Product Maintenance

Information

Model
FA150KGi

(Dwg. MHP2738)

Save These Instructions

Form MHD56313
Edition 2
June 2010
71456198
© 2010 Ingersoll-Rand Company
Only allow Ingersoll Rand trained technicians to perform maintenance on this product. For additional information contact Ingersoll Rand factory or nearest
Distributor.
For additional supporting documentation refer to Table 1 ‘Product Information Manuals’ on page 2.
Manuals can be downloaded from www.ingersollrandproducts.com.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate all warranties.
The original language of this manual is English.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.

Table 1: Product Information Manuals

Publication Part/Document Number Publication Part/Document Number
Product Safety Information Manual (Man Rider) MHD56251 Product Information Manual MHD56314
Product Parts Information Manual MHD56315

INSPECTION
Frequent inspections should be performed on equipment in regular service. Refer to
Product Information Manual.

n Periodic Inspection
Refer to Table 2 ‘Inspection Classifications’ on page 2 for suggested winch
inspection classifications for Periodic Inspection intervals. Select conditions most
appropriate to application.

Table 2: Inspection Classifications

Conditions Normal Heavy Severe
Typical Use (operating time) Infrequent Regular Continual/Constant
Load Range 60% of Capacity 75% of Times Used 80% of Capacity 75% of Times Used 100% of Capacity 75% of Times Used
Installation Protected/Enclosed/Dry Not Sheltered/Exterior Full Exposure
Atmosphere Clean/Non-Corrosive Dirty/Non-Corrosive/Freshwater Marine Dirty/Corrosive/Saltwater Marine
Climate Dry/Stable Temperature Wet/Moderate Temperature Fluctuations Wet/Severe Temperature Fluctuations

Maintain written records of periodic inspections to provide an accumulative basis for 6. Brakes. Individually test brakes installed to ensure proper operation. Brakes must
continuing evaluation. Inspect all items listed in the ‘Frequent Inspection’ section of hold a 125% rated load at mid drum without slipping. If indicated by poor
the Product Information Manual. Also inspect the following at the suggested intervals operation or visual damage, disassemble and repair brake(s). Check all brake
recommended in Table 3 ‘Maintenance Interval Chart’ on page 3: surfaces for wear, deformation or foreign deposits. Clean and replace components
as necessary. Adjustments can be made to the band brake to compensate for
1. Siderails and Uprights. Check for deformed, cracked or corroded main normal brake lining wear. Refer to ‘Adjustments’ on page 7. If brake band
components. Replace damaged parts. cannot be adjusted to hold rated load, replace the brake band assembly.
2. Fasteners. Check retainer rings, capscrews, nuts and other fasteners on winch, Adjustments cannot be made to the disc brake. The disc brake must be repaired
including mounting bolts. Replace if missing or damaged and tighten if loose. as described in “MAINTENANCE” on page 7.
3. Drum and Sheaves. Check for cracks, wear or damage. Replace if necessary. 7. Foundation or Supporting Structure. Check for distortion, wear and continued
4. Wire Rope. In addition to ‘Frequent Inspection’ requirements, also inspect for ability to support winch and rated load. Ensure winch is firmly mounted and that
the following: fasteners are in good condition and tight.
a. Build-up of dirt and corrosion. Clean with steam or a stiff wire brush to remove 8. Labels and Tags. Check for presence and legibility of labels. Replace if damaged
dirt and corrosion if necessary. or missing.
b. Loose or damaged end connection. Replace if loose or damaged. 9. Limit Switches. Operate winch in both directions to activate limit switches. Limit
c. Check wire rope anchor is secure in drum. switches should engage (stop winch operation) at established settings (+/- 2 feet
d. Verify wire rope diameter. Measure the diameter of the wire rope from crown- [+/- 0.6 metres]). Reset limit switch by operating winch in opposite direction.
to-crown throughout the life of the wire rope. Recording of the actual Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.
diameter should only be done with the wire rope under equivalent loading 10. Winch Guard. Verify fasteners are tight and in good condition. Ensure guard is
and in the same operating section as accomplished during previous in good condition and panels are correctly positioned.
inspections. If the actual diameter of the wire rope has decreased more than 11. Emergency Stop Valve. During winch operation verify the emergency stop valve
1/64 inch (0.4 mm) a thorough examination of the wire rope should be operation. Valve must stop winch operation quickly. Valve must reset properly.
conducted by an experienced inspector to determine the suitability of the Refer to ‘Emergency Stop Valve’ in the “OPERATION” section in Product
wire rope to remain in service. Refer to Dwg. MHP0056 on page 2, A. Wire; Information Manual for procedures.
B. Crown to Crown; C. Wire Strand; D. One Lay. 12. Overload Device. 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.
A 13. Press Roller. Inspect rollers for wear and grooves. Ensure rollers freely rotate.
Replace rollers if worn or grooved. Replace bearings if rotation is rough or stiff.
14. Slack Wire Device. Inspect rollers for wear and grooves. Ensure rollers freely
rotate. Replace rollers if worn or grooved. Replace bearings if rotation is rough
or stiff.
B
n 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 review.
C

n Maintenance Intervals
Refer to ‘Periodic Inspection’ and Table 2 ‘Inspection Classifications’ on page 2 for
maintenance interval guidance.

NOTICE
D
• Perform an annual winch load test for all applications.
(Dwg. MHP0056)
5. All Components. Inspect for wear, damage, cracking, 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.

2 Form MHD56313 Edition 2

Table 3: Maintenance Interval Chart
Normal Application
The following work can be completed by owner maintenance personnel

System Air Filter Inspect system air filter every 45 days or 100 hours.
Grease Fittings Lubricate grease fittings every 180 days or 250 hours.
Gearbox Oil Level Check oil level in gearbox every 120 days or 250 hours. Replace oil yearly.

It is recommended that the following work be completed by an Ingersoll Rand trained service technician.

1 year or 2 years or 3 years or 4 years or 5 years or 6 years or 8 years or 8,000

Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs hrs
Inspect Motor X X X X
Inspect Disc Brake X X
Inspect Manual Band Brake (Note 1) X X X X X X X
Inspect Gearbox X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Automatic Band Brake *(Note 1) X X X X
Heavy Application
The following work can be completed by owner maintenance personnel
Inspect system air filter every 30 days or 100 hours.
Grease Fittings Lubricate grease fittings every 90 days or 250 hours.
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours. Replace oil yearly.
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
1 year or 2 years or 3 years or years or 5 years or 6 years or 7 years or 7,000
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs hrs
Inspect Motor X X X
Inspect Disc Brake X X
Inspect Manual Band Brake (Note 1) X X X X X X X
Inspect Gearbox X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Automatic Band Brake * (Note 1) X X X X

Form MHD56313 Edition 2 3

 Severe Application
The following work can be completed by owner maintenance personnel
System Air Filter Inspect system air filter every 30 days or 100 hours.
Grease Fittings Lubricate grease fittings every 90 days or 250 hours.
Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours. Replace oil yearly.
It is recommended that the following work be completed by an Ingersoll Rand trained service technician.
1 year or 2 years or 3 years or 4 years or 5 years or 6 years or 7 years or
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs 7,000 hrs
Inspect Motor X X X X X X
Inspect Disc Brake X X X
Inspect Manual Band Brake (Note 1) X X X X X X X
Inspect Gearbox X X X
Replace Winch Anchor Bolts X X X
Inspect Control Valve X X X X X X
Inspect Drum, Housings and Main Frames X X X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X X X
Limit Switches X X X X X X X
Automatic Band Brake * (Note 1) X X X X X X

Note: Hours are for actual winch drum rotation. Perform an annual winch load test for all applications.
* Do not disassemble air cylinder unless brake operation or visual inspection indicates a requirement.

Recommend complete general overhaul.

4 Form MHD56313 Edition 2

 INSPECTION REPORT

Ingersoll Rand FA150KGi-MR Winch

Model Number: Date:

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

1. Scheduled Periodic Inspection:

(_____ Quarterly _____ Semiannually _____ Yearly)
Operating Environment:
2. Discrepancy(s) noted during Frequent Inspection Normal ____ Heavy ____ Severe ____
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________
Refer to the Product Information Manual for the frequent “INSPECTION” criteria. Also, refer to appropriate National Standards and Codes of practice. If in doubt about an
existing condition, contact the nearest Ingersoll Rand Distributor or the factory for technical assistance.
CONDITION CORRECTIVE ACTION
COMPONENT NOTES
Pass Fail Repair Replace
Uprights and Siderails
Drum Band Brake (125% Load Test)
Automatic Disc Brake (125% Load Test)
Drum Band Brake (Visual Inspection)
Disc Brake (Visual Inspection)
Motor
Limit Switch
Controls
Emergency Stop Valve
Overload Device
Emergency Brake Release Valve
Stowage Valve (if equipped)
Air System
Reduction Gear
Fasteners ---
Shafts ---
Labels and Tags ---
Slack Line Detector
Drum Guard
Wire Rope Wedge ---
Press Roller
Wire Rope

Testing: Pass Fail NOTES

Operational (No Load)
Operational (10% Load)
Operational (Maximum Test Load*)

* Maximum test load is 125% of rated line pull at full drum. 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 page may be photo copied and used as an inspection record.

Form MHD56313 Edition 2 5

 TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by personnel
instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common winch symptoms, probable causes and remedies.

SYMPTOM CAUSE REMEDY

Winch will not operate. No air supply to winch. Check air supply line connections and hoses.
Winch is overloaded. Reduce load to within rated capacity. Verify overload settings.
Shipping plugs may still be in place. Remove shipping plugs in control valve.
Drum brake not released. Disengage manual drum brake or refer to ‘Automatic Drum Brake’ below.
Load continues to move when winch is Brake(s) slipping. Check brake band adjustment and brake band lining wear. Disassemble and inspect
stopped. disc brake.
Winch motor controls sticking. Check pendant/throttle levers return to normal (neutral) positions when released.
Disassemble, inspect and repair the pilot air control valve. Verify spool adjustment.
Winch does not lift load. Motor may be damaged. Remove and disassemble motor. Examine all parts and replace any that are worn or
damaged.
Insufficient air supply. Verify air supply pressure and volume at winch inlet meets requirements. Refer to
“SPECIFICATIONS” section in Product Information Manual. Clean air line filter.
Upper limit switch activated. Lower load and check limit switch settings.
Winch hauls in but does not payout. Lower limit switch activated. Raise load and check limit switch settings.
Slack line detector activated. Determine cause of slack line and rectify problem.
Throttle moves but winch does not operate. Motor may be damaged. Disassemble and clean the motor and replace any worn or damaged parts.
Insufficient air supply. Ensure air pressure at the winch inlet is at least 90 psig (6.3 bar/630 kPa) at rated
volume. Clean air line filter.
Air leak. Check hose connections. Check hose lines for wear or damage. Replace worn or
damaged hoses and fittings.
Winch runs slow. Improper hose or fitting sizes. Check fittings, connections and hoses for correct size and length. Replace parts that
may cause restricted air flow. Inspect air line filter.
Motor may be damaged. Remove and disassemble motor. Inspect all parts and replace all worn or damaged
parts.
Brake(s) may not be releasing. Refer to brake sections below.
Ice in exhaust ports and/or air lines. Check aftercoolers and traps. Add airline antifreeze to air supply.
Motor piston ring wear. Inspect piston rings and replace if worn.
Excessive water in motor. Drain water in motor. Refer to ‘Draining Motor Housing’ in “OPERATION” section.
Air lines freeze. Water in air supply. Install or drain air system moisture traps, moisture collecting air receivers and
compressor aftercoolers. After corrective action has been taken, disconnect lines at
winch inlet and purge with clean, dry air or nitrogen.
Air Motor:
Motor runs hot or makes excessive noise Damaged or broken motor internal parts. Disassemble and repair motor.
during operation. Moisture in motor housing. Drain motor housing. Refill to correct level. Refer to “LUBRICATION” section in
Product Information Manual.
Automatic Drum Brake:
If air is noticed escaping from around the cylinder cover when attempting to release
Damaged or leaking cylinder seals. the brake disassemble and inspect cylinder. Replace all seals and repair or replace
Brake will not release.
worn or damaged parts.
Dirty filter in air supply. Clean or replace filter.
Brake does not set when controls are Hole in exhaust valve restricted or exhaust
Remove and inspect exhaust valve. Clean hole or replace damaged exhaust valve.
released. valve damaged.
Automatic Disc Brake:
Brake will not release. Low air supply pressure. Ensure supply air pressure at the brake inlet is at least 60 psig (410 kPa/4.1 bar).
Leaking brake piston seals Disassemble brake and replace seals.
No release pressure at brake port. Verify proper operation of winch controls.

6 Form MHD56313 Edition 2

 MAINTENANCE
WARNING NOTICE
• Never perform maintenance on the winch while it is supporting a load. • If brake band cannot be adjusted to hold rated load, replace brake band
• Before performing maintenance, tag controls: assembly.

WARNING - DO NOT OPERATE, EQUIPMENT BEING REPAIRED. 6. Adjust brake so when brake handle locks (goes over-center), brake will hold rated
load.
7. Install cotter pin (352) and bend ends apart when adjustment is complete.
• Only allow Ingersoll Rand trained Technicians to perform maintenance on this
winch. CAUTION
• Shut off air system and depressurize air lines before performing any
maintenance.
• Do not use Trichloroethylene to clean parts. • When any part of the brake lining measures 0.062 in. (2 mm) or less, brake
• Use of other than genuine Ingersoll Rand parts may result in safety hazards, bands (376) must be replaced. This also applies to Auto Band Brake.
decreased performance and increased maintenance and will invalidate all
warranties.
• After performing any maintenance on the winch, test winch to 125% of its For new Brake Linings:
rated line pull at mid drum before returning to service. (Testing to more than Run-in new brake linings to remove loose material and allow new lining to conform
125% of rated line pull may be required to comply with standards and to brake drum.
regulations set forth in areas outside the USA.)
1. Operate winch while applying increasing pressure to brake band handle until drum
stops.
NOTICE
CAUTION
Refer to Product Information and Safety Manuals for specific information.
• Observe end of load line. Drum should only complete three to five full
rotations before stopping.
n General
Correct disassembly (to prevent loss or damage of good parts), repair, assembly, 2. Repeat step 1 twice while operating winch in both directions (payout and haul-
testing and adjusting are critical to proper winch operation. Maintenance procedures in). The brake link stud may require tightening to stop drum rotation.
are technical in nature and require training and experience to accomplish correctly. 3. Adjust brake as described in steps 1 through 7 above.
In addition, repair and testing require specialized equipment that is not typically
found at the winch-mounting site. WARNING
Proper use, inspections and maintenance increase the life and usefulness of your
Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and all
machined threads with applicable lubricants. Use of antiseize compound and/or • Ensure brake band has been adjusted properly. Chattering of brake band
thread lubricant on capscrew and nut threaded areas prevents corrosion and allows during winch operation is an indication of improper adjustment. Continual
for easy disassembly of components. chattering could cause fatigue to brake band, resulting in cracking near the
bracket area and cause brake band to fail.
It is extremely important that anyone involved with maintaining the winch be familiar
with the servicing procedures of these winches and be physically capable of n Automatic Drum Brake Band
conducting the procedures. These personnel shall have skills that include:
Refer to Dwg. MHP2743.
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 NOTICE
standards.
• If brake band cannot be adjusted to hold rated load, replace the brake band
Ingersoll Rand cannot know of or provide all the procedures by which product assembly. Refer to Manual Band Brake adjustments.
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 1. Remove cotter pin (352) and washer (385) at adjustment clevis (358).
by the actions taken. If unsure of an operation or maintenance procedure or step, 2. Apply air to the brake cylinder (362) and remove pin (357) to disconnect clevis
personnel should place the product in a safe condition and contact supervisors and/ from brake lever (355).
or the factory for technical assistance. 3. Turn adjustment clevis (358) clockwise to increase cylinder rod extension. Turn
clevis counterclockwise to decrease cylinder rod extension.
NOTICE 4. Assemble clevis (358) to brake lever (355) using pin (357). Release air to brake
cylinder (362).
5. Brake should hold rated load when cylinder (362) is retracted. Brake band should
• Refer to the Product Parts Information Manual for drawings unless specified not drag on drum when cylinder is extended. Refer to “INSPECTION” section in
elsewhere. the Product Information Manual.
6. Install cotter pin (352) and washer (385), bend ends of pin apart to secure clevis
to brake lever when adjustment is complete. Discard and replace cotter pin (352),
n Maintenance Intervals if necessary.

Refer to Table 3 ‘Maintenance Interval Chart’ on page 3 for recommended maintenance n Overload Device
schedule.
Contact factory for adjustment information.
n Adjustments n Limit Switch
Refer to “INSTALLATION” section in the Product Information Manual for slack wire
rope detector adjustments. Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.

n Disc Brake
n Disassembly
Refer to Dwg. MHP2741.
Brake adjustment is not required. If disc brake does not hold 125% of rated load at n General Disassembly Instructions
mid drum, disassemble and repair.
The following instructions provide necessary information to disassemble, inspect,
n Manual Drum Brake Band repair, and assemble product. Parts drawings are provided in Product Parts
Information Manual.
If a product is being completely disassembled for any reason, follow the order of
Refer to Dwg. MHP2743. topics as they are presented. It is recommended that all maintenance work on product
1. Release wire rope tension on the drum. be performed in a clean dust-free work area.
2. Raise handle (354) to free brake band assembly (376). In the process of disassembling product, observe the following:
3. Remove cotter pin (352) and pin (351) from link stud (353).
4. Rotate brake link stud (353) clockwise to increase brake torque. Discard and
replace cotter pin (352), if necessary. 1. Never disassemble product any further than is necessary to accomplish needed
5. Install pin (351) and check adjustment. repair. A good part can be damaged during the course of disassembly.
2. Never use excessive force when removing parts. Tapping gently around perimeter
of a cover or housing with a soft hammer, for example, is sufficient to break the
seal.
3. Do not heat a part with a flame to free it for removal, unless part being heated
is already worn or damaged beyond repair and no additional damage will occur
to other parts.

Form MHD56313 Edition 2 7

 In general, products are designed to permit easy disassembly and assembly. The n Motor Disassembly (full flow)
use of heat or excessive force should not be required.

4. Keep work area as clean as practical, to prevent dirt and other foreign matter Refer to Dwg. MHP2742.
from getting into bearings or other moving parts. 1. Remove control valve as described in “Control Valve Removal”.
5. All seals, gaskets and ‘O’ rings should be discarded once they have been removed. 2. Using a 7/16 in. -14 thread bolt, remove rotary valve (107) from rotary valve
New seals and ‘O’ rings should be used when assembling product. bushing (106).
6. When grasping a part in a vise, always use leather-covered or copper-covered vise 3. Unscrew eight motor case capscrews (119) and remove motor housing (118)
jaws to protect the surface of part and help prevent distortion. This is particularly containing assembled motor from motor adapter (139).
true of threaded members, machined surfaces and housings. 4. Unscrew four cylinder capscrews (112) from any one of the four cylinder heads
7. Do not remove any part which is a press fit in or on a subassembly unless removal (114) and remove the cylinder head, cylinder sleeve (111) and gasket (115).
of that part is necessary for repairs or replacement. 5. Crank assembly (135) until piston (108) is at top dead center. Push piston wrist
8. When removing ball bearings from shafts, it is best to use a bearing puller. When pin (109) out of piston, freeing piston from connecting rod (134). Repeat until
removing bearings from housings, drive out bearing with a sleeve slightly smaller all four cylinders and pistons have been removed freeing the crank assembly (135)
than outside diameter of bearing. The end of sleeve or pipe which contacts and assembled parts.
bearing must be square. Protect bearings from dirt by keeping them wrapped in 6. Using two screw drivers, pry crank pin sleeve (131) from crank and remove
clean cloths. connecting rod rings (133), connecting rods (134) and connecting rod bushing
(132).
7. Remove crank bearing (138) (only if replacement is necessary) by supporting
n Winch Disassembly inner ring of bearing and pressing on face of motor pinion.
8. If pinion on crankshaft (135) is damaged or worn, it will be necessary to replace
Refer to Dwgs. MHP2719, MHP2742, MHP2741, and MHP2744. entire crankshaft.
1. Remove wire rope from drum. 9. Unscrew four oil wall buttonhead screws (129) and remove oil wall (127). Removal
2. Operate winch to position reduction gear drain plug at its lowest position. of the oil wall is seldom necessary unless reverse valve bushing (252) is to be
3. Relieve pressure in air lines by operating winch control several times after air removed.
supply has been shut off. 10. Rotary valve bushing (106) and reverse valve bushing (252) are press fits in the
motor case and should never be removed unless replacement is necessary. To
WARNING remove, heat bushings to 450° F (232° C) to loosen Loctite®. Support the face
of the motor case that contacts the valve chest cover, and, with a suitable arbor
• Shut off, bleed down and depressurize air lines before performing any inserted into motor case and against the face of the bushing, press bushing out
disassembly procedures. while it is hot.

CAUTION
4. Disconnect and tag air lines.
5. Remove winch from its mounting and take to a suitable work area before
beginning disassembly. • Use an arbor that will clear the pins (120) that project into each bushing
6. Remove lower drain plug (121) on motor housing (118) and allow oil to drain into bore in motor case. Pressing bushings out in the opposite direction or using
a suitable container. Loosen fill cap (117) to vent motor housing. an arbor that will not clear the bushing keys will result in the keys being
7. Drain oil from reduction gear assembly by removing plug (34) when positioned sheared off.
at its lowest point, and similar plug (34) from its highest point to vent.

NOTICE n Rotary Valve Bushing Removal

• Refer to Dwgs. MHP2271 and MHP2297 in “LUBRICATION” section in Product Refer to Dwg. MHP1463 on page 9. A. Press bushings OUT; B. Housing Supports;
Information Manual. C. Motor Housing; D. Press bushings IN; E. Reverse Valve Bushing; F. Rotary Valve
Bushing.
1. Fabricate one of the two punches shown in Dwg. MHP1461 on page 8, A. Plain
8. Remove pipe plug (177) in disc brake housing (4) to drain brake oil. Punch; B. Shoulder guide required to keep punch centered in bushing; C. Punch
9. Remove drum band brake, winch guard and any other externally mounted winch with slot; D. Shoulder guide is optional; E. Not to scale. The first punch will clear
components. Refer to appropriate disassembly text. the pin (120), the second one has a slot to clear the bushing key. Press old rotary
valve bushing (106) out of motor housing (118).
WARNING 2. Measure motor housing bore. If greater than 1.313 in. (33.35 mm) replace
housing.
• The air motor weighs approximately 45 lbs (21 kg). Adequately support air
motor before removing motor mounting capscrews. CAUTION
• Press rotary valve bushing out from inside motor housing only. Bushing has
10. Remove capscrews (119) and washers (113) securing motor assembly to motor a groove to clear pin (120).
adapter (139). Using a hoist to support motor, pull motor straight away from • Support motor housing to prevent damage during pressing.
winch. Reference the applicable ‘Motor Disassembly’ section if motor disassembly
is required.
11. Remove capscrews (3) and separate brake assembly. If brake assembly sticks, tap A
brake housing with a soft faced hammer until parts separate. Note position of all Plain Punch
brake parts for reassembly.
12. Support drum (60) and remove capscrews (13) from drum shaft (15). Pry drum Shoulder guide required
shaft (15) from inboard upright (17).
13. Remove capscrews (65) and lockwashers (22) which secure siderails (62) to to keep punch centered
inboard upright (17). Drive out dowel pins (19). in bushing
14. Remove inboard upright (17).
15. Remove capscrews (70) and lockwashers (5) that secure limit switch assembly to B
upright (64).
16. Remove capscrews (13) and shaft retainer (72) from drum (60).
17. Remove drum (60) and reduction gear assembly (30). in.
18. Remove remaining capscrews (65) and lockwashers (22) which attach siderails in. ) 3.0 mm)
1.0 mm 0.203 in.
(62) to outboard upright (64). Drive out dowel pins (19). . 4 (76
19. Remove bearing (71) from outboard upright (64). n. ) (25 (5.2 mm)
20. Remove capscrews (21) and lockwashers (22) securing gear carrier (23) to drum 3i
(60). 1.2 mm
. 0
21. Install two 1/2 in. - 13 NC x 3 in. long capscrews into threaded holes in outer (31
bolt pattern ring of gear carrier (23). Use these capscrews to break seal. Remove
reduction gear assembly (30) from drum (60).
C Punch with slot
To disassemble reduction gear assembly refer to ‘Reduction Gear Disassembly’ section.
0.09 in.
n Control Valve Removal Shoulder guide is
optional (2.3 mm)
Refer to Dwg. MHP2742. Complete handle disassembly is not recommended.
D
in. )
1. Remove capscrews (245) and washers (244) from valve chest cover (247).
2. Remove cover (247), gasket (103) and assembled parts: handle assembly, rotary in. ) 3.0 mm
valve (106) and reverse valve (251). 1.0 mm 6
3. Carefully pry off cap from throttle lever (242). .4 (7
4. Remove reverse valve nut (241) and tab lockwasher (122) from reverse valve n. ) (25
0i
(251). 1.3 mm
.0 E (Not to scale)
NOTICE (33

• Observe spring (243) connection during disassembly. This spring is under

tension and is required to return handle to neutral position.
(Dwg. MHP1461)
5. Pull throttle lever (242) and spring (243) from reverse valve.
6. Remove reverse valve (251), ‘O’ ring (249) and ‘O’ ring (248) from valve chest
cover.
7. Remover thrust washer (105).

8 Form MHD56313 Edition 2

 A n Manual or Automatic Drum Brake
Press bushings Refer to Dwg. MHP2743.
OUT 1. Automatic Brake
a. Disconnect and remove hose, fittings and dump valve (364) from the cylinder
(362).
b. Remove cotter pin (352), washer (378) and pin (351) from the link stud (353)
and brake band assembly (376).
c. Remove cotter pin (352), washers (385) and pin (357) from clevis (358).
Separate the clevis (358) from brake lever (355).
d. Remove cotter pin (352) and pin (357) from cylinder (362) and bracket (372).
e. Remove cylinder (362) from bracket (372).

WARNING
C
B • Do not disassemble cylinder (354). Cylinder is under spring pressure.
Motor
Housing Housing
Supports 2. Manual Brake:
a. Remove cotter pin (352) and pin (351) from handle (354), then remove
handle (354) from brake band (376).

Brake Disassembly:
Reverse E 1. Remove capscrew (63), adjustment screw (383), lockwasher (22) and locknut
D (374) that secure stop plate (382).
Valve Bushing 2. Use a hoist to raise the winch approximately 6 in. (15 cm). Separate the brake
Press bushings band (376) halves and rotate the brake band assembly slowly until it can be
IN removed from the drum (60).
Rotary F 3. Remove cotter pins (352) and pins (375) so brake band halves (376) can be
Valve Bushing removed from the arm (379). Lower winch when brake band assembly has been
removed.

n Press Roller Disassembly

Refer to Dwgs. MHP2740 and MHP2719.
1. Compress ends of springs (223) and (225) to disengage from siderail (62) and pin
on press roller arm (224).

(Dwg. MHP1463) CAUTION

• Use care when releasing springs (223) and (225) from press roller. Springs
n Reverse Valve Bushing Removal are under tension.
Refer to Dwg. MHP1463 on page 9.
1. Fabricate one of the two punches shown in Dwg. MHP1461 on page 8. The first 2. Loosen lock collars (226).
punch will clear the pin (120), the second one has a slot to clear the bushing
key. Press old reverse valve bushing (252) out of motor housing (118). NOTE: This NOTICE
bushing is only 2 inches (51 mm) long.
• Ensure press roller assembly is adequately supported before removing shaft
CAUTION (228).

• Press reverse valve bushing out from inside motor housing only. Bushing has
a groove to clear pin (120). 3. Remove capscrews (201) and washers (220) from both ends of shaft (228),
• Support motor housing to prevent damage during pressing. carefully slide shaft (228) through hole in upright. Press roller assembly (200)
and collar (226) will fall away from shaft (228).
4. It is not necessary to remove bushings (227) unless replacing.
n Disc Brake Disassembly 5. Remove springs (223) and (225) from press roller arm (224).
6. Remove capscrews (201), washers (220), and rollers (221) from ends of press
Refer to Dwg. MHP2741. roller arm bar (224).
1. Carefully loosen capscrews (151) 4 or 5 turns each, progressively around motor
adapter (139) until brake spring compression is relaxed. Do not allow adapter to n Emergency Stop Valve
become cocked during removal.
2. When brake spring compression is relaxed remove capscrews (151), adapter (139)
and springs (154). Refer to MHP2540.
3. Remove cylinder (164) and brake piston (157) as an assembly from brake housing It is not recommended to disassemble Emergency Stop Valve unless repair is required,
(4). contact factory.
4. Tap brake piston (157) out of cylinder (164) and remove seals (155) and (158).
n Overload Valve and Brake Release Valve Removal
NOTICE
Refer to Dwgs. MHP2756 and MHP2752.
• When any part of friction disc thickness measures 0.072 in. (1.83 mm) or 1. Remove and tag hose connections if not already done.
less, or if oil groove pattern is not clearly visible, friction discs must be 2. Remove capscrew (500), nut (436) and lockwasher (435) securing overload valve
replaced. (549) to bracket (508).
3. Remove and store overload valve assembly (549), in a clean, dry area until ready
5. Remove brake hub assembly, brake discs (173) and friction discs (172). to reassemble winch.
6. If brake hub must be disassembled for inspection or repair, remove retainer ring 4. Remove capscrews (433), washers (399) and nuts (434) securing brake release
(16), bearing (174) and spacer (152) from shaft (8). Carefully tap or press bushing valve (432) to bracket (508).
(168) out of back side. Take sprag clutch (169) out of brake hub (171). 5. Remove and store brake release valve (432) in a clean, dry area until ready to
reassemble winch.
n Reduction Gear Disassembly
NOTICE
NOTICE • It is not recommended to disassemble brake release valve (432). If
disassembly of overload valve (549) is necessary refer to Dwg. MHP2756.
• It is not recommended to disassemble reduction gear unless necessary.
n Slack Line Detector Disassembly
Refer to Dwg. MHP2719.
1. Remove capscrews (21) and lockwashers (22) from gear carrier (23), separating Refer to Dwg. MHP2739.
it and the reduction gear assembly (30) from drum (60). 1. Remove and tag hose connections if not already done
2. Unfasten capscrews (24) from reduction gear assembly, separating it from gear 2. Remove capscrews (216), washers (217), and plate (218) that secure limit valve
carrier (23). (213) to bracket (211). It is not necessary to remove bracket (211) unless
3. Remove capscrews (35), retaining ring (31), and seal (32). Pry off output housing replacing.
(33). 3. Remove capscrews (201) and washers (385) from both arms (203) that secure
4. Remove retainer ring (36), bearing (37), and retainer ring (38) from end of rollers (204) and shaft (205).
planetary assembly (39). Separate planetary assembly (39) and ring gear (41) 4. Remove shaft (205) from roller (204).
from spacer (45). 5. From outboard side, remove lower capscrew (201), washer (385), and spacer plate
5. Unfasten retainer ring (44) from sun gear (43) and remove sun gear from planetary (212) that secure arm to cam shaft (210).
assembly (46). 6. Remove capscrews (201) and (206) and washers (385) and (297) that attach cam
6. Separate spacer (45), ring gear (41), and planetary assembly (46). Remove pinion actuator (208) and arm (203) to cam shaft (210).
(47) from planetary assembly (46). 7. Remove both cam shafts (210) from lifting lugs (12). It is not necessary to remove
lifting lugs.

Form MHD56313 Edition 2 9

 • - use new gaskets and seals.
NOTICE - replace worn parts.
- assemble parts using match marks applied during disassembly. Compare
• To replace bushing (209), press out of arm. replacement parts with originals to identify installation alignments.

n Drum Guard Disassembly n Motor Assembly

Refer to Dwgs. MHP2757 and MHP2739. Refer to Dwg. MHP2742.
1. Remove capscrews (10) and washers (11) securing lifting lugs (12) to upright. 1. Place motor housing assembly (118) on a flat table with open side facing up.
2. Remove guard panels (805), (802) or (807) one section at a time, by removing 2. Clean bushing bore in motor housing with Loctite® 790 cleaner. Ensure that entire
nuts (804) and crossbars (806). bore is clean then dry using low pressure, filtered compressed air.
3. Apply a thin even coat of Loctite® 609 to entire outside surface of new rotary
Automatic Band Brake only valve bushing (106).
4. Using a swab, apply a thin even coat of Loctite® 609 to entire inner bore of motor
1. Remove capscrews (456) and washers (96) securing frames (802) to guard frame housing.
(801). 5. Align keyway in rotary valve bushing with bushing key in bore of motor case. Start
bushing squarely in bore and gently press it (by hand) flush with the top face of
n Limit Switch Disassembly the case. Once bushing has been installed allow Loctite® to cure for 10 minutes.
Full cure requires 24 hours.
6. Clean reverse valve bushing bore in motor housing with Loctite® 790 cleaner.
Refer to Dwg. MHP2744. Ensure that entire bore is clean then dry using low pressure, filtered compressed
air.
NOTICE 7. Apply a thin even coat of Loctite® 609 to entire outside surface of new reverse
valve bushing (252).
• It is not recommended to disassemble limit switch. Contact factory if repair 8. Using a swab, apply a thin even coat of Loctite® 609 to entire inner bore of motor
is required. housing.

1. Remove and tag hose connections if not already done. NOTICE

2. Remove capscrews (70) and washers (5) that secure limit switch assembly to
upright (64). • Applying Loctite® 609 to both surfaces is necessary to ensure an airtight seal
3. Store limit switch assembly in a clean, dry area until winch reassembly. between rotary valve bushing and motor housing.
9. Align groove in reverse valve bushing (252) with dowel pin (120) in motor
n Cleaning, Inspection and Repair housing. Press rotary valve bushing into motor housing until reverse valve
bushing is flush with motor housing.
10. Check fit of rotary valve (107) in bushing. It must be a good running fit. Lap if
n Cleaning necessary using a mild, fine grain, lapping compound. If bushing has closed in
sufficiently to make lapping impossible, ream to 1.000 in. (25.4 mm) diameter.
Clean all product component parts in solvent (except brake bands and disc brake 11. Check fit of the reverse valve (251) in its bushing. If it is tight, ream bushing to
friction plates). The use of a stiff bristle brush will facilitate removal of accumulated 1.000 in. (25.4 mm) diameter.
dirt and sediments in the reduction assembly, on housings, frame and drum. Dry each 12. Place oil wall (127) in motor case and retain with four oil wall screws (129) and
part using low pressure, filtered compressed air. Clean brake band using a wire brush lockwashers (128). Apply a small amount of Loctite® 202 to threads of screws
or emery cloth. Do not wash brake band in solvent. If brake band lining is oil soaked, (129).
it must be replaced. 13. Support inner ring of shielded side of crank bearing (138) and press crank
assembly (135) into bearing until shoulder on crank contacts inner ring. Ensure
n Inspection crank bearing (138) is installed with unshielded side nearest the flanged end of
crankshaft assembly (135).
All disassembled parts should be inspected to determine their fitness for continued 14. Place motor case assembly on bench with open side up and inlet bushing (123)
use. Pay particular attention to the following: to the left.
15. Lubricate rotary valve bushing (106) and rotary valve (107).
1. Inspect all gears for worn, cracked, or broken teeth. 16. Insert rotary valve into rotary valve bushing. The raised tang on rotary valve
2. Inspect all bushings for wear, scoring, or galling. should be pointing toward the inlet bushing.
3. Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent 17. Lubricate the inside and outside of crank pin sleeve (131) and place on rotary
on shafts, replace shaft. Inspect all surfaces on which oil seal lips seat. valve tang, all the way to the left.
4. Inspect all bearings for play, distorted races, pitting and roller or ball wear or 18. Slide crank pin sleeve to the right, until it falls onto the rotary valve tang.
damage. Inspect bearings for freedom of rotation. 19. Lubricate bushing (132) and place bushing over crank pin sleeve.
5. Inspect all threaded items and replace those having damaged threads. 20. Place one connecting rod ring (133) over bushing.
6. Inspect band brake lining for oil, grease and glazing. If band brake lining is oil- 21. Place feet of four connecting rods (134) into the space between bushing and ring.
soaked replace brake bands as a set. Remove glazed areas of band brake lining 22. Place second connecting rod ring over the connecting rod ends, beveled face first.
by sanding lightly with a fine grit emery cloth. Apply oil to this assembly.
7. Measure thickness of band brake lining. If brake band linings are less than 0.062 23. Insert crankshaft assembly into crank pin sleeve. Ensure that the slot in
inch (2 mm) thick anywhere along edges replace brake bands as a set. crankshaft end and tang on rotary valve are aligned.
8. Inspect cylinder bores. Minor scratches in bore lining may be repaired by lightly 24. When crankshaft is seated, move assembly to the left. There should be a slight
honing to remove. Refer to tolerances listed below for acceptable clearances. drop as assembly seats onto the rotary valve.
Replace liner if deep scratches or gouges are apparent. Measure inside diameter 25. Install piston rings (110) into grooves in pistons (108). Ensure that the piston
of liner. If measurement is greater than 4.764 inches (121 mm) replace liner. ring face marked with a dot is toward the top (closed) end of the piston (108).
‘Ring Gap’ may also be used to determine wear; place compression ring into liner, Do not expand piston rings more than is necessary to slip rings over pistons.
using a piston, push ring until approximately half way in liner and measure ‘Gap’ Expand and slide the Ingersoll-Rand ring tool D01-933 over piston ring on piston.
— 0.003 inch (0.076 mm) is normal; replace rings, or liner, if ‘Gap’ exceeds 0.020 Ensure upper and lower piston ring ends are offset from each other.
inch (0.51 mm). 26. Insert a wrist pin (109) partially into piston.
9. Inspect the drive plates for warpage or other damage, and replace damaged parts 27. Place this assembly onto the connecting rod and push wrist pin fully into piston.
as necessary. Replace the input pinion shaft oil seal. 28. Place cylinder gasket (115) onto cylinder sleeve (111).
10. Measure the thickness of the brake friction disc. The brake friction disc must show 29. Using fingers, compress top piston ring and press the cylinder sleeve down over
an even wear pattern. If the brake friction disc is 0.076 inch (1.93 mm) or less, the piston. Sleeve will push Ingersoll-Rand ring tool D01-933 off piston. Remove
replace the disc. ring tool.
30. Place a copper washer (113) on capscrew (112). Ensure that the flat side of copper
washer faces cylinder head (114).
n Repair 31. Align gasket and motor case capscrew holes. Insert capscrew and washer through
cylinder head (114) and loosely secure it to motor case. Repeat for the other three
Actual repairs are limited to removal of small burrs and other minor surface capscrews.
imperfections from gears and shafts. Use a fine stone or emery cloth for this work. 32. Holding motor case still, rotate crankshaft 90°. This will bring the next
Do not use steel wool. connecting rod to its highest position.
33. Repeat steps 25 to 32 above for the other three pistons.
1. Worn or damaged parts must be replaced. Refer to the applicable parts list in the 34. Snug up the four capscrews. DO NOT final tighten.
Product Parts Information Manual for specific replacement parts information. 35. Snug up the capscrews on opposite cylinder head.
2. Inspect all remaining parts for evidence of damage. Replace or repair any part 36. Repeat this procedure for the other two cylinder heads.
which is in questionable condition. Cost of the part is often minor in comparison 37. Repeat these steps until ALL cylinder heads are final tightened. Hold the
with cost of redoing job. crankshaft FIRMLY and in a vertical position. Spin the motor case 4 to 8 complete
3. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings. revolutions. Assembly should rotate freely without any signs of binding or
4. Examine all gear teeth carefully, and remove nicks or burrs. knocking.
5. Polish edges of all shaft shoulders to remove small nicks which may have been 38. Match hole pattern in gasket (125) with motor housing assembly (118). Press
caused during handling. gasket into position. Use of a small amount of grease along the surface of motor
6. Remove all nicks and burrs caused by lockwashers. will help keep gasket in place.
7. Replace all gaskets, oil seals, and ‘O’ rings removed during product disassembly. 39. Align hole pattern of motor adapter (139) to gasket (125) and motor assembly
and place on motor assembly.

n Assembly NOTICE
Refer to Product Parts Information Manual for item numbers referenced in this • It may be necessary to use capscrew (119) as a locator, to align holes in
section. motor case and adapter.

General instructions: 40. Slide motor assembly to the edge of the bench. Insert one capscrew (119) through
lockwasher (113) and secure adapter to motor case. DO NOT Final Tighten.
41. Rotate assembly 180° and install one more capscrew and washer.

10 Form MHD56313 Edition 2

42. Tip motor assembly onto its base and install remaining capscrews (119) and 9. Install stop plate (382) on the inside of siderail (62) and secure with capscrew
washers (113). (63) and washer (22). Place in top hole of plate. Bend ends of cotter pin apart
43. Tighten all capscrews to recommended torque value. Refer to ‘Torque Chart’ to secure pin.
on page 13. 10. Install adjusting screw (383) and locknut (374) through the siderail (62) and stop
44. Note that an arrow is stamped on the face of the valve chest cover (247) and that plate (382) until it contacts the arm (379).
a line is scribed on the shank of the reverse valve (251). Turn reverse valve until 11. Adjust brake as described at the start of “MAINTENANCE” on page 7.
line and arrow are in alignment and slide stem of valve into valve chest cover,
entering square shank in square hole in control arm. Ensure main port in reverse
valve is installed facing down. Apply reverse valve nut (241) to threaded end of
n Automatic Brake Drum Assembly
reverse valve.
Refer to Dwg. MHP2743.
n Control Valve Assembly 1. Install bracket (372) on siderail (62) with capscrews (63) and lockwashers (22).
2. Screw nut (359) and clevis (358) onto cylinder rod.
Refer to Dwg. MHP2742. 3. Attach brake lever (355) to brake band (376).
4. Install cylinder (362) so it connects with bracket (372) and brake lever (355).
1. Insert six capscrews (119) and lockwashers (113) into motor case (118). Hand Use pins (357), washers (385) and cotter pins (352) to secure in position. Bend
tighten. DO NOT final tighten. ends of cotter pin apart to secure pin.
2. Attach the vent cap assembly (117) to one of the left side capscrews on motor 5. Install fitting (363) in cylinder (362) and dump valve (364) to fitting (363).
housing and final tighten all capscrews to 10 ft/lbs. (1.4 kg/m). 6. Adjust automatic brake as described at the start of “MAINTENANCE” on page 7.
3. Install and tighten stop pin (246) into valve chest cover (247) if it was removed. 7. Install second fitting (363) in dump valve (364).
4. Insert thrust washer (105) into valve chest cover. 8. Install valve (360) to fitting (363) and hose assemblies (442) and (443) to valve
5. Slide ‘O’ rings (248) and (249) onto reverse valve (251). Lubricate with oil. (360).
6. Insert the reverse valve into valve chest housing. Ensure that ‘O’ ring is not cut
upon installation.
7. Place gasket (103) onto valve chest cover.
n Disc Brake Assembly
8. Insert throttle lever (242) onto outside of reverse valve.
9. Install valve chest cover assembly. Ensuring that throttle lever and main (large) Refer to Dwg. MHP2741.
ports in reverse valve are face UP. 1. Install pipe plug (177) in brake housing (4).
10. Secure valve chest cover with capscrews (245) and lockwashers (244), tighten to 2. Press one bushing (168) into brake hub (171). Install shaft (8) into assembly.
10 ft lbs. (1.4 Nm). Remove throttle lever. 3. Slide sprag clutch (169) onto shaft (8) and into brake hub (171). Press in second
11. Place spring (243) onto throttle lever, on right side of stud. bushing (168).
12. Use bench to hold free end of spring. Then, twist throttle lever so the stud goes
past the free end of spring. NOTICE
13. Continue twisting the throttle lever while pushing free end of spring over stud.
• Ensure sprags are assembled all in the same direction and springs are not
CAUTION twisted or out of location. Sprag clutch must be installed so that the end with
the stamped arrow is farthest from the motor adapter (139).
• The spring can SNAP off throttle lever. KEEP the throttle lever pointed away 4. Check that shaft rotates freely clockwise when looking at the non splined end of
from your body. brake hub (171) and locks up instantly in the counterclockwise direction. Check
14. Align the square hole in throttle lever with the reverse valve and press onto the rotation of shaft in free sprag clutch direction is smooth. If tightness or rough
reverse valve. rotation exists disassemble and inspect.
15. Rotate throttle lever slightly to the left and right to allow spring to ‘pop’ over 5. Install spacer (152) and bearing (174) on shaft (8) and secure with retainer ring
stop pin. (16).
16. Install tab lockwasher to end of reverse valve (251). Ensure tabs on lockwasher 6. Starting with a friction disc (172) and alternating with brake discs (173), install
align with grooves in handle (242). friction discs (172) and brake discs (173) in brake housing (4).
17. Use nut (241) to secure throttle lever to reverse valve and final tighten. 7. Install assembled shaft and brake hub assembly through brake. Remove pipe plug
18. Bend long end of tab lockwasher over nut (241). Ensure tab is bent over a flat (177) in brake housing (4) to check that brake hub is properly engaged with each
side of nut. friction disc (172). Use of artificial light will aid inspection. Line up plates and
19. Ensure lever rotates freely in both directions and spring returns to neutral when tap gently on shaft if bearing (174) is tight in brake housing (4).
released. 8. Install capscrews (151) in two locations in brake cylinder (164). Use Loctite® 242
on capscrew threads.
9. Lubricate and install seals (155) and (158) on brake piston (157). Seal lips must
n Reduction Gear Assembly face each other. Refer to Dwg. on page 0 , A. Seal Lip, B. Seal, C. Brake Piston.
10. Lubricate and install ‘O’ ring (165) in recessed grooves in brake cylinder (164).
Refer to Dwg. MHP2719.
1. Lubricate and install ‘O’ rings (40) on ring gear (41). Assemble ring gear (41) and
spacer (45). Ensure capscrew holes are aligned. Seal Lip A
2. Install pinion (47) into planetary assembly (46), and planetary assembly (46) into
ring gear (41). Position assembled parts vertically with end cover (48) down.
Ensure capscrew holes are aligned.
3. Press thrust bearing (42) into sun gear (43) and install sun gear (43) into
planetary assembly (46) with retainer ring (44).
4. Lubricate and install ‘O’ rings (40) on ring gear (41). Assemble ring gear (41) and Seal B
spacer (45). Ensure capscrew holes are aligned.
C
5. Install planetary assembly (46) on sun gear (43). Install ring gear (41) and spacer Brake
(45) over planetary assembly. Ensure capscrew holes are aligned. Piston
6. Press thrust bearing (42) into sun gear (43) and install sun gear into planetary
assembly (46) with retainer ring (44).
7. Install planetary assembly (39) in ring gear (41). Position ring gear so capscrew
holes are aligned with spacer (45).
8. Install retainer ring (38), bearing (37) and retainer ring (36) on planetary
assembly (39).
9. Install output housing (33) over end of planetary assembly (39). Align capscrew
holes. Install capscrews (35) with Loctite® 242. Refer to torque chart for torque
values.
10. Install steel plug assembly (34) on output housing (33).
11. Install seal (32) and retainer ring (31).

n Brake Drum Assembly

Refer to Dwg. MHP2743.
(Dwg. MHP0139)
1. Install pivot bracket (377) on the end of arm (379) with pin (375), washer (378)
and cotter pin (352). 11. Apply a light film of grease to bore of brake cylinder (164) and install brake piston
2. Install connecting link (381) on the arm (379) and secure in position with pin (157).
(375), washer (378) and cotter pin (352). Bend ends of cotter pin apart to secure 12. Install assembled brake piston and cylinder on brake housing (4) so brake port
pin. Assemble connecting link (381) so curved surface matches contour of the hole is positioned on the right hand side and machined pad is at the bottom.
brake band. 13. Set brake springs (154) into holes provided in the brake piston (157).
3. Install halves of brake band (376) to the connecting link (381) and secure with 14. Lubricate and install ‘O’ ring (1) in recessed groove in motor adapter (139).
pin (351) and cotter pin (352). Bend ends of cotter pin apart to secure pin. 15. Install motor adapter (139) on brake cylinder (164) so the threaded hole, which
4. Lift the winch assembly, with a suitable hoist, approximately 6 in. (15 cm) off is located dead center between the counterbored mounting bolt holes, is located
the floor or work bench. at the bottom (6 o’clock position.)
5. Position the brake band sub-assembly around the brake diameter on the drum 16. Secure motor adapter (139) with capscrews (151) and washers (5). Apply Loctite®
(60) so arm (379) lays at the bottom. When positioned, lower the winch. 242 to capscrews threads. Refer to torque chart for torque values. Pull motor
6. Mount pivot bracket (377) on the inside surface of the siderail (62) and secure adapter down evenly to compress the brake springs (154). Tighten capscrews 4
in position with capscrews (63) and lockwashers (22). to 5 turns each progressively around the motor adapter (139). Do not allow motor
7. Screw link stud (353) into handle (354) and install handle (354) into lug on the adapter (139) to become cocked.
end of the brake band (376). Lubricate the pivot points being careful not to get
grease on the brake band lining.
8. Pull halves of the brake band together and install pin (351) through lug on the
n Winch Assembly
brake band (376) and link stud (353) on the handle assembly.
Refer to Dwgs. MHP2719 and MHP2742.

Form MHD56313 Edition 2 11

1. Assemble reduction gear assembly (30) using reduction gear assembly section. 4. One person positions press roller so the top of arm (224) is curved up towards
Refer to “MAINTENANCE” on page 7. the under side of the drum (60), and holds press roller in place while the other
2. Assemble drum (60), uprights (17) and (64), and sides (62) using drum assembly person completes installation.
text in “MAINTENANCE” section on page 6. 5. Adjust both springs (223) and (225) so that the long end of springs are on the
3. Install oil seal (2) in drum shaft (15) with lip facing toward drum shaft. inside of siderail (62).
4. Assemble band brake assembly using brake band assembly text . Refer to
“MAINTENANCE” on page 7. NOTICE
5. Lubricate and position ‘O’ ring (1) on drum shaft (15).
6. Carefully install disc brake assembly on drum shaft to avoid damaging ‘O’ ring (1). • Do not engage shorter end of spring behind tabs of arm (224) until after
Secure in position with capscrews (3). Apply Loctite® 242 to capscrew threads. shaft (228) has been installed and secured, and press roller assembly
Refer to torque chart for torque values. adjusted to center of drum.
7. Install motor assembly (100) to motor adapter (139) using washers (113) and
capscrews (119). Apply Loctite® to capscrew threads. Refer to torque chart for 6. Install shaft (228) through hole in leg of upright (64) only.
torque values. 7. Install one collar (226) on end of shaft (228) between upright and press roller
assembly. Do not tighten collar (226) until step 10 and 11 have been completed.
n Drum Assembly 8. Install shaft (228) through press roller assembly (200).
9. Install second collar (226) and slide shaft through hole in leg of upright (17).
Refer to Dwg. MHP2719. Ensure that the long end springs (223) and (225) are still between the siderail
1. Assemble reduction gear assembly (30) using reduction gear assembly section. (62) and drum (60). Do not tighten collar (226) until step 10 and 11 have been
Refer to “MAINTENANCE” on page 7 completed.
2. Stand drum (60) in a vertical position with large bore up. 10. Secure shaft (228) to uprights using capscrews (201) and washers (220). Apply
3. Install gear carrier (23) onto reduction gear assembly (30), align capscrew holes a small amount of Loctite 242 to threads of capscrews.
and secure using capscrews (24). 11. Adjust press roller assembly so that it is centered between the drum flanges, and
4. Clean surfaces of the drum (60) and gear carrier (23). Apply Loctite® 515 gasket tight collars (226).
sealant to drum mating surface. Lower reduction gear assembly (30) into drum 12. Use extreme caution and pry short end of one spring (223) so that it is positioned
(60). Take care to align mounting holes. behind the tab of arm (224).
5. Install capscrews (21) and lockwashers (22) with Loctite® 242 . Refer to torque 13. Repeat step 11 for spring (225).
chart for torque values.
6. Install drum shaft (15) in inboard upright (17) and secure with capscrews (13). CAUTION
Torque to 44 to 49 ft lbs (60 to 66 Nm). Lubricate and install ‘O’ ring (14) on
drum shaft. Carefully lower inboard upright assembly into the drum, making sure • Use caution when installing springs (223) and (224), springs are under
splines on drum shaft (15) mesh in the reduction gear assembly. tension.
7. Using a ‘C’ clamp, fasten the inboard flange assembly to the drum flange and place
complete assembly in horizontal position.
8. Pack bearing (71) with grease and install in outboard upright (64). n Drum Guard Assembly
9. Install outboard upright (64) on drum end. Ensure assembly is kept centered
during this step to avoid seal or bearing damage. Refer to Dwg. MHP2757.
10. Install shaft retainer (72) using flathead screws (73) with Loctite® 242. Refer to 1. Secure frames (802) and (801) to uprights (17) and (64) with capscrews (809)
torque chart for torque values. and washers (96).
11. Apply a light coat of Loctite® 515 to the mating surface of outboard upright (64) 2. Secure lifting lugs (12) to uprights with capscrews (10) and washers (11).
and install limit switch adapter (398) using capscrews (70) and lockwashers (5). 3. Install panels (807) and (805) one at a time, beginning with either the upper
Apply a small amount of Loctite® 242 to capscrew (70) threads . Refer to torque (807) or lower (805) panel.
chart for torque values. a. Install first crossbar (806) with nuts (804).
12. Install siderails to uprights and loosely secure using capscrews (65) and b. Attach panel to crossbar (806).
lockwashers (22). Remove ‘C’ clamp. c. Holding second panel (805) in place, install second crossbar (806) by sliding
13. Apply Loctite® 242 to capscrews (65). Refer to torque chart for torque values. through [hooked] edges of the two panels.
14. Install dowel pins (19). d. Secure crossbar (806) with nuts (804).
e. Continue until all panels are in place.
4. Tighten all fasteners and check winch guard is secure. Ensure wire rope does not
n Slack Line Detector Assembly interfere with winch guard during winch operation.
Refer to Dwg. MHP2739.
1. Install cam shafts (210) in lifting lugs (12). Apply a small amount of grease to
smaller diameter end of cam shaft (210). n Testing
2. If bushings (209) have been removed, replace and install in arms (203).
3. Secure lower end of outboard arm (203) to lifting lug (12) with capscrew (201), n Operational Test
washer (385), and spacer plate (212).
4. If bracket (211) has been removed, install on inboard lifting lug (12) with Prior to initial use, all new or repaired winches shall be tested to ensure proper
capscrews (10). operation.
5. Install lower end of inboard arm (203) and cam actuator (208) to lifting lug (12) 1. Ensure oil level in reduction gear assembly and disc brake is correct. Top off levels
with capscrews (201) and (208) and washers (385) and (207). For arm tension as required before operation as described in “LUBRICATION” section of the
adjustment, refer to label on arm (203). Product Information Manual.
2. To initially ‘break in’ new or overhauled motors, operate winch without load, in
NOTICE both directions, for 15 minutes at 100-200 RPM.
3. Check operation of brakes. Adjust if necessary, as described in “adjustments”
• Prior to initial use adjust slackline cam when wire rope is fully paid out but section on page 7
not slack. Refer to Product Information Manual for complete adjustment 4. Ensure foundation mounting fasteners are secure.
procedure. 5. Install drum guard.
6. Ensure limit switches and slack line detector are correctly adjusted. Refer to
6. Slide rollers (204) over shafts (205). “INSTALLATION” section of the Product Information Manual.
7. Slip washers (385) over capscrews (201), and secure in upper end of arms (203)
to shaft (205) and roller (204) assemblies. n Load Test
8. Secure limit valve (213) to bracket (211) with capscrews (216), washers (217),
and plate (218). Prior to initial use, all new, extensively repaired, or altered winches shall be load
9. Replace fittings (215) and (389) on limit valve (213). 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
n Overload and Brake Release Valve Installation shall not be less than 100% of rated line pull at mid drum and should not exceed
125% of the rated line pull at mid drum. To test the winch at 125% of the rated load
Refer to Dwg. MHP2752. at mid drum apply the following load:
1. Install overload valve (549) to bracket (508) and secure using capscrews (500),
lockwashers (435) and nuts (436). FA150KGi Winch 125% Test Load 412 lb (187 kg) mid-drum
2. Install brake release valve (432) to bracket (508) and secure using capscrews
(433), washers (399) and nuts (434). NOTICE
n Press Roller Assembly
• Testing to more than 125% of rated line pull may be required to comply with
Refer to Dwg. MHP2740 and MHP2719. standards and regulations set forth in areas outside the USA.
Two people are recommended when installing press roller assembly.
1. If bushings (227) have been removed, replace and install in uprights (17) and
(64), and in both ends of arm (224). Grease bushings (227) for ease of n Limit Switch
installation.
2. Install rollers (221) on smaller ends of press roller arm (224) and secure with Operate winch through three complete cycles to ensure consistent limit switch
capscrews (201) and washers (220). Apply a small amount of Loctite 242 to operation within +/- 2 ft (+/- 0.6 m) of setpoints. Refer to ‘Limit Switch’ section of
threads of capscrews. the Product Information Manual to establish setpoints.
3. Install springs (223) and (225) so that the shorter end of springs are towards the
inner portion of the arm (224) where the tabs are located.

12 Form MHD56313 Edition 2

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

Notes:

1. Definitions:
DRY: Cadmium plate, zinc plate, and oiled fasteners.
LUBRICATED: Molysulfide paste, carnaba wax, molysulfide grease and
copper-based anti-seize coated fasteners.
PTFE: 2% minimum PTFE (teflon) coated fasteners.
2. All torque values foot-pounds unless noted.
3. SAE grade 5 equivalent to ASTM A325 Type 2 and ASTM A449.
4. SAE grade 8 equivalent to ASTM A354 Grade BD, ASTM A490 Type 1.
5. If mixing fasteners use lowest torque value.
6. Torque values 75 to 85% of fastener proof load ref.

Form MHD56313 Edition 2 13

 SERVICE NOTES

14 Form MHD56313 Edition 2

 SERVICE NOTES

Form MHD56313 Edition 2 15

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