Form MHD56298
IMPORTANT INFORMATION:
• A copy of our “Safe Operating Practices” Manuals are always available free of charge either by downloading it from our
(206) 624-0466 for International. The Safe Operating Practices manual must be read prior to anyone operating a
Ingersoll-Rand winch or hoist. The manual form numbers are as follows:
“Safe Operating Practices Non-Man Rider™ Winches” Manual, Form No. MHD56250
“Safe Operating Practices for Man Rider™ Winches” Manual, Form No. MHD56251
“Safe Operating Practices for Pneumatic, Hydraulic and Electric Hoists” Manual, Form No. MHD56295
• Available winch options may require additional supplements to the basic winch manual.
• For Man Rider™ winches ensure a copy of the Man Rider™ supplement is made available to the operator prior to winch
operation.
Winch Man Rider™ Supplements:
Model:
Publication No.
Model:
LS500RLP
Publication No.
SAM0011
FA2, FA2.5,
MHD56046
FH2, FH2.5
FA5
LS1000RLP
LS150RLP
SAM0012
SAM0082
MHD56042 and
MHD56220
LS150RLP/500/
1000
SAM0115
FA10
MHD56252
MHD56236
FA2.5A
LS150RLP and
LS150PLP-PH
SAM0120
SAM0122
SAM0184
SAM0222
FA2B and
HU40A
MHD56207
LS500RLP-E
FH10MR
MHD56212
MHD56277
LS150RLP-
DP5M-F
Fulcrum Electric
LS150HLP
LS500HLP/
LS1000HLP
SAM0004
• We strongly recommend that ALL maintenance on Ingersoll-Rand equipment be carried out by personnel certified by
Ingersoll-Rand, or by Ingersoll-Rand Authorized Service Centers.
• Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions.
• Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist.
• ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested
prior to being placed into service:
*
Winches - ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
Hoists - ANSI / ASME B30.16 (OVERHEAD HOISTS - UNDERHUNG) Refer to section 16.2.2 - Testing.
*
Form MHD56298
Edition 2
November 2004
71441844
© 2004 Ingersoll-Rand Company
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TABLE OF CONTENTS
Description
Page No.
Safety Information
Danger, Warning, Caution and Notice .................................................................................................................................................................3
Safety Summary...................................................................................................................................................................................................3
Safe Operating Instructions .................................................................................................................................................................................4
Warning Labels and Tag ......................................................................................................................................................................................4
Specifications
Model Code Explanation .....................................................................................................................................................................................5
General Specifications .........................................................................................................................................................................................6
Winch Weight and Wire Rope Capacities............................................................................................................................................................6
FA5A Performance Curve....................................................................................................................................................................................7
Description of Operation .....................................................................................................................................................................................7
Traceability ..........................................................................................................................................................................................................7
Installation
Mounting............................................................................................................................................................................................................. 8
Wire Rope ........................................................................................................................................................................................................... 8
Air Supply..........................................................................................................................................................................................................10
Motor .................................................................................................................................................................................................................11
Emergency Stop and Overload System..............................................................................................................................................................11
Initial Winch Operating Checks.........................................................................................................................................................................11
Operation
Controls..............................................................................................................................................................................................................12
Winch Brakes.....................................................................................................................................................................................................15
Constant Tension Manifold (optional feature)...................................................................................................................................................15
Free Spool (optional feature) .............................................................................................................................................................................15
Inspection
Records and Reports ..........................................................................................................................................................................................16
Frequent Inspection............................................................................................................................................................................................17
Periodic Inspection ............................................................................................................................................................................................17
Winches Not in Regular Use..............................................................................................................................................................................18
Inspection and Maintenance Report .................................................................................................................................................................19
Troubleshooting................................................................................................................................................................................................20
Lubrication.......................................................................................................................................................................................................21
General Lubrication ...........................................................................................................................................................................................21
Wire Rope ..........................................................................................................................................................................................................22
Maintenance
Maintenance Intervals........................................................................................................................................................................................23
Adjustments .......................................................................................................................................................................................................24
Disassembly.......................................................................................................................................................................................................25
Cleaning, Inspection and Repair....................................................................................................................................................................... 29
Assembly ...........................................................................................................................................................................................................29
Testing ...............................................................................................................................................................................................................34
Parts Section
Winch Cross Section Drawing.......................................................................................................................................................................... 36
Winch Drawings and Parts Lists Table of Contents...........................................................................................................................................37
Winch Parts Drawings and Parts Lists........................................................................................................................................................38 - 66
Parts Ordering Information............................................................................................................................................................................70
Warranty...........................................................................................................................................................................................................71
Office Locations ...............................................................................................................................................................................................72
2
MHD56087 - Edition 4
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SAFETY INFORMATION
This manual provides important information for all personnel
The National Safety Council, Accident Prevention Manual for
Industrial Operations, Eighth Edition and other recognized safety
sources make a common point: Employees who work near
suspended loads or assist in hooking on or arranging a load should
be instructed to keep out from under the load. From a safety
standpoint, one factor is paramount: conduct all lifting or pulling
operations in such a manner that if there were an equipment
failure, no personnel would be injured. This means keep out from
under a raised load and keep out of the line of force of any load.
involved with the safe installation, operation and proper
maintenance of this product. Even if you feel you are familiar with
this or similar equipment, you should read this manual before
operating the winch.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures which, if
not followed, may result in a hazard. The following signal words
The Occupational Safety and Health Act of 1970 generally places
the burden of compliance with the user, not the manufacturer.
Many OSHA requirements are not concerned or connected with
the manufactured product but are, rather, associated with the final
installation. It is the owner’s and user’s responsibility to determine
the suitability of a product for any particular use. It is
are used to identify the level of potential hazard.
.
Danger is used to indicate the presence of
a hazard which will cause severe injury,
death, or substantial property damage if
the warning is ignored.
recommended that all applicable industry, trade association,
federal, state and local regulations be checked. Read all operating
instructions and warnings before operation.
Warning is used to indicate the presence
of a hazard which can cause severe
injury, death, or substantial property
damage if the warning is ignored.
Rigging: It is the responsibility of the operator to exercise caution,
use common sense and be familiar with proper rigging techniques.
Refer to ASME B30.9 for rigging information, American National
Standards Institute, 1430 Broadway, New York, NY 10018.
Caution is used to indicate the presence
of a hazard which will or can cause
injury or property damage if the warning
is ignored.
This manual has been produced by Ingersoll-Rand to provide
dealers, mechanics, operators and company personnel with the
information required to install, operate, maintain and repair the
products described herein.
Notice is used to notify people of
installation, operation, or maintenance
information which is important but not
hazard-related.
It is extremely important that mechanics and operators be familiar
with the servicing procedures of these products, or like or similar
products, and are physically capable of conducting the procedures.
These personnel shall have a general working knowledge that
includes:
Safety Summary
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.
WARNING
• Do not use this winch for lifting, supporting, or transporting
people or lifting or supporting loads over people.
• The supporting structures and load-attaching devices used in
conjunction with this winch must provide an adequate safety
factor to handle the rated load, plus the weight of the winch
and attached equipment. This is the customer’s responsibility.
If in doubt, consult a registered structural engineer.
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.
Ingersoll-Rand winches are manufactured in accordance with the
latest ASME B30.7 standards.
MHD56087 - Edition 4
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SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions have been
5. Never lift a load greater than the rated capacity of the winch.
Refer to “SPECIFICATIONS” section.
adapted in part from American National (Safety) Standard ASME
B30.7 and are intended to avoid unsafe operating practices which
might lead to injury or property damage.
6. Keep hands, clothing, etc., clear of moving parts.
7. Never place your hand in the throat area of a hook or near
wire rope spooling onto or off of the winch drum.
8. Always rig loads properly and carefully.
9. Be certain the load is properly seated in the saddle of the
hook. Do not support the load on the tip of the hook.
10. Do not “side pull” or “yard”.
11. Always ensure that you, and all other people, are clear of the
path of the load. Do not lift a load over people.
12. Never use the winch for lifting or lowering people, and never
allow anyone to stand on a suspended load.
Ingersoll-Rand recognizes that most companies who use winches
have a safety program in force at their facility. In the event that
some conflict exists between a rule set forth in this publication and
a similar rule already set by an individual company, the more
stringent of the two should take precedence.
Safe Operating Instructions are provided to make an operator
aware of dangerous practices to avoid and are not necessarily
limited to the following list. Refer to specific sections in the
manual for additional safety information.
13. Ease the slack out of the wire rope when starting a lift or pull.
Do not jerk the load.
14. Do not swing a suspended load.
1. Only allow people, trained in safety and operation of this
product, to operate and maintain this winch.
2. Only operate a winch if you are physically fit to do so.
3. When a “DO NOT OPERATE” sign is placed on the winch,
or controls, do not operate the winch until the sign has been
removed by designated personnel.
15. Do not leave a suspended load unattended.
16. Never operate a winch with twisted, kinked or damaged wire
rope.
17. Pay attention to the load at all times when operating the
winch.
18. Never use the wire rope as a sling.
4. Before each shift, inspect winch for wear and damage. Never
use a winch that inspection indicates is worn or damaged.
19. After use, or when in a non-operational mode, the winch
should be secured against unauthorized and unwarranted use.
WARNING LABELS AND TAG
Each winch is shipped from the factory with the warning labels
and tag shown. If the labels or tag are not attached to your winch,
order new labels and tag and install. Refer to the parts list for the
part numbers. Labels and tag shown are smaller than actual size.
WARNING
Failure to follow these
warnings may result in
death, severe injury or
property damage:
WARNING
Do not operate
this winch before
reading operation
and maintenance
manual.
Do not lift people or loads
over people.
Do not lift more than rated
load.
Welded mountings
can fail.
Can cause severe
injury or death.
Do not weld, braze or
Do not allow less than three
wraps of wire rope to remain
on drum at all times.
Do not operate a damaged
or malfunctioning winch.
solder to winch.
71270813
Do not remove or obscure
warning labels.
Read the latest edition of ASME B30.7.
Comply with other federal, state and local rules.
P/N 71056410/A
for winches
?
4
MHD56087 - Edition 4
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SPECIFICATIONS
Model Code Explanation: (Example FA5A-LXK1G)
Series
FA
5
A
-
L
X
K
1
G
FA = Force 5 Air Powered
Capacity: (Based on wire rope at mid drum)
5
= (5 tons (10,000 lbs [4,536 kg])
Generation:
A
= Third Generation
Drum Length:
S
S
L
L
= Short without Drum Brake (15 inches [381 mm])
= Short with Drum Brake (12 inches [305 mm])
= Long without Drum Brake (27 inches [686 mm])
= Long with Drum Brake (24 inches [610 mm])
Drum Brake: Note: addition of drum brake reduces the drum length 3 inches [76 mm]
A
= Automatic Drum Brake
= Manual Drum Brake
= None
M
X
Disc Brake:
K
= Automatic Disc Brake (Standard)
X
Control:
1
= None
= Winch mounted lever throttle (Standard)
*
2
= Remote pilot pendant throttle with standard length (6 ft/1.8 m) hose
**
**
**
2XX = Remote full flow lever throttle (maximum 20 ft/6 m)
3XX = Remote pilot pendant throttle (standard = 6 ft/1.8 m; maximum 66 ft/20 m)
4XX = Remote pilot lever throttle (maximum 66 ft/20 m)
5XX = Remote electric over air throttle †
Options:
7
C
D
E
= Drum grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch) †
= Low Temperature Components; specify -10° C (14° F) or -20° C (-4° F)
= Drum divider flange and additional wire rope anchor †
= Construction Cage
F
= Free spool clutch (available only with manual drum brake)
= Drum Guard
= Open Front frame for horizontal pulling
= K6 footprint base
G
H
K
***
***
***
M1 = Material Traceability (typical material results) ††
M2 = Material Traceability (actual material results) ††
M3 = Material Traceability (actual material results for these parts in finished, as-delivered condition) ††
N
= Type Approval - Specify:
• Det Norske Veritas (DNV)
= Special Paint
• American Bureau of Shipping (ABS)
• Lloyd’s Register of Shipping (LRS)
Q
T
= Tensioning Manifold
U
V
-E
= Underwound wire rope operation (available only with automatic disc brake)
= Press Roller †
= Compliance with European Community Machinery Directive:
• Main air supply emergency shut off • Drum Guard
• Muffler
• Overload Device
• CE Documentation
Notes:
*
Available only with auto disc brake or with auto drum brake.
**
Remote throttles are provided with 6 feet (1.8 metres) of hose. Specify hose lengths greater than 6 feet (1.8 metres).
Contact your Ingersoll-Rand distributor or the factory for control acceptability for hose lengths greater than 60 feet
(18.3 metres). Metric lengths are provided for reference only, order lengths in feet.
Documentation, witness testing and material traceability available; must be requested at time of order. Specify options or
contact the factory or your nearest Ingersoll-Rand distributor for information.
***
†
Not covered in this manual.
††
Refer to ‘Traceability’ on page 7 for a description of the differences between M1, M2 and M3.
MHD56087 - Edition 4
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General Specifications
Air System
Rated Operating Pressure
Air Consumption
(at rated pressure and load)
90 psig (6.3 bar/630 kPa)
20 cu.m/min
700 scfm
Mid Drum Line Pull
Mid Drum Line Speed
Air Motor Pipe Inlet Size
10,000 lbs
32 fpm
4,536 kg
10 m/min
32 mm
Rated Performance
(at rated pressure / volume)
1.25 inches
1.5 inches
17,000 lbs
12.75 inches
24.25 inches
Minimum Air System Hose Size
Maximum Stall at First Layer
Drum Barrel Diameter
38 mm
7,727 kg
324 mm
616 mm
Drum Flange Diameter
Winch Net Weight (without wire rope)
Model
lbs
kg
Model
lbs
kg
FA5A-SXK1
FA5A-SMK1
FA5A-SAK1
FA5A-SMX1
FA5A-SAX1
FA5A-LXK1
FA5A-LMK1
FA5A-LAK1
FA5A-LMX1
FA5A-LAX1
1,048
1,170
1,175
1,120
1,165
1,251
1,363
1,390
1,333
1,378
476
532
534
509
530
569
620
632
606
626
FA5A-SXK2
FA5A-SMK2
FA5A-SAK2
N/A
FA5A-SAX2
FA5A-LXK2
FA5A-LMK2
FA5A-LAK2
N/A
1,050
1,145
1,175
- - -
1,165
1,263
1,380
1,390
- - -
477
520
534
- - -
530
574
627
632
- - -
626
FA5A-LAX2
1,378
Winch Wire Rope Storage Capacities (feet/metres)
Wire Rope Diameter
Drum Length
Storage Notes
5/8 inch
feet
668
844
1,373
1,549
16 mm
metres
202
256
416
469
3/4 inch
feet
489
18 mm
metres
156
197
321
inches
12
mm
305
381
610
686
Full Drum Storage less
15
24
27
619
1/2 inch (13 mm) (meets
ANSI B30.7) *
1,010
1,140
362
* Per ASME B30.7 wire rope top layer must be located a minimum of 1/2 inch (13 mm) below drum flange. The wire rope storage capacities
listed may vary from figures stated elsewhere.
6
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FA5A Performance Curve
7257
6350
5443
900
800
25.5
22.7
16000
14000
12000
700
19.8
10000
600
500
400
16.9
14.2
11.3
4536
3629
2122
1814
Full Drum
8000
6000
4000
300
200
8.5
5.7
2000
0
907
0
100
2.8
0
16 32 48 64 80 96 112 128 144 160 176 192 208 224 240 256
Line Speed (ft/min)
(Dwg. MHP0895)
Description of Operation
Traceability
FA5A winches are air powered, planetary geared units designed
for lifting and pulling applications. FA5A winches are supplied
with either an internal automatic disc brake, a manual or automatic
externally mounted drum band brake, or a combination of both.
Load bearing parts are documented to provide traceability.
Documentation includes chemical and physical properties of raw
material, heat treating, and hardening, tensile and charpy tests as
required for the part.
The output from an externally mounted piston air motor is
transmitted through a coupling and shaft to the planetary reduction
gear assembly.
Units with M1, M2 or M3 in the model code have traceable load-
bearing components.
M1–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 2.2 on load bearing parts. Conformity documents
affirm (by the manufacturer) that parts are in compliance with the
requirements of the order based on non-specific inspection and
testing (i.e. results are typical material properties for these parts).
The output from the planetary reduction gear assembly is
connected to the wire rope drum through the output shaft.
The disc brake attaches to the outboard upright opposite the motor
end and is connected to the intermediate sun gear through the
brake shaft. The disc brake is automatically applied when the
winch is in the neutral or operated in the haul-in positions;
disengaged when the winch is operated in the payout direction.
During winch operation a sprag type clutch in the disc brake
allows drum rotation in the haul-in direction with the disc brake
engaged. This ensures the brake will respond quickly to hold the
load when winch operation stops. Operation of the winch in the
payout direction directs pressurized air to the disc brake
diaphragm to overcome spring tension and release the brake.
When the payout operation is complete the air is vented and the
brake is automatically applied.
M2–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 3.1b on load bearing parts. Conformity documents
affirm (by a department independent of the manufacturing
department) that the actual parts are in compliance with the
requirements of the order based on specific inspection and testing
(i.e. results are actual material properties for these parts).
M3–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 3.1b on load bearing parts. Conformity documents
affirm (by a department independent of the manufacturing
department) that the actual parts used in the product are in
compliance with the order based on specific inspection and testing
(i.e. results are actual material properties for these parts in a
finished, as delivered condition).
The drum band brake operates by applying a friction force
between the drum band and the winch drum. The manual brake
requires an operator to engage and disengage the brake using a
lever located near the air motor end of the winch. The automatic
drum band brake operation is similar to the disc brake with the
following exception: the automatic drum band brake fully
disengages in both the haul-in and payout directions.
Components with part numbers ending in CH are charpy parts for
use under extreme cold conditions. Traceability requirements must
be stated when reordering these parts for continued certification.
MHD56087 - Edition 4
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INSTALLATION
Prior to installing the winch, carefully inspect it for possible
3. Mounting bolts must be 3/4 inch-NC (18 mm) Grade 8 or
better. Use self-locking nuts or nuts with lockwashers.
4. Tighten 3/4 inch (18 mm) mounting bolts evenly and torque
to 380 ft lbs. (515 Nm) for dry thread fasteners. If the
fasteners are plated, lubricated or a thread locking compound
is used, torque to 280 ft lbs. (380 Nm).
shipping damage. Winches are supplied fully lubricated from the
factory. Check oil levels and adjust as necessary before operating
winch. Refer to “LUBRICATION” section for recommended oils.
5. Maintain a fleet angle between the lead sheave and winch of
no more than 1-1/2°. The lead sheave must be on a center line
with the drum, and for every inch (25 mm) of drum length, be
at least 1.6 feet (0.5 metre) from the drum. Refer to Dwg.
MHP0498 on page 10.
• Owners and users are advised to examine specific, local or
other regulations, including American National Standards
Institute and/or OSHA Regulations which may apply to a
particular type of use of this product before installing or
putting winch to use.
6. Do not weld to any part of the winch.
Mounting
Refer to Dwg. MHP0124 and Table 1 on page 8.
Care must be taken when moving, positioning or mounting the
winch. Ensure that the winch, when lifted, will be properly
balanced. Determine the weight of the winch by referring to the
“SPECIFICATIONS” section. Lift the winch 3 to 4 inches (75 to
100 mm) off the ground. Verify winch is balanced and secure
before continuing lift. Mount the winch so the axis of the drum is
horizontal and that the motor vent cap is not more than 15° off top
vertical center. If the winch is to be mounted in an inverted
position, the motor case must be rotated to position the vent cap at
the top and adequate clearance must be provided for control valve
operation. The breather (8) and drain plug (21) on the disc brake
must be swapped.
(Dwg. MHP0124)
Table 1 - Mounting Bolt Hole Dimensions
WARNING
Drum Length (inches)
Dimension
12
15
24
27
in.
mm
in.
17.89
455
29.89
760
“A”
“B”
“C”
22
559
0.81
21
mm
in.
Welded mountings
can fail.
mm
Can cause severe
injury or death.
Do not weld, braze or
Wire Rope
solder to winch.
71270813
• Maintain at least 3 tight wraps of wire rope on drum at all
times. Refer to Dwg. MHP0498 on page 10.
• .Winch frame material is not suitable for welding. FA5A
winches must only be mounted by bolting to a suitable
foundation. Do not attempt to mount winch by welding to a
foundation structure. Refer to warning label part number
71270813 on winch.
Standard and Open Frame (Face) Winch
Install the winch such that the wire rope, when at the take-off
angle limits does not contact the mounting surface. Refer to Dwg.
MHP1142 on page 9.
1. Winch mounting surface must be flat and of sufficient
strength to handle the rated load plus the weight of the winch
and attached equipment. An inadequate foundation may
cause distortion or twisting of winch uprights and side rails
resulting in winch damage.
•
• Exceeding wire rope take-off angles will cause wire rope to
come into contact with winch frame supports resulting in
damage to wire rope and winch.
2. Make sure the mounting surface is flat to within 1/32 inch
(0.8 mm). Shim if necessary.
8
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Installing Wire Rope
Refer to Dwg. MHP0652 on page 9.
1. Cut wire rope to length and fuse end to prevent fraying of
strands in accordance with the wire rope manufacturer’s
instructions.
2. Feed the end of the wire rope into the wire rope anchor hole
in the drum and pull through approximately three feet
(1 metre) of wire rope.
3. Forming a large loop with the wire rope, insert the end back
into the top of the anchor hole.
4. Place the wire rope wedge into the wire rope anchor pocket in
the drum. Install the wedge such that the wire rope will wrap
around the wedge as shown in Dwg. MHP0652 on page 9.
Wire Rope Installation
(Dwg. MHP0652)
(Dwg. MHP1142)
5. Pull the wire rope into position in the drum anchor pocket.
Ensure the wire rope is installed below the edge of the drum
flange diameter. Use of a copper drift or similar tool may be
required to fully insert wire rope and wedge into the anchor
pocket.
Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor for
assistance in selecting the appropriate type and size of wire rope,
and where necessary, a protective coating. Use a wire rope which
provides an adequate safety factor to handle the actual working
load and that meets all applicable industry, trade association,
federal, state and local regulations.
CAUTION
• Make sure first wrap of wire rope is tight and lays flush
against drum flange.
When considering wire rope requirements the actual working load
must include not only the static or dead load but also loads
resulting from acceleration, retardation and shock load.
Consideration must also be given to the size of the winch wire
rope drum, sheaves and method of reeving. Wire rope construction
must be 6 X 19 or 6 X 37 Extra Improved IWRC right lay. Refer to
Table 2 for minimum and maximum recommended wire rope
diameters.
• Ensure correct wire rope anchor is used.
• Install wire rope to come off drum in an overwind position.
Improper installation of wire rope can result in failure of the
disc brake to hold load. Refer to Dwg. MHP0652 on page 9.
Safe Wire Rope Handling Procedures
1. Always use gloves when handling wire rope.
2. Never use wire rope which is frayed or kinked.
3. Never use wire rope as a sling.
Table 2 - Minimum and Maximum Wire Rope Size
4. Always ensure wire rope is correctly spooled and the first
layer is tight against the drum.
5. Always follow wire rope manufacturers’ recommendation on
use and maintenance of wire rope.
Wire Rope
Anchor Part
No.
Minimum
Maximum
inch
mm
inch
mm
Contact Factory
24258
1/4
8
1/2
3/4
13
18
9/16
14
Note: To maintain 5:1 safety factor ratio 9/16 inch (14 mm) wire
rope must be used.
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Wire Rope and Drum Diagram
Rigging
Make sure all wire rope blocks, tackle and fasteners have a
sufficient safety margin to handle the required load under all
conditions. Do not allow wire rope to contact sharp edges or make
sharp bends which will cause damage to wire rope, use a sheave.
Refer to the wire rope manufacturer’s handbook for proper sizing,
use and care of wire rope.
Safe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not attach a welding electrode to winch or wire rope.
3. Never run the wire rope over a sharp edge. Use a correctly
sized sheave.
4. When a lead sheave is used, it must be aligned with the center
of the drum. The diameter of the lead sheave must be at least
18 times the diameter of the wire rope. Refer to Dwg.
MHP0498 on page 10.
5. Always maintain at least three full, tight wraps of wire rope
on the drum.
(Dwg. MHP0498)
‘A’ = 1.6 feet (0.5 metre) per inch of drum length:
‘A’ = 19.2 feet (5.85 metres) for 12 inch drum.
‘A’ = 24.0 feet (7.31 metres) for 15 inch drum.
‘A’ = 38.4 feet (11.7 metres) for 24 inch drum.
‘A’ = 43.2 feet (13.2 metres) for 27 inch drum.
Air Supply
The air supply must be clean, free from moisture and lubricated to
ensure optimum motor performance. Foreign particles, moisture
and lack of lubrication are the primary causes of premature motor
wear and breakdown. Using an air filter, lubricator and moisture
separator will improve overall winch performance and reduce
unscheduled down time. The air consumption is 700 scfm
(20 cu. m/min) at rated operating pressure of 90 psig (6.3 bar/
630 kPa) at the winch motor inlet. If air supply varies from
recommended, then winch performance will change.
Notes:
1. Maintain a minimum of 3 tight wraps of wire rope on drum at
all times.
2. Ensure wire rope does not exceed top layer requirement.
Refer to “SPECIFICATIONS” section.
3. If drum is grooved ensure wire rope width is proper size to
seat in grooves on last wrap.
Wire Rope Spooling
Air Lines
To compensate for uneven spooling and the decrease in line pull
capacity as the drum fills up, use as short a wire rope as practical.
When rewinding apply tension to the end of the wire rope to
eliminate line slack. This helps achieve level winding and tight
spooling.
The inside diameter of the winch air supply lines must be at least
1-1/2 inch (38 mm). Before making final connections, all air
supply lines should be purged with clean, moisture free air or
nitrogen before connecting to winch inlet. Supply lines should be
as short and straight as installation conditions will permit. Long
air transmission lines and excessive use of fittings, elbows, tees,
globe valves etc. cause a reduction in pressure due to restrictions
and surface friction in the lines.
Support wire rope spool and have wire rope come off top of spool
and over top of winch drum. This will prevent damage to wire rope.
Overwound
CORRECT
Air Line Lubricator
Refer to Dwg. MHP0191 on page 11.
Winch
Drum
Wire Rope
Spooling
Always use an air line lubricator with these motors. The lubricator
must have an inlet and outlet at least as large as the inlet on the
motor directional control valve. Install the air line lubricator as
close to the air inlet on the motor as possible.
Spool
Spool
Underwound
CORRECT
Winch
Drum
• Lubricator must be located no more than 10 ft. (3 m) from
the motor.
• Shut off air supply before filling air line lubricator.
Wire Rope
Spooling
The air line lubricator should be replenished daily and set to
provide 6 to 9 drops per minute of ISO VG 32 (SAE 10W) oil. A
fine mist will be exhausted from throttle control valve when air
line lubricator is functioning properly.
INCORRECT
Winch
Drum
Wire Rope
Spooling
Spool
(Dwg. MHP2450)
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Description of Part
Fitting, Nipple
Ball Valve
Part Number
51704
71404628
Mufflers (optional feature)
Make sure mufflers are installed in winch exhaust manifold and
control valve exhaust ports. An additional muffler is used on
winches equipped with an emergency stop and overload device.
Check mufflers periodically to ensure they are functioning
correctly.
Motor
(Dwg. MHP0191)
For optimum performance and maximum durability of parts,
provide an air supply of 700 scfm (20 cu. m/m) at 90 psig (6.3
bar/630 kPa). The air motor should be installed as near as possible
to the compressor or air receiver. Recommended pressures and
volumes are measured at point of entry to air motor directional
control valve.
Air Line Filter
Refer to Dwg. MHP0191 on page 11.
It is recommended that an airline strainer/filter be installed as
close as practical to the motor air inlet port, but before lubricator,
to prevent dirt from entering the valve and motor. The
strainer/filter should provide 20 micron filtration and include a
moisture trap. Clean the strainer/filter periodically to maintain its
operating efficiency.
Emergency Stop and Overload System
Refer to Dwg. MHP2434 on page 50.
Air supply line is connected to air control valve. When emergency
stop or overload valve is activated, all winch movement will stop.
Air Pressure Regulator
Refer to Dwg. MHP0191 on page 11.
If an air pressure regulator is used, install between the lubricator
and filter.
• If winch continues to move (payout load) after emergency
stop activates, brake(s) are not holding load and may require
adjustment or repair.
Moisture in Air Lines
When control valve senses a preset pressure difference between
ports, a pilot signal is sent to stop flow of air, all winch movement
will stop.
Moisture that reaches the air motor through air supply lines is a
primary factor in determining the length of time between service
overhauls. Moisture traps can help to eliminate moisture. Other
methods, such as an air receiver which collects moisture before it
reaches the motor, or an aftercooler at the compressor that cools
the air to condense and collect moisture prior to distribution
through the supply lines are also helpful.
Initial Winch Operating Checks
Winches are tested for proper operation prior to leaving the
factory. Before the winch is placed into service the following
initial operating checks should be performed.
1. When first running the motor inject some light oil into the
inlet connection to provide initial lubrication.
Ball Valve Shut Off
2. When first operating the winch it is recommended that the
motor be driven slowly in both directions for a few minutes.
Refer to Dwg. MHP2459 on page 11.
Install in air supply line upstream of control valve. Ensure ball
valve is conveniently located and easily accessible. Advise
operators and support personnel of its location and use.
For winches that have been in storage the following start-up
procedures are required.
1. Give the winch an inspection conforming to the requirements
of “Winches Not in Regular Use” in the “INSPECTION”
section.
Open
2. Pour a small amount of ISO VG 32 (10W) lubricant in the
motor inlet port.
Air
3. Operate the motor for 10 seconds in both directions to flush
out any impurities.
Flow
4. Check to ensure oil levels are “full”.
5. The winch is now ready for normal use.
Closed
Ball Valve
Fitting,
Nipple
(Dwg. MHP2459)
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OPERATION
The four most important aspects of winch operation are:
Winch Mounted Throttle Control Valve Operation
1. Follow all safety instructions when operating the winch.
2. Allow only people trained in safety and operation of this
winch to operate this equipment.
3. Subject each winch to a regular inspection and maintenance
procedure.
4. Be aware of winch capacity and weight of load at all times.
CAUTION
• To avoid damage to rigging, the structure supporting the
rigging and winch, do not “two-block*” the end of wire rope.
* Two blocking occurs when the winch wire rope is multi reeved
using two separate sheave blocks which are allowed to come into
contact with each other during winch operation. When this occurs
extreme forces are exerted on the wire rope and sheave blocks
which may result in equipment and or rigging failure.
WARNING
• The winch is not designed or suitable for lifting, lowering or
moving people. Never lift loads over people.
Operators must be physically competent. Operators must have no
health condition which might affect their ability to act, and they
must have good hearing, vision and depth perception. The winch
operator must be carefully instructed in his duties and must
understand the operation of the winch, including a study of the
manufacturer’s literature. The operator must thoroughly
understand proper methods of hitching loads and should have a
good attitude regarding safety. It is the operator’s responsibility to
refuse to operate the winch under unsafe conditions.
(Dwg. MHP1809)
Remote Mounted Control Valve (optional feature)
Refer to Dwg. MHP2043 on page 12.
Provides for remote mounting of winch control at a fixed location
at up to 20 feet (6 metres) away from winch motor. Air hoses
connect throttle to winch motor to provide winch operation.
Move control throttle handle to the right (clockwise) to payout
wire rope and to the left (counterclockwise) to haul-in wire rope.
Avoid sudden movements of control valve to ensure smooth
operation of winch.
Controls
A spring loaded, motor mounted, live air manual throttle control
valve is supplied as a standard feature on this winch. Optional
remote throttle controls are available. Reference model code on
the winch nameplate and compare it to the “SPECIFICATIONS”
section on page 5 to determine your configuration. The throttle
control provides operator control of the motor speed and direction
of drum rotation. Operate winch throttle control using smooth,
even movements. Do not slam or jerk throttle controls during
operation.
Remote Mounted Control Valve
Winch Mounted Control Valve (standard feature)
Refer to Dwg. MHP1809 on page 12.
The spring loaded, live air, manual control valve mounts to rotary
housing.
To operate control valve, place palm of hand on control knob and
wrap fingers around flange of sliding handle. Squeeze fingers,
lifting sliding handle up to unlock control lever. Shift control lever
in desired direction to payout or haul-in wire rope.
(Dwg. MHP2043)
As viewed from air motor end, move control throttle handle to the
right (clockwise) to payout wire rope and to the left
(counterclockwise) to haul-in wire rope. Avoid sudden movements
of control valve to ensure smooth operation of winch.
When released, handle will return to neutral or center position.
The sliding handle will drop down to engage and lock control
handle in place.
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Remote Pilot Pendant Control (optional feature)
Underwound Operation (optional feature)
Refer to Dwg. MHP2233 on page 13.
Underwound operation is where wire rope haul-in or payout is off
the bottom of drum. This is a special operation and requires a
winch specifically designed for this usage.
Provides for remote winch control at distances of up to 50* feet
(15 metres) away from winch. The pendant pilot control throttle is
a two lever movable control station for winch operation. Pilot
pressure from pendant pilot control throttle activates winch control
valve. The winch control valve, located on winch motor, controls
motor speed and direction of drum rotation. Direction of rotation
is determined by the pendant lever pressed.
Underwound operation requires a reverse bias valve installed in
the control valve.
Control valve operation will be opposite as shown in Dwg.
MHP1809 on page 12. As viewed from air motor end, lift slider
handle up to unlock control lever. Move control throttle handle to
the left (counterclockwise) to payout, and to the right (clockwise)
to haul-in.
Pendant Hose and Operating Levers
Red
Yellow
Green
Emergency Stop (optional feature)
Refer to Dwg. MHP2047 on page 13.
Emergency stop device is located on the control valve. When
activated, winch drum rotation will immediately cease. To activate
emergency stop, conduct the following:
1. Press (push down) red palm valve, located on top of control
valve.
Haul-In
Load
Emergency Stop Operation
Payout
Load
(Dwg. MHP2233)
Press pendant levers using smooth, even movements. To operate
winch using pendant:
1. To haul-in, press ‘RIGHT’ lever.
2. To payout, press ‘LEFT’ lever.
3. To throttle operating speed, regulate amount pendant lever is
pressed. Press lever fully for maximum speed; partially for
slower speeds.
4. To stop haul-in or payout operation, release pendant lever.
Lever will spring return to off position and winch operation
will stop.
Remote Pilot Lever Throttle (optional feature)
(Dwg. MHP2047)
Refer to Dwg. MHP2444, item 358 on page 58.
Provides for remote winch control at distances of up to 50* feet
(15 metres) away from winch. The lever pilot control throttle is a
fixed mount lever control station for winch operation. Pilot
pressure from lever pilot control throttle activates winch control
valve. The winch control valve, located on winch motor, controls
motor speed and direction of drum rotation. Direction of rotation
is determined by direction in which lever is shifted.
• If winch overload occurs, overload device, if equipped, also
stops winch. To operate winch after an overload, reduce load
and reset overload.
Emergency Stop Reset
* For distances greater than 50 feet (15 metres) contact
Ingersoll-Rand Technical Support for control suitability.
Refer to Dwg. MHP2048 on page 14.
1. Rotate red stop button, in counterclockwise direction until
red stop button ‘pops’ up.
2. Winch is ready to resume operation.
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Emergency Stop Reset
Overload Valve Adjustment
(Dwg. MHP2048)
(Dwg. MHP2216)
Overload Device (optional feature)
Checking Overload Valve Setting
An overload device is available on winches with the emergency
shutoff option. Overload device operation is based on differential
pressure between air motor inlet and exhaust. The overload device
is factory preset to actuate at 150% ( 25%) of winch rated
capacity. When an overload condition is sensed, the valve poppet
closes, to cut off supply air to winch, stopping winch operation. If
an overload shutoff occurs, winch load must be reduced. Reset the
overload valve and operate winch in payout direction to lower
load. Refer to ‘Emergency Stop Reset’ section on page 13.
1. Attach load line to a load that is calibrated to maximum load
for which winch is rated.
2. Move control lever to haul-in position. If winch does not lift
load, adjust the adjustment screw. Refer to ‘Overload Valve
Adjustment’ section on page 14.
Setting the Overload
Attach load line to a load that is calibrated to 150% of winch rated
capacity. Shift control lever to haul-in position.
1. If overload valve activates, reset overload valve. Winch is
ready for normal operation.
Overload Valve Adjustment
Refer to Dwg. MHP2216 on page 14.
2. If winch lifts load, lower load. Turn adjustment screw
counterclockwise in 1/4 turn increments until overload valve
activates when control lever is shifted to haul-in position.
After each 1/4 turn, retest winch.
5/16 in. or 8 mm open ended wrench required.
1. Adjust overload valve by turning adjustment screw located at
bottom of control valve.
2. Rotating adjustment screw clockwise will increase pressure
required to activate overload valve.
Overload Valve Reset
• This adjustment can cause overload device to NOT activate
before winch’s overload limit is exceeded. This procedure
should only be done by personnel trained in testing and
servicing this winch.
3. Rotating adjustment screw counterclockwise will decrease
pressure required to activate overload valve.
(Dwg. MHP2049)
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Automatic Drum Brake (optional feature)
Winch Brakes
Automatic Disc Brake
The automatic drum brake is a spring applied, air released,
externally mounted brake which uses an air actuated, spring
loaded cylinder to automatically disengage the brake when the
motor is operated in either the haul-in or payout directions. Air
pressure directed to the cylinder overcomes spring pressure to
release brake and allow drum to rotate.
When the control valve is placed in the neutral position, air in the
cylinder is vented which allows the cylinder spring to
automatically engage brake and prevent drum rotation.
The automatic disc brake is spring applied, air released. When the
winch is operated in payout direction, air pressure acting on the
diaphragm overcomes spring pressure and releases brake. The
brake automatically engages when winch operation is returned
from payout direction to neutral or when shifted to haul-in
direction. When winch is in neutral or haul-in positions the brake
air is vented and brake springs apply the brake. The springs, acting
on the pressure plate, compress brake friction and separator plates
and engage brake to prevent drum rotation in payout direction.
The cam type sprag clutch assembly allows drum rotation in haul-
in direction with brake plates engaged, but prevents drum from
rotating in payout direction.
Adjustments to the cylinder clevis can be made to compensate for
normal brake lining wear. The drum brake must be kept properly
adjusted to hold the required load. Refer to ‘Adjustments’ in the
“MAINTENANCE” section. If brake band cannot be adjusted to
hold rated load, the brake must be disassembled, inspected and
repaired.
A minimum air pressure of 25 psi (1.72 bar/172.4 kPa) is required
to release brake.
Disc brake adjustment is not required. If disc brake does not
operate properly it must be disassembled, inspected and repaired.
Constant Tension Manifold (optional feature)
Refer to Dwg. MHP2436 on page 52.
With auxiliary valve (744) in the ‘NORMAL’ position, the winch
control valve will provide normal winch operation. With auxiliary
valve selector in the ‘TENSIONING’ position, the winch will
automatically haul-in wire rope to maintain tension.
Manual Drum Brake (optional feature)
Refer to Dwg. MHP1375 on page 15.
The manual drum brake may be applied by pushing down on the
handle and released by pulling up. By pushing the handle down
fully, it will go over-center and lock in that position, preventing
drum rotation. The drum brake must be kept properly adjusted to
hold the required load. Refer to ‘Adjustments’ in the
“MAINTENANCE” section. If brake band cannot be adjusted to
hold the rated load, the brake must be disassembled, inspected and
repaired.
The auxiliary valve provides a preset air pressure to the air motor
and disc brake. This allows the brake to be released, and winch to
over haul during ‘TENSIONING’ operations. In this position the
winch will maintain a constant tension on the wire rope.
The auxiliary valve comes set at zero from the factory. All
adjustments must be made in the field. These adjustments can be
changed at any time to accommodate the current load. Refer to
‘Adjustments’ in the “MAINTENANCE” section for procedures.
Drum Brake Handle Operation
Operation
Place auxiliary valve in ‘NORMAL’ position and use winch
control to position the end of load line at the load. Connect load
line to the load and use winch control to remove all slack from the
load line.
• Ensure slack load line is taken up by operating winch control
valve with selector in NORMAL position. If selector lever is
placed in TENSION position the winch will immediately
attempt to establish line tension causing line to ‘snap’
resulting in injury or damage to property.
Actuate auxiliary valve to ‘TENSIONING’ position. Winch will
automatically haul-in to maintain tension on load line.
Free Spool (optional feature)
Refer to Dwg. MHP2414 on page 61.
The Free Spool option allows wire rope to be spooled from the
drum without operating winch motor.
(Dwg. MHP1375)
During normal winch operations the free spool is in non-free spool
position. The output shaft connects outboard upright to drum. The
free spool handle is in the ‘DOWN’ position.
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Free Spool Operation
Drum
Engaged
Position
• To avoid damage to mounting structure and winch, the winch
drum must be stationary and there must be no load on wire
rope during Free Spool operation.
Step 1.
Free Spool Position:
1. Engage drum band brake to lock drum in position.
2. Pull handle (512) out.
3. Rotate handle (512) counterclockwise, 180° to the ‘UP’
position.
4. Release handle. Ensure handle is engaged in slots in detent
plate (514).
Step 2.
The drum is now in free spool. During free spool operations use
drum band brake to control drum speed during wire rope payout.
Non Free Spool Position:
Step 3.
Before operating winch with motor, ensure winch is not in free
spool mode.
1. Engage drum band brake.
2. Pull handle (512) out.
3. Rotate handle clockwise, 180° to the ‘DOWN’ position. This
connects winch drum to outboard upright. If required, band
brake can be released and drum slowly rotated by hand to
assist in lining up output shaft (28) splines with upright.
4. Release handle. Ensure handle is engaged in slot in detent
plate (514).
Drum
Free Spool
Position
NOTE: Reverse prodedure
before operating winch.
(Dwg. MHP1322)
INSPECTION
Inspection information is based in part on American National
Standards Institute Safety Codes (ASME B30.7).
Deficiencies revealed through inspection, or noted during
operation, must be reported to designated personnel instructed in
safety, operation and maintenance of this equipment.
A determination as to whether a condition constitutes a safety
hazard must be decided, and the correction of noted safety hazards
accomplished and documented by written report before placing
the equipment in service.
WARNING
• All new, altered or modified equipment should be inspected
and tested by personnel instructed in safety, operation and
maintenance of this equipment to ensure safe operation at
rated specifications before placing equipment in service.
• Never use a winch that inspection indicates is damaged.
Records 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 authorized review.
Frequent and periodic inspections should be performed on
equipment in regular service. Frequent inspections are visual
examinations performed by operators or personnel trained in
safety and operation of this equipment and include observations
made during routine equipment operation. Periodic inspections are
thorough inspections conducted by personnel trained in the safety,
operation and maintenance of this equipment.
ASME B30.7 states inspection intervals depend upon the nature of
the critical components of the equipment and the severity of usage.
The inspection intervals recommended in this manual are based on
intermittent operation of the winch eight hours each day, five days
per week, in an environment relatively free of dust, moisture, and
corrosive fumes. If the winch is operated almost continuously or
more than the eight hours each day, more frequent inspections will
be required.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages, allowing
corrective action to be taken before the condition becomes
dangerous.
Wire Rope Reports
Records should be maintained as part of a long-range wire rope
inspection program. Records should include the condition of wire
rope removed from service. Accurate records will establish a
relationship between visual observations noted during frequent
inspections and the actual condition of wire rope as determined by
periodic inspections.
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Frequent Inspection
Periodic Inspection
On equipment in continuous service, frequent inspection should
be made by operators at the beginning of each shift. In addition,
visual inspections should be conducted during regular operation
for indications of damage or evidence of malfunction (such as
abnormal noises).
Periodic inspection intervals for winch use under various
conditions is listed below:
NORMAL
HEAVY
semiannually
SEVERE
quarterly
yearly
1. WINCH. Prior to operation, visually inspect winch housings,
controls, brakes, side rails, uprights and drum for indications
of damage. Any discrepancies noted must be reviewed and
inspected further by authorized personnel instructed in the
operation, safety and maintenance of this winch.
2. WIRE ROPE. Visually inspect all wire rope which can be
expected to be in use during the day’s operations. Inspect for
wear and damage indicated by distortion of wire rope such as
kinking, “birdcaging,” core protrusion, main strand
Disassembly may be required as a result of frequent inspection
findings or in order to properly inspect individual components.
Disassembly steps are described in the “MAINTENANCE”
section. Maintain written records of periodic inspections to
provide an accumulative basis for continuing evaluation. Inspect
all items listed in ‘Frequent Inspection.’ Also inspect the
following:
1. RAILS and UPRIGHTS. Check for deformed, cracked or
corroded main components. Replace damaged parts.
2. FASTENERS. Check retainer rings, split pins, 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.
displacement, corrosion, broken or cut strands. If damage is
evident, do not operate winch until discrepancies have been
reviewed and inspected further by personnel knowledgeable
on wire rope safety and maintenance procedures.
4. WIRE ROPE. In addition to ‘Frequent Inspection’
requirements, also inspect for the following:
NOTICE
• The full extent of wire rope wear cannot be determined by
visual inspection. At any indication of wear inspect the wire
rope in accordance with instructions in “Periodic Inspection.”
a. Buildup 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
3. AIR SYSTEM. Visually inspect all connections, fittings,
hoses and components for indication of air leaks. Repair any
leaks or damage.
4. CONTROLS. During operation of winch, verify response to
control is quick and smooth. If winch responds slowly or
controls stick, do not operate winch until all problems have
been corrected.
5. BRAKES. During winch operation test brakes. Brakes must
hold load without slipping. Automatic brakes must release
when winch motor throttle is operated. If brakes do not hold
load, or do not release properly, brakes must be adjusted or
repaired.
6. WIRE ROPE REEVING. Check reeving and ensure wire
rope is properly secured to the drum. Do not operate winch
unless wire rope feeds onto the drum smoothly.
7. LUBRICATION. Refer to “LUBRICATION” section for
recommended procedures and lubricants.
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 o remain in
service. Refer to Dwg. MHP0056 on page 17.
8. PENDANT (optional feature). Ensure operation of pendant
levers is smooth and that winch is responsive to pendant
control. Pendant levers must spring return to neutral position
when released.
9. MANUAL THROTTLE LEVER. Ensure operation of
manual throttle lever is smooth and winch is responsive to
lever movement. Lever must return to neutral and lock in
place when released. If winch responds slowly or controls
stick, do not operate winch until all problems have been
corrected.
10. MOTOR. During operation check motor housing for excess
heat build up. Housing should not be hot to touch. Listen for
grinding or knocking noises. Ensure lubricated air supply
provides 6 to 9 drops per minute of ISO VG 32 (SAE 10W)
oil when winch is operated at rated capacity. Operate winch
slowly in both directions to verify operation.
(Dwg. MHP0056)
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.
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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 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 drum band brake to compensate for normal brake
lining wear. Refer to ‘Adjustments’ in the
11. OVERLOAD DEVICE (optional feature). Ensure overload
device is properly set to stop the winch when loads exceed
150% (+/- 25%) of winch rated capacity. If winch does not
shut down, contact your distributor or the factory for repair
information.
Winches Not in Regular Use
“MAINTENANCE” section. 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 as described in the “MAINTENANCE”
section.
1. Equipment which has been idle for a period of one month or
more, but less than six months, shall be given an inspection
conforming to the requirements of ‘Frequent Inspection’
before being placed in service.
2. Equipment which has been idle for a period of over six
months shall be given a complete inspection conforming with
the requirements of ‘Periodic Inspection’ before being place
in service.
3. Standby equipment shall be inspected at least semiannually
in accordance with the requirements of ‘Frequent
Inspection’. In abnormal operating conditions equipment
should be inspected at shorter intervals.
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 fasteners
are in good condition and tight.
8. LABELS AND TAGS. Check for presence and legibility of
labels. Replace if damaged or missing.
9. DRUM GUARD (optional feature). Verify fasteners are tight
and in good condition. Ensure guard is in good condition.
10. EMERGENCY STOP VALVE (optional feature). During
winch operation verify the emergency shut-off valve
operation. Valve must stop winch operation quickly. Valve
must reset properly. Refer to ‘Emergency Stop Valve’ in the
“OPERATION” section for procedures.
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INSPECTION AND MAINTENANCE REPORT
Ingersoll-Rand Force 5 Series FA5A Air Winch
Model Number:
Serial Number:
Date:
Inspected by:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection:
(_____ Quarterly _____ Semiannually _____ Yearly)
Operating Environment:
Normal: ___ Heavy: ___ Severe: ___
2. Discrepancy(s) noted during Frequent Inspection
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________
Refer to the Parts, Operation and Maintenance Manual “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.
CORRECTIVE
CONDITION
ACTION
COMPONENT
Uprights and
NOTES
Pass
Fail
Repair Replace
Side Rails
Drum Band Brake
(125% Load Test)
Disc Brake
(125% Load Test)
Drum Band Brake
(Visual Inspection)
Disc Brake
(Visual Inspection)
Motor
Controls
Air System
Fasteners
Reduction Gears
Labels and Tags
Shafts
---
---
Drum Guard
Wire Rope Wedge
Emergency Stop Valve
Overload Device
Wire Rope
---
---
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 copied and used as an inspection/maintenance record.
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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. No air supply to winch.
Winch is overloaded.
Check air supply line connections and hoses.
Reduce load to within rated capacity.
Reset Emergency Shut-off valve.
Emergency Stop Valve engaged.
Shipping plugs may still be in place. Remove shipping plugs in valve.
Load continues to move Brake(s) slipping.
when winch is stopped.
Check brake band adjustment and brake band lining wear. Disassemble and
inspect disc brake. Refer to “MAINTENANCE” section on page 24.
Check pendant/throttle levers spring return to normal (neutral) position when
released.
Winch motor controls sticking.
Winch is overloaded.
Reduce load to within rated capacity.
Winch does not lift/pull Motor may be damaged.
load.
Remove and disassemble motor. Examine all parts and replace any that are
worn or damaged.
Winch is overloaded.
Reduce load to within rated capacity.
Insufficient air supply.
Verify air supply pressure and volume at winch inlet meets the requirements.
Refer to “SPECIFICATIONS” section on page 5. Clean air line filter.
Throttle lever or
pendant lever moves
but winch does not
operate.
Motor may be damaged.
Insufficient air supply.
Disassemble and clean the motor and replace any broken or damaged parts.
Ensure the air pressure at the winch inlet is at least 90 psig (6.3 bar/630 kPa)
at rated volume. Clean air line filter.
Check hose and fitting connections. Inspect hose(s) for breaks. Tighten
fittings and repair or replace hoses as necessary.
Air leak.
Emergency Stop Valve engaged.
Low oil level.
Improper lubrication.
Reset Emergency Shut-off valve.
Motor runs hot or
makes excessive noise
during operation.
Check oil levels in the motor. Add oil as required to obtain the proper level.
Replace oil with type recommended in “LUBRICATION” section on page
21. 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.
Air lines freeze.
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.
Remove and disassemble motor. Inspect all parts and replace all worn or
damaged parts.
Motor may be damaged.
Brake(s) not releasing.
Water in air supply.
Refer to brakes in “MAINTENANCE” section on page 24.
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.
Lubricate valve through grease fitting with recommended lubricant. Refer to
‘Air Throttle’ on page 22 in “LUBRICATION” section.
Throttle lever hard to
actuate, or lever does
not spring return to
neutral.
Valve body sticking in bushing.
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TROUBLESHOOTING (CONTINUED)
Automatic Band Brake:
Brake cylinder will not Band brake out of adjustment.
Adjust band brake to maintain correct cylinder stroke.
If air is noticed escaping from cinder breather when attempting to release
brake, replace or repair cylinder.
release.
Leaking cylinder seals.
Dirty filter in air supply.
Faulty dump valve.
Clean or replace filter.
Check dump valve exhaust port. Air should exhaust when control valve
handle is neutral. If no air escapes, replace dump valve.
Automatic Disc Brake:
Brake fails to release. Low air supply pressure.
Leaking piston seals.
Ensure air pressure at inlet to disc brake is at least 50 psig (3.4 bar/340 kPa).
Inspect brake breather. If air escapes from brake breather when attempting to
release brake, replace brake seals.
No release pressure at brake port.
Sticking brake piston.
Check for proper operation of winch controls.
Apply 50 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” section.
LUBRICATION
To ensure continued satisfactory operation of the winch, all points
requiring lubrication must be serviced with correct lubricant at the
proper time interval as indicated for each assembly.
2. Always inspect removed oil for evidence of internal damage
or contamination (metal shavings, dirt, water, etc.). If
indications of damage are noted, investigate and correct
before returning winch to service.
3. After winch operation, allow oil to settle before topping off.
4. Always collect lubricants in suitable containers and dispose
of in an environmentally safe manner.
Lubrication intervals recommended in this manual are based on
intermittent operation of winch, eight hours each day, five days per
week. If winch is operated almost continuously or more than eight
hours each day, more frequent lubrication will be required. Also,
lubricant types and change intervals are based on operation in an
environment relatively free of dust, moisture, and corrosive fumes.
Use only those lubricants recommended. Other lubricants may
affect performance of winch. Approval for the use of other
lubricants must be obtained from your Ingersoll-Rand distributor.
Failure to observe this precaution may result in damage to the
winch and its associated components.
Reduction Gear and Disc Brake Lubrication
Refer to Dwg. MHP0501 on page 22.
The reduction gear and disc brake are filled and shipped with oil
from the factory. Check oil level before initial winch operation.
These components are splash lubricated by the oil in the housing
and have no other means of lubrication. It is therefore important to
use high quality Extreme Pressure (EP) rust and oxidation
inhibited gear oils to ensure maximum performance and minimum
down time for repairs. Oil capacity is approximately 3 quarts (2.8
litres). Oil from the reduction gear assembly also provides
lubrication for the disc brake.
INTERVAL
LUBRICATION CHECKS
Start of each
shift
Check flow and level of air line lubricator
(approximately 6 to 9 drops per minute required
at maximum motor speed).
On winches equipped with a disc brake, the reduction gear is
vented through the disc brake breather plug.
Check winch motor oil level.
Monthly
Yearly
Lubricate components supplied by grease
fittings.
Recommended Lubricant
Inspect and clean or replace air line filter.
Check reduction gear oil level.
Temperature
Below 32° F (0° C)
Type Oil
ISO VG 68 (SAE 2 EP)
ISO VG 100 (SAE 3 EP)*
ISO VG 150 (SAE 4 EP)
Drain and refill winch reduction gear oil.
Drain and refill winch motor oil.
32° to 80° F (0° to 27° C)
Above 80° F (27° C)
Note: Intervals are based on winch operation in a normal
environment as described in “INSPECTION” section. In ‘Heavy’
or ‘Severe’ operating conditions adjust lubrication intervals
accordingly.
* Units are shipped from factory with ISO VG 100 (SAE 3 EP)
lubricant. Reduction Gear capacity is approximately 3 quarts
(2.8 litres).
Recommended Grease
General Lubrication
Temperature
Type Grease
-20° to 50° F
(-30° to 10° C)
EP 1 multipurpose
lithium based grease
1. Drain and replace oil in the motor, disc brake and reduction
gear after the first 50 hours of initial winch operation.
Thereafter, drain and replace oil according to intervals
recommended.
30° to 120° F
(-1° to 49° C)
EP 2 multipurpose
lithium based grease
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Reduction Gear and Disc Brake Fill and Drain Procedures
Motor
Refer to Dwg. MHP0501 on page 22.
Refer to Dwg. MHP2126 on page 22.
To Fill:
The motor is splash lubricated by oil in the motor housing and has
no other means of lubrication. It is therefore important to use only
high quality rust and oxidation inhibiting lubricant to ensure
maximum performance and minimum downtime for repairs. Refer
to ‘Recommended Motor Lubricant’ table on page 22.
1. Rotate the winch drum to align the reduction gear plugs to the
fill position. Fill plug position is at top center.
2. Remove the fill plug on the reduction gear and the level plug
on the disc brake housing. Fill slowly until oil flows from the
disc brake level plug hole.
3. Reinstall the plugs.
Oil capacity for the winch motor is 3 quarts (2.8 litres). Add oil
through the filler opening until oil flows from the level plug hole.
Add oil slowly to prevent spilling.
NOTICE
• Depending on ambient temperature it may take several
The motor should be level-checked daily or at the start of each
shift after any accumulated water has been drained off. When
motors are operated in temperatures below freezing, wait long
enough at end of shift for water to separate from oil but not long
enough for it to freeze. Drain the water then refill to the level plug
located on side of motor housing. If desired, all the oil may be
drained at the end of the shift and the motor refilled with new oil.
minutes for oil to flow from the disc brake level plug hole. Wait
10 minutes after oil starts to flow from level plug hole before
reinstalling plug fittings.
CAUTION
• Do not over fill. Excess oil will reduce operating efficiency
and increase oil temperature.
Recommended Motor Lubricant
Temperature
Under 32° F (0° C)
Recommended Viscosity
ISO VG 46 (SAE 10W)
ISO VG 68 (SAE 20W) *
ISO VG 100 (SAE 30W)
The use of unsuitable oil may result in excessive temperature rise,
loss of efficiency and possible damage to the gears. Use only high
quality Extreme Pressure (EP) rust and oxidation inhibiting
lubricant.
32° to 80° F (0° to 27° C)
Above 80° F (27° C)
To Drain:
* Units are shipped from factory with ISO VG 68 (SAE 20W)
lubricant. Motor oil capacity is approximately 3 quarts (2.8 litres).
1. Rotate the winch drum to align the reduction gear plugs to the
drain position. Drain plug is located at bottom center.
2. Remove the reduction gear drain plug and install long pipe
nipple threaded at one end to 3/8-18 NPT. Remove drain vent
plug. Remove the disc brake drain plug.
• DO NOT use synthetic lubrication in air motor. Synthetic
lubricants will cause oil to blow by piston.
NOTICE
Motor Lubrication Locations
• Always drain oil into a suitable container and inspect
drained oil for evidence of damage, metal shavings, dirt, water,
etc. Dispose of oil in an environmentally safe manner.
3. Collect the drained oil and dispose of properly. If replacing
oil, refer to ‘To Fill’ instructions. Reinstall the reduction gear
and disc brake plugs.
Oil Fill and Drain Plug Locations
(Dwg. MHP2126)
(Dwg. MHP0501)
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Motor Fill and Drain Procedures
Wire Rope
Refer to Dwg. MHP2126 on page 22.
Follow the wire rope manufacturer’s instructions. At a minimum,
observe the following guidelines.
1. Clean with a brush or steam to remove dirt, rock dust or other
foreign material on the surface of the wire rope.
To Fill:
1. Remove fill cap and level plug. Fill with oil slowly until oil
drains from level plug hole.
CAUTION
CAUTION
• Do not use an acid-based solvent. Only use cleaning fluids
specified by the wire rope manufacturer.
• Do not over fill. Excess oil will reduce operating efficiency
and increase oil temperature.
2. Apply a wire rope lubricant, Ingersoll-Rand LUBRI LINK-
GREEN or ISO VG 100 (SAE 30W) lubricant.
3. Brush, drip or spray lubricant weekly, or more frequently,
depending on severity of service.
The use of unsuitable oil may result in excessive temperature rise,
loss of efficiency and possible damage to the motor. Use only high
quality rust and oxidation inhibiting lubricant.
To Drain:
1. Remove lower case drain plug in motor housing. Loosen fill
Seals and Bearings
cap to vent the motor housing.
If winch is disassembled, clean all parts thoroughly and coat
bearings and seals with clean grease. Refer to the ‘Recommended
Lubricants’ section. Use sufficient grease to provide a good
protective coat.
Air Throttle Control Valve
The control valve is lubricated through the lubricator filter. It is
not necessary to lubricate control valve, maintain proper levels on
lubricator.
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MAINTENANCE
Cleaning Parts
WARNING
The area to be coated must be clean and free from loose coating.
Remove any surface corrosion. To paint thermoplastic coated
parts, the parts must be sand blasted in order to ‘rough up’ the
surface for proper paint adhesion. Sand blasting will not remove
thermoplastic coating (abrasive material will bounce off).
• 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 personnel trained in safety and service on this
winch to perform maintenance.
Loose coating can be removed by cutting with a sharp cutting tool
(chisel, putty knife or knife).
• 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 regulations set forth in
areas outside the USA.)
Heat Source
• Shut off air system and depressurize air lines before
performing any maintenance.
WARNING
• When using an open flame be aware of the materials around
the work area. Some solvents, lubricants and materials are
extremely flammable.
Maintenance Intervals
• Drain all components of lubricants, water or any other
fluids. Remove, or open all vents and drains. Components will
be hot and may discharge hot fluids or gases. Allow sufficient
time for components to cool, or cool off components, prior to
handling. Gaskets, seals, ‘O’ rings, and any components that
may be damaged should be removed prior to applying coating.
The Maintenance Interval chart is based on intermittent operation
of winch eight hours each day, five days per week. If winch
operation exceeds eight hours per day, or use is under HEAVY or
SEVERE conditions, more frequent maintenance should be
performed. Refer to ‘Periodic Inspection’ on page 17 in
“INSPECTION” section for interval guidance.
Thermoplastic coating is heat applied. The surface of the
component to which the thermoplastic coating is being applied
must be maintained at a temperature of at least 150° F (66° C),
but not over 170° F (77° C). Optimum temperature is 300° F
(149° C) for best results. A small propane torch (Ingersoll-Rand
Part No. 71308886) or heat gun (Ingersoll-Rand Part No.
71308894) can be used.
INTERVAL
MAINTENANCE CHECK
Start of each shift Make a thorough visual inspection of the
(Operator or
Maintenance
Personnel)
winch for damage. Do not operate winch if
damaged.
Operate winch at low RPM in both
directions. Winch must operate smoothly
without sticking, binding or abnormal
noises. Check operation of the brake(s).
NOTICE
3 Months
(Maintenance
Personnel)
Inspect drum brake friction linings. Clean
or replace parts as required. Adjust drum
brake as necessary.
• When using a heat source always keep it moving. Small
circles work best. Failure to do so will result in a scorched area
at the repair.
Yearly
(Maintenance
Personnel)
Inspect the winch gearing, shafts and
bearings for wear and damage. Repair or
replace as necessary.
The choice of heat gun or propane torch depends on the size of the
area to be coated and the amount of time available to accomplish
the task. The propane torch heats the surface faster, but is hard to
control and can scorch the coating. The heat gun is slower, easier
to control and generally results in a better looking finish.
Check all supporting members, including
foundations, fasteners, nuts, sheaves and
rigging, etc. for indications of damage or
wear. Repair or replace as required.
Repairing Surfaces
Reduction Gear Assembly
For minor repairs to the thermoplastic coating conduct the
following:
It is recommend that the first oil change be done after
approximately 50 hours initial operation. Always inspect removed
oil for evidence of internal damage (metal shavings, dirt, water,
etc.). Refer to the “LUBRICATION” section for recommended
lubricants.
1. If the under laying surface is not corroded and the scratch is
less than 1/16 inch (1.6 mm) wide the surrounding
thermoplastic coating can be heated until the material flows
together. For clean surfaces with damage greater than 1/16
inch (1.6 mm) heat the area and then apply thermoplastic
coating powder (Ingersoll-Rand Part No. 71308902 [2 oz.
(56.7 g)] to fill the area. Continue heating until coating
liquefies and flows together with the existing coating.
2. Corrosion in damaged area must be removed. Sandblast or
wire brush the area to remove corrosion. If corrosion exists,
ensure the corrosion has not penetrated below the surface of
existing thermoplastic coating. This can usually be easily
determined by checking to see if the coating is loose around
Thermoplastic Coating
Thermoplastic coating is an extremely tough and durable coating
designed to take the toughest treatment without chipping or
peeling. Special steps must be taken to protect the coating when
parts are removed, replaced and if excessive environmental or
operational conditions have damaged the coating.
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the corroded area. Cut away coating as necessary to expose
corrosion for removal. If the damaged area is less than 1/16
inch (1.6 mm) wide the surrounding thermoplastic coating
can be heated until the material flows together. For surfaces
with damage greater than 1/16 inch (1.6 mm) heat the area
and then apply thermoplastic coating powder (Ingersoll-
Rand Part No. 71308902 [2 oz. (56.7 g)] to fill the area.
Continue heating until coating liquefies and flows together
with the existing coating.
2. Repeat step 1 twice while operating winch in both directions
(payout and haul-in). The brake link stud may require
tightening to stop drum rotation.
3. Adjust brake as described in steps 1 through 7 above.
Automatic Drum Band Brake (optional feature)
Refer to Dwg. MHP2433 on page 45.
For adjustments described in the following text, references to
“clockwise” and “counterclockwise” directions refer to directions
as viewed from the head end of capscrew (120).
3. Allow the repaired area to cool. Quenching with water is
acceptable. Inspect the repair. Rough spots, minor scorching
and excess coating deposits can be wet sanded to remove the
imperfections. To return the gloss finish, reheat the surface
carefully.
For large bare surfaces or new parts:
• If brake band cannot be adjusted to hold rated load, replace
the brake band assembly.
1. Coating these components can be done more economically
and with better end results by using an electrostatic powder
application process or flamespray process. Contact Ingersoll
Rand Technical Assistance for more information.
1. Loosen jam nut (117) closest to plunger (114).
2. Adjust band assembly using capscrew (120).
a. To loosen band brake, turn capscrew (120) in a
counterclockwise direction.
For specific disassembly and assembly information refer to
‘Assembly’ or ‘Disassembly’ in the “MAINTENANCE” section.
b. To tighten band brake, turn capscrew (120) in a
clockwise direction.
Adjustments
Disc Brake
• If capscrew (120) is not accessible, jam nut (117) [located
closest to the head of capscrew (120)] may be used to adjust
band brake. Ensure capscrew turns with nut.
Brake adjustment is not required. If the disc brake does not hold
rated load, disassemble and repair.
3. When adjustments are complete tighten jam nut (117) closest
to plunger (114).
NOTICE
• Winches are provided with a breather plug located at the top
of the disc brake housing. If the brake assembly is removed or
repaired ensure the breather is installed and located at the top
of the brake housing during reassembly.
Pilot Air Control Valve Adjustment (optional feature)
Refer to Dwg. MHP2416 on page 48.
Manual Drum Band Brake (optional feature)
If winch operating speeds differ from performance specifications
pilot air control valve may require adjustment.
1. Loosen nut (264) and adjust adjusting screw (270), located in
valve cap end (268), until drum speed for no-load haul-in
equals drum speed for full load payout.
2. Rotate screw (270) ‘out’ to increase drum speed and ‘in’ to
decrease drum speed. It is suggested that a chalk mark be
placed on drum flange so that drum rpm can be accurately
counted.
Refer to Dwg. MHP1448 on page 44.
1. Release wire rope tension on the drum.
2. Raise handle (135) to free brake bands (136) and (137).
3. Remove cotter pin (139) and pin (138).
4. Rotate brake link stud (141) clockwise to increase brake
torque.
5. Install pin (138) and check adjustment.
Constant Tension Manifold (optional feature)
• If brake band cannot be adjusted to hold rated load, replace
brake band assembly.
Refer to Dwg. MHP2416 on page 48.
The regulator is preset at 0 psig (0 bar/0 kPa), therefore requires
adjustment when winch is installed. To adjust for specific load
applications, regulator pressure may be adjusted to increase or
decrease tension setting.
6. Adjust brake so when brake handle locks (goes over-center),
brake will hold rated load.
7. Install cotter pin (139) and bend ends apart when adjustment
is complete.
Regulator gauge and regulator are accessible through cover.
For new Brake Linings:
Run-in new brake linings to remove loose material and allow new
lining to conform to brake drum.
1. Operate winch while applying increasing pressure to brake
band handle until drum stops.
• When adjusting regulator, ensure winch control lever is
locked in neutral position and tension selector lever is in the
NORMAL position.
• Winch supply air is NOT turned off during regulator
adjustments. To prevent accidental winch operation, allow
only a single person, trained in operation, safety and
maintenance of this product, to conduct regulator
adjustments.
• Observe end of load line. Drum should only complete 3-5 full
rotations before stopping.
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Regulator Adjustment Procedure:
Refer to Dwg. MHP2416 on page 48.
1. Attach test load of desired weight to load line, or connect
load line to scale.
7. Do not remove any part which is a press fit in or on a
subassembly unless the removal 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 the bearing with a sleeve slightly smaller than the outside
diameter of the bearing. The end of the sleeve or pipe which
contacts the bearing must be square. Protect bearings from
dirt by keeping them wrapped in clean cloths.
• Ensure load line is connected to load and excessive slack is
taken up before activating auxiliary valve. When activated,
auxiliary valve will automatically engage and winch will
operate at full speed to set tension on load line.
Thermoplastic Coated Parts Disassembly
Thermoplastic coating on capscrew heads, nuts, housings and
other components can be removed as follows:
2. With winch control valve remove all slack from load line.
Setting with test load:
1. Actuate auxiliary valve to TENSIONING position. Winch
should operate, causing load line to become taut. To increase
tension, turn regulator knob clockwise until load begins to
rise. Turn regulator knob counterclockwise a minimum of ¼
turn, or until load is balanced (does not raise or lower). Note
pressure indicated on gauge for future setting reference.
CAUTION
• Separate parts using proper tools. Ensure machined surfaces
are not damaged during disassembly.
1. Fasteners:
a. Push tool into or over fastener, forcing coating off of the
fastener.
b. If coating is too thick, then heat the fastener to soften
coating. Socket or wrench will push softened coating
off, allowing removal of part.
c. For socket head capscrews, setscrews, etc., heat the
component until coating is softened. Use a small
screwdriver or similar tool to remove coating to allow
access for wrench.
Setting with scale:
1. Actuate auxiliary valve to TENSIONING position. Winch
should operate, causing load line to become taut. To increase
tension, turn regulator knob clockwise until scale indicates
desired tension. Note pressure indicated on gauge for future
setting reference.
2. For housings, plates and other coated mating components use
a sharp knife or similar tool to cut through coating around
mating area of components.
Disassembly
General Disassembly Instructions
The following instructions provide the necessary information to
disassemble, inspect, repair, and assemble the winch. Parts
drawings are provided in the Parts Section.
Drum Guard Disassembly (optional feature)
Refer to Dwg. MHP0658 on page 62.
If a winch is being completely disassembled for any reason, follow
the order of the topics as they are presented. It is recommended
that all maintenance work on the winch be performed in a clean
dust free work area.
1. Remove capscrews (592).
2. Remove brackets (591) or (595) by sliding out of drum guard
(590).
3. Remove ‘O’ rings (109) and discard.
In the process of disassembling the winch, observe the following:
1. Never disassemble the winch any further than is necessary to
accomplish the needed repair. A good part can be damaged
during the course of disassembly.
2. Never use excessive force when removing parts. Tapping
gently around the 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
the part being heated is already worn or damaged beyond
repair and no additional damage will occur to other parts.
4. Carefully remove drum guard (590) from rear (drum brake
side) side rail (65). The drum guard attaches to side rail using
tabs. The smaller, upper tabs are visible on top of the side
rail. The longer, lower tab is located beneath side rail edge.
During removal care must be taken not to bend tabs. To
correctly remove, at the point where drum guard and side rail
meet, push or tap lower portion of drum guard in towards
winch drum (62). The direction of force should be directly
away from side rail. Do not pull up or down as tabs may
become deformed.
In general, the winch is designed to permit easy disassembly and
assembly. The use of heat or excessive force should not be
required.
Winch Disassembly
Refer to Dwgs. MHP0649 on page 38 and MHP0690 on page 40.
1. Remove the wire rope from the drum. Remove wire rope
anchor (63) and store for reassembly.
2. Relieve pressure in air lines and winch air components by
operating winch control several times after air supply has
been turned off.
4. Keep the work area as clean as practical, to prevent dirt and
other foreign matter from getting into bearings or other
moving parts.
5. All seals and ‘O’ rings should be discarded once they have
been removed. New seals and ‘O’ rings should be used when
assembling the winch.
6. When grasping a part in a vise, always use leather-covered or
copper-covered vise jaws to protect the surface of the part
and help prevent distortion. This is particularly true of
threaded members, machined surfaces and housings.
WARNING
• Shut off, bleed down and disconnect air supply line before
performing any disassembly procedures.
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3. Disconnect and tag air lines.
13. Remove capscrews (33) and cover (72) from drum if not
equipped with a band brake.
14. Outboard upright (26) removal:
4. To drain oil refer to “LUBRICATION” section.
5. Remove capscrews and nuts securing winch to its foundation
and move to a suitable work area before beginning
disassembly.
a. For units without disc brake: remove cover (2) by
removing six capscrews (1). Pry cover and gasket (18)
from upright. Pull upright away from drum (62) in a
straight horizontal direction. Remove output shaft (28),
oil seal (29) and bearing (30) from upright. Discard oil
seal. Discard bearing if inspection indicates
replacement. Note the condition of capscrews (27)
located in output shaft. Note positions for reinstallation.
b. For units with a disc brake: pull upright away from
drum (62) in a straight horizontal direction. Remove
output shaft (28), oil seal (29) and bearing (30) from
upright. Discard oil seal. Discard bearing if inspection
indicates replacement.
WARNING
• The air motor weighs approximately 260 lbs. (118 kg).
Adequately support air motor before removing motor
mounting capscrews.
6. Remove the ten capscrews (197), lockwashers (196),
securing the motor assembly to the motor adapter (71).
Using a hoist to support the motor, pull the motor straight
away from the winch. Refer to the ‘Motor Disassembly’
section if motor disassembly is required.
7. Remove drive shaft (61) and coupling (60).
8. If equipped, disconnect drum band brake as described below.
• Ensure the reduction gear oil is drained before disassembly
and that the drain and fill plugs are removed. When using
jacking bolts, ensure the cover lifts evenly by turning bolt one
full turn and then repeating on the other bolt. If cover jams,
remove jacking bolts and gently tap around the cover to reseat
it before starting over. Careful prying of the cover along its
diameter during jacking, using a soft material wedge, to guide
the cover is acceptable. Care must be taken not to scar, gouge
or damage the machined finishes on the cover and the reducer
housing mating surfaces during parts separation.
Manual Drum Brake:
Refer to Dwg. MHP1448 on page 44.
a. Remove cotter pin (144) and pin (138).
b. To disassemble further, refer to ‘Manual Band Brake
Disassembly’ on page 29.
Automatic Drum Brake:
Refer to Dwg. MHP2433 on page 45.
a. Remove capscrews (101), spacers (102) and (103).
b. Remove and save spacer (105).
c. Loosen two nuts (117).
15. Stand drum on end with reduction gear on top. Remove
reduction gear assembly from drum (62) by removing six
capscrews (33) attaching end cover (34) to drum. Screw two
7/16 - 20 UNF x 1-1/2 inch capscrews into the threaded holes
in cover (34). Turn both screws evenly until cover is
separated from housing. Remove cover.
16. Screw two 1/2 - 13 UNC x 1-1/2 inch capscrews into the
threaded holes in the reducer housing (48). Turn both screws
evenly until housing is separated from drum. Attach suitable
lifting eyes to the capscrews and remove housing from drum.
17. To further disassemble reduction gear refer to ‘Reduction
Gear Disassembly’ section.
d. Remove capscrew (120), pivot bar (119) and nuts (117).
e. To disassemble further, refer to ‘Automatic Band Brake
Disassembly’ on page 29.
9. Remove drum guard and any other externally mounted winch
attachments. Refer to applicable sections for disassembly
instructions.
CAUTION
• There are a total of eight capscrews securing the brake cover
to the brake housing. Two of these capscrews (41) hold the
brake assembly together, but do not attach to the outboard
upright. One capscrew attaching the brake assembly is located
directly beneath the brake air line fitting connection; the other
is located 180 degrees from the air fitting. The heads of these
two capscrews sit deeper into the counterbores of the brake
cover. Do not remove these two capscrews (41) until the brake
has been separated as an assembly from the winch and the
directions in the ‘Disc Brake Disassembly’ section have been
reviewed.
K5C2-X Control Valve Disassembly
Refer to Dwg. MHP2427 on page 46.
Handle Removal
If handle is not damaged it is not necessary to disassemble
completely.
1. Carefully pry off plug (935).
2. Remove capscrew (901) and tab lock washer (909).
10. Disconnect and remove brake hose (75). Remove six
capscrews (1) attaching disc brake assembly to outboard
upright (26). Remove disc brake assembly by tapping around
housing with a soft hammer or mallet while pulling out and
away from upright in a horizontal direction. Remove dowel
pin (20) and store until reinstallation. To further disassemble
the disc brake assembly, refer to Dwg. MHP1230 on page 42
and the ‘Disc Brake Disassembly’ section.
• Observe spring (937) connection during disassembly. This
spring is under tension and is required to return handle to
neutral position.
11. Using a hoist to support the drum, remove side rails (65), one
at a time, by removing four capscrews (66) attaching each
side rail to uprights (26) and (68).
3. Carefully pull handle assembly (930) from reverse valve
(943). Remove spring (937).
12. Remove the inboard (motor end) upright (68) by pulling
straight away from drum (62) in a horizontal direction.
Remove oil seal (29) and bearing (30) from upright. Discard
oil seal. Discard bearing if inspection indicate replacement.
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3. Move reverse valve (943) out exhaust flange side of housing
until ball (916) is visible on reverse valve. Allow ball (916) to
drop out of bushing (944) and remove ball (916).
Reverse Valve Removal
1. Remove capscrews (938), (925) and washers (924) from seal
bracket (939). Remove seal bracket from housing. Remove
and discard ‘O’ rings (941) and (942).
4. Remove bushing (944) out exhaust flange side of housing.
2. Remove capscrews (901) and washers (902) from exhaust
flange (955). Remove flange from housing. Remove and
discard ‘O’ ring (942).
3. Move reverse valve (943) out exhaust flange side of housing
until ball (916) is visible on reverse valve. Allow ball (916) to
drop out of bushing (944) and remove ball (916).
• Dowel pin (945) allows the bushing to be removed only from
the exhaust flange side of housing. Ball (916) retains reverse
valve (943) in bushing (944).
• Do not remove reverse valve (943), bushing (944) and ball
(916) at the same time, damage may occur to bushing.
4. Remove bushing (944) out exhaust flange side of housing.
Piston Removal
• Dowel pin (945) allows the bushing to be removed only from
the exhaust flange side of housing. Ball (916) retains reverse
valve (943) in bushing (944).
• Do not remove reverse valve (943), bushing (944) and ball
(916) at the same time, damage may occur to bushing.
• Take care to not allow ball (916) to drop in motor. If this
occurs it may be necessary to disassemble motor to retrieve
ball (916).
Follow disassembly instructions for K5C2-X Control Valve.
Pilot Valve Removal
Follow disassembly instructions for K5C2-X Control Valve.
Emergency Stop Removal
1. Remove adapter (706) and E-Stop button (705).
2. Remove plunger (707). Remove and discard ‘O’ rings (703).
3. Pull spring (711) out of valve housing and discard.
Piston Removal
1. Remove capscrews (901) and washers (902) from piston
cover (919). Remove cover and discard gasket (918).
2. Remove capscrews (901) and washers (902) from poppet
cover (903). Remove cover and discard gasket (904).
3. Remove the following items from housing poppet bore:
spring (905), poppet cap (906) and poppet seal (907).
4. From poppet side, push piston (922) out of housing. Remove
‘O’ rings (921) and (923) and discard.
Overload Valve Removal
1. Remove cap (700). Remove and discard grommet (701).
2. Pull out plunger (702), remove and discard ‘O’ rings (703).
3. Remove capscrews (901) and washers (902) from cover (719)
underneath valve housing.
Pilot Valve Removal
• Cover (719) retains spring (718). To remove capscrews (901)
and washer (902) unscrew in a crisscross pattern.
4. Remove adjusting screw (720).
5. Remove and discard ‘O’ ring (716), gasket (714) and ‘O’ ring
(713) from piston.
6. Do not remove seal from piston, if piston appears damaged or
worn replace.
• For easier removal it is recommended to use I-R pilot seat
tool (920). This must be purchased separately. Operation of
this tool (920) is similar to an allen wrench or screw driver.
If pilot valve is not damaged it is not necessary to disassemble
completely.
Motor Disassembly
1. Remove plug (912).
2. Remove pilot valve assembly (910) as an assembly.
3. Discard and replace pilot valve assembly (910) if necessary.
Refer to Dwg. MHP0690 on page 40.
1. Remove the five capscrews (255) from the exhaust flange
(254).
K5C2-EX Control Valve Disassembly
2. Remove the rotary valve housing (247) by pulling it out of
the motor housing (217) as an assembly with the exhaust
flange (254).
Refer to Dwg. MHP2434 on page 50.
3. Remove rotary valve (250) by pulling it out from the
assembly through the motor end of the rotary valve housing
(247).
Handle Removal
4. Remove exhaust flange (254) from rotary valve housing
(247) by gently tapping edges of flange with a soft hammer
until seal is loosened.
5. Remove each cylinder head (201) by removing the four
capscrews (200). Remove head gaskets (209) and discard.
6. Remove mounting flange (216) from motor by pulling
straight away from motor.
7. Pull the cylinder liner (208) straight out.
8. Position the piston (204) at the top of its stroke. In this
position, with the cylinder liner pulled out in step 7, the wrist
Follow disassembly instructions for K5C2-X Control Valve.
Reverse Valve Removal
1. Remove capscrews (938), (925) and washers (924) from seal
bracket (939). Remove seal bracket from housing. Remove
and discard ‘O’ rings (941) and (942).
2. Remove capscrews (721) and washers (902) from exhaust
flange (955) and exhaust adapter (723). Remove and discard
‘O’ rings (942) and (722).
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pin (203) can be removed. Remove one retainer ring (205)
from either side of piston (204). Push the wrist pin (203) out
by hand from one side. If the wrist pin is too tight it is
acceptable to carefully heat the piston to 200° F (93° C) or
less and then push the wrist pin out.
10. To remove the bearing (21) from the support plate (19) first
remove the retainer ring (22) and then press the bearing out
of the support plate recess.
NOTICE
• To prevent accidental damage, remove the bearing (21) only
if it requires replacement.
• If original piston, wrist pin, connecting rod or cylinder liner
are to be reassembled, number each set. Also add radial
alignment marks for each piston and cylinder liner to the
motor housing.
11. Separate the sprag clutch assembly into its component parts.
The sprag clutch assembly consists of the inner race (10), two
spacers (11), the outer race (12) and the sprag clutch (16).
The sprag clutch can be further disassembled into two
wearing plates and the sprag cage.
9. Remove the remaining cylinder liners and pistons as
described in steps 7 and 8. To remove the crank assembly, all
pistons and cylinder liners must be removed.
10. Crank assembly (231) can now be removed with the oil
slinger (230) by pulling straight out from the motor housing
(217). Use care while guiding the connecting rods (206)
through the inside of the motor housing.
Automatic Drum Band Brake Disassembly
Optional feature. Refer to Dwg. MHP2433 on page 45.
1. Loosen jam nut (117) closest to plunger (114). Turn capscrew
(120) counterclockwise until disconnected from plunger.
2. Disconnect air line (76) from exhaust valve (79). Remove
exhaust valve from brake cylinder (121). With the aid of a
strap wrench, remove brake cylinder (121) and components
as an assembly by turning brake cylinder counterclockwise
until disconnected from brake bracket (106).
3. Disconnect brake bracket (106) from band assembly by
removing three capscrews (101), spacers (102) and spacer
tubes (103). Remove spacer plate (105).
4. Disconnect brake bracket from motor end upright (68) by
removing two capscrews (107) and two capscrews (112).
Crankshaft Disassembly
1. Remove cotter pin (236) and the pin nut (237).
2. Remove lock pin (235) by carefully driving it out of its
location. Use care not to damage the threads.
3. Pull the crankshaft valve end (231) off the crankshaft.
4. Remove connecting rod rings (234), connecting rod bushing
(233), sleeve (232) and connecting rods (206). Record the
five connecting rod (206) numbers and foot directions so they
can be reinstalled in the same order.
5. Oil slinger (230) does not have to be removed unless
damaged. If removal is required, heating of the five screws
(229) may be necessary to loosen the Loctite® connection.
•
• Springs (124) and (127) exert a considerable force on cover
(125). Extreme care must be taken when disassembling the
cylinder assembly and removing cover (125).
Disc Brake Disassembly
Refer to Dwg. MHP1230 on page 42.
5. To disassemble cylinder (121) assembly into its component
parts conduct the following:
a. Use a press to compress cover (125) enough to remove
retainer ring (126). Slowly, and carefully, relax the load
exerted on cover (125) by springs (124) and (127).
Remove cover and springs.
NOTICE
• Prior to disassembly, matchmark the cover (2), housing (6)
and support plate (19) to assist in proper alignment of parts
during reassembly.
b. Remove washer (128).
c. Remove piston (123) assembly.
1. Remove capscrew (1) securing brake to upright (26).
2. Remove brake shaft (25) and retainer ring (23). Place brake
assembly on a flat surface with cover (2) on top. Remove
elbow fitting (80) and brake valve (79). Alternately and
evenly loosen the two capscrews (41) until the brake spring
(17) compression has been relaxed. Remove capscrews.
3. Remove cover (2) and diaphragm (3).
d. Disassemble piston assembly into component parts by
removing retainer ring (141) and separating cylinder rod
(108) from piston (123). Remove ‘O’ rings (109), (110)
and (122). Discard ‘O’ rings.
6. Remove plunger (114) assembly and spring (113) from brake
bracket (106).
4. Using a small tipped screwdriver or similar tool, remove ring
(4). Remove diaphragm support (5).
Manual Drum Band Brake Disassembly
5. Remove housing (6) by lifting straight away from brake parts.
Collect the three dowel pins (9) and store until reinstallation.
Inspect pins for deformation, wear and damage. Replace if
parts fail inspection.
Optional feature. Refer to Dwg. MHP1448 on page 44.
The winch does not have to be removed or disassembled to
disassemble the manual band brake.
6. Alternately remove the six separator plates (14) and five
friction plates (13).
7. Remove the pressure plate (15) and springs (17).
8. Grasp the outer race (12) and remove the sprag clutch as an
assembly. Remove the spacer (11) between the sprag clutch
assembly and support plate (19).
• Release wire rope tension on the drum and disconnect main
air supply line.
9. Remove gasket (18) from support plate (19). Discard gasket.
1. Raise handle (135) to free brake bands (136) and (137).
2. Remove cotter pin (139) and pin (138).
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3. Rotate brake link stud (141) counterclockwise until free
from brake handle.
5. Remove the oil seal (58) and discard. Remove the caged
needle bearing (46) only if replacing. To remove press
bearing out of housing.
4. Remove grip from brake handle (135). Loosen screws in
brake handle until handle can be freed from brake band
bracket, remove brake handle. Remove pivot nut (134).
5. Remove cotter pin (144) and washer (142).
6. Loosen capscrews (132).
7. Spread brake band (136) and (137) apart slightly and slide
out over drum flange. Rotate brake band around drum and
remove.
8. Repeat this procedure for other half of brake band (136) and
(137).
9. Remove capscrews (132), washers (131), and adapter plate
(145).
Cleaning, Inspection and Repair
Clean all winch component parts in solvent (except the drum
brake bands and disc brake friction plates). The use of a stiff
bristle brush will facilitate the removal of accumulated dirt and
sediments on the housings, frame and drum. If bushings have been
removed it may be necessary to carefully scrape old Loctite® from
the bushing bores. Dry each part using low pressure, filtered
compressed air. Clean the drum brake band using a wire brush or
emery cloth. Do not wash the drum brake band in solvent. If the
drum brake band lining is oil soaked, it must be replaced.
10. Press bushings (143) out of brake band pivot brackets.
Free Spool Disassembly
Inspection
Refer to Dwg. MHP2414 on page 61.
All disassembled parts should be inspected to determine their
fitness for continued use. Pay particular attention to the following:
1. Inspect all gears for worn, cracked, or broken teeth.
2. Inspect all bushings for wear, scoring, or galling.
3. Inspect shafts for ridges caused by wear. If ridges caused by
wear are apparent on shafts, replace the shaft.
1. Relieve pressure in the air lines and winch air components by
operating the winch control several times after the air supply
has been turned off.
WARNING
4. Inspect all threaded items and replace those having damaged
threads.
• Shut off, bleed down and disconnect the air supply line
before performing any disassembly procedures.
• Do not attempt repairs with load on wire rope.
5. Inspect the drum band brake lining for oil, grease and
glazing. If the drum band brake lining is oil-soaked,
excessively greasy or overly glazed replace the brake band.
Remove small glazed areas of band brake lining by sanding
lightly with a fine grit emery cloth.
6. Measure the thickness of the drum band brake lining. If the
drum brake band lining is less than 0.062 in. (2 mm) thick
anywhere along the edges replace the brake band assembly
for automatic (104) and manual (136) and (137).
2. To assist in reassembly, place match marks on the housing
(502) and outboard upright (26).
3. Remove free spool shifter assembly (507) by pulling it out of
housing (502). This assembly is held in place by ‘O’ ring
(501). Remove and discard ‘O’ ring (501).
4. Pin (508) and handle (512) are held in position by Loctite®
applied during assembly. To remove these parts, carefully
heat the shifter (515) until parts are removable.
5. Remove capscrew and washers (902). Remove cover (2) and
gasket (18). Discard gasket.
Repair
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 the
applicable parts listing for specific replacement parts
information.
6. Remove capscrews (505) and carefully pull housing (502)
away from outboard upright (26).
7. Remove output shaft (28) from drum (62).
Reduction Gear Disassembly
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 the edges of all shaft shoulders to remove small nicks
which may have been caused during handling.
• It is not recommended to disassemble reduction gear.
Refer to Dwg. MHP0649 on page 38.
1. Place the reduction gear assembly on a clean work bench
such that reducer housing (48) with oil seal (58) is down.
2. Remove capscrews (33) and cover (34) from housing (38).
3. Remove thrust washer (35) and output carrier assembly (36).
4. Remove the input carrier assembly (42) by grasping the
intermediate sun gear (39) and removing as an assembly. This
also removes the input sun gear (43). Ensure that thrust
bearing (45) and thrust washers (44), located on the end of
the input sun gear (43), are removed.
6. Remove all nicks and burrs caused by lockwashers.
Assembly
General Instructions
•
•
•
Use all new gaskets and seals.
Replace worn parts.
Assemble parts using match marks applied during
disassembly. Compare replacement parts with originals
to identify installation alignments.
NOTICE
• Do not disassemble carrier assemblies (36) and (42). Replace
if damaged or worn.
•
Lubricate all internal parts with rust and oxidation
inhibiting lubricant, ISO VG 100 (SAE 30W).
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(217). Ensure the bearing (228) is seated and connecting rods
(206) are centered in the cylinder holes.
Thermoplastic Coated Parts Assembly
NOTICE
CAUTION
• Make certain that the roll pin (240) and the three lugs on the
rotary valve (250) line up with the corresponding hole and lugs
on the crank shaft.
• Do not allow the rotary valve (250) to slide back in rotary
valve housing (247). If the rotary valve slides in too far, the
rotary valve and crankshaft will not align properly and will
restrict further assembly.
• During application of thermoplastic coating to assemblies
use a flame to localize the heat. Do not heat entire assembly.
Assemblies contain gaskets, ‘O’ rings and other components
that may be damaged by exposure to excessive heat.
1. When assembling parts already coated, the mating areas can
be heated to soften the coating enough to flow together and
seal the parts.
15. Rotate the crank assembly until one connecting rod (206) is
at the top of its stroke. Install a piston (204) with its rings
(202 and 207) to the connecting rod (206) with wrist pin
(203) and retainer rings (205).
16. Install a new cylinder head gasket (209) before installing the
cylinder liner (208).
17. Install the cylinder liner (208) over the piston (204) by
compressing both piston rings (202) and (207) with a single
band ring compressor.
18. Install cylinder head (201) over the cylinder and secure
cylinder head to motor housing (217) with four capscrews
(200). Torque capscrews to 60 ft lbs (81 Nm).
2. When installing a new component in an assembly, remove
coating from existing parts as necessary to ensure parts mate
correctly.
3. Install fasteners and torque as required. Apply coating to bare
areas as described in ‘Thermoplastic Coating’ repairing
surfaces instructions in the “MAINTENANCE” section for
areas larger than 1/16 inch (1.6 mm).
4. Allow the repaired area to cool. Quenching with water is
acceptable. Rough spots, minor scorching and excess coating
deposits can be wet sanded to remove the imperfections. To
return the gloss finish, reheat the surface carefully.
19. Repeat Steps 15 through 18 with the remaining cylinders.
Motor Assembly
Refer to Dwg. MHP0690 on page 40.
NOTICE
1. Install two seal rings (251) on each end of rotary valve (250).
Place bearing (252) onto the rear of rotary valve (250) and
press into position. Press only on the bearing inner race. With
the rotary valve housing (247) exhaust flange side down,
install rotary valve into housing.
2. Install ‘O’ ring (244) into motor housing (217).
3. Install the rotary valve housing gasket (243) onto rotary valve
housing (247). With the exhaust flange down on the bench,
install motor housing (217) onto rotary valve housing (247).
Check for any evidence of damage to ‘O’ ring (244) when the
rotary valve housing is fully engaged. Install exhaust flange
(254) and tighten capscrews (255) to 50 ft lbs (68 Nm).
4. If removed, press crank bearing (228) on crank assembly
(231). Press only on the inner race of the bearing.
5. Place crank assembly (231) on a work bench with the oil
slinger (230) down and slide the sleeve (232), with tang up,
on the crankpin.
• When installing the two lowest cylinder heads (201), use seal
washers on capscrews (200).
20. Rotate motor by hand. Motor should rotate without binding.
21. Install mounting flange (216) and gasket (226) on the front of
the motor housing (217). Make sure notches on both parts are
aligned.
22. Lightly lubricate ‘O’ ring (70) and install in groove on motor
adapter (71).
23. Install eye bolts (213), vent cap assembly (210) and pipe plug
(218) in the motor housing (217). From the rotary valve
housing end of the motor, ensure plug (218) is installed in the
left oil fill hole of the motor.
24. Install motor on winch at motor adapter (71) using capscrews
(197), lockwashers (196) and washers (198).
25. Ensure oil drain (225) and level plug (225) are installed.
6. Slide connecting rod bushing (233) over the sleeve (232) and
first connecting rod ring (234) with the chamfer up.
7. Install the connecting rods (206) in the same order as
removed, with all feet pointing in the same direction, using
the first connecting rod ring (234) to hold one side of the
connecting rod feet.
K5C2-X Control Valve Assembly
Refer to Dwg. MHP2427 on page 46.
Reverse Valve Assembly
8. Slide the second connecting rod ring (234) over the other side
of the connecting rod feet with the chamfer on the ring facing
down (toward the stem of the connecting rod).
1. Insert reverse valve (943) into bushing (944) with ball slot
oriented UP, approximately 2-1/2 in. (64 mm).
9. Slide the crank shaft valve end over the crank pin while
simultaneously aligning the tang on the sleeve (232) with the
slot in the crank shaft.
2. Insert bushing (944) and reverse valve (943) into valve
housing (917) from exhaust flange side, ensuring that groove
in bushing is aligned with pin (945).
10. Rotate and position the crank shaft valve end relative to the
crank pin to allow installation of the lock pin (235).
11. Tap the lock pin (235) into place and install the pin nut (237).
Torque nut to 60 ft lbs (81 Nm).
12. Install cotter pin (236).
13. Install roll pin (240) and bearing (228) into the valve end of
the crank shaft.
3. Insert ball (916) onto 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 neutral position to approximately
45 degrees in either direction. Ball will ‘walk’ up side of
reverse valve platform and move in ball hole in bushing.
14. Check that all connecting rods move freely around the crank.
Position the crank assembly (231) into the motor housing
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3. Secure handle assembly (930) to reverse valve with tab lock
washer (909) and capscrew (901), torque to 15 ft. lbs. (21
Nm). Washer (909) has small tab on side, engage with small
hole in handle.
4. Bend tabs of washer (909) over flats of capscrew.
5. Press plug (935) into handle assembly to cover capscrew.
Check control handle movement. Correct any discrepancies.
• Do not rotate reverse valve past a 90 degree position, it may
result in the ball (916) falling in motor.
5. Slowly push reverse valve, while still in the 45 degree
position, the rest of the way in housing until flush with
surface. From other side of valve rotate reverse valve back to
neutral position, ball should be seated in ball slot at that time.
6. Lubricate ‘O’ ring (942) and place it in groove in exhaust
flange (955).
K5C2-EX Control Valve Assembly
Refer to Dwg. MHP2434 on page 50.
7. Secure exhaust flange (955) to valve housing with capscrews
(901) and washers (902).
Reverse Valve Assembly
8. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’
ring (942) and place into groove in seal bracket.
9. Place seal bracket over end of reverse valve. Using finger
pressure, press until seal is seated on reverse valve and seal
bracket is seated on valve housing. Secure with washers
(924) and capscrews (925) and (938).
1. Insert reverse valve (943) into bushing (944) with ball slot
oriented UP. Apply grease to ball (916) and insert into ball
slot of reverse valve (943) through bushing (944).
2. Insert bushing (944), reverse valve (943) and ball (916) into
valve housing (917) from exhaust flange side, ensuring that
groove in bushing is aligned with pin (945).
3. Lubricate ‘O’ rings (942) and (722), and place in grooves in
exhaust adapter (723).
Pilot Valve Assembly
4. Lubricate ‘O’ rings (942) and place in grooves in exhaust
flange (955).
5. Secure exhaust adapter with exhaust flange to valve housing
with capscrews (721) and washers (902).
• For easier installation it is recommended to use I-R pilot seat
tool (920). This must be purchased separately. Operation of
this tool (920) is similar to an allen wrench or screw driver.
6. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’
ring (942) and place into groove in seal bracket.
7. Place seal bracket over end of reverse valve. Using finger
pressure, press until seal is seated on reverse valve and seal
bracket is seated on valve housing. Secure with washers
(924) and capscrews (925) and (938).
1. Install pilot valve assembly (910).
2. Apply thread sealant Loctite 567® to pilot seat (914), place
pilot valve assembly into valve housing. Use a large flat
tipped screw driver to engage slots in pilot seat and tighten
until pilot assembly is 1/8 in. (3.175 mm) from housing bore.
3. Insert plug (912) and tighten.
Pilot Valve Assembly
Follow assembly instructions for K5C2-X Control Valve.
Piston Assembly
Piston Assembly
1. Lubricate and install ‘O’ rings (921) and (923) on piston
(922).
2. Insert assembled piston into valve housing (917) from handle
side.
3. Secure with gasket (918), piston cover (919), washers (902)
and capscrews (901).
4. Place poppet seal (907) into poppet cap (906). Place this
assembly into valve housing and seat on piston (922).
5. Place spring (905) over this assembly.
6. Secure with gasket (904), poppet cover (903), washers (902)
and capscrews (901).
Follow assembly instructions for K5C2-X Control Valve.
Handle Assembly
Follow assembly instructions for K5C2-X Control Valve.
Emergency Stop Assembly
1. Insert spring (711) into valve housing (917).
2. Place ‘O’ rings (703) on plunger (707).
3. Insert plunger into valve housing.
4. Screw adapter (706) and E-Stop button (705) into valve
housing.
Handle Assembly
1. Place spring (937) over reverse valve handle end in seal
bracket.
5. Tighten adapter until snug, do not over tighten.
Overload Valve Assembly
• Spring (937) will have to be ‘Cocked’ over stud in seal
bracket. This will ensure handle returns to neutral.
1. Replace ‘O’ rings (703) on plunger (702).
2. Insert plunger (702) with ‘O’ rings in valve housing (917).
3. Replace grommet (701) in cap (700).
2. Place handle assembly over reverse valve end. Slide handle
will have to be lifted slightly to allow pin to fit into slot in
seal bracket.
4. Install and tighten cap (700) flush to valve housing.
5. Replace piston (712) if appears damaged or worn.
6. Insert ‘O’ ring (713) on piston (712).
7. Replace gasket (714).
32
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11. Cover the reduction gear to prevent dirt and contaminants
from entering assembly and place in a safe place until ready
for assembly to winch uprights.
• Cover (719) retains springs (718), adjustment nut (717) and
plate (715). Insert capscrews (902) and washers (901) in a
crisscross patter until tightened evenly.
Winch Assembly
Refer to Dwg. MHP0649 on page 38.
8. Insert adjusting screw (720), refer to ‘OPERATION’ section
for overload valve adjustment.
NOTICE
Freespool Assembly
• Unless otherwise stated capscrew torque values listed are for
lubricated or plated threads. This assembly uses “blue bolts”
in numerous locations. These are plated and should not be
lubricated.
Refer to Dwg. MHP2414 on page 61.
1. Assemble shaft support (503) to output shaft (28) and secure
with socket capscrews (504). Torque capscrews to 18 ft lb (25
Nm).
2. Apply Loctite® 609 to handle (512) and press into free spool
shifter (515).
3. Apply Loctite® 242 to threads of plunger (511) and screw
into detent plate (514).
4. Place new ‘O’ ring (501) into groove in housing (502).
Lubricate with a mixture of half ISO VG 68 (SAE 20W)
lubricant and half molybdenum disulfide lubricant
compound.
5. Lubricate free spool shifter assembly (507) with above
compound, place into housing (502).
6. Slide shaft support (503) and output shaft (28) as an assembly
into housing (502) until groove in shaft support aligns with
pin (516) in free spool shifter assembly (507). Tap into place
with suitable soft headed hammer.
7. Insert this assembly into winch drum (62), twisting slightly to
align gears and until housing (502) fits tightly against
outboard upright (26). Align marks made in ‘Disassembly’
step 2.
8. Install capscrews (505) into housing (502) tighten and torque
to 18 ft lb (25 Nm).
1. Using a hoist, support the drum.
2. Install bearing (30) in inboard (motor end) upright (68). With
oil seal (29) lip facing towards drum, install oil seal in
inboard upright.
3. Install output shaft (28), bearing (30) and oil seal (29) in
outboard upright (26). Install the outboard upright onto drum
by aligning splines of output shaft to reduction gear output
carrier assembly splines.
a. a. For units with disc brake, refer to the ‘Disc Brake
Assembly’ section.
b. b. For units without disc brake, ensure three capscrews
(27) are installed in the output shaft. Apply Loctite® 515
on mating surfaces of outboard upright (26) and end
cover (2). Install gasket (18). Install six capscrews (1)
and secure end cover to upright. Torque capscrews to 18
ft lbs (24 Nm).
4. If unit is equipped with drum band brake, install the drum
band brake bracket and piston assemblies. Do not attach the
brake band assembly (147) or (130). Refer to the applicable
‘Drum Band Brake’ section for instructions.
5. Install coupling (60) on shaft (61) and install on end of the
input sun gear (43), located in the reduction gear assembly.
6. If unit is equipped with drum band brake, place brake band
assembly (147) or (130) onto drum brake flange. Place
inboard (motor end) upright (68) on drum.
7. Loosely attach the side rails (65) to the uprights (26) and (68)
using four capscrews (66) for each sideframe. Tighten
capscrews and torque to 75 ft lbs (102 Nm) for dry threads, or
55 ft lbs (75 Nm) if thread lubrication is used.
8. Align holes in motor adapter (71) and install on upright.
Secure with six capscrews (73). Torque capscrews to 125 ft
lbs (170 Nm) for dry threads, or 95 ft lbs (129 Nm) if thread
lubrication is used.
9. Apply light coat of EP grease to face of housing (502), place
gasket (18) on housing face and align bolt holes.
10. Using capscrews (1) and washers (902) install cover (2) onto
housing (502).
11. Operate free spool several times to ensure smooth operation.
Reduction Gear Assembly
Refer to Dwg. MHP0649 on page 38.
1. Install oil seal (58) in housing (48).
2. Install needle bearing (46) if removed during disassembly.
3. Install thrust washers (44) on input sun gear (43).
4. Install input sun gear assembly (43) in housing (48).
5. Install (40) on either side of input gear carrier (42).
6. Install input gear carrier (42) on input sun gear (43).
7. Align intermediate sun gear (39) with input gear carrier (42)
and install in gear carrier (42). Take care not to damage teeth
on either part while installing.
9. If equipped with drum band brake, attach band brake
assembly (147) or (130). Refer to applicable assembly
sections.
Manual Drum Band Brake Assembly
8. Install thrust washer (35) and output gear carrier (36) in
housing (48). Align with intermediate sun gear (39). Take
care not to damage teeth on either part while installing.
9. Align holes in cover (34) with housing (48) and secure with
capscrews (33). Torque to 60 ft lbs (81 Nm).
10. With drum standing on end, place reduction gear assembly
into drum. Place Loctite® 515 on mating surfaces of housing
(87) and end cover. Align the 3/8 inch NPT holes in the end
cover with counterbore marks on the housing mating flange.
Secure in place by evenly installing sixteen capscrews (33).
Torque capscrews to 60 ft lbs. (81 Nm).
Optional feature. Refer to Dwg. MHP1448 on page 44.
1. Press bushings (143) into brake band pivot brackets. Bushing
flanges must be to motor upright side.
2. Attach adapter plate (145) to motor side upright (68) loosely
with capscrews (132) (apply Loctite® 242 to threads) and
washers (131).
3. Place brake band (136) and (137) onto drum and rotate
around drum (close to mounting position). Spread brake
band halves (136) and (137) apart slightly and slide in over
drum flange. Place brake band pivot bracket over pin in
adapter plate (145).
4. Repeat this procedure for other brake band halves (136) and
(137).
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5. Place washer (142) over pin in adapter plate (145) and secure
with cotter pin (144). Bend cotter pin ends apart.
6. Insert pivot nut (134) into brake handle (135).
7. Place brake handle (135) into bracket in brake band halves
(136) and (137) and tighten screws in handle. Slide grip over
brake handle.
8. Place brake link stud (141) into pivot nut (134) and rotate
clockwise until approximately 1 inch (25 mm) of threads are
exposed.
Conduct the following when winch is assembled, but prior to
mounting to foundation. The motor end of winch should be raised
enough to allow access to brake components located on the inside
surface of inboard (motor end) upright (68).
5. Place spacer (105) between upper brake band flange and
bracket. Attach band assembly (104) to bracket (106) using
three capscrews (101), spacers (102) and spacer tubes (103).
Torque capscrews to 35 ft lbs (48 Nm).
6. Install pivot bar (119) and capscrew (120) through lower
flange of brake band assembly (104). At lowest point of
threads, place a bead of Loctite® 680 and install jam nut
(117) fully. Jam nut threads must become coated with
sealant. Install second jam nut (117) to approximate middle
of thread length. Thread capscrew (120) into bottom of
plunger (114) a minimum of five thread lengths. Lock in
place, against plunger, using jam nut (117). Adjust brake as
described in ‘Drum Band Brake Adjustment’ section.
• Refer to ‘Adjustment’ section for instructions on adjusting
brake.
9. Lift up brake handle (135) until hole in brake link stud (141)
and bracket in brake band halves (136) and (137) are aligned.
Insert pin (138) and secure with cotter pin (139). Bend cotter
pin ends apart.
10. Push brake handle (135) down to the lock position.
11. Torque capscrews (132) to 50 ft lbs (68 Nm).
Adjusting Automatic Drum Band Brake
Optional feature. Refer to Dwg. MHP2433 on page 45.
Automatic Drum Band Brake Assembly
Optional feature. Refer to Dwg. MHP2433 on page 45.
For ease of assembly install bracket (106), cylinder (121)
assembly and brake handle stop to motor end upright (68) prior to
assembling upright to drum.
• This adjustment is done after a rebuild. It is only a rough
adjustment intended to remove major slack prior to adjusting
with a load.
1. Assemble brake cylinder (121) as follows:
a. Install ‘O’ ring (122) on piston (123).
This procedure can be done at a work bench using a 50 psig
(3.44 bar/344 kPa) air supply applied to the brake cylinder. After
completion of this procedure the brake must further be adjusted
using the recommended air supply and a test load.
1. Insert a length of 3/8 inch NC threaded rod, fully into the
cylinder rod (108). With brake band slack and no air
supplied to brake, push end of threaded rod to position
plunger all the way inside brake bracket (106). Place a nut on
threaded rod, and locate nut until it is just touching cover
(126). Apply air to brake. Threaded rod should move out
from cylinder approximately 1 inch (25 mm).
b. Heavily coat piston and cylinder rod with “LubriPlate”
MO-LITH No. 2 or equivalent lubricant. Install ‘O’
rings (109) and (110) on cylinder rod (108). Place
cylinder rod (108) into piston (123) and secure in place
using retainer ring (111).
c. Install piston assembly in brake cylinder (121).
d. Install washer (128) and springs (124) and (127).
•
2. Tighten capscrew (120) in plunger (114) to remove slack
from band brake. Release air pressure. Nut should move
closer to end cover (125) and stop.
3. Repeat step 1 until nut stops at approximately 9/16 inch
(14 mm) from cover (125).
• Springs (124) and (127) exert a considerable force on cover
(125) when assembled. Extreme care must be taken when
assembling and installing cover (125) and retainer ring (126).
e. Using a press, slowly compress cover (125) and springs
until retainer ring groove is accessible. Install retainer
ring (126). To ensure that retainer ring is properly
installed, tap end of retainer ring with a punch until
entire retainer ring rotates in brake cylinder groove.
Slowly release press and ensure retainer ring securely
holds cover in place.
4. Refer to further adjusting in ‘Automatic Drum Brake
Adjustment’.
Disc Brake Assembly
Refer to Dwg. MHP1230 on page 42.
2. If not accomplished during ‘Winch Assembly’ steps, install
bracket (106) to inside of motor end upright (68) and secure
in place using capscrews (107) and (112). Torque capscrews
to 35 ft lbs (48 Nm).
3. Assemble roller (116) in plunger (114) and secure using
dowel pin (115). Heavily coat plunger assembly with
“LubriPlate” MO-LITH No. 2 or equivalent lubricant. Install
spring (113) and plunger assembly in brake bracket (106).
Align groove in plunger towards hole in motor end (68)
upright.
1. Install bearing (21) into support plate (19) and secure with
retainer ring (22).
2. In this order, place spacer (11), sprag clutch (16), outer race
(12) and spacer (11) on inner race (10). Test sprag clutch
operation. Refer to Dwg. MHP1197 on page 35.
NOTICE
• Correct sprag clutch installation prevents clockwise rotation
(brake engages) and allows counterclockwise rotation when
viewed from the cover (2) end of the brake assembly.
4. Align cylinder rod roller surface to groove in plunger. Turn
cylinder (121) clockwise until snug. Adjust cylinder (121)
such that air hose connection port is horizontal and towards
the motor.
34
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Drum Guard Assembly (optional feature)
WARNING
Refer to Dwg. MHP0658 on page 62.
• Incorrect assembly of the sprag clutch will adversely affect
1. Place drum guard (590) on rear side rails (65) with longer
inside tab located under side rails edge and smaller outside
tabs located on top of side rails edge.
2. Place ‘O’ rings (109) on brackets (591) or bracket shaft
(596). Install ‘O’ rings in quantities required to remove any
‘play’ or gap between drum guard and brackets.
winch operation. In haul-in operation, sprag clutch will be
engaged resulting in restricted winch operation. In neutral
and payout positions, the sprag clutch can rotate resulting in
brake not holding load. Ensure the sprag clutch is correctly
installed.
3. Align brackets (591) or (595) on mounting holes in uprights
(26) and (68). Secure in place with capscrews (592).
3. Install assembly on support plate (19).
4. Install twelve springs (17) in holes on inside of support plate
(19).
5. Install gasket (18) and pressure plate (15).
6. Determine correct alignment of cover (2), housing (6) and
support plate (19) by checking matchmarks placed during
disassembly, or by placing housing on support plate and
matching capscrew holes.
7. Correctly align with dowel slots on the housing (6) and
alternately install six separator plates (14) and five friction
plates (13), beginning with a separator plate. Align the outer
three indentations on plates to form a single groove.
8. Install the three dowel pins (9) in housing (6). Apply Loctite®
515 sealant on mating surfaces of housing and end cover (2).
Install housing by aligning dowel pins with separator (13)
and friction plate (14) grooves and, also aligning capscrew
holes in housing with holes in end cover.
Testing
Operational Test
Prior to initial use, all new, altered or repaired winches shall be
tested to ensure proper operation.
1. Check oil level in motor, reduction gear assembly and disc
brake are correct. Top off levels as required before operation
as described in the “LUBRICATION” section.
2. To initially ‘break in’ new or overhauled motors, operate
winch without load, in both directions, for 15 minutes at 100 -
200 RPM.
3. Check operation of brakes. Adjust if necessary as described
in the “MAINTENANCE” section.
4. Check operation of limit switches, locking mechanisms and
all safety devices when equipped.
Sprag Clutch Assembly
5. Check foundation mounting fasteners are secure.
6. Install drum guard when provided.
Load Test
Prior to initial use, all new, extensively repaired, or altered
winches shall be load tested by or under the direction of a person
trained in safety and operation of this winch and a written report
furnished confirming the rating of the winch. Test loads shall not
be less than 100% of rated line pull at mid drum and must not
exceed 125% of the rated line pull at mid drum. To test the winch
at 125% of the rated load at mid drum apply the following load:
FA5A Winch 125% Test Load 12,500 lb. (9,058 kg)
NOTICE
• Testing to more than 125% of rated line pull may be required
to comply with standards and regulations set forth in areas
outside the USA.
(Dwg. MHP1197)
9. Install ring (4), and diaphragm support plate (5). Support
plate radius must be next to diaphragm (3).
10. Install diaphragm (3) and cover (2).
11. Locate as shown on Dwg. MHP1230 on page 42, and install
two capscrews (41). Evenly and alternately tighten capscrews
to compress springs. Torque capscrews to 18 ft lbs (24 Nm).
12. Install brake shaft (25) and place assembly on outboard
(opposite motor end) upright (26).
13. Align capscrew holes such that the breather (8) is slightly off
top dead center. Install six capscrews (1). Torque capscrews
to 18 ft lbs (24 Nm).
14. Install capscrews (1) securing brake to upright (26).
15. Install exhaust valve (79), elbow fitting (80) and connect air
hose (75) to elbow fitting.
16. Winch drum must rotate freely in the haul-in direction and
must not rotate in the payout direction, unless air is applied
to the brake, when assembled properly.
MHD56087 - Edition 4
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WINCH CROSS SECTION DRAWING
Motor
Assembly
Outboard
Upright
Inboard
Upright
Control
Valve
Assembly
Reduction
Gear Assembly
Disc Brake
Assembly
Drum
Motor
Adapter
(Dwg. MHP1224)
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WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS
Page
Winch Cross Section Drawing (MHP1224) .....................................................................................................................................................36
Drum, Base and Reduction Gear Parts Drawing (MHP0649) .........................................................................................................................37
Drum, Base and Reduction Gear Parts List .......................................................................................................................................................39
Motor Assembly Drawing (MHP0690) ............................................................................................................................................................40
Motor Assembly Parts List ...............................................................................................................................................................................41
Disc Brake Assembly Drawing (MHP1230).....................................................................................................................................................42
Disc Brake Assembly Parts List ........................................................................................................................................................................43
Manual Drum Brake Assembly Drawing (MHP1448) and Parts List...............................................................................................................44
Automatic Drum Brake Assembly Drawing (MHP2433) and Parts List..........................................................................................................45
K5C2-X Control Valve Assembly Drawing (MHP2427) .................................................................................................................................46
K5C2-X Control Valve Assembly Parts List .....................................................................................................................................................47
Pilot Air Control Valve (Optional) Assembly Drawing (MHP2416) and Parts List.........................................................................................48
Full Flow Remote Control Valve Assembly Drawing (MHP2432) and Parts List ...........................................................................................49
Emergency Stop and Overload K5C2-EX Valve Assembly Drawing (MHP2434) ..........................................................................................50
Emergency Stop and Overload K5C2-EX Valve Assembly Parts List..............................................................................................................51
Tensioning Manifold Assembly Drawing (MHP2436).....................................................................................................................................52
Tensioning Manifold Assembly Parts List.........................................................................................................................................................53
Remote Pendant Assembly Drawings (MHP2346) and (MHP1677)...............................................................................................................54
Remote Pendant Assembly Parts List................................................................................................................................................................55
Open Frame (Face) Winch Assembly Drawing (MHP1231)............................................................................................................................56
Open Frame (Face) Winch Assembly Parts List................................................................................................................................................57
Remote Pilot Air Control (Optional) Parts Drawing (MHP2444) ....................................................................................................................58
Remote Pilot Air Control (Optional) Parts List.................................................................................................................................................59
Muffler Assembly Drawing (MHP1189) and Parts List ...................................................................................................................................60
Free Spool Assembly Drawing (MHP2414) and Parts List ..............................................................................................................................61
Drum Guard Assembly Drawing (MHP0658) and Parts List ...........................................................................................................................62
Air Preparation Assembly Drawing (MHP0223) and Parts List.......................................................................................................................63
Winch Label/Tag Location Parts Drawing (MHP1229)....................................................................................................................................64
Winch Label/Tag Location Parts List ................................................................................................................................................................65
Construction Cage Assembly Drawing (MHP2438) and Parts List..................................................................................................................66
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DRUM, BASE AND REDUCTION GEAR PARTS DRAWING
74
73
68
66
82
65
81
30
72
70
69
71
82
62
81
29
33
64
67
66
74
61
63
60
58
46
48
47
36
44
43
34
40
40
42
39
33
32
35
26
29
32
30
28
27
1
81
82
18
2
(Dwg. MHP0649)
38
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DRUM, BASE AND REDUCTION GEAR PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
1
Capscrew (1)
End Cover (1)
Gasket
6
1
1
1
3
1
2
2
71266613
21732
Drive Shaft - Long Drum
(24 and 27 inch)
61
62
1
23902
2
•
•
18
26
27
28
29
30
71262257
25566
Drum, 12 in (305 mm) with
Band Brake** (3) †
23750
24046
21729
Upright, Outboard †
Capscrew (1)
Output Shaft †
Oil Seal
71266936
21019
Drum, 15 in (381 mm) (3) †
1
Drum, 24 in (610 mm) with
Band Brake** (3) †
71053862
71053854
Bearing
Drum, 27 in (686 mm) (3) †
Wire Rope Anchor (4)
24048
24258
63
64
1
1
Reduction Gear Assembly (2)
(incl’s items 32, 34-48 and 58)
31
1
26985
Label, Wire Rope Cover
71148282
32
33
34
35
36
39
40
42
43
44
46
47
Plug
2
71408439
71113161
71408371
71408397
71408322
71408330
71408405
71408348
71408355
71408421
71408413
71408447
Side Rail - Short Drum
(12 and 15 inch)
2
2
24674-P
24675-P
Capscrew (5)
Cover u
32 (16)
65
1
1
1
1
2
1
1
2
1
2
Side Rail - Long Drum
(24 and 27 inch)
Thrust Washer
Planetary Assembly
Intermediate Sun Gear
Retainer Ring
Planetary Assembly
Input Sun Gear
Retainer Ring
Bearing
66
67
68
69
70
71
72
73
Capscrew
Rivet
8
4
1
1
1
1
1
6
8
7126461
50915
Upright, Inboard †
Dowel Pin
‘O’ Ring
25567
71136923
51459
•
Motor Adapter
Cover (5) †
Capscrew
Washer
22034
24440
Capscrew
71311674
71274807
Order Item
31
48
Reducer Housing
1
74
•
58
60
Oil Seal
1
1
71408363
50775
81
82
Capscrew
8
4
71264709
21882
Coupling
Corner Bar
Drive Shaft - Short Drum
(12 and 15 inch)
61
1
24035
**
†
Item 62, size 12 and 24 inch drum with band brake is not illustrated.
These parts also come in a cold weather version. For winches with a -C in the model code, adding CH (DNV) or CHA (ABS) to
the end of these part numbers is required to retain winch certification. Example: Order Drum (15 in. long) (item 62) part number
24046 as part number 24046CH or 24046CHA.
Certification Type
Example Part Number To Order
ABS
---
24046CHA
---
DNV
24046CH
•
Recommended spare for one winch, 2 years of normal operation
Notes: (1) Winches with disc brakes will use items 1, 2 and 18 shown in drawing MHP1230 on page 42.
(2) It is not recommended to disassemble reduction gear assembly unless necessary.
(2) Sizes 12 and 24 inch refer to drums equipped with band brake. Sizes 25 and 27 inch refer to drums without band brake.
(3) Wire rope anchor for 9/16 to 3/4 inch (14 to 18 mm) wire rope only.
(4) Winches with drum brakes will not use item 72, cover and only require a quantity of (16) for item 33, capscrew.
MHD56087 - Edition 4
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MOTOR ASSEMBLY DRAWING
200
216
201
202
204
205
207
227
228
205
203
202
204
205
206
203
208
213
206
200
213
201
209
218
205
210
207
208
229
951
949
209
244
225
243
230
946
226
225
247
217
197
196
236
246
237
251
252
232
231
233
243
251
234
250
235
231
240
228
255
254
(Dwg. MHP0690)
40
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MOTOR ASSEMBLY PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
Item
No.
Description
of Part
Total
Qty
Part
Number
190
196
197
200
201
202
203
204
205
206
207
208
209
210
213
216
217
218
225
226
227
228
Motor Assembly **
Lockwasher
Capscrew
1
10
10
20
5
K5B-546LP
71268213
71268205
52317
229
230
231
232
233
234
235
236
237
240
243
244
246
247
250
251
252
254
255
946
949
951
Button Head Screw
Oil Slinger
Crank Assembly
Sleeve
5
*
*
1
1
*
Capscrew
1
K5B-519
K5B-511
K5B-510
*
Cylinder Head
Compression Ring
Wrist Pin
K5B-H505
K5B546-KRING
HU-514A
*
Bushing
1
1 Set
5
Connecting Rod Ring
Lock Pin
2
1
Piston
5
Cotter Pin
1
*
Retainer Ring
Connecting Rod
Oil Ring
10
5
902A45-632
K5B-509
Order Item 202
K5B-L505-47
K5B-507-5
26604
Pin Nut
1
*
Roll Pin
1
54257
5
Gasket
2
K5B-928
20A11CM248
53095
Cylinder Liner
Head Gasket
Vent Cap Assembly
Eye Bolt
5
‘O’ Ring
1
1 Set
1
Grease Fitting
Rotary Valve Housing
Rotary Valve Assembly
Seal Ring ***
Bearing
1
1
K5B-546
K5B-526EQ-RS
K5B-607A
50138
2
KU-888
1
1 Set
1
Mounting Flange
Motor Housing
Pipe Plug
1
K5B-502A
K5B-501A
71263297
54912
1
1
Exhaust Flange
Capscrew
1
KK5B-276M
51471
Pipe Plug
2
5
Gasket
1
K5B-592
K5B-270
51066
Gasket
1 set
4
27115
Oil Seal
1
Washer
71376370
71369276
Crank Bearing
2
Capscrew
4
*
Parts not sold separately, Refer to the “Motor Assembly Kit List.”
Motor Assembly (190) includes items 200 through 255.
Seal Ring, item 251, set = quantity of 4.
**
***
Motor Assembly Kit List:
Item
No.
Description
of Part
Total
Qty
Part
Number
231
261
---
Crank Assembly (includes items 229, 230 and 235 through 237)
Piston Assembly (includes items 202 through 205 and item 207)
Motor Gasket Kit (includes items 209, 226, 243, 244 and 248)
1
K5B-A516
K5B-A513-47
26823
1
1
•
•
---
Motor Service Kit (includes items 196, 197, 200, 202, 207-209, 226, 243, 244 and 251)
1
71390181
Recommended spare for one winch, 2 years of normal operation
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DISC BRAKE ASSEMBLY DRAWING
23
22
19
21
18
25
20
17
11
16
15
14
13
65
75
12
11
10
80
79
41
(Dwg. MHP1230)
42
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DISC BRAKE ASSEMBLY PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
320 Disc Brake Assembly *
1
6
1
1
1
1
1
2
1
3
1
2
1
5
6
24140
71264717
23605
15
16
17
18
19
20
21
22
23
25
41
50
79
80
Pressure Plate
Sprag Clutch Kit ***
Spring
1
1
24137
27724
1
2
Capscrew
End Cover **
Diaphragm
Ring
12
1
71053730
71262257
24138
3
22031
•
Gasket
4
22028
Support Plate
Dowel Pin
1
5
Diaphragm Support
Housing
22027
1
71126759
50449
6
22026
Bearing
1
7
Plug
71069009
71271175
71126882
***
Retainer Ring
Retainer Ring
Brake Shaft †
Capscrew
1
54375
8
Breather
1
71053748
24039
9
Dowel Pin
Inner Race †
Spacer
1
10
11
12
13
14
2
71354146
71306518
71047898
24141
19007
Label ††
1
Outer Race †
Friction Plate
Separator Plate
***
Valve Exhaust
Elbow Fitting
1
71126874
22033
1
Side Rails
Brake Hose
Short Drum (15 in.)
Long Drum (27 in.)
24674
24675
Short Drum (15 in.)
Long Drum (27 in.)
23230-63
23230-75
65
1
75
1
•
Recommended spare for one winch, 2 years of normal operation
Disc Brake Assembly includes items 1 through 25, 41 and 50.
*
**
As viewed from the brake end, the air line attaches to the brake cover on the left hand side on standard winches and on the
right hand side on winches supplied with the optional Open Frame (Face) configuration. On winches with the optional Open
Frame (Face) configuration, install the end cover (item 2) rotated 180° from view shown.
*** Sprag Clutch Kit (16) includes Inner Race (10) and Outer Race (12).
†
These parts also come in a cold weather version. For winches with a -C in the model code, adding CH (DNV) or CHA (ABS)
to the end of these part numbers is required to retain winch certification. Example: Order Drum (15 in. long) (item 62) part
number 24046 as part number 24046CH or 24046CHA.
Certification Type
Example Part Number To Order
ABS
---
24046CHA
---
DNV
24046CH
††
Item not illustrated
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MANUAL DRUM BRAKE ASSEMBLY DRAWING AND PARTS LIST
132
131
141
68
138
139
145
144
137
62
134
145
136
135
144
143
143
142
(Dwg. MHP1448)
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
Brake Assembly
Front Brake Band Assembly
(only available as a set) †
147
1
1
26377
137
1
26641
(includes items 131 through 145)
Drum, Short (12 inch (305 mm))
Drum, Long (24 inch (610 mm))
Upright, Motor End
23750
21729
138 Pin †
1
1
1
1
2
1
1
4308-S
51996
62
68
139 Cotter Pin
141 Brake Link Stud †
142 Washer
1
4
4
1
1
25567
4115
131 Washer
71334411
71335459
2445
71334379
71334403
50965
132 Capscrew
134 Pivot Nut
135 Brake Handle
143 Bushing
144 Cotter Pin
145 Adapter Plate
26388
26350
Rear Brake Band Assembly
(only available as a set) †
Brake Lining Kit
---
136
1
26641
1
26642
(includes brake lining and rivets)
†
These parts also come in a cold weather version. For winches with a -C in the model code, adding CH (DNV) or CHA (ABS) to
the end of these part numbers is required to retain winch certification. Example: Order Drum (15 in. long) (item 62) part number
24046 as part number 24046CH or 24046CHA.
Certification Type
Example Part Number To Order
ABS
---
24046CHA
---
DNV
24046CH
44
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AUTOMATIC DRUM BRAKE ASSEMBLY DRAWING AND PARTS LIST
126
101
127
124
125
76
104
120
128
123
102
119
103
122
111
121
105
106
79
107
149
109
108
110
112
116
114
113
115
117
(Dwg. MHP2433)
Item Description
No. of Part
Total
Qty
Part
Item Description
No. of Part
Total
Part
Number
23890
Qty
1
Number
130 Brake Assembly *
1
1
1
3
3
3
1
1
1
2
1
1
1
1
2
1
114 Plunger †
115 Dowel Pin
116 Roller †
117 Jam Nut
119 Pivot Bar
120 Capscrew
121 Cylinder
23886
71144968
23883
76
79
Hose Assembly
Valve, Exhaust
24403-39
1
71047898
71264808
21899
1
101 Capscrew
102 Spacer
2
71267413
23755
1
103 Spacer Tube
• 104 Band Assembly †
105 Spacer
21891
1
71267405
23889
24367
1
23029
• 122 ‘O’ Ring
123 Piston
1
52536
106 Brake Bracket †
107 Capscrew
22984
1
23884
71264832
23885
124 Spring
125 Cover
1
71144943
23887
108 Cylinder Rod
• 109 ‘O’ Ring
• 110 ‘O’ Ring
111 Retainer Ring
112 Capscrew
1
71049423
52662
126 Retainer Ring
127 Spring
1
71126668
71144935
71145080
52092
1
54136
128 Washer
1
71264824
71126643
149 Fitting, Nipple
1
113 Spring
* Automatic Drum Brake Assembly (130), includes items 101-128.
Recommended spare for one winch, 2 years of normal operation
•
†
These parts also come in a cold weather version. For winches with a -C in the model code, adding CH (DNV) or CHA (ABS) to
the end of these part numbers is required to retain winch certification. Example: Order Drum (15 in. long) (item 62) part number
24046 as part number 24046CH or 24046CHA.
Note: See certification type cold weather chart on page 44 for example of part number to order.
MHD56087 - Edition 4
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K5C2-X CONTROL VALVE ASSEMBLY DRAWING
902
903
901
904
955
905
Note: (956)
901
956
907
Brake Fitting
912
910
917
906
947
950
962
940
918
919
902
942
901
916
944
960
921
943
218
922
923
951
949
948
924
925
945
942
935
901
957
958
959
941
946
939
Optional
938
937
930
909
920
(Dwg. MHP2427)
46
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K5C2-X CONTROL VALVE ASSEMBLY PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
900 Control Valve Assembly
218 Plug
1
1
9
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
K5C2-X
71263297
71342034
71303408
26997
938 Buttonhead Screw
939 Seal Bracket (Note 2)
940 Tag, No FA2B
941 ‘O’ Ring
2
1
1
1
2
71394407
28733-S
71392757
71357198
51651
901 Capscrew
902 Washer
903 Cover, Poppet
904 Gasket, Poppet
905 Spring, Poppet
906 Cap, Poppet
907 Seal, Poppet
909 Washer, Tab Lock
910 Pilot Valve Assembly
912 Plug
942 ‘O’ Ring
27064
Reverse Valve Kit (Normal)**
27925-SX
28002
71351068
28734
943 Reverse Valve (Reverse Bias)**
Reverse Valve (Unbiased)
Bushing (Normal)***
944 Bushing (Reverse Bias)***
Bushing (Unbiased)
945 Pin
1
1
****
26991
26686
71398051
28696
27450
****
71267561
D10-280
*
1
1 set
2
71146674
27115
916 Ball
946 Gasket
917 Valve Housing
918 Gasket, Cover
919 Cover, Piston
920 I-R Pilot Valve Tool
921 ‘O’ Ring
947 Rivet
71028849
71352777
71376370
71366348
71369276
26691
26999
948 Label, Throttle Direction
949 Washer
1
26998
4
28690
950 Plug
1
52537
951 Capscrew
4
922 Piston (Note 1)
923 ‘O’ Ring
28735-S
71355796
71271985
71348338
27239-1
71348965
26966
955 Exhaust Flange
956 Fitting
1
1
71367932
71273676
71057483
52472
924 Washer
957 Fitting, Elbow
958 Fitting, Nipple
959 Muffler
1
925 Capscrew
1
930 Handle Assembly
935 Plug
1
960 Label, Warning
962 Breather
1
71373229
51559
937 Spring
1
*
Item 917 not sold separately, order item 900.
Reverse Valve (Normal) for Standard Overwound operation. Reverse Valve (Reverse Bias) for Optional Underwound operation.
**
*** Ensure Bushing matches Reverse Valve (Reverse Valve (Normal) and Bushing (Normal)). Mixing these components can result in
erratic winch operation.
**** Reverse Valve (Unbiased) and Bushing (Unbiased) contact factory for application.
Note 1: Item 922 not sold separately, includes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
Note 2: Item 939 not sold separately, includes items (1) each of 901 and 909, items 924, 925, 935, 937, 938, 941 and 942.
Item
No.
Total
Qty
Part
Number
Kit Description
Control Valve Service Kit Standard (includes items 901, 902, 904, 905, 907, 909, 916, 918, 921, 923-925,
935, 937, 938, 941, 942, 946, 949 and 951) (K5C2-X only)
• 780
1
27240
784 Reverse Valve Kit (includes items 940, 943 and 947) (All other winch models)
• 786 Overload Valve Service Kit (includes items 701, 703, 712 through 714, 716, 722 and 942)
• 788 Emergency Stop Service Kit (includes items 703 and 711)
789 Emergency Stop Kit (Optional Feature)*
1
1
1
1
1
27925-SX
27995
27994
28026
930 Handle Assembly Kit (includes items 901, 909, 930 and 935)
27239-1
•
Recommended spare for one winch, 2 years of normal operation.
* Kits can be installed to K5C2-X control valve for emergency stop option.
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PILOT AIR CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST
265
269
266
267
271
266
272
280
273
268
269
274
275
264
276
277
270
278
279
(Dwg. MHP2416)
Part Number
510 size
Item Description
No. of Part
Total
Qty
355 Valve Assembly (includes items 265 through 280)
264 Locknut
265 End Cap
266 Gasket
267 Valve Body
268 End Cap Assembly (includes items 270 and 271)
269 Capscrew
270 Adjusting Screw
271 Nut
272 Shoulder Screw
273 Guide
274 Spring
1
1
1
2
1
1
8
1
2
1
1
1
1
1
1
1
1
1
20993-P
71069132
71136725
71136733
Not sold separately, order item 355
25591
71030118
53545
50176
54710
71136741
71136758
71136774
71136766
Order Kit
275 Washer
276 Spacer
277 ‘O’ Ring (only available in Pilot Air Control Valve Service Kit)
278 Valve Sleeve
279 Valve Spool
280 Washer
Not sold separately, order item 355
71332324
Service Kit
Part Number
• Pilot Air Control Valve Service Kit (includes items 266 (qty 2) and 277 (qty 6))
71356406
•
Recommended spare for one winch, 2 years of normal operation
48
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FULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST
321
322
323
900
956
To Brake
738
782
321
322
255
254
243
(Dwg. MHP2432)
Item Description
No. of Part
Total
Qty
Part
Number
K5B-928
KK5B-276M
51471
243 Gasket
1
254 Exhaust Cover
255 Capscrew
1
5
321 Fitting, Elbow
322 Fitting Hose End
323 Hose (bulk)
738 Hose End
4
54270
4
54738
As Req’d
54737
2
51029
782 Hose (bulk)
900 Control Valve Assembly
956 Fitting, Elbow
As Req’d
50923
1
1
K5C2-SBK-X
71367932
Note: To convert live air control to remote live air control contact factory for kit part numbers.
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EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE ASSEMBLY DRAWING
700
903
901
701
902
904
702
703
905
704
906
907
705
706
Note: Brake
Fitting
721
956
902
955
707
912
910
722
703
916
918
711
947
919
942
723
940
902
917
901
726
942
960
921
944
943
922
923
948
218
924
951
949
925
945
946
942
963
941
712
715
935
901
713
939
714
717
938
930
718
719
937
909
902
901
920
716
720
(Dwg. MHP2434)
50
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EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
• 908 Control Valve Assembly
218 Plug
1
1
1
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
11
12
1
1
1
1
1
1
1
1
1
1
1
K5C2-EX
71263297
27491
919 Cover, Piston
920 I-R Pilot Valve Tool
921 ‘O’ Ring
1
1
1
1
1
2
2
1
1
1
2
1
1
1
3
26998
28690
700 Cap
52537
701 Grommet
702 Plunger
71365779
27490
922 Piston (Note 1)
923 ‘O’ Ring
28735-S
71355796
71271985
71348338
27239-1
71348965
26966
703 ‘O’ Ring
71127039
95790099
71372601
27488
924 Washer
704 Label, Stop
705 Button, E-Stop
706 Adapter
925 Capscrew
930 Handle Assembly
935 Plug
707 Plunger
27489
937 Spring
711 Spring
71365787
27964
938 Buttonhead Screw
939 Seal Bracket (Note 2)
940 Tag, No FA2B
941 ‘O’ Ring
71394407
28733-S
71392757
71357198
51651
712 Piston
713 ‘O’ Ring
51768
714 Gasket
27493
715 Plate
27624
942 ‘O’ Ring
716 ‘O’ Ring
71365795
24374
Reverse Valve Kit (Normal)**
27925-SX
28002
717 Adjustment Nut
718 Spring
943 Reverse Valve (Reverse Bias)**
Reverse Valve (Unbiased)
Bushing (Normal)***
944 Bushing (Reverse Bias)***
Bushing (Unbiased)
945 Pin
1
1
71053730
27494
****
719 Cover
26686
720 Screw, Adjusting
721 Capscrew
722 ‘O’ Ring
27571
27450
71365811
71138135
27540
****
1
1 set
2
71146674
27115
723 Adapter, Exhaust
726 Plug
946 Gasket
27945
947 Rivet
71028849
71352777
71376370
71369276
26691
901 Capscrew
902 Washer
71342034
71303408
26997
948 Label, Throttle Direction
949 Washer
1
4
903 Cover, Poppet
904 Gasket, Poppet
905 Spring, Poppet
906 Cap, Poppet
907 Seal, Poppet
909 Washer, Tab Lock
910 Pilot Valve Assembly
912 Plug
951 Capscrew
4
27064
955 Exhaust Flange
956 Fitting
1
71351068
28734
1
71367932
Fitting, Elbow
957
1
1
1
71273676
71057483
52472
(refer to Dwg. MHP2427)
26991
71398051
28696
Fitting, Nipple
958
(refer to Dwg. MHP2427)
71267561
D10-280
*
Muffler
959
(refer to Dwg. MHP2427)
916 Ball
917 Valve Housing
918 Gasket, Cover
960 Label, Warning
963 Plug
1
3
71373229
28628
26999
*
Item 917 not sold separately, order item 908.
Reverse Valve (Normal) for Standard Overwound operation. Reverse Valve (Reverse Bias) for Optional Underwound operation.
**
*** Ensure Bushing matches Reverse Valve (Reverse Valve (Normal) and Bushing (Normal)). Mixing these components can result in
erratic winch operation.
**** Reverse Valve (Unbiased) and Bushing (Unbiased) contact factory for application.
Note 1: Item 922 not sold separately, includes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
Note 2: Item 939 not sold separately, includes items (1) each of 901 and 909, items 924, 925, 935, 937, 938 and 940.
Note 3: Refer to page 45 for kits and spare part kits.
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TENSIONING MANIFOLD ASSEMBLY DRAWING
734
735
736
739
784
739
783
737
738
737
738
739
743
742
779
741
777
748
782
741
744
745
756
739
758 749
738
776
753
741
752
751
782
761
To Disc
Brake
746
747
775
751
785
774
946
749
773
751
758
771
772
741
769
759
765
761
741
741
767
766
764
248
741
745
741
751
(Dwg. MHP2436)
52
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TENSIONING MANIFOLD ASSEMBLY PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
67
Rivet
6
50915
K5B-547
71320964
71127054
26217
756 Fitting, Bushing
758 Fitting, Nipple
759 Fitting, Elbow
761 Fitting, Nipple
764 Manifold, Control Valve
765 Union
1
50934
71308258
50928
248 Gasket
1
2
731 Washer
4
1
732 Capscrew
734 Label, Tensioning Manifold
735 Gasket
4
2
50933
1
1
25874
1
26216
1
71328330
71328314
71320915
71328249
71320956
71320949
71069132
26095
736 Cover
1
26215
766 Fitting, Nipple
767 Check Valve
769 Fitting, Nipple
771 Washer
1
737 Fitting, Elbow
738 Fitting, Hose End
739 Fitting, Elbow
741 Fitting, Elbow
742 Capscrew
743 Handle Ball
744 Valve
2
54869
1
3
51029
1
5
52803
4
8
54243
772 Capscrew
4
3
71319073
71138051
71316434
71069017
51001
773 Nut
3
1
774 Bracket
1
1
775 Fitting, Nipple
776 Fitting, Elbow
777 Regulator and Gauge*
779 Fitting, Connector
782 Hose**
1
71320907
26057
745 Plug
2
1
746 Fitting, Elbow
747 Spacer
1
1
71325047
54943
3
14998-8B
26149
1
748 Handle
1
As Req’d
50923
749 Hose**
As Req’d
51003
783 Shuttle Valve
784 Fitting, Tube Extension
785 Fitting, Elbow
946 Gasket
1
1
50277
751 Fitting, Hose End
752 Washer
4
4
4
51002
71325591
71149975
27115
51581
1
753 Capscrew
71328199
1 set
*
Items not sold separately
Order in even foot increments, i.e. 51003-02 = 2 feet (0.6 metres)
**
MHD56087 - Edition 4
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REMOTE PENDANT ASSEMBLY DRAWINGS
Pendant without Emergency Stop
455
444
440
453
448
447
445
446
449
456
470
451
450
454
443
452
457
458
(Dwg. MHP2346)
Pendant with Emergency Stop
455
440
442
443
444
448
453
447
446
445
446
456
441
449
451
450
449
443
454
443
452
451
452
457
458
(Dwg. MHP1677)
54
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REMOTE PENDANT ASSEMBLY PARTS LIST
Part
Item Description
Total
Qty
Number
No.
of Part
Without E-Stop
With E-Stop
353
440
Pendant Assembly*
Lifting Eye
Emergency Stop Valve
Plug
1
1
PHS2E
PHS2E-U
64222332
441
1
95790108
95790106
---
442
1
• 443
444
‘O’ Ring
Plug
2(5)
2(4)
2(4)
2(5)
1
58209229
54292
445
Spring
69128541
69401625
95790040
42008607
58235329
42008307
95790107
95790104
95790122
446
Ball
447
Pin
448
Setscrew
‘O’ Ring
Setscrew
Protector
Valve
2
• 449
450
2(3)
2(3)
2(3)
2(3)
2
451
452
453
Lever
454
Pendant Handle
Fitting
1
order item 353
71078158
95790111
95790114
47713030
455
3(5)
1
456
Label Kit
Exhaust Washer
Retainer Ring
Plug
457
1
458
1
470
1
65129541
---
*
**
Pendant assembly without E-Stop includes items 440, 443-449 and 451-458 and 470.
Pendant assembly with E-Stop includes 440-449 and 451-458.
•
Recommended spare for one winch, 2 years of normal operation.
MHD56087 - Edition 4
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OPEN FRAME (FACE) WINCH ASSEMBLY DRAWING
(Dwg. MHP1231)
56
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OPEN FRAME (FACE) WINCH ASSEMBLY PARTS LIST
Item Description
Total
Qty
Part
Item
No.
Description
of Part
Total
Qty
Part
No.
26
68
81
82
of Part
Number
Number
Upright, Outboard End
Upright, Motor End
Capscrew
1
1
4
2
25566
25567
571
572
573
574
Sideframe, Outboard End
Capscrew
1
4
1
4
25548
71306450
25549
71264709
21882
Sideframe, Motor End
Capscrew
Corner Bar
71306443
Side Rail:
Bar:
65
75
Short Drum
Long Drum
Brake Hose:
Short Drum
Long Drum
24674
24675
570
Short Drum
Long Drum
*
1
1
2
25550
23230-63
23230-75
Open Frame (Face) Kit Assembly (includes Items 570 through 574):
Short Drum
1
*
Long Drum
1
25546
* Contact factory.
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REMOTE PILOT AIR CONTROL (OPTIONAL) PARTS DRAWING
365
364
782
355
363
951
949
362
358
949
361
738
455
359
353
Remote Pilot
Lever Throttle
360
Remote Pilot
Pendant Throttle
(Dwg. MHP2444)
58
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REMOTE PILOT AIR CONTROL (OPTIONAL) PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
353
355
358
359
360
361
362
363
364
365
455
738
782
949
951
Remote Pilot Pendant
Valve Assembly
Remote Pilot Lever Throttle
Fitting, Nipple
Fitting, Elbow
Capscrew
1
PHS2E
20993-P
71386064
71048268
51281
1
1
1
2
4
71355895
13881-P
53939
Manifold
1
Fitting, Nipple
Fitting, Hose
Fitting, Tee
2
3
52179
1
52181
Fitting, Nipple
Fitting, Hose
Hose (bulk) †
Washer
3
71078158
51029
3
As Req’d
50923
8
4
71376370
71369276
Capscrew
† Hose lengths exceeding 50 ft (16 m), contact factory.
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MUFFLER ASSEMBLY DRAWING AND PARTS LIST
713
714
715
712
711
710
(Dwg. MHP1189)
Item Description
Total
Qty
Part
Number
No.
of Part
Motor Muffler and Fittings:
710 Muffler
1
1
1
50594
711 Elbow Fitting
712 Reducer
71106439
71057459
Control Valve Muffler and Fittings:
713 Nipple Fitting
714 Elbow Fitting
715 Muffler
1
1
1
71311260
54299
71264360
60
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FREE SPOOL ASSEMBLY DRAWING AND PARTS LIST
28
504
518
517
502
18
510
518
503
516
509
515
506
514
513
501
505
902
508
18
1
2
511
512
507
(Dwg. MHP2414)
Item Description
Total
Qty
Part
Item
No.
Description
of Part
Pin
Total
Qty
Part
No.
500
1
of Part
Number
27361
Number
Free Spool Assembly*
Capscrew
1
6
1
2
1
1
1
1
6
6
1
508
509
510
511
512
513
514
515
516
517
518
902
1
1
1
1
1
4
1
1
1
1
2
6
71328173
71328181
71069009
HU-566
HU-565P
71307284
26182
71266613
21732
Spring
2
Cover
Plug
18
Gasket
71262257
24817
Plunger
Handle
Capscrew
Detent Plate
Shifter
28
Output Shaft
‘O’ Ring
501
502
503
504
505
506
71137988
27315
Housing
Shaft Support
Capscrew
27314
26173
54610
Dowel Pin
Shoe
71053722
27318
Capscrew
71138275
71328793
Label, Instruction
Guide Ring
Washer
27316
71303408
Shifter Assembly
(includes items 507-516)
507
*
1
26172
Includes items 1, 2, 18, 28, 501-518.
MHD56087 - Edition 4
61
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DRUM GUARD ASSEMBLY DRAWING AND PARTS LIST
592
591
109
590
109
591
Manual Drum Brake
592
595
596
594
109
(Dwg. MHP0658)
Item
No.
Description
of Part
Total
Qty
Part
Number
Drum Guard Assemblies - Short Drum (12 and 15 inch) *
23835
23507
590
1
Drum Guard Assemblies - Long Drum (24 and 27 inch) *
109
591
592
594
595
596
‘O’ ring
Bracket
As Required
71049423
23608
2
4
1
1
1
Capscrew
Capscrew
Pin
71261739
71306443
26376
Bracket Shaft
26367
* Drum Guard Assemblies include items 109, 591-592.
* Contact factory for drum and guard assemblies with drum band brake.
62
MHD56087 - Edition 4
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AIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST
(Dwg. MHP0223)
Note: Drawing for reference only; components may not resemble
those shown in drawing.
Item Description
No. of Part
Total
Qty
Part
Number
575 Filter (1-1/2 FNPT)
1
F35-0B-C28
R40-0B-G00
---
577 Regulator (1-1/2 FNPT)
578 Pipe Nipple (1-1/2 FNPT*)
580 Lubricator (1-1/2 FNPT)
1
As Req’d
1
1
L40-0B-G00
8834-W1-000
**
Liquidator (2 FNPT)
Air preparation components for 1-1/2 inch FNPT system.
* Length as required for installation.
** Item not illustrated.
ACCESSORIES AND KITS
Description
of Accessory
Total
Qty
Part
Number
Thermoplastic Power
2 ounce
1 each
1 each
1
71308902
71308886
Propane Torch
Heat Gun
71308894
Adapter Rail Kit for FA5A Short Drum to K6U Foot Print
Yellow Touch-Up Paint
24333
1 can
16 fl. oz
1
FAP-237Y
Lubricant
LUBRI-LINK-GREEN
24332
Adapter Rail Kit for FA5A Long Drum to K6U Foot Print
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WINCH LABEL/TAG LOCATION PARTS DRAWING
940
Install over wire
947
rope anchor hole
with arrow
960
342
64
67
toward operator
341
948
Oil
343
Level/Fill
Label
346
345
Oil
Level/Fill
Label
346
347
349
347
354
Oil
Drain
Label
Oil
Drain
Label
Viewed from inboard side of winch
350
67
50
351
348
Oil
Level/Fill
Label
346
356
354
Oil
Drain
Label
Viewed from end
opposite motor
347
354
(Dwg. MHP1229)
64
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WINCH LABEL/TAG LOCATION PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
Label Kit (Short)**
23510-1-S
23510-2-S
71306518
71148282
50915
300
1
Label Kit (Long)***
Label, Disc Instructions
Label, Wire Rope Cover
Rivet
50
64
67
1
1
8
1
1
341 Label, Warning
342 Tag, Warning
04306445
71056410
71107148
343 Tag, Notice Check Oil Level
345 Label, Exhaust
1
346 Label, Oil Level/Fill
347 Label, Oil Drain
1 set
71295240
Product Label (Short)
348
71111777
71109508
71106272
71109102
71126585
Contact Factory
71270813
71137780
71392757
71028849
71352777
71373229
1
1
Product Label (Long)
I-R Logo (Short)
349
I-R Logo (Long)
350 Label, Throttle Direction
351 Nameplate
1
1
2
1
1
2
1
1
354 Label, Warning
356 Label, I-R Monogram
940 Tag, No FA2B
947 Rivet
948 Label, Throttle Direction
960 Label, Warning
Contact factory with winch serial number for new nameplate orders.
**
23510-1-S (includes items 341-343, 345-347, 349, 350 and 354-356)
*** 23510-2-S (includes items 341-343, 345-347, 349, 350 and 354-356)
Note: Contact factory for (CE) European label information.
MHD56087 - Edition 4
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CONSTRUCTION CAGE ASSEMBLY DRAWING AND PARTS LIST
561
562
560
563
600
948
568
565
601
567
564
566
(Dwg. MHP2438)
Item Description
No. of Part
Total
Qty
Part
Number
Construction Cage (Short)
Construction Cage (Long)
CC-FA5A-SM
CC-FA5A-LM
71355838
71316830
71355846
71359129
51831
560
1
561 Capscrews
562 Lockwasher
563 Locknut
4
4
4
4
4
1
1
4
1
1
4
564 Buttonhead Screw
565 Washer
566 Cover, Label
567 Label, Specification
568 Nut
27426
71359137
50852
600 Nameplate
601 Label, Warning
948 Rivet
Contact Factory
71359384
71028849
66
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SERVICE NOTES
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SERVICE NOTES
68
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SERVICE NOTES
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PARTS ORDERING INFORMATION
The use of other than Ingersoll-Rand replacement parts may
adversely affect the safe operation and performance of this
Return Goods Policy
product.
Ingersoll-Rand will not accept any returned goods for warranty
or service work unless prior arrangements have been made and
written authorization has been provided from the location where
the goods were purchased.
For your convenience and future reference it is recommended that
the following information be recorded.
Model Number _______________________________________
Serial Number ________________________________________
Date Purchased _______________________________________
Winches which have been modified without Ingersoll-Rand
approval, mishandled or overloaded will not be repaired or
replaced under warranty. A printed copy of the warranty which
applies to this winch is provided inside the back cover of this
manual.
When ordering replacement parts, please specify the following:
1. Complete model number and serial number as it appears on
the nameplate.
2. Part number(s) and part description as shown in this manual.
3. Quantity required.
Disposal
When the life of the unit has expired, it is recommended that it be
disassembled, degreased and parts separated as to materials so that
they may be recycled.
The nameplate is located on the winch outboard upright.
For additional information contact:
Ingersoll-Rand
P.O. Box 24046
• Continuing improvement and advancement of design may
cause changes to this equipment which are not included in this
manual. Manuals are periodically revised to incorporate
changes. Always check the manual edition number on the
front cover for the latest issue.
2724 Sixth Avenue South
Seattle, WA 98124-0046 USA
Phone: (206) 624-0466
Fax: (206) 624-6265
• Sections of this manual may not apply to your winch.
or
Ingersoll-Rand
Douai Operations
111, Avenue Roger Salengro
59450 Sin Le Noble, France
Phone: (33) 3-27-93-08-08
Fax: (33) 3-27-93-08-00
70
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WARRANTY
LIMITED WARRANTY
Ingersoll-Rand Company (I-R) warrants to the original user its
I-R makes no other warranty, and all implied warranties
including any warranty of merchantability or fitness for a
particular purpose are limited to the duration of the
expressed warranty period as set forth above. I-R’s maximum
liability is limited to the purchase price of the Product and in
no event shall I-R be liable for any consequential, indirect,
incidental, or special damages of any nature rising from the
sale or use of the Product, whether based on contract, tort, or
otherwise.
Hoists and Winches (Products) to be free of defects in material
and workmanship for a period of one year from the date of
purchase. I-R will repair, without cost, any Product found to be
defective, including parts and labor charges, or at its option, will
replace such Products or refund the purchase price less a
reasonable allowance for depreciation, in exchange for the
Product. Repairs or replacements are warranted for the remainder
of the original warranty period.
If any Product proves defective within its original one year
warranty period, it should be returned to any Authorized Hoist
and Winch Service Distributor, transportation prepaid with proof
of purchase or warranty card.
Note: Some states do not allow limitations on incidental or
consequential damages or how long an implied warranty lasts so
that the above limitations may not apply to you.
This warranty gives you specific legal rights and you may also
have other rights which may vary from state to state.
This warranty does not apply to Products which I-R has
determined to have been misused or abused, improperly
maintained by the user, or where the malfunction or defect can be
attributed to the use of non-genuine I-R parts.
IMPORTANT NOTICE
It is our policy to promote safe delivery of all orders.
Damage Claims
You must file claims for damage with the carrier. It is the
transportation company’s responsibility to reimburse you for
repair or replacement of goods damaged in shipment. Claims for
loss or damage in shipment must not be deducted from the
Ingersoll-Rand invoice, nor should payment of Ingersoll-Rand
invoice be withheld awaiting adjustment of such claims as the
carrier guarantees safe delivery.
This shipment has been thoroughly checked, packed and
inspected before leaving our plant and receipt for it in good
condition has been received from the carrier. Any loss or damage
which occurs to this shipment while enroute is not due to any
action or conduct of the manufacturer.
Visible Loss or Damage
If any of the goods called for on the bill of lading or express
receipt are damaged or the quantity is short, do not accept them
until the freight or express agent makes an appropriate notation on
your freight bill or express receipt.
You may return products damaged in shipment to us for repair,
which services will be for your account and form your basis for
claim against the carrier.
Concealed Loss or Damage
When a shipment has been delivered to you in apparent good
condition, but upon opening the crate or container, loss or damage
has taken place while in transit, notify the carrier’s agent
immediately.
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United States Office Locations
International Office Locations
For Order Entry and
Order Status
Regional Sales Offices
Offices and distributors in
principal cities throughout the Africa
Europe, Middle East and
Annandale, NJ
P.O. Box 970
1467 Route 31 South
Annandale, NJ 08801
Phone: (908) 238-7000
Fax: (908) 238-7048
world. Contact the nearest
Ingersoll-Rand office for the
name and address of the
distributor in your country or
write/fax to:
Ingersoll-Rand
Douai Operations
111, avenue Roger Salengro
59450 Sin Le Noble, France
Phone: (33) 3-27-93-08-08
Fax: (33) 3-27-93-08-00
Ingersoll-Rand
Distribution Center
P.O. Box 618
510 Hester Drive
White House, TN 37188
Phone: (615) 672-0321
Fax: (615) 672-0801
Canada
Detroit, MI
National Sales Office
Regional Warehouse
Toronto, Ontario
51 Worcester Road
Rexdale, Ontario
M9W 4K2
Asia Pacific Operations
Ingersoll-Rand
42 Benoi Road
Jurong, Singapore 629903
Phone: 65-861-1555
Fax: 65-861-0317
1872 Enterprise Drive
Rochester, MI 48309
Phone: (248) 293-5700
Fax: (248) 293-5800
For Technical Support
Ingersoll-Rand
P.O. Box 24046
2724 Sixth Avenue South
Seattle, WA 98124-0046
Phone: (206) 624-0466 or
(866) 273-FAST (3278)
Fax: (206) 624-6265
Phone: (416) 213-4500
Fax: (416) 213-4510
Order Desk
Russia
Ingersoll-Rand
Kuznetsky Most 21/5
Entrance 3
Fax: (416) 213-4506
Latin America Operations
Ingersoll-Rand
730 N.W. 107 Avenue
Suite 300, Miami, FL, USA
33172-3107
Moscow 103895 Russia
Phone: 7-501-923-9134
Fax: 7-501-924-4625
Web Site:
Australia
Phone: (305) 559-0500
Fax: (305) 222-0864
Ingersoll-Rand Aust
1 Hartnett Drive
Seaford, Vic 3198
Australia
Phone: 613 95541642
Fax: 613 95541607
Printed in USA
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