is taken up before
disassemble and repair. activating auxiliary valve. When activated, auxiliary valve will automatically
If brake assembly is removed or disassembled ensure breather (23) is installed and engage and winch will operate at full speed to set tension on load line.
located at top of brake housing during reassembly.
2. Using winch control valve remove all slack from load line.
n Manual Band Brake (optional feature)
1. Release wire rope tension on drum.
2. Rotate handwheel (104) counterclockwise to release brake bands.

Setting with test load:
Actuate auxiliary valve to TENSIONING position. Winch should operate, causing load
WARNING
line to become taut. To increase tension, rotate regulator knob clockwise until load
begins to rise. Rotate regulator knob counterclockwise a minimum of 1/4 turn, or until • Air motor weighs approximately 260 lb. (118 kg). Adequately support air
load is balanced (does not raise or lower). Note pressure indicated on gauge for future motor before removing motor mounting capscrews.
setting reference.
11. For winches with a disc brake, remove tubing and fittings from control valve to
Setting with scale: brake housing (21).
12. Remove capscrews (4) and lockwashers (3) securing motor assembly to motor
Actuate auxiliary valve to TENSIONING position. Winch should operate, causing load adapter (6). Using a hoist to support motor, pull motor straight away from winch.
line to become taut. To increase tension, rotate regulator knob clockwise until scale Refer to ‘Motor Disassembly’ on page 7 if motor disassembly is required.
indicates desired tension. Note pressure indicated on gauge for future setting
reference. Instructions 13 through 21 apply only to winches with a disc brake.
13. Alternately and evenly loosen eight capscrews (2) until brake spring compression
n Disassembly is relaxed. Remove capscrews (2) and motor adapter (6).
14. Remove brake reaction plate (8) and springs (9).
n General Disassembly Instructions 15. Remove brake housing (21) and ‘O’ ring (15). If brake housing sticks, tap it with
a plastic mallet until parts separate.
The following instructions provide necessary information to disassemble, inspect, 16. Remove seal sleeve (14). Remove ‘O’ ring (13) from inside seal sleeve (14).
repair, and assemble product. Parts drawings are provided in Product Parts 17. Pull out input shaft (7) with geared hub (19).
Information Manual. 18. Remove seven friction plates (16) and eight drive plates (17).
If a product is being completely disassembled for any reason, follow the order of 19. Remove brake piston (10) from brake housing (21). Tap lightly with a plastic
topics as they are presented. It is recommended that all maintenance work on product mallet to separate parts if necessary.
be performed in a clean dust-free work area. 20. Remove seals (11) and (12) from brake piston (10).
In the process of disassembling product, observe the following: 21. Remove retainer ring (38) from input shaft (7) and remove geared hub (19).
1. Never disassemble product any further than is necessary to accomplish needed 22. Remove retainer ring (36) and bearing (37) from inside drum shaft (41). Tap with
repair. A good part can be damaged during the course of disassembly. a plastic mallet if necessary.
2. Never use excessive force when removing parts. Tapping gently around perimeter 23. If coupling (49) came out with input shaft (7) remove at this time. If not, reach
of a cover or housing with a soft hammer, for example, is sufficient to break the into drum shaft (41) and remove coupling (49). Remove retainer ring (45) from
seal. inside coupling (49).
3. Do not heat a part with a flame to free it for removal, unless part being heated 24. Support drum (96).
is already worn or damaged beyond repair and no additional damage will occur 25. Remove capscrews (119) and lockwashers (117) which secure siderails (98) to
to other parts. inboard upright (42). Drive out dowel pins (183).
26. Remove inboard upright (42).
In general, products are designed to permit easy disassembly and assembly. The use 27. Remove capscrews (39) from drum shaft (41). Drive out dowels (62). Pry drum
of heat or excessive force should not be required. shaft (41) from upright (42).
28. Remove ‘O’ ring (43).
4. Keep work area as clean as practical, to prevent dirt and other foreign matter 29. Remove capscrews (582) and lockwashers (306).
from getting into bearings or other moving parts. 30. Tap end cover (193) loose and remove.
5. All seals, gaskets and ‘O’ rings should be discarded once they have been removed. 31. Remove capscrews (192) and bearing retainer (191).
New seals and ‘O’ rings should be used when assembling product. 32. Remove remaining capscrews (119) and lockwashers (117) that attach siderails
6. When grasping a part in a vise, always use leather-covered or copper-covered vise (98) to outboard upright (184). Drive out remaining dowel pins (183) and remove
jaws to protect the surface of part and help prevent distortion. This is particularly siderails (98).
true of threaded members, machined surfaces and housings. 33. Pull outboard upright (184) away from drum (96).
7. Do not remove any part which is a press fit in or on a subassembly unless removal 34. Remove bearing (188).
of that part is necessary for repairs or replacement. 35. Position drum (96) vertically (with reduction gear assembly facing up).
8. When removing ball bearings from shafts, it is best to use a bearing puller. When 36. Remove capscrews (63) holding adapter (52) onto drum.
removing bearings from housings, drive out bearing with a sleeve slightly smaller 37. Install two 1/2 inch - 13 NC x 2 inch capscrews into threaded holes in outer bolt
than outside diameter of bearing. The end of sleeve or pipe which contacts pattern ring of adapter (52). Use these capscrews as jacking bolts to break seal.
bearing must be square. Protect bearings from dirt by keeping them wrapped in Attach suitable lifting eyes to these bolts and lift reduction gear assembly out of
clean cloths. drum and place on a clean work surface.
38. Remove all plugs (406) from reduction gear.
39. Remove capscrews (50) and nuts (48). Using a hammer and punch, tap spring
pins (40) into support (405). With a plastic mallet, tap adapter (52) until it is
n Winch Disassembly free of support (405).
40. Replace plugs (406) and loosely tighten.
NOTICE
n Winch Guard Disassembly
• Remove band brake if equipped. Refer to ‘Manual Band Brake (optional
feature)’ on page 6 and ‘Automatic Band Brake (optional feature)’ Refer to Dwg. MHP2945.
on page 6 for specific instructions. 1. Remove capscrews (197) and washers (117) securing lifting lugs (194) to
uprights.
Refer to Dwgs. MHP0875, MHP1007, MHP2944 and MHP2948. 2. Remove panels (805) and (807) one section at a time, by removing nuts (804)
1. Remove wire rope from drum. and crossbars (806).
2. Operate winch to position reduction gear drain plug at its lowest position. 3. Remove capscrews (408) and washers (306) that secure panels (801), (802), (803)
3. Relieve pressure in air lines by operating winch control several times after air and (810) to winch uprights.
supply has been turned off. 4. Remove guards.
WARNING n Motor Disassembly
• Shut off, bleed down and disconnect air supply line before performing any Refer to Dwg, MHP1007.
disassembly procedures. 1. Remove five capscrews (253) from exhaust flange (254).
• The weight of a winch with a 24 inch (610 mm) long drum and no wire rope 2. Remove rotary valve housing (247) by pulling it out of motor housing (217) as
is 3550 lb. (1610 kg). Exercise caution when lifting and moving winch. an assembly with exhaust flange (254).
4. Disconnect and tag air lines. CAUTION

5. Remove winch from its mounting and take to a suitable work area before
beginning disassembly. • Do not remove exhaust flange (254) until rotary valve (250) has been
6. Remove lower case pipe plug (218) on motor housing (217) and allow oil to drain removed from rotary valve housing (247).
into a suitable container and dispose of in an environmentally safe manner.
Loosen vent cap (210) to vent motor housing. 3. Remove rotary valve (250) by pulling it out from assembly through motor housing
7. Drain oil from reduction gear assembly by removing one plug (406) when end of rotary valve housing (247).
positioned at its lowest point and one plug (406) from its highest point to vent. 4. Remove exhaust flange (254), capscrews (551), lockwashers (549) and control
Refer to Dwg. MHP0567 in Product Information Manual. If winch is equipped with valve assembly (500).
a band brake, elevate the winch outboard end (opposite from motor end) to 5. Remove each cylinder (201) by removing four capscrews (200). Remove head
prevent draining oil from contaminating brake band lining. gasket (209) and discard.
8. For winches with a disc brake, remove pipe plug (24) in brake housing (21) to 6. Remove mounting flange (216) by removing capscrews (4) and lockwashers (3),
drain brake oil. and then pulling mounting flange straight off.
9. Remove band brake, winch guard and any other externally mounted winch 7. Position one piston (204) at top of its stroke. In this position, wrist pin (203)
attachments. can be removed. Remove one retainer ring (205) from either side of piston (204).
10. Refer to ‘Winch Guard Disassembly’ on page 7. Push wrist pin (203) out by hand from one side. If wrist pin is too tight it is
a. Remove panels (805) and (807), one section at a time, by removing locknuts acceptable to carefully heat piston to 200°F (93°C) or less and then push wrist
(804) and crossbars (806). pin out.
b. Remove capscrews (197) and washers (117) securing lifting lugs (194) to
uprights.
c. Remove capscrews (408) and washers (306) securing guards (801), (802),
(803) and (810) to uprights (42) and (184).

3. Move reverse valve (943) out exhaust flange side of valve housing (917) until ball
NOTICE (916) is visible on reverse valve. Allow ball (916) to drop out of bushing (944)
and remove ball.
• If piston, wrist pin, connecting rod or cylinder head are to be reassembled, 4. Remove bushing (944) from exhaust flange side of housing.
number each set. Add radial alignment marks for each piston and cylinder
head to motor housing. NOTICE
8. Remove remaining pistons as described in step 7 as required. To remove crank
assembly, all pistons and cylinder heads must be removed. • Dowel pin (945) allows the bushing (944) to be removed only from the
9. Crank assembly (231) can now be removed, with oil slinger (230), by pulling exhaust flange side of housing. Ball (916) retains reverse valve (943) in
straight out from motor housing (217). Use care while guiding connecting rods bushing.
(206) through inside of motor housing. • Do not remove reverse valve (943), bushing (944) and ball (916) at the same
time; damage may occur to bushing.
Crankshaft Disassembly: • Take care to not allow ball (916) to drop into motor. If this occurs it may be
1. Remove cotter pin (236) and pin nut (237). necessary to disassemble motor to retrieve ball.
2. Remove lock pin (235) by carefully driving it out of its location. Use care not to
damage threads. Piston Removal:
3. Pull crankshaft valve end (231) off the crankshaft. Follow disassembly instructions in ‘Control Valve Disassembly’ on page 8.
4. Remove connecting rod rings (234), bushing (233), sleeve (232) and connecting
rods (206). Record the five connecting rod (206) numbers and foot directions so Pilot Valve Removal:
they can be reinstalled in the same order. Follow disassembly instructions in ‘Control Valve Disassembly’ on page 8.
5. Oil slinger (230) does not have to be removed unless damaged. If removal is
required, heating of the five screws (229) may be required to loosen Loctite® Emergency Stop Removal:
connection. 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.
n Control Valve Disassembly
Overload Valve Removal:
Refer to Dwg. MHP2696. 1. Unscrew cap (700). Remove and discard grommet (701).
2. Pull out plunger (702), remove and discard ‘O’ rings (703).
Handle Removal: 3. Remove capscrews (901) and washers (902) from cover (719) underneath valve
Handle disassembly is not recommended. housing (917).
1. Carefully pry off plug (935).
2. Remove capscrew (901) and tablock washer (909).
NOTICE
NOTICE • Cover (719) retains spring (718). To remove capscrews (901) and washer
(902), unscrew in a crisscross pattern.
• Observe spring (937) connection during disassembly. This spring is under
tension and is required to return handle to neutral position. 4. Remove adjusting screw (720) and ‘O’ ring (716).
5. Remove adjusting nut (717), plate (715), gasket (714), ‘O’ ring (713) and piston
3. Carefully pull handle assembly (930) from reverse valve (943). Remove spring (712) from valve housing (917). Discard gasket (714) and ‘O’ ring (713).
(937).
Reverse Valve Removal: n Pendant Operated Pilot Control Valve Disassembly (optional
1. Remove buttonhead screws (938), capscrews (925) and washers (924) from seal feature)
bracket (939). Remove seal bracket from valve housing (917). Remove and discard
‘O’ rings (941) and (942). Refer to Dwg. MHP2969.
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 CAUTION
visible on reverse valve. Allow ball (916) to drop out of bushing (944) and remove
ball. • Do not disassemble control valve.
4. Remove bushing (944) from exhaust flange side of housing. • Contact an Ingersoll Rand Service Center for repair.
NOTICE n Manual Band Brake Disassembly (optional feature)

• Dowel pin (945) allows the bushing (944) to be removed only from the Refer to Dwg. MHP0627.
exhaust flange side of housing. Ball (916) retains reverse valve (943) in 1. Remove nuts (102), lockwashers (103) and U-bolts (109).
bushing. 2. Remove nut (110), handwheel (104), bearing (111) and tube (112).
• Do not remove reverse valve (943), bushing (944), and ball (916) at the 3. Pull out brake screw (114). Catch spring (113) as brake screw clears.
same time; damage may occur to bushing. 4. Remove capscrews (116) and lockwashers (117). Remove anchor (118) and plate
• Take care to not allow ball (916) to drop into motor. If this occurs it may be (122).
necessary to disassemble motor to retrieve ball. 5. Remove capscrews (119) and washers (117). Remove support (126).
6. Slide brake band halves (128) off drum (96).
Piston Removal: 7. Remove capscrews (124), washers (123) and nuts (115) and separate brake band
1. Remove capscrews (901) and washers (902) from piston cover (919). Remove halves.
cover and discard gasket (918).
2. Remove capscrews (901) and washers (902) from poppet cover (903). Remove
cover and discard gasket (904).
n Automatic Band Brake Disassembly (optional feature)
3. Remove the following items from housing poppet bore: poppet spring (905), Refer to Dwg. MHP2329.
poppet cap (906) and poppet seal (907). 1. Disconnect and remove hose, fittings and exhaust valve (71) from cylinder (134).
4. From poppet side, push piston (922) out of valve housing (917). Remove ‘O’ rings 2. Remove cotter pin (57) and pin (58) from link stud (56) and brake band (59).
(921) and (923) and discard. 3. Remove cotter pin (44) and pin (46). Separate clevis (51) from lever arms (34)
and (61).
Pilot Valve Removal: 4. Remove nuts (60), washers (32) and capscrews (25) from lever arms (34) and
NOTICE (61).
5. Remove spacers (35), bushings (54) and pivot nuts (55).
6. Remove cotter pin (44) and pin (65) from bracket (74). Remove cylinder (134)
• For easier removal, it is recommended to use Ingersoll Rand pilot valve tool from bracket (74).
(920). This must be purchased separately. 7. Remove capscrews (67) and (116) and lockwashers (117). Remove anchor (118),
bracket (74) and plate (122).
If pilot valve is not damaged, it is not necessary to disassemble completely. 8. Remove capscrews (119) and washers (117). Remove support (126).
1. Remove plug (912). 9. Slide brake band halves (128) off drum (96).
2. Remove pilot valve assembly (910) as an assembly. 10. Remove capscrews (124), washers (123) and nuts (115) and separate brake band
3. Discard and replace pilot valve assembly (910) if necessary. halves.
n Emergency Stop and Overload Control Valve Disassembly CAUTION

Refer to Dwg. MHP2697. • It is not recommended to disassemble cylinder (134) due to extreme
Handle Removal: pressure of loaded spring. Contact factory for service.
Follow disassembly instructions in ‘Control Valve Disassembly’ on page 8.
n Reduction Gear Disassembly
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 NOTICE
‘O’ rings (941) and (942).
2. Remove capscrews (721), washers (902), exhaust flange (955) and exhaust • It is extremely important to maintain a clean work area when reduction gear
adapter (723). Remove and discard ‘O’ rings (942) and (722). assembly is disassembled.
• Disassembly is not recommended. If it is unavoidable, use the following
steps.

1. Place reduction gear assembly on a clean work bench. Have a couple of wooden NOTICE
blocks available to prevent assembly from rolling around. There will also be a
small amount of oil remaining in housing so have some absorbent material readily • It is not recommended to disassemble limit switch. Contact factory if repair
available. is required.
2. Using a hammer and punch, drive spring pins (404) in, until they are completely
in input housing (424). 1. Remove and tag hose connection if not already done.
3. Remove capscrews (401) and, using a plastic mallet, tap seal support (400) until 2. Remove capscrews (97) and washers (96) that secure limit switch assembly to
loose and remove. upright (84).
4. Remove oil seal (402) and ‘O’ ring (403). 3. Store limit switch assembly in a clean, dry area until winch reassembly.
5. Remove capscrews (425).
6. Using a plastic mallet, tap support (405) and ring gear (409) to separate.
7. Remove ‘O’ ring (408) and bearing (407). n Cleaning, Inspection and Repair
8. Pull out planetary support (410) assembly.
9. From planet gear side reach into planetary support hub and remove retainer ring
(420). Spacer (422) may be on shaft (445) or still in spacer (418). Remove at this n Cleaning
time.
10. Push spacer (418) out of planetary support and remove ‘O’ ring (419). Clean all product component parts in solvent (except brake bands and disc brake
friction plates). The use of a stiff bristle brush will facilitate removal of accumulated
NOTICE dirt and sediments in the reduction assembly, on housings, frame and drum. Dry each
part using low pressure, filtered compressed air. Clean brake band using a wire brush
• Do not disassemble planetary gears from their housings unless required to or emery cloth. Do not wash brake band in solvent. If brake band lining is oil soaked,
replace damaged parts. Disassembly directions 11 and 12 apply only to it must be replaced.
planetary gears (415) housed in planetary support (410). For information
on other planetary assemblies (430 and 440) contact your Ingersoll Rand n Inspection
distributor or the factory.
All disassembled parts should be inspected to determine their fitness for continued
11. Place planetary support (410) in a container. Holding the planet gear (415) with use. Pay particular attention to the following:
one hand, slowly push planet gear shaft (417) out of support. Carefully remove 1. Inspect all gears for worn, cracked, or broken teeth.
planet gear. When thrust bearings (413) become free squeeze together with 2. Inspect all bushings for wear, scoring, or galling.
fingers. Once spring pins (412) are free they may fly out or roller bearings (414) 3. Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent
might start to fall out. Remove planet gear assembly and carefully place in on shafts, replace shaft. Inspect all surfaces on which oil seal lips seat.
container. 4. Inspect all bearings for play, distorted races, pitting and roller or ball wear or
12. Slide thrust bearings (413) off ends of planet gear (415) and push out all roller damage. Inspect bearings for freedom of rotation.
bearings (414) into container. 5. Inspect all threaded items and replace those having damaged threads.
13. Separate ring gear (409) from input housing (424) and remove ‘O’ ring (408). 6. Inspect band brake lining for oil, grease and glazing. If band brake lining is oil-
14. Remove spacer (423). soaked replace brake bands as a set. Remove glazed areas of band brake lining
15. Remove capscrews (439). by sanding lightly with a fine grit emery cloth.
16. Separate input housing (424) from ring gear (436) and remove ‘O’ ring (434). 7. Measure thickness of band brake lining. If brake band linings are less than 0.062
17. Remove retainer ring (427) from input housing (424) and pull out cylinder roller inch (2 mm) thick anywhere along edges replace brake bands as a set.
bearing (426). 8. Inspect cylinder bores. Minor scratches in bore lining may be repaired by lightly
18. Remove sun gear (429) and spacer (428). Separate the two. honing to remove. Refer to tolerances listed below for acceptable clearances.
19. Remove planetary assembly (430). Replace liner if deep scratches or gouges are apparent. Measure inside diameter
20. Remove sun gear (433) and spacer (422). Separate the two. of liner. If measurement is greater than 4.764 inches (121 mm) replace liner.
21. Remove retainer ring (435) from sun gear (433). ‘Ring Gap’ may also be used to determine wear; place compression ring into liner,
22. Tap out spring pins (437). Separate ring gear (436) from input housing (438) and using a piston, push ring until approximately half way in liner and measure ‘Gap’
remove ‘O’ ring (434). — 0.003 inch (0.076 mm) is normal; replace rings, or liner, if ‘Gap’ exceeds 0.020
23. Tap out spring pins (443). Remove capscrews (448) and separate input housing inch (0.51 mm).
(438) from ring gear (444) and end cover (446). 9. Inspect the drive plates for warpage or other damage, and replace damaged parts
24. Remove planetary assembly (440) and ‘O’ ring (442). as necessary. Replace the input pinion shaft oil seal.
25. Remove ‘O’ ring (442) and shaft (445). 10. Measure the thickness of the brake friction disc. The brake friction disc must show
26. Remove capscrews (452) and separate front cover (450). Remove thrust plate an even wear pattern. If the brake friction disc is 0.076 inch (1.93 mm) or less,
(449) and gasket (447). replace the disc.
27. Remove adjusting screw (453).
n Repair
n Press Roller Disassembly (optional feature)
Actual repairs are limited to removal of small burrs and other minor surface
Refer to Dwg. MHP2945. imperfections from gears and shafts. Use a fine stone or emery cloth for this work.
1. Compress the ends of springs (405) and (406) to disengage from siderail (98) and Do not use steel wool.
pins (413) on press roller arm (407). 1. Worn or damaged parts must be replaced. Refer to the applicable parts list in the
2. Loosen collars (404). Product Parts Information Manual for specific replacement parts information.
3. Remove capscrews (408) and washers (409) from both ends of shaft (403), and 2. Inspect all remaining parts for evidence of damage. Replace or repair any part
carefully slide shaft (403) through hole in upright (42). Press roller assembly which is in questionable condition. Cost of the part is often minor in comparison
(400) will fall away from shaft (403). with cost of redoing job.
4. It is not necessary to remove bushings (410) unless replacing. 3. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings.
5. Remove springs (405) and (406) from press roller arm (407). 4. Examine all gear teeth carefully, and remove nicks or burrs.
6. Remove capscrews (408), washers (409) and rollers (401) from shaft (411). 5. Polish edges of all shaft shoulders to remove small nicks which may have been
7. Remove shaft (411) and center roller (402) from press roller arm (407). caused during handling.
6. Remove all nicks and burrs caused by lockwashers.
n Drum Locking Pin Disassembly (optional feature) 7. Replace all gaskets, oil seals, and ‘O’ rings removed during product disassembly.

1. Remove capscrews (305) and washers (306) to separate drum locking pin assembly n Assembly
from winch upright (184).
2. Unscrew drum lock pin (312) from shaft (304). Separate spring (310), drum lock n General Instructions
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. • Use all new gaskets and seals.
• Replace worn parts.
• Assemble parts using matchmarks attached during disassembly. Compare
n Two Function Pendant Disassembly (optional feature) replacement parts with originals to identify installation alignments.
• Lubricate all internal parts with rust and oxidation inhibiting lubricant, ISO
Refer to Dwg. MHP1677 or MHP2346. VG 100 (SAE 30W).
1. Remove fittings (348) and lifting eye (440). • Apply a light coat of Loctite® 243 to all threaded components prior to
2. Unscrew plugs (444). Remove springs (445) and balls (446). assembly, unless otherwise specified.
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 n Control Valve Assembly
(451). Discard ‘O’ rings.
6. Remove plug (470) or emergency stop valve (441) from pendant handle. Refer to Dwg. MHP2696.
7. Remove retainer ring (458) and exhaust washer (457).
Reverse Valve Assembly:
n Limit Switch Disassembly (optional feature) 1. Insert reverse valve (943) into bushing (944) with ball slot oriented UP,
approximately 2-1/2 inches (64 mm).
2. Insert bushing (944) and reverse valve (943) into valve housing (917) from
Refer to Dwg. MHP2677. exhaust flange side, ensuring that groove in bushing is aligned with dowel pin
(945).
3. Apply grease to ball (916) and insert into reverse valve platform. With finger,
push ball (916) in housing until ball hits end of reverse valve.

4. Holding ball (916) in position on reverse valve platform, rotate reverse valve from Piston Assembly:
neutral position to approximately 45 degrees in either direction. Ball will ‘walk’ Follow assembly instructions in ‘Control Valve Assembly’ on page 9.
up side of reverse valve platform and move in ball hole in bushing (944).
Handle Assembly:
NOTICE Follow assembly instructions in ‘Control Valve Assembly’ on page 9.
• Do not rotate reverse valve past a 90 degree position; it may result in ball Emergency Stop Assembly:
(916) falling into motor. 1. Insert spring (711) into valve housing (917).
2. Place ‘O’ rings (703) on plunger (707).
5. Slowly push reverse valve, while still in the 45 degree position, the rest of the 3. Insert plunger into valve housing.
way in housing until flush with surface. From other side of valve, rotate reverse 4. Screw adapter (706) and E-Stop button (705) into valve housing.
valve back to neutral position. Ball should be seated in ball slot at that time. 5. Tighten adapter until snug; do not over tighten.
6. Lubricate ‘O’ ring (942) and place into groove in exhaust flange (955).
7. Secure exhaust flange (955) to valve housing (917) with capscrews (901) and Overload Valve Assembly:
washers (902). 1. Replace ‘O’ rings (703) on plunger (702).
8. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’ ring (942) and place in 2. Insert plunger (702) with ‘O’ rings in valve housing (917).
groove in seal bracket. 3. Replace grommet (701) in cap (700).
9. Place seal bracket over end of reverse valve. Using finger pressure, press until 4. Install and tighten cap (700) flush to valve housing.
seal is seated on reverse valve and seal bracket is seated on valve housing. Secure 5. Replace piston (712) if it appears damaged or worn.
with washers (924), capscrews (925) and buttonhead screws (938). 6. Insert ‘O’ ring (713) on piston (712).
7. Replace gasket (714).
Pilot Valve Assembly:
NOTICE NOTICE
• Cover (719) retains spring (718), adjustment nut (717) and plate (715).
• For easier installation, it is recommended to use Ingersoll Rand pilot valve Insert capscrews (901) and washers (902) in a crisscross pattern until
tool (920). This must be purchased separately. tightened evenly.
1. Install pilot valve assembly (910). 8. Insert adjusting screw (720). Refer to “OPERATION” section ‘Overload Device’ in
2. Apply thread sealant Loctite® 567 to pilot valve assembly (910) and place pilot Product Information Manual for adjustment.
valve assembly into valve housing (917). Use a large flat-tipped screwdriver to 9. Secure control valve assembly to intake manifold using capscrews (951) and
engage slots in pilot seat to tighten until pilot assembly is 1/8 inch (3.175 mm) washers (949). Use new gaskets (946) between control valve and manifold.
from housing bore. 10. Test control valve for proper operation. Lift slide handle and move handle all the
3. Insert plug (912) and tighten. way in one direction and release hand. Control handle should return and lock in
the neutral position. Repeat for other direction.
Piston Assembly: 11. Connect brake line.
1. Lubricate and install ‘O’ rings (921) and (923) on piston (922). 12. Connect air supply line.
2. Insert assembled piston into valve housing (917) from handle side.
3. Secure gasket (918), piston cover (919) and washers (902) with capscrews (901).
4. Place poppet seal (907) into poppet cap (906). Place this assembly into valve n Motor Assembly
housing and seat on piston (922).
5. Place spring (905) over this assembly. Refer to Dwg. MHP1007.
6. Secure with gasket (904), poppet cover (903), washers (902) and capscrews
(901). Crankshaft Assembly:
1. If removed, press crank bearing (228) on crank shaft assembly (231). Press only
Handle Assembly: on inner race of bearing.
1. Place spring (937) over reverse valve handle end in seal bracket (939). 2. Place crank assembly (231) on a work bench with oil slinger (230) down and slide
sleeve (232) (with tang up) on crankpin.
3. Slide bushing (233) over sleeve (232) and first connecting rod ring (234) with
NOTICE chamfer up.
4. Install connecting rods (206) in same order as removed, with all feet pointing in
• Spring (937) will have to be 'cocked' over stud in bracket. This will ensure same direction, using first connecting rod ring (234) to hold one side of
handle returns to neutral. connecting rod feet.
5. Slide second connecting rod ring (234) over other side of connecting rod feet
2. Install handle assembly (930) over reverse valve end. Handle will have to be lifted with chamfer on ring facing down (toward stem of connecting rod).
slightly to allow pin to fit into slot in seal bracket (939). 6. Slide crank shaft (231) (valve end) over crankpin while simultaneously aligning
3. Secure handle assembly (930) to reverse valve with tab lockwasher (909) and tang on sleeve (232) with slot in crank shaft.
capscrew (901). Refer to “TORQUE CHART” on page 15 for torque requirements. 7. Rotate and position crank shaft (valve end) relative to crankpin to allow
Washer (909) has small tab on side; engage with small hole in handle. installation of lock pin (235).
4. Bend tabs of washer (909) over flats of capscrew. 8. Tap lock pin (235) in place and install pin nut (237). Refer to “TORQUE CHART”
5. Press plug (935) into handle assembly to cover capscrew. Check control handle on page 15 for torque requirements.
movement. Correct any discrepancies. 9. Install cotter pin (236).
10. Install roll pin (240) and bearing (228) into valve end of crank shaft.
n Emergency Stop and Overload Control Valve Assembly 11. Check that all connecting rods move freely around crank.
Refer to Dwg. MHP2697. Motor Body Assembly:

1. Position crank assembly (231) in motor housing (217) with bearing (228) seated
Reverse Valve Assembly: and connecting rods (206) centered in cylinder holes.
1. Insert reverse valve (943) into bushing (944) with ball slot oriented UP, 2. Assemble throttle valve assembly (500), gaskets (546) and exhaust flange (254)
approximately 2-1/2 inches (64 mm). to rotary valve housing (247) using four capscrews (551) and lockwashers (549).
2. Insert bushing (944) and reverse valve (943) into valve housing (917) from 3. Install bearing (252) on rotary valve (250) by pressing only on inner race of
exhaust flange side, ensuring that groove in bushing is aligned with dowel pin bearing. With exhaust flange (254) down, install rotary valve (250) into rotary
(945). valve housing (247). Slide rotary valve out of rotary valve housing far enough to
3. Apply grease to ball (916) and insert into reverse valve platform. With finger, install seal ring (251) on crank shaft end of rotary valve (250). Slide rotary valve
push ball (916) in housing until ball hits end of reverse valve. back into rotary valve housing (247).
4. Holding ball (916) in position on reverse valve platform, rotate reverse valve from 4. Install ‘O’ ring (244) into motor housing (217).
neutral position to approximately 45 degrees in either direction. Ball will ‘walk’ 5. Install rotary valve housing gasket (243) onto rotary valve housing (247). With
up side of reverse valve platform and move in ball hole in bushing (944). exhaust flange down on bench, install motor housing (217) on to rotary valve
housing (247). Check for any evidence of damage to ‘O’ ring (244) when rotary
NOTICE valve housing is fully engaged. Install capscrews (253). Refer to “TORQUE CHART”
on page 15 for torque requirements.
• Do not rotate reverse valve past a 90 degree position; it may result in ball
(916) falling into motor. NOTICE
5. Slowly push reverse valve, while still in the 45 degree position, the rest of the • Make certain that roll pin (240) and three lugs on rotary valve (250) line up
way in housing until flush with surface. From other side of valve, rotate reverse with corresponding hole and lugs on crank shaft.
valve back to neutral position. Ball should be seated in ball slot at that time. • Do not allow rotary valve (250) to slide back in rotary valve housing (247).
6. Lubricate ‘O’ rings (942) and (722), and place in grooves in exhaust adapter (723). If rotary valve slides in too far, seal ring (251) will lock up in internal grooves
7. Lubricate ‘O’ ring (942) and place in groove in exhaust flange (955). of rotary valve housing (247) and restrict further assembly.
8. Secure exhaust adapter (723) with exhaust flange (955) to valve housing (917)
with capscrews (721) and washers (902). 6. Rotate crank assembly to position one connecting rod (206) at the top of its
9. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’ ring (942) and place stroke. Install a piston (204) with its rings (202) and (207) to connecting rod
into groove in seal bracket. (206) with wrist pin (203) and retainer rings (205). Refer to Dwg. MHP0224
10. Place seal bracket over end of reverse valve. Using finger pressure, press until on page 11 for oil and compression ring installation. A. Piston Head; B.
seal is seated on reverse valve and seal bracket is seated on valve housing. Secure Compression Ring Groove; C. Ends of compression rings must be staggered to
with washers (924), capscrews (925) and buttonhead screws (938). avoid alignment with wrist pin opening and ends of oil ring; D. Colored ends of
oil ring must butt together and must not overlap; E. Install one compression ring
Pilot Valve Assembly: on either side of oil ring; F. Wrist pin opening.
Follow assembly instructions in ‘Control Valve Assembly’ on page 9. 7. Install a new cylinder head gasket (209) before installing cylinder (201).

8. Install cylinder (201) over piston (204) by compressing both piston rings (202) 7. Slide shaft (445) into planetary assembly (440). Insert this assembly into ring
and (207). Secure cylinder head to motor housing (217) with four capscrews gear (444).
(200). Refer to “TORQUE CHART” on page 15 for torque requirements. 8. Align spring pins (443) with input housing (438) and press down.
9. Repeat Steps 6 through 9 with remaining cylinders. 9. Insert capscrews (448) through end cover (446) and into input housing (438).
10. Rotate motor by hand. Motor should rotate without binding. Refer to “TORQUE CHART” on page 15 for torque requirements.
11. Press bearing (228) into motor side of mounting flange (216). 10. Lubricate and install new ‘O’ ring (434) into groove on input housing (438). Apply
12. Install mounting flange (216) and gasket (226) on large base side of motor a bead of Loctite® 515 sealant to mating surface.
housing (217). Make sure notches on both parts are aligned. Temporarily secure 11. Align ring gear (436) with spring pins (437) and press down.
parts with one capscrew (4), lockwasher (3) and a 1/2-NC nut. 12. Install retaining ring (435) onto sun gear (433) and slide down shaft (445) into
13. Lightly lubricate ‘O’ ring (5) and install in groove on motor adapter (6). planetary assembly (440).
13. Install spacer (422) into sun gear (433).
NOTICE 14. Install planetary assembly (430) into ring gear (436).
15. Slide sun gear (429) onto shaft (445) and into planetary assembly (430). Insert
• ‘O’ ring (5) listed in step 13 refers to part number 51459 as shown on winch spacer (428) into sun gear (429).
assembly Dwg. MHP2948 in the Parts Information Manual. This part must be 16. Insert bearing (426) into input housing (424). Install retainer ring (427).
placed between mounting flange (216) and motor adapter (6). 17. Lubricate and install new ‘O’ ring (434) into groove on input housing (424). Apply
a bead of Loctite® 515 sealant to mating surface.
14. Install eye bolts (213) and vent cap assembly (210) in motor housing (217). 18. Align spring pins (437) with input housing (424) and press down.
15. Ensure oil drain and level plugs (218) are installed. 19. Insert capscrews (439) through input housing (438) and into input housing
(424). Refer to “TORQUE CHART” on page 15 for torque requirements.
20. Insert spacer (423) into input housing (424) with bevel facing housing.
21. Lubricate and install new ‘O’ ring (419) onto outer groove on spacer (418). Insert
spacer (422) into center recess in spacer (418). Place this assembly into planetary
Piston Head A support (410) from planet gear end.
22. Insert retainer ring (420) in planetary support to hold spacer assembly in place.
23. Lubricate and install new ‘O’ ring (408) into groove in input housing (424). Apply
a bead of Loctite® 515 sealant to mating surface.
24. Align ring gear (409) with spring pins (404) and push down.
Compression Ring Groove B 25. Insert planetary support assembly into ring gear (409).
26. Lubricate and install new ‘O’ ring (408) into groove in support (405). Apply a bead
of Loctite® 515 sealant to mating surface.
27. Align support (405) with spring pins (404) and push down.
28. Insert capscrews (425) through input housing (424) into support (405). Refer to
“TORQUE CHART” on page 15 for torque requirements.
29. Insert ball bearing (407) into support (405).
Ends of compression rings 30. Insert oil seal (402) into seal support (400) (lip facing out).
must be staggered to avoid 31. Lubricate and install new ‘O’ ring (403) in groove in support (405). Apply a bead
alignment with wrist pin of Loctite® 515 sealant to mating surface.
opening and ends of oil ring C 32. Align bolt holes with seal support (400) and support (405).
33. Insert capscrews (401) through seal support, into support and tighten.
34. Turn adjusting screw (453) in until end play is eliminated, then back it out two
turns.
Wrist pin opening F
n Drum Assembly
Colored ends of oil ring Refer to Dwgs. MHP2948 and MHP0875.

must butt together,
and must not overlap D NOTICE
• During assembly of components apply a light coat of Loctite® 242 to all
threaded fasteners.
• Clean all mating surfaces. ‘O’ rings can be held in place with a coating of EP
grease applied to groove.
Install one compression 1. Position drum (96) in vertical position, with reduction gear side facing up.
ring on either side of oil ring E 2. Remove plugs (406) from reduction gear support (405). Apply a bead of Loctite®
515 sealant on reduction gear surface that mates with adapter (52).
3. Place adapter (52) on reduction gear and align bolt holes. There is one place on
adapter with no hole. This should be positioned over one of plug (406) holes.
This becomes the drain/fill location (other 3 plugs will be blocked). Install
capscrews (50) through adapter (52) and attach nuts (48). Refer to “TORQUE
(Dwg. MHP0224) CHART” on page 15 for torque requirements. With a hammer and punch, drive
spring pins (404) into adapter (52) until about 1/16 inch (1.5 mm) below surface.
4. Apply a bead of Loctite® 515 sealant to surface of drum (96) where adapter (52)
n Reduction Gear Assembly will mate.
5. Install two 1/2 inch - 13 NC x 2 inch capscrews with suitable lifting eyes into
Refer to Dwg. MHP0875. threaded holes in outer bolt pattern ring of drum adapter (52). Lift reduction gear
assembly into drum (96). Align bolt holes and install capscrews (63) through
NOTICE adapter (52) and into drum (96). Refer to “TORQUE CHART” on page 15 for
torque requirements.
• During assembly of components apply a light coat of Loctite® 242 to all 6. Place drum in horizontal position.
threaded fasteners. Clean all mating surfaces. ‘O’ rings can be held in place
with a coating of EP grease applied to groove. n Winch Assembly
• It is extremely important to maintain a clean work area when reduction gear
assembly is reassembled. During reassembly clean each part thoroughly and Refer to Dwgs. MHP2948 and MHP2944.
lightly coat with appropriate lubricant as described in ‘Recommended
Lubricants’ of “LUBRICATION” section in the Product Information Manual. NOTICE
1. If removed, install planetary gears (415) into planetary support (410) as follows:
a. Install a pair of spring pins (412) into holes in planetary support (410). • During assembly of components apply a light coat of Loctite® 242 to all
b. Install and center roller spacer (416) in planet gear (415) bore. threaded fasteners.
c. Place 40 roller bearings (414) in each side of planet gear (415), a light coat • Clean all mating surfaces. ‘O’ rings can be held in place with a coating of EP
of grease will help to hold them in place. Place a thrust bearing (413) on grease applied to groove.
each side of planetary gear assembly and squeeze.
d. Depress one spring pin (412) and slide planetary gear assembly over it. 1. Install bearing (188) in outboard upright (184).
Depress other side and tip gear assembly into planetary support. Rotate gear 2. Install outboard upright (184) on drum end. Ensure assembly is kept centered on
assembly around spring pins until shaft hole aligns. journal during this step.
e. Push planet gear shaft (417) into place. Repeat for remaining two gear 3. Install bearing retainer (191). Secure with capscrews (192). Refer to “TORQUE
assemblies. CHART” on page 15 for torque requirements.
f. Ensure each planet gear (415) rotates freely, without sticking or binding. 4. Apply a bead of Loctite® 515 sealant to mating surface of outboard upright (184)
2. Fasten thrust plate (449) to front cover (450) with screws (453) and loosely and install end cover (193). Secure with capscrews (582) and washers (306). Refer
tighten. to “TORQUE CHART” on page 15 for torque requirements.
3. Place a new gasket (447) on end cover (446). Install capscrews (452) through 5. Lubricate and install ‘O’ ring (43) on drum shaft (41).
front cover (450), gasket (447) and into end cover (446) and tighten. 6. Insert drum shaft (41) into inboard upright (42), aligning dowel pin holes.
4. Lubricate and install new ‘O’ ring (442) into groove on end cover (446). Apply a 7. Install dowel pins (62) flush or slightly below surface of drum shaft (41).
bead of Loctite® 515 sealant to mating surface. 8. Install capscrews (39). Refer to “TORQUE CHART” on page 15 for torque
5. Align ring gear (444) with spring pins (443) and press ring gear on end cover requirements.
(446). Apply a bead of Loctite® 515 sealant to mating surface. 9. Install inboard upright (42) onto reduction gear input shaft. Ensure splines on
6. Lubricate and install new ‘O’ ring (442) into input housing (438). drum shaft (41) align with splines in reduction gear.
10. Install siderails (98) to uprights (42) and (184) and loosely secure using
capscrews (119) and washers (117).

11. Tap dowel pins (183) into position until flush with siderails. n Manual Band Brake Assembly (optional feature)
12. Tighten capscrews (119) evenly. Refer to “TORQUE CHART” on page 15 for torque
requirements.
13. Lightly coat input shaft (7) with Loctite® 609 and press bearing (37) onto input Refer to Dwg. MHP0627.
shaft (7). Install retainer ring (38). 1. Clamp top of brake bands (128) together with a C-clamp.
14. Insert retainer ring (45) into middle of coupling (49). Place onto reduction gear 2. Slide this assembly over drum (96).
end of input shaft (7). 3. Install capscrews (124), washers (123) and nuts (115) through bottom blocks on
15. Install input shaft assembly into drum shaft (41). Install retainer ring (36) in brake bands (128) and tighten.
bore of drum shaft (41). 4. Remove C-clamp.
5. Install brake screw (114) through lugs on top of brake bands (128), with spring
Instructions 16 through 27 cover winches with a disc brake. For winches without (113) located between lugs.
a disc brake skip to instruction 28. 6. Slide tube (112) onto brake screw (114) followed by bearing (111).
7. Thread handwheel (104) onto brake screw (114) and loosely tighten.
16. Slide splined hub (19) onto input shaft (7), gear teeth side in first. Install retainer 8. Thread nut (110) onto brake screw (114) until 1/4 inch (6.5 mm) of threads are
ring (38). exposed.
17. Place seven friction plates (16) and eight drive plates (17) onto splined hub (19). 9. Place anchor (118) over rear lug on brake band (128). Rotate brake band (128)
Lubricate all plates with ISO VG 46 (SAE 10W) oil, starting with a drive plate (17), until bolt holes in anchor align with holes in rear siderail (98).
then friction plate (16) until all plates are used. 10. Install capscrews (116) and washers (117) through anchor (118), siderail (98)
18. Locate brake port. This should be 45 degrees to the right of top center. There are and into plate (122) and tighten.
two other ports which should be straight up and straight down (one becomes the 11. Install adjustment screw (127) through nut (120) and into support (126). Expose
drain, the other becomes a vent). 1/4 inch (6.5 mm) of threads.
19. Install pipe plug (24) into lower port in brake housing (21). Install reducer 12. Install capscrews (119) and washers (117) through siderail (98) and into support
bushing (22) and breather (23) into top port on brake housing (21). (126) and tighten.
20. Slide brake housing (21) over brake plates. Apply a coating of ISO VG 100 (SAE 13. Tighten handwheel (104) all the way tight. Screw adjustment screw up or down
3EP) oil to inside surface of brake housing (21). until there is 1/16 to 1/8 inch (1.6 to 3.2 mm) clearance between screw (127)
21. Lubricate and install seals (11) and (12) in brake piston (10) grooves so lips face and lug on brake band (128).
each other. Do not over stretch seals during this procedure. Refer to Dwg. 14. When handwheel is loosened, brake band (128) should NOT touch drum surface.
MHP0139 on page 12, A. Seal Lip; B. Seal; C. Brake Piston. If brake band does touch drum then decrease gap in 1/16 inch (1.5 mm)
22. Install brake piston assembly into brake housing (21), ensuring that lips of seals increments until band does not touch.
are not pinched or rolled over. Gently tap into position using a plastic mallet until 15. With handwheel (104) fully tightened, place capscrews (106) through washers
seated. (Cover brake port during tapping; oil can spray out.) (125) and bracket (108) into brake band (128). Loosely tighten.
23. Lubricate and install brake springs (9) into each brake piston hole. 16. Place U-bolt (109) over tube (112) and through bracket (108). Place lockwashers
24. Lubricate and install ‘O’ ring (15) into top groove in brake housing (21). (103) and nuts (102) onto U-bolt (109) and loosely tighten.
25. Tap reaction plate (8) into motor adapter (6). 17. Move bracket (108) up or down until tube (112) is level. Tighten all capscrews
and nuts. Refer to “TORQUE CHART” on page 15 for torque requirements.
Seal Lip A n Automatic Band Brake Assembly (optional feature)

1. Install brake band halves on drum (96).
2. Install capscrews (124), washers (123) and nuts (115) through bottom blocks on
Seal B brake bands (128) and tighten.
C 3. Place anchor (118) over rear lug on brake band (128). Rotate brake band (128)
until bolt holes in anchor align with holes in rear siderail (98).
Brake 4. Install capscrews (116) with washers (117) through bracket (74), siderail (98)
Piston and anchor (118) into plate (122) and tighten.
5. Install adjustment screw (127) through nut (120) and into support (126). Expose
1/4 inch (6.5 mm) of threads.
6. Install capscrews (119) and washers (117) through siderail (98) and into support
(126) and tighten.
7. Install nut (130) and clevis (51) on cylinder (134).
8. Press bushings (54) into lever arms (34) and (61).
9. Install link stud (56) in pivot nut (55). Connect link stud to brake band lug with
pin (58) and cotter pins (57). Bend cotter pin ends apart. Position pivot nut
between lever arms (34) and (61).
10. Install capscrews (25), washers (32), spacers (35) with nuts (60) onto lever arms
(34) and (61).
11. Install cylinder (134) so it connects with bracket (74) and between lever arms.
Use pins (46) and (65) and secure with cotter pins (44). Bend ends of cotter pins
apart to secure cylinder when adjustment is complete.
12. Install fitting (73), dump valve (71), fitting (70) and hose (68) to the cylinder
(134).
(Dwg. MHP0139) 13. Adjust automatic brake as described under ‘Adjustments’ in the “MAINTENANCE”
26. Mount motor adapter (6) to brake housing (21) and drum shaft (41). There is a section on page 6.
pair of holes on the outer bolt hole pattern that are aligned with bolt holes on
the inner hole pattern. The smaller diameter holes on the outer pattern are the n Limit Switch Assembly (optional feature)
motor mounting holes. The larger diameter holes on the inner pattern are the
brake housing mounting holes. The matched/aligned holes must be in the 6 Refer to Dwg. MHP2677.
o’clock position. 1. Secure limit switch assembly to upright (184) with capscrews (97) and washers
27. There are three methods to compress springs (9) and fasten capscrews (2). (96).
a. Use three— 1/2 inch - NC x 5 inch socket head capscrews and evenly space 2. Install hose connections. Refer to label 71459929 on page 13.
them around motor adapter (6). Mark each position. Evenly tighten them
down (compressing springs). Install regular capscrews (2). Refer to “TORQUE
CHART” on page 15 for torque requirements.
b. Remove the three extra long capscrews and replace with capscrews (2). Refer
to “TORQUE CHART” on page 15 for torque requirements.
c. Press down brake piston (10) until capscrews (2) can engage threads. Refer
to “TORQUE CHART” on page 15 for torque requirements.
WARNING
The air motor weighs approximately 260 lb. (118 kg). Adequately support air
motor while installing motor mounting capscrews.
28. Install ‘O’ ring (13) into center of seal sleeve (14). Slide this assembly onto input
shaft (7). Ensure that bevel is facing motor. Apply a coating of grease over sleeve
and exposed input shaft.
29. Apply a coating of grease to oil seal (227) and crank bearing (228) in motor.
30. Lubricate and install ‘O’ ring (5) in groove in motor adapter (6).
31. Slide motor over input shaft (7). Be careful not to damage oil seal. Motor might
have to be rotated around input shaft slightly to align splines.
32. Remove 1/2 inch nut from mounting flange (216). Push motor until flush with
motor adapter (6). Insert capscrews (4) and lockwasher (3) through motor into
motor adapter (6). Refer to “TORQUE CHART” on page 15 for torque
requirements.
33. On winches with a disc brake install fitting (31) into brake housing port. Attach
tee fitting (86) and dump valve (30) to fitting (31) followed by vented fitting
(29). Connect air line assembly (28), (20) and (27) between vented fitting (29)
and hose fitting (26) on control valve.

CAUTION
• Do not disassemble pilot cap assemblies. Valve cylinder and valve cap are
press fit together. Close fit tolerances cannot be maintained if disassembled.
If repair is required, replacement of the pilot cap assembly is required.
Pendant Valve Adjustment:

1. Lubricate threads and install capscrews (366) and (368), lockwashers (924),
gasket (340) and pilot cap assembly (367) to valve body (339). Tighten capscrew,
but do not torque.
2. Reaching into exhaust port on valve body (339), grasp shaft (331) and check for
movement in either direction. Any movement requires adjustment.
3. If there is shaft movement, remove pilot cap assembly and back out setscrews in
pistons 1/4 turn. Repeat until there is no movement.
4. When adjustment is complete, tighten capscrews (366) and (368). Refer to
“TORQUE CHART” on page 15 for torque requirements.
Adapter Installation:
1. Place gasket (358) on mating face of adapter (369) and align holes with valve
body (339). Coat threads with Loctite® 242 and, from the bottom side of adapter,
install capscrews (370) into valve body. Refer to “TORQUE CHART” on page 15
for torque requirements.
n Two Function Pendant Assembly (optional feature)

Refer to Dwg. MHP1677 with emergency stop or MHP2346 without emergency stop.
1. Install ‘O’ rings (443) and (449) along with protector (451) on valves (452).
Install valve assemblies in handle (454).
2. Install levers (453) in pendant handle (454) with pin (447). Stake pin in pendant
handle at both ends to secure.
3. Install screws (448) in levers.
4. Install balls (446) and springs (445) in handle (454). Secure in position with
plugs (444).
5. On pendants with emergency stop, install emergency stop button (441). On
pendants without emergency stop, install plug (470).
6. Install exhaust washer (457) and secure in handle with retainer ring (458).
7. Attach hoses to fittings located on top of pendant handle. Locate hoses to fittings
as shown in Dwg. MHP2398 in Product Information Manual.
n Brake Connection
(Dwg. 71459929)
n Pendant Operated Pilot Control Valve Assembly Winches without overload valve and/or emergency stop will use configuration 3. Disc
and automatic band brake will require a tee at disc brake port. Contact factory for
replacement.
Valve Shaft A Winches with an overload valve and/or emergency stop will use configuration 4 and
will require a tee at brake port.
n Winch Guard Assembly (optional feature)

1. Secure frames (801), (802), (803) and (810) to uprights (42) and (184) with
capscrews (408) and washers (306).
2. Secure lifting lugs (194) to uprights with capscrews (197) and washers (117).
3. Install panels (805) and (807) one at a time, beginning with the lower (805)
panel.
(Dwg. MHP1022) 4. Install first crossbar (806) with nuts (804).
5. Attach panel to crossbar (806).
Brake Release Valve Installation and Adjustment: 6. Hold second panel (805) in place and install second crossbar (806) by sliding
Refer to Dwgs. MHP2969 in the Product Information Manual and MHP1027 through (hooked) edges of the two panels.
on page 13, A. Sleeve. 7. Secure crossbar (806) with nuts (804).
8. Continue until all panels are in place.
9. Tighten all fasteners and check winch guard is secure. Ensure wire rope does not
NOTICE interfere with winch guard during winch operation.
• Valve assembly (341) shaft body is longer on one side of middle groove than n Drum Locking Pin Assembly (optional feature)
the other. Correct placement of valve assembly is with longer shaft section
located toward bottom of valve body (339). The shorter section will protrude
up, through valve body. Refer to Dwg. MHP2675.
• To adjust brake release valve, ensure sleeve (338) is loose on shaft (331). 1. Install new bushing (311) in winch upright (184) if replacement was required.
If not loose, back off (turn counterclockwise) setscrew (337). 2. Install shaft (304) in handle (301) and secure with nut (303) and capscrew (302).
3. Install cover (307) on shaft (304) so capscrew holes are aligned with holes in
1. Rotate sleeve (338) to place the longer edge on top. Refer to Dwg. MHP1027 upright when handle (301) is in a horizontal position.
on page 13. 4. Install housing (308), spring (310), and drum lock pin (312) on shaft (304).
2. Using gentle hand pressure to prevent damage to valve assembly (341) shaft Tighten drum lock pin (312) on thread of shaft (304). Apply a small amount of
body, press valve assembly down until ball is in firm contact with sleeve (338). Loctite® 242 to threads. Refer to “TORQUE CHART” on page 15 for torque
requirements.
5. Install drum locking pin assembly in upright and secure with capscrews (305) and
washers (306).
n Press Roller Assembly (optional feature)

1. If bushings (410) have been removed, replace and install in uprights (42) and
(184), and in both ends of arm (407). Grease bushings (410) for ease of
installation.
2. Install center roller (402) in press roller arm (407) and install shaft (411) through
Sleeve A both parts.
3. Install outside rollers (401) and secure with capscrews (408) and washers (409).
Apply a small amount of Loctite® 242 to threads of capscrews.
4. Install springs (405) and (406) so that the shorter end of the springs is toward
the inner portion of the arm (407) where the pins (413) are located.
5. One person positions press roller so the top of arm (407) is curved up toward the
underside of the drum (96), and holds press roller in place while the other person
completes installation.
6. Adjust both springs (405) and (406) so that the long end of springs is on the
(Dwg. MHP1027) inside of siderail (98).

c. New Brake Band Lining Run-in Procedure: All new brake band linings require
NOTICE a ‘run-in’ period.
d. Operate the winch without load in the payout direction while gradually
• Do not engage shorter end of spring behind pins of arm (407) until after applying the brake. Allow the brake to slip for approximately one minute.
shaft (403) has been installed and secured, and press roller assembly Winch motor may stall as brake band lining fully engages. Do not allow brake
adjusted to center of drum. to overheat.
e. Check operation of brakes. Adjust if necessary as described in the
7. Install shaft (403) through hole in leg of upright (42) only. “MAINTENANCE” section.
8. Install one collar (404) on end of shaft (403) between upright and press roller f. Check operation of limit switches, locking devices and all safety devices when
assembly. Do not tighten collar (404) until steps 11 and 12 have been completed. equipped.
9. Install shaft (403) through press roller assembly (400). g. Check foundation mounting fasteners are secure.
10. Install second collar (404) and slide shaft through hole in leg of upright (184). h. Install winch guard.
Ensure that the long end of springs (405) and (406) are still between the siderail
(98) and drum (96). Do not tighten collar (404) until steps 11 and 12 have been
completed. n Load Test
11. Secure shaft (403) to uprights using capscrews (408) and washers (409). Apply
a small amount of Loctite® 242 to threads of capscrews. Prior to initial use, all extensively repaired winches shall be load tested by or under
12. Adjust press roller assembly so that it is centered between the drum flanges, and the direction of an Ingersoll Rand trained Technician and a written report furnished
tighten collars (404). confirming the rating of winch. Test loads shall not be less than 100% of rated line
13. Use extreme caution and pry short end of one spring (405) so that it is positioned pull and should not exceed 125% of rated line pull. To test winch at 125% of rated
behind the pin (413) of arm (407). load apply following load with wire rope on the first layer of the drum:
14. Repeat step 13 for spring (406).
FA10i Winch 34,500 lb. (15,698 kg)
NOTICE
• Use caution when installing springs (405) and (406); springs are under NOTICE
tension.
• Testing to more than 125% of rated line pull may be required to set overload
device or comply with standards and regulations set forth in areas outside of
the USA.
n Testing
n Operational Test n Limit Switches (optional feature)
Prior to initial use, all new, altered or repaired winches shall be tested to ensure Operate winch through three complete cycles to ensure consistent limit switch
proper operation. operation within +/- 2 feet (0.6 m) of set points. Refer to 'Limit Switch Adjustment'
a. Check oil level in motor, reduction gear assembly and disc brake are correct. procedure in Product Information Manual to establish set points.
b. To initially ‘break in’ new or overhauled motors, operate without load, in both
directions, for 15 minutes at 100 - 200 RPM.

TORQUE CHART
Standard Coarse Thread Torque
SAE Grade 5 SAE Grade 8
Size
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
SAE Grade 5 SAE Grade 8
Size
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
Class 8.8 / 9.8 Class 10.9
Size
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
Class 8.8 / 9.8 Class 10.9
Size
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 (teflon) 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.

www.winchandhoistsolutions.com

MODEL FA10i

Uploaded by

Copyright:

Available Formats

MODEL FA10i

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MODEL FA10i

Uploaded by

Copyright:

Available Formats

Product

Save These Instructions

Table 1: Product Information Manuals

Table 2: Inspection Classifications

2 Form MHD56401 Edition 2

Note: Hours are for actual winch drum rotation.

Recommend complete general overhaul.

Form MHD56401 Edition 2 3

Ingersoll Rand Force 5 Infinity Series Models FA10i Air Winches

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

4 Form MHD56401 Edition 2

SYMPTOM CAUSE REMEDY

Automatic Band Brake:

Form MHD56401 Edition 2 5

n General n Pendant Operated Pilot Control Valve (optional feature)

6 Form MHD56401 Edition 2

WARNING n Motor Disassembly

4. Disconnect and tag air lines. CAUTION

Form MHD56401 Edition 2 7

NOTICE n Manual Band Brake Disassembly (optional feature)

n Emergency Stop and Overload Control Valve Disassembly CAUTION

8 Form MHD56401 Edition 2

Refer to Dwg. MHP2675.

Form MHD56401 Edition 2 9

Refer to Dwg. MHP2697. Motor Body Assembly:

10 Form MHD56401 Edition 2

Colored ends of oil ring Refer to Dwgs. MHP2948 and MHP0875.

Form MHD56401 Edition 2 11

Seal Lip A n Automatic Band Brake Assembly (optional feature)

12 Form MHD56401 Edition 2

Pendant Valve Adjustment:

n Two Function Pendant Assembly (optional feature)

n Winch Guard Assembly (optional feature)

n Press Roller Assembly (optional feature)

Form MHD56401 Edition 2 13

14 Form MHD56401 Edition 2

Form MHD56401 Edition 2 15

You might also like