Form MHD56037
PARTS, OPERATION AND MAINTENANCE MANUAL
MODEL FA5 AND FA5T
(Dwg. MHP2107)
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance
information. Make this manual available to all persons responsible for the
installation, operation and maintenance of these products.
WARNING
Do not use this winch for lifting, supporting, or transporting people unless winch is
TM
approved for Man Rider applications. Do not lift or support loads over people.
Always operate, inspect and maintain this winch in accordance with American Society of
Mechanical Engineers Standards Safety Code (ASME B30.7) and any other applicable
safety codes and regulations.
Form MHD56037
Edition 5
May 2006
71062103
© 2006 Ingersoll Rand Company
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SAFETY INFORMATION
This manual provides important information for all personnel
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
recommended that all applicable industry, trade association,
federal, state and local regulations be checked. Read all operating
instructions and warnings before operation.
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
are used to identify the level of potential hazard.
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 Society of Mechanical Engineers, Three Park Avenue,
New York, NY 10015.
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.
DANGER
This manual has been produced by Ingersoll Rand to provide
dealers, mechanics, operators and company personnel with
information required to install, operate, maintain and repair the
products described herein.
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.
WARNING
Caution is used to indicate the presence of
a hazard which will or can cause injury or
property damage if the warning is
ignored.
It is extremely important that mechanics and operators be familiar
with 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:
1. Proper and safe use and application of mechanics common
hand tools as well as special Ingersoll Rand or
recommended tools.
CAUTION
Notice is used to notify people of
installation, operation, or maintenance
information which is important but not
hazard-related.
NOTICE
2. Safety procedures, precautions and work habits established
by accepted industry standards.
Safety Summary
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.
WARNING
• Do not use this winch for lifting, supporting, or transporting
people unless winch is approved for Man RiderTM
applications. Do not lift or support 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 winches are manufactured in accordance with the
latest ASME B30.7 standards.
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 intended
path of any load.
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SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions have been
5. Never lift a load greater than rated capacity of the winch.
Refer to labels attached to winch or to “SPECIFICATIONS”
section.
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 winch drum.
8. Always rig loads properly and carefully.
9. Be certain the load is properly seated in saddle of hook. Do
not support load on tip of hook.
adapted in part from American Society of Mechanical Engineers
(Safety) Standard ASME B30.7 and are intended to avoid unsafe
operating practices which might lead to injury or property
damage.
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.
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.
13. Ease slack out of wire rope when starting a lift or pull. Do
not jerk the load.
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.
14. Do not swing a suspended load.
1. Only allow personnel 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 winch, or
controls, do not operate winch until 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 winch wire rope as a sling.
19. After use, or when in a non-operational mode, winch should
be secured against unauthorized and unwarranted use.
4. Before each shift, check winch for wear and damage. Never
use a winch that inspection indicates is worn or damaged.
WARNING LABEL
Each unit is shipped from the factory with warning label shown.
If the label is not attached to your unit, order a new label and
install it. Refer to the parts list for part number. Label is shown
smaller than actual size.
(Dwg. 71060529)
4
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SPECIFICATIONS
Model Code Explanation
Example: FA5-24MK320P
FA5
-
24
M
K
320
P
Series (Capacity)
FA5 = Air Powered Winch (5 metric ton / 11,000 lbs.)
Drum Flange Height or Man Rider®
:
-
T
= Standard flange: 27 inch (660 mm) diameter
= Tall flange: 35 inch (890 mm) diameter
Man RiderTM (Refer to FA5 Man RiderTM Supplement Form #MHD56042)
MR
=
Drum Length (Distance between drum flanges):
12
= 12 inch (306 mm)
16
= 16 inch (406 mm)
24
= 24 inch (610 mm) (Standard)
= 30 inch (760 mm)
30
36
= 36 inch (915 mm) Tall Flange Winch only
Drum Brake:
A
= Automatic Drum Brake
= Manual Drum Brake
= None
M
X
Disc Brake:
K
= Automatic Disc Brake
X
Control:
1
= None
= Winch mounted lever throttle. (Standard)
*
*
*
*
2XX = Remote full flow lever throttle (XX = Specify hose length (feet). Maximum 20 ft. (6 metres))
3XX = Remote pilot pendant throttle (XX = Specify hose length (feet). Maximum 50 ft. (15 metres))
4XX = Remote pilot lever throttle (XX = Specify length (feet). Maximum 50 ft. (15 metres))
5XX = Remote electric over air throttle†
Options: **
7
= 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†
**
C
D
E
G
L
= Drum Guard
= Drum Locking Pin
**
**
**
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) ††
Type Approval – Specify:
N
=
A = American Bureau of Shipping (ABS); N = Det Norske Veritas (DNV); R = Lloyd’s Register of Shipping (LRS)
P
Q
S
= Marine Grade Corrosion Preventative Finish
= Special paint
U
V
= Underwound wire rope operation †
= Press Roller
= Limit Switch (upper and lower)
= Tensioning Manifold
T
W
X
= Witness; please specify **
= Testing; please specify
Z
= Sandblast and Carbozinc Primer
-E
= Compliance with European Machinery Directive (includes Emergency Stop and Overload Protection)
Notes:
* Remote throttles are provided with 10 feet (3 metres) of hose. Specify hose lengths greater than 10 feet. For lengths
greater than 20 ft. (6 metres) with the Remote Full Flow Throttle, or 50 ft. (15 metres) with the Remote Pilot Lever and
Remote Pilot Pendant Throttles contact your Ingersoll Rand distributor or the factory for control acceptability. 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.
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Performance Graphs
FA5 Winch
(Dwg. MHP1890)
FA5T Winch
(Dwg. MHP1891)
6
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Model
General Specifications:
Rated Operating Pressure
FA5
FA5T
90 psig (6.3 bar)
Air System
Air Consumption
(at rated pressure and load)
700 scfm
20 cu.m/min.
700 scfm
20 cu.m/min.
Full Drum Line Pull
Mid Drum Line Speed
11,000 lbs
65 fpm
4,490 kgs
20 m/min.
10,886 kgs
873 kgs
- - -
8,400 lbs
80 fpm
3,810 kgs
24 m/min.
10,886 kgs
- - -
Rated Performance
(at rated pressure / volume)
Max Stall Pull - 1st Layer
FA5-24MX1 Ship Weight
FA5T-24MX1 Ship Weight
24,000 lbs
1,920 lbs
- - -
24,000 lbs
- - -
2,115 lbs
1.25 inch
1.5 inch
961 kgs
32 mm
Air Motor Pipe Inlet Size
1.25 inch
1.5 inch
32 mm
Minimum Air System Hose Size
Drum Barrel Diameter
38 mm
38 mm
15 inches
27.25 inches
381 mm
692 mm
15 inches
35.25 inches
381mm
895 mm
Drum Flange Diameter
Wire Rope Diameter
Drum Length (inches)
0.625 inch
874 ft
16 mm
266 m
360 m
547 m
688 m
18 mm
168 m
227 m
347 m
436 m
- - -
12
0.625 inch (16 mm) diameter
wire rope not recommended for
use on FA5T winches.
16
24 (Standard)
30
1181 ft
1795 ft
2256 ft
0.75 inch
550 ft
0.75 inch
1240 ft
1681 ft
2564 ft
3225 ft
3887 ft
0.875 inch
886 ft
18 mm
378 m
512 m
782 m
983 m
1185 m
20 mm
270 m
367 m
561 m
706 m
852 m
12
* Drum Wire Rope
Storage Capacity
(feet / metres)
16
24 (Standard)
30
746 ft
1138 ft
1431 ft
- - -
36 (Tall flange only)
0.875 inch
400 ft
20 mm
122 m
166 m
254 m
319 m
- - -
12
16
24 (Standard)
30
544 ft
1204 ft
1841 ft
2318 ft
2796 ft
832 ft
1047 ft
- - -
36 (Tall flange only)
* Wire rope storage capacity based on wire rope top layer located a minimum of 1/2 inch (13 mm) below drum flange and meets ASME
B30.7. The wire rope storage capacities listed may vary from figures stated elsewhere.
FA5 winches can be provided with an optional disc brake
Description of Operation
assembly consisting of friction plates splined to a hub which in
turn is connected to the drive shaft from the air motor. Brake
friction plates are clamped to the drum shaft through a spring
applied piston. The brake remains applied until the winch control
FA5 winches are air powered, planetary geared units designed for
lifting and pulling applications. FA5 winches are available with
either an internal automatic disc brake, a manual or automatic
valve is operated and winch payout or haul-in occurs. Air is
band brake, or a combination of both.
introduced into the brake piston chamber, which is formed
between brake piston and brake housing, causing the brake piston
The output from an externally mounted piston air motor is
to react, compressing brake springs and releasing friction plates
transmitted through a coupling and shaft to the planetary
allowing motor shaft to rotate. A power failure or sudden loss of
reduction gear assembly.
air will immediately cause the spring applied brake to engage.
The output from planetary reduction gear assembly is connected
The drum band brake operates by applying a friction force
to the wire rope drum through the output shaft.
between drum brake band and winch drum. The manual brake
requires an operator to engage and disengage brake using a lever
located on top of brake band. The automatic drum band brake
operation is similar to disc brake operation; they are both fully
disengaged in the haul-in and payout direction.
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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).
Traceability
Load bearing parts are documented to provide traceability. The
documentation includes chemical and physical properties of raw
material, heat treating, hardening, tensile and charpy tests as
required for the part.
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).
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 manufacturer) that parts are in compliance with
requirements of order based on non-specific inspection and
testing (i.e. results are typical material properties for these parts).
Components with part numbers ending in CH or CHA are charpy
parts for use under extreme cold conditions. Traceability
requirements must be stated when reordering these parts for
continued certification.
INSTALLATION
Prior to installing winch, carefully inspect it for possible shipping
damage.
Winches are supplied fully lubricated from the factory. Before
operation check oil levels and adjust as necessary. Use the proper
type of oil as recommended in “LUBRICATION” section.
4. Tighten 3/4 inch (18 mm) mounting bolts evenly and torque
to 380 ft lbs (515 Nm) for dry thread fasteners. If fasteners
are plated, lubricated or a thread locking compound is used,
torque to 280 ft lbs (380 Nm).
5. Maintain a fleet angle between sheave and winch of no more
than 1-1/2°. The lead sheave must be on a center line with
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. MHP2123
on page 9.
CAUTION
• Owners and users are advised to examine specific, local or
other regulations, including American Society of Mechanical
Engineers Standards 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 any part of winch.
Table 1–Mounting Surface Tolerance
Mounting Surface Minimum Flatness
Drum
Length
inch
0.06
0.08
0.12
0.15
0.18
mm
1.52
2.03
3.05
3.81
4.57
Mounting
12
16
24
30
36
Refer to Dwg. MHP0133 and Table 1 on page 8, and Table 2 on
page 9.
Care must be taken when moving, positioning or mounting the
winch. In most cases, lifting lugs have been provided to assist in
handling the winch. If lug locations are improper for your specific
installation, great care should be taken to ensure that winch, when
lifted, will be properly balanced. Determine weight of your winch
by referring to “SPECIFICATIONS” section. Lift winch 3 to 4
inches (75 to 100 mm) off ground.
Winch Bolt Hole Mounting Dimension Drawing
Verify winch is balanced and secure before continuing lift.
Mount winch so axis of drum is horizontal and that motor vent cap
is not more than 15° off top vertical center. If winch is to be
mounted in an inverted position, motor case must be rotated to
position vent cap at top.
1. The winch mounting surface must be flat and of sufficient
strength to handle rated load plus weight of winch and
attached equipment. An inadequate foundation may cause
distortion or twisting of winch uprights and side rails
resulting in winch damage.
2. Make sure mounting surface is flat to within 0.005 inch
(0.127 mm) per inch of drum length. Shim if necessary.
Refer to Table 1.
(Dwg. MHP0133)
3. Mounting bolts must be 3/4 inch (18 mm) Grade 8 or better.
Use self-locking nuts or nuts with lockwashers.
8
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Table 2–Winch Bolt Hole Mounting Dimensions
Wire Rope
Drum Length (inches)
Dimension
12
16
24
30
36*
CAUTION
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
31.25
794
“A” FA5
- - -
• Maintain at least 3 tight wraps of wire rope on drum at all
times.
• Install wire rope to come off drum for overwind operation.
(normal application.) Refer to Dwg. MHP2124 on page 9.
34.25
870
10.5
267
9
“A” FA5T
7.5
190
6
9
10
254
12
11.5
292
14
“B” (with
Drum Brake)
229
6.25
159
“B” (without
Drum Brake)
152
229
13/16
20
305
356
“C”
Bolt Hole Qty each
Side Rail
4
5
* 36 inch drum length applies to FA5T (tall flange) only.
(Dwg. MHP2124)
NOTICE
• For underwound applications order the “U” option or
contact factory prior to operation.
Wire Rope Selection
Consult a reputable wire rope manufacturer or distributor for
assistance in selecting 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 actual working load
and that meets all applicable industry, trade association, federal,
state and local regulations.
When considering wire rope requirements the actual working load
must include not only static or dead load but also loads resulting
from acceleration, retardation and shock load. Consideration must
also be given to the size of winch wire rope drum, sheaves and
method of reeving. Wire rope construction should be 6 X 19 or 6
X 37 IWRC EIPS right regular lay. Refer to Table 3 on page 9 for
minimum and maximum recommended wire rope sizes.
(Dwg. MHP2123)
‘A’ = 1.6 feet (0.5 metre) per inch of drum length:
‘A’ = 19.2 feet (5.85 metres) for 12 inch drum.
‘A’ = 25.6 feet (7.80 metres) for 16 inch drum.
‘A’ = 38.4 feet (11.7 metres) for 24 inch drum.
‘A’ = 48.0 feet (14.6 metres) for 30 inch drum.
‘A’ = 57.6 feet (17.5 metres) for 36 inch drum.
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.
Table 3–Minimum and Maximum Wire Rope Size
Minimum
Maximum
Model
inch
mm
16
inch
mm
FA5
5/8
3/4
7/8
22
FA5T
20
Note: Maximum wire rope diameter is limited by size of wire
rope anchor hole. Refer to parts list for correct wire rope anchor
part numbers.
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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.
Installing Wire Rope
CAUTION
Spooling Wire Rope onto Winch Drum
• To avoid disc brake damage when installing wire rope
pressurize brake with a minimum of 60 psi (4.1 bar) air from
an auxiliary source.
Refer to Dwg. MHP0166 on page 10.
1. Cut wire rope to length in accordance with wire rope
manufacturer’s instructions.
2. Feed end of wire rope into wire rope anchor hole in drum
and pull through approximately one foot (305 mm) of wire
rope.
(Dwg. MHP2125)
Rigging
Make sure all wire rope blocks, tackle and fasteners have a
sufficient safety margin to handle 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 wire rope manufacturer’s handbook for proper
sizing, use and care of wire rope.
(Dwg. MHP0166)
3. Wrap wire rope with wire a distance from the end equal to
wedge length plus one inch (25 mm).
4. Slide sleeve over end of wire rope so larger diameter of taper
bore is nearest the end of wire rope.
5. Spread end strands of wire rope and insert split wedge until
it is below the end of wire rope.
6. Pull sleeve over wire rope end until tight. Check that wire
rope strands stay in the slots located on split wedge.
7. Pull wire rope anchor into position in drum anchor pocket.
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 wire rope over a sharp edge. Use a correctly sized
sheave.
4. When a lead sheave is used, it must be aligned with center of
drum. The diameter of lead sheave must be at least 18 times
diameter of wire rope. Refer to Dwg. MHP2123 on page 9.
5. Always maintain at least three full, tight wraps of wire rope
on drum.
CAUTION
• Make sure first wrap of wire rope is tight and lays flush
against drum flange.
Air Supply
Safe Wire Rope Handling Procedures
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.
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.
4. Always ensure wire rope is correctly spooled and the first
layer is tight against drum.
5. Always follow wire rope manufacturers’ recommendation on
use and maintenance of wire rope.
Air consumption for the FA5 and FA5T air motor is 700 scfm (20
cu. m/min.) at rated operating pressure of 90 psig (6.3 bar) at
winch motor inlet. If air supply varies from recommended, then
winch performance will change.
Wire Rope Spooling
Refer to Dwg. MHP2125 on page 10.
To compensate for uneven spooling and decrease in line pull
capacity as drum fills up, use as short a wire rope as practical.
When rewinding apply tension to the end of wire rope to eliminate
slack. This helps achieve level winding and tight spooling.
10
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Air Lines
Air Pressure Regulator
Inside diameter of winch air supply lines must not be less than
sizes shown in Table 4 on page 11. 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 transmission lines and excessive use
of fittings, elbows, tees, globe valves etc. cause a reduction in
pressure due to restrictions and surface friction in lines.
If an air pressure regulator is used, install between lubricator and
filter. Refer to Dwg. MHP0191 on page 11.
Moisture in Air Lines
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 motor or an aftercooler at compressor that cools air to
condense and collect moisture prior to distribution through supply
lines are also helpful.
Table 4–Minimum Allowable Air Supply Line Sizes
Model
FA5
inch
mm
1-1/2
38
Mufflers
FA5T
Make sure mufflers are installed in winch exhaust manifold and
control valve exhaust port. An additional muffler is used on
winches equipped with an emergency stop and overload device.
Check mufflers periodically to ensure they are functioning
correctly.
Air Line Lubricator
Refer to Dwg. MHP0191 on page 11.
Always use an air line lubricator with these motors. The lubricator
must have an inlet and outlet at least as large as inlet on motor.
Install air line lubricator as close to air inlet on motor as possible.
Motor
For optimum performance and maximum durability of parts,
provide an air supply of 90 psig at 700 scfm (6.3 bar/630 kPa at
20 cu. m/m) as measured at motor inlet. The air motor should be
installed as near as possible to compressor or air receiver.
CAUTION
• Lubricator must be located no more than 10 ft. (3 m) from
motor.
• Shut off air supply before filling air line lubricator.
Emergency Stop and Overload System (optional feature)
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.
Refer to Dwg. MHP1492 on page 12.
old style
The air supply line is connected to the shutoff valve which is
connected to the air control valve. When Emergency Stop valve is
activated, a pilot signal is sent to the shut off pilot valve which
directs shutoff valve to cut off air to winch, immediately stopping
all winch movement.
Air Line Filter
Refer to Dwg. MHP0191 on page 11.
It is recommended that an air line strainer/filter be installed as
close as practical to motor air inlet port, but before lubricator, to
prevent dirt from entering 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.
CAUTION
• If winch continues to move (payout load) after shutoff valve
activates, brake(s) are not holding load and need to be
adjusted or repaired.
Air Out
The overload system also activates shutoff valve. When Delta-P
valve senses a preset pressure difference between the two ports,
located on rotary housing, it directs a pilot signal to shutoff pilot
valve activating the shutoff valve. Refer to Dwg. MHP1491 on
page 12.
Regulator
Air In
Lubricator
Filter
(Dwg. MHP0191)
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Emergency Stop and Overload System Components
(old style)
Constant Tension (optional feature)
Refer to Dwg. MHP1865 on page 12 and Dwg. MHP1176 on
page 12.
The air supply line is connected to one of the two top ports on the
control valve. This will allow air to supply either the normal
control valve or the auxiliary valve.
CAUTION
• Use only one control valve to operate winch at any time.
Attempting to OVER-RIDE one control valve with the other
will result in total loss of winch control.
Air Schematic–Constant Tension Winches
(Dwg. MHP1492)
Air Schematic–Emergency Stop and Overload System
(old style)
(Dwg. MHP1176)
Constant Tension Components
(Dwg. MHP1491)
(Dwg. MHP1865)
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For winches that have been in storage the following start-up
procedures are required.
Initial Operating Checks
1. Give the winch an inspection conforming to requirements of
“Winches Not in Regular Use” in the “INSPECTION”
section.
2. Pour a small amount of ISO VG 32 (SAE 10W) oil in motor
inlet port.
3. Operate motor for 10 seconds in both directions to flush out
any impurities.
4. The winch is now ready for normal use.
Winches are tested for proper operation prior to leaving factory.
Before winch is placed into service the following initial operating
checks should be performed.
1. When first running motor inject some light oil into inlet
connection to provide initial lubrication.
2. When first operating winch it is recommended that motor be
operated slowly in both directions for a few minutes.
OPERATION
The four most important aspects of winch operation are:
1. Follow all safety instructions when operating winch.
2. Allow only people trained in safety and operation of this
winch to operate this equipment.
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.
3. Subject each winch to a regular inspection and maintenance
procedure.
4. Be aware of winch capacity and weight of load at all times.
As viewed from the air motor end, move the 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 the control valve to ensure smooth operation of the winch.
When released, handle will return to the neutral or center position.
The sliding handle will drop down to engage and lock the control
handle in place.
CAUTION
• To avoid damage to rigging, the structure supporting rigging
and winch, do not “two-block” the end of wire rope.
Winch Mounted Throttle Control Valve Operation
Lift Slider
Handle
UP to
* Two blocking occurs when 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 wire rope and sheave blocks which
may result in equipment and or rigging failure.
Unlock
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 winch, including a study of the
manufacturers’ literature. The operator must thoroughly
understand proper methods of hitching loads and must have a
good attitude regarding safety. It is the operator’s responsibility to
refuse to operate winch under unsafe conditions.
Haul-In
Payout
Air Inlet Port
1-1/4 NPT
Brake Release Port
1/4 NPT
WARNING
Exhaust Port
1-1/2 NPT
• Winch is not designed or suitable for lifting, lowering or
moving persons. Never lift loads over people.
(Dwg. MHP1809)
Winch Controls
old style
Refer to Dwgs. MHP0165 on page 54 and MHP0566 on page 14.
The spring loaded, live air, manual control throttle valve mounts
to air motor.
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 winch is not in use, engage latch to prevent inadvertent
movement of control throttle.
The 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
determine your configuration. The throttle controls provide
operator control of motor speed and direction of drum rotation.
Winch Mounted Air Throttle (standard feature)
New Style
Refer to Dwg. MHP1809 on page 13.
The spring loaded, live air, manual control throttle valve mounts
to the rotary housing.
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Winch Mounted Throttle Control Valve Operation
(old style)
(Dwg. MHP2043)
Remote Pilot Pendant Throttle (optional feature)
Refer to Dwg. MHP2233 on page 14 and MHP1311 on page 15.
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 depressed.
Dwg. MHP0566)
Pendant Hose and Operating Levers (new style)
Red
Underwound Operation (optional feature)
Yellow
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.
Green
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 13. 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.
Haul-In
Load
Payout
Load
Remote Live Air Throttle (optional feature)
Refer to Dwgs. MHP2043 on page 14.
(Dwg. MHP2233)
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.
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Pendant Hose and Operating Levers (old style)
Emergency Stop Operation
(Dwg. MHP1311)
(Dwg. MHP2047)
* For distances greater than 50 feet (15 metres) contact
Ingersoll Rand Technical Sales for control suitability.
NOTICE
Remote Pilot Lever Throttle (optional feature)
• If winch overload occurs, overload device, if equipped, also
stops winch. To operate winch after an overload, reduce load
and reset overload.
• Cannot be added to old style control valve. Refer to
Dwg. MHP2036 on page 50.
Refer to Dwg. MHP0167 on page 56, item 358.
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.
Emergency Stop Reset
Refer to Dwg. MHP2048 on page 15.
1. Rotate red stop button, in counterclockwise direction until
red stop button ‘pops’ up.
* For distances greater than 50 feet (15 metres) contact
Ingersoll Rand Technical Sales for control suitability.
2. Winch is ready to resume operation.
Emergency Stop Reset
Emergency Stop and Overload System
Refer to Dwg. MHP2180 on page 52.
Air supply line is connected to air control valve. When emergency
stop or overload valve is activated, all winch movement will stop.
CAUTION
• If winch continues to move (payout load) after emergency
stop activates, brake(s) are not holding load and may require
adjustment or repair.
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.
Emergency Stop (optional feature)
Refer to Dwg. MHP2047on page 15.
Emergency stop device is located on the control valve. When
activated, winch drum rotation will immediately cease. To activate
emergency stop, conduct the following:
(Dwg. MHP2048)
1. Depress (push down) red palm valve, located on top of
control valve.
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2. To operate winch, depress appropriate ‘Haul-in’ or ‘Payout’
lever.
Overload Device
3. In event of an emergency all winch operation can be stopped
by pushing the emergency stop button. This will prevent air
from reaching winch motor, engage winch automatic
brake(s) and stop winch haul-in or payout movement.
4. If depressed, the ‘OFF’ button will also stop winch
operation.
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.
5. To reset Emergency Stop Valve:
a. Locate serrated ring directly below emergency stop
button. Rotating serrated ring clockwise, will cause
emergency stop button to ‘pop up’.
b. Depress emergency stop valve ‘ON’ button.
Checking Overload Valve Setting
Emergency Stop Operation (old style)
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
Setting the Overload
Refer to MHP2049 on page 16 and MHP2216 on page 27.
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.
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.
(Dwg. MHP1485)
Local Control Emergency Stop Valve Operation
Overload Valve Reset
(Dwg. MHP0754)
(Dwg. MHP2049)
Emergency Stop (optional feature)
Refer to Dwgs. MHP1485, MHP0754 on page 16 and MHP1892
on page 17.
The emergency stop device is located at air inlet of winch on local
control models, and on pendant on remote control models. When
activated, winch drum rotation will immediately cease.
1. To start winch operation depress the ‘ON’ button.
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Remote Pendant Emergency Stop Valve Operation
WARNING
• 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.
4. Operate winch normally to remove slack from load line.
5. Actuate valve to TENSION position to set winch to
automatically haul-in load line and maintain line tension.
Winch Brakes
Manual Drum Brake
Refer to Dwg. MHP0153 on page 48.
The manual drum brake may be applied by pushing down on
handle (104) and released by pulling up. If handle is pushed down
fully, it should lock in that position and prevent drum rotation,
until released by operator. The brake must be kept properly
adjusted to hold required load. Refer to ‘Adjustments’ on page 26
in “MAINTENANCE” section for adjustment instructions.
(Dwg. MHP1892)
Winch Overload Device (optional feature)
Automatic Drum Brake (optional feature)
The overload device is integrated into winch air motor control air
system and prevents winch from lifting a load greater than
an overload is detected, inlet supply air is stopped and winch will
not operate.
If overload device is activated load must be lowered and reduced.
To lower load and reset emergency stop valve:
1. Locate serrated ring directly below emergency stop button.
Rotating serrated ring clockwise, causes emergency stop
button to ‘pop up’.
Refer to Dwg. MHP0153 on page 48.
The automatic drum brake is a spring applied, air released brake
which utilizes an air actuated, spring loaded cylinder (110), that
automatically disengages brake when motor is operated. Air
pressure in cylinder overcomes spring pressure to release brake.
When control valve is placed in neutral position, air in cylinder
(110) is vented and spring automatically engages brake to prevent
drum rotation.
2. Depress emergency stop valve ‘ON’ button.
3. Operate winch control in payout direction.
The cylinder clevis (107) must be kept properly adjusted to hold
required load.
Constant Tension (optional feature)
Automatic Disc Brake (optional feature)
Refer to Dwg. MHP1865 on page 12.
Refer to Dwg. MHP0152 on page 46.
With auxiliary valve in the NORMAL position, winch provides
normal operation. Placing valve selector in TENSIONING
position allows winch to automatically operate to haul-in slack
wire rope to maintain tension.
The automatic disc brake is a spring applied, air released brake.
Using an air actuated, spring loaded piston (10), the brake
automatically disengages when motor is operated and engages
when throttle is returned to neutral position.
Auxiliary valve provides preset air pressure to air motor and disc
brake. This allows brake to be released and winch to overhaul
during TENSIONING operations. In this position, winch will
maintain constant tension on wire rope.
Air pressure ported through brake housing (21) overcomes spring
(9) pressure and moves piston (10) which releases brake. When
control valve is placed in neutral position, air is vented, spring
pressure overcomes air pressure and spring (9) pressure moves
piston, engages brake and prevents drum rotation.
Auxiliary valve is pre-set at zero from the factory. Specific
adjustments must be made in the field. Adjustments can be
modified at anytime to accommodate the load conditions. Refer to
‘Regulator Adjustment’ in the “MAINTENANCE” section for
specific procedure.
Drum Locking Pin (optional feature)
Refer to Dwg. MHP0155 on page 61.
The drum locking pin is mounted to winch on outboard upright,
opposite motor. It should be engaged if a load is left suspended.
The drum lock is operated by rotating a pin between a shallow
groove (disengaged) and a deep groove (engaged).
Constant Tension (operation)
1. Place auxiliary valve in NORMAL position.
2. Operate winch normally to position end of load line.
3. Connect load line to load.
To Engage:
1. Rotate drum (80) to align one of the holes in flange with
locking pin (136). Pull out, straight away from outboard
upright, pull rod (140) and rotate counterclockwise 90°,
aligning pin (135) with deep groove in gland (138). Release
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pull rod and ensure locking pin engages and is seated in drum
hole and gland deep groove.
WARNING
• Ensure that all braking mechanisms are engaged and all
personnel are clear of winch load and rigging before
disengaging locking pin.
• Extremely difficult locking pin release is an indication that
load is held by locking pin and braking mechanisms are not
functioning properly. Do not release locking pin until load
control is established.
To Disengage:
1. Pull out, straight away from outboard upright, pull rod (140)
and rotate clockwise 90°. Align pin (135) with the shallow
groove in gland (138) and release pull rod. Ensure locking
pin (136) is clear of the drum (80) flange and pin is seated in
gland shallow groove.
Limit Switch (optional feature)
Pre-set limit switch settings prevent winch wire rope payout and
haul-in by stopping air flow to the winch motor when a defined
set point has been reached. It is the owner’s and operator’s
responsibility to adjust winch operating limits prior to using
winch.
To adjust set points refer to ‘Adjustments’ in “MAINTENANCE”
section.
WARNING
• Ensure limit switch set points are established and operating
properly before using winch.
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LUBRICATION
To ensure continued satisfactory operation of winch, all points
requiring lubrication must be serviced with correct lubricant at
proper time interval as indicated for each assembly.
Recommended Grease
Temperature
Type Oil
The 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
the 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 winch performance. Approval for use of
other lubricants must be obtained from your Ingersoll Rand
distributor. Failure to observe this precaution may result in
damage to winch and/or its associated components.
-20° to 50° F
(-30° to 10° C)
EP 1 multipurpose
lithium based grease
30° to 120° F
(-1° to 49° C)
EP 2 multipurpose
lithium based grease
NOTICE
• Do NOT use synthetic lubricants in air motor. Synthetic
lubricants will result in oil blowing by piston rings.
INTERVAL
LUBRICATION CHECKS
Component Lubrication
General Lubrication
Start of each shift Check flow and level of air line lubricator
(approximately 6 to 9 drops per minute
required at maximum motor speed).
Check winch motor oil level.
Correct lubrication is one of the most important factors in
maintaining efficient winch operation.
Monthly
Lubricate components supplied by grease
fittings.
1. The recommended grade of oil must be used at all times. Use
of unsuitable oil may result in excessive temperature rise,
loss of efficiency and possible damage to lubricated
components. Refer to ‘Recommended Lubricants’ section.
2. Drain and replace oil in motor, disc brake and reduction gear
after the first 50 hours of initial winch operation. Thereafter,
drain and replace oil according to operating environment
(yearly in NORMAL and HEAVY; quarterly in SEVERE), or
more frequently if desired.
3. 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.
Inspect and clean or replace air line filter.
Check reduction gear oil level.
Yearly
Drain and refill winch reduction gear oil.
Drain and refill winch motor oil.
Note: Intervals are based on winch operation in a normal
environment as described in the “INSPECTION” section. In
‘Heavy’ or ‘Severe’ operating conditions adjust lubrication
intervals accordingly.
Recommended Lubricants
4. After winch operation, allow oil to settle before topping off.
5. Always collect lubricants in suitable containers and dispose
of in an environmentally safe manner.
Reduction Gear Recommended Lubricant
Motor
Temperature
Below 32° F (0° C)
Type Oil
ISO VG 68 (2 EP)
ISO VG 100 (3 EP) *
ISO VG 150 (4 EP)
Refer to Dwg. MHP2126 on page 20.
32° to 80° F (0° to 27° C)
Above 80° F (27° C)
The motor is splash lubricated by oil in motor housing and has no
other means of lubrication. It is therefore important to use only
good quality, non-detergent motor oil to ensure maximum
performance and minimum downtime for repairs. Refer to
‘Recommended Lubricants’ section.
* Units are shipped from factory with ISO VG 100 (3 EP) lubri-
cant. Reduction gear capacity is approximately 2 quarts (1.9
litres).
Oil capacity for the K5B-546 motor is 3 quarts (2.8 litres). Add
oil through filler opening until oil flows from level plug hole.
Add oil slowly to prevent spilling.
Air Motor and Disc Brake Recommended Lubricant
Temperature
Below 32° F (0° C)
Type Oil
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 water then refill to level plug (225),
located on side of motor housing (217). If desired, all oil may be
drained at end of shift and motor refilled with new oil.
ISO VG 32 (SAE 10W)
ISO VG 68 (SAE 20W) *
ISO VG 100 (SAE 30W)
32° to 80° F (0° to 27° C)
Above 80° F (27° C)
* Units are shipped from factory with ISO VG 68 (SAE 20W)
lubricant. Motor oil capacity is approximately 3 quarts (2.8
litres).
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K5B Motor Lubrication Locations
To ensure correct performance, highest efficiency and long life, it
is essential that lubricating oil be maintained at correct level.
Rotate drum until fill plug is located at top dead center then add
oil up to level plug hole. Oil capacity for reduction gear assembly
is 4 quarts (3.8 litres).
Reduction Gear Lubrication Plug Locations
(Dwg. MHP2126)
(Dwg. MHP0140)
Air Throttle
Refer to Dwg. MHP0165 on page 54. Periodically, depending on
winch usage and severity of environment, lubricate lever air
throttle (local and remote) with recommended grease at grease
fitting (246).
Disc Brake (optional feature)
Refer to Dwg. MHP1348 on page 20.
The friction plates and drive plates are in a self contained oil bath
and have no other means lubrication. After an oil change or winch
overhaul remove the breather plug (22) and pour a small amount
of oil [4 to 6 ounces (0.2 litres)] through breather hole in brake
housing. Allow oil to fully settle between fillings.
Wire Rope
Follow 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 surface of wire rope.
NOTICE
• If too much oil is added excess oil will be discharged through
breather plug when control valve is actuated.
CAUTION
• Do not use an acid-based solvent. Only use cleaning fluids
specified by wire rope manufacturer.
2. Apply Ingersoll Rand LUBRI-LINK-GREEN or ISO VG
100 (SAE 30W) oil as a wire rope lubricant.
3. Brush, drip or spray lubricant weekly, or more frequently,
depending on severity of service.
Reduction Gear Assembly
Refer to Dwg. MHP0140 on page 20.
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.).
The reduction gear is filled to the correct levels prior to shipment
from the factory. Check oil level before initial winch operation.
This component is splash lubricated by oil in the housing and has
no other means of lubrication. It is therefore important to use high
quality Extreme Pressure (EP) rust and oxidation inhibited gear oil
to ensure maximum performance and minimum down time for
repair.
(Dwg. MHP1348)
Seals and Bearings
If winch is disassembled, clean all parts thoroughly and coat
bearings and seals with clean grease. Refer to ‘Recommended
Lubricants’ section. Use sufficient grease to provide a good
protective coat. Lubricate grease fittings monthly with 2 or 3
pumps of a grease gun.
CAUTION
• Do not over fill. Excess oil will reduce operating efficiency
and increase oil temperature.
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If drum locking pin is disassembled, clean all parts thoroughly
and coat with clean grease. Refer to ‘Recommended Lubricants’
section. Use sufficient grease to provide a good protective coat.
Drum Locking Pin (optional feature)
Refer to Dwg. MHP0155 on page 61.
Lubricate at least once every month, depending on environment
and duty cycle, through grease fitting (139) located in gland (138)
with 2 or 3 pumps of a grease gun.
Lubrication will help to prevent rust and allow easier locking pin
operation.
INSPECTION
Inspection information is based in part on American Society of
Mechanical Engineers Standards Safety Codes (ASME B30.7).
Frequent 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).
WARNING
• All new or repaired 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.
1. WINCH. Prior to operation, visually inspect winch housings,
controls, brakes, side rails and drum for indications of
damage. Do not operate winch unless the wire rope feeds
onto drum smoothly. Any discrepancies noted must be
reviewed and inspected further by authorized personnel
instructed in 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
displacement, corrosion, broken or cut strands. If damage is
evident, do not operate winch until the discrepancies have
been reviewed and inspected further by personnel
knowledgeable on wire rope safety and maintenance
procedures.
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 safety,
operation and maintenance of this equipment. ASME B30.7 states
inspection intervals depend upon the nature of critical
components of the equipment and severity of usage. The
inspection intervals recommended in this manual are based on
intermittent operation of winch eight hours each day, five days
per week, in an environment relatively free of dust, moisture, and
corrosive fumes. If winch is operated almost continuously, or
more than 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 condition becomes dangerous.
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(s) must be decided, and correction of noted safety
hazard(s) accomplished and documented by written report before
placing equipment in service.
NOTICE
• The full extent of wire rope wear cannot be determined by
visual inspection. At any indication of wear inspect wire rope
in accordance with instructions in “Periodic Inspection.”
3. AIR SYSTEM. Visually inspect all connections, fittings,
hoses and components for indication of air leaks. Repair any
leaks or damage.
4. PENDANT (optional feature). Ensure operation of pendant
levers is smooth and winch is responsive to pendant control.
Pendant levers must spring return to the neutral position
when released.
5. 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.
6. 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.
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 condition
of critical parts as a method of documenting periodic inspections.
These reports should be dated, signed by the person who
performed inspection, and kept on file where they are readily
available for authorized review.
7. WIRE ROPE REEVING. Check reeving and ensure wire
rope is properly secured to the drum. Do not operate winch
unless wire rope feeds onto drum smoothly.
8. LUBRICATION. Refer to “LUBRICATION” section for
recommended procedures and lubricants.
9. LIMIT SWITCHES (optional feature). If equipped, ensure
limit switches engage and prevent operation at the required
set point and with drum rotating in correct direction. Ensure
limit switch properly resets.
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 actual condition of wire rope as determined by
periodic inspections.
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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.
5. ALL COMPONENTS. Inspect for wear, damage, distortion,
deformation and cleanliness. If external evidence indicates
damage, disassemble as required to conduct a detailed
inspection. Inspect gears, shafts, bearings, sheaves, springs
and covers. Replace worn or damaged parts. Clean, lubricate
and reassemble.
6. BRAKES. Individually test brakes installed to ensure proper
operation. Brakes must hold a 125% rated load at mid drum
without slipping. If indicated by poor operation or visual
damage, disassemble and repair brake(s). Check all brake
surfaces for wear, deformation or foreign deposits. If brake
lining thickness is less than minimum as described in
“MAINTENANCE” section replace brakes. Clean and
replace components as necessary. Adjustments cannot be
made to disc brake. The disc brake must be repaired as
described in “MAINTENANCE” section.
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. LIMIT SWITCHES (optional feature). Operate winch in
both directions to activate limit switches. Limit switches
should engage (stop winch operation) at established settings
(+/- 2 feet [+/- 0.6 metres]). Reset limit switch by operating
winch in opposite direction. Refer to ‘Limit Switch
Adjustment’ in “MAINTENANCE” section.
10. DRUM GUARD (optional feature). Verify fasteners are tight
and in good condition. Ensure guard is in good condition.
11. EMERGENCY STOP VALVE (optional feature). During
winch operation verify emergency shut-off valve operation.
Valve must stop winch operation quickly. Valve must reset
properly. Refer to ‘Emergency Stop Valve’ in the
Periodic Inspection
Periodic inspection intervals for winch use under various
conditions is listed below:
NORMAL
yearly
HEAVY
semiannually
SEVERE
quarterly
Disassembly may be required as a result of frequent inspection
findings or in order to properly inspect individual components.
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. SIDE 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.
4. WIRE ROPE. In addition to “Frequent Inspection”
requirements, also inspect for the following:
a. Build-up of dirt and corrosion. Clean with steam or a
stiff wire brush to remove dirt and corrosion if
necessary.
b. Loose or damaged end connection. Replace if loose or
damaged.
“OPERATION” section for procedures.
12. OVERLOAD DEVICE (optional feature). Ensure overload
device is properly set to stop winch when load exceeds
150% (+/- 25%) of winch rated capacity. If winch does not
shut down, contact your distributor or factory for repair
information.
c. Check wire rope anchor is secure in drum.
d. Verify wire rope diameter. Measure diameter of wire
rope from crown-to-crown throughout life of wire rope.
Recording of actual diameter should only be done with
wire rope under equivalent loading and in same
operating section as accomplished during previous
inspections. If actual diameter of wire rope has
decreased more than 1/64 inch (0.4 mm) a thorough
examination of wire rope should be conducted by an
experienced inspector to determine suitability of wire
rope to remain in service. Refer to Dwg. MHP0056 on
page 22.
Winches Not in Regular Use
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 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 requirements of “Periodic Inspection” before being
place in service.
3. Standby equipment shall be inspected at least semi-annually
in accordance with requirements of “Frequent Inspection”.
(Dwg. MHP0056)
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INSPECTION AND MAINTENANCE REPORT
Ingersoll-Rand Force 5 Series FA5 and FA5T Air Winches
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
Limit Switches
Controls
Air System
Fasteners
Reduction Gears
Labels and Tags
Shafts
---
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.
Disc brake does not release.
Check air supply line connections and hoses.
Reduce load to within rated capacity.
Pressurize disc brake release port and check for leakage. Replace brake
piston seals if leakage is found. Ensure air pressure at inlet to disc brake is
at least 50 psig (3.4 bar/340 kPa).
Shipping plugs may still be in Remove shipping plugs in valve and motor exhaust ports.
place.
Drum brake does not release. Disengage manual drum brake, or refer to ‘Automatic Drum Brake
Load continues to move when Drum brake is slipping.
Check drum brake adjustment on page 26 and brake band lining wear.
Reduce load to within rated capacity.
winch is stopped.
Winch is overloaded.
Winch motor controls sticking. Check pendant/throttle levers spring return to normal (neutral) positions
when released.
Winch does not lift load or
does not lift rated capacity.
Motor may be damaged.
Remove and disassemble motor as described in the “MAINTENANCE”
damaged.
Insufficient air supply.
Verify air supply pressure and volume at winch inlet meets requirements
Throttle or pendant lever
moves but winch does not
operate.
Motor may be damaged.
Insufficient air supply.
Disassemble and clean motor and replace any broken or damaged parts.
Ensure air pressure at winch inlet is at least 90 psig (6.3 bar/630 kPa) at
rated volume. Clean air line filter.
Air leak.
Check hose and fitting connections. Inspect hose(s) for breaks. Tighten
fittings and repair or replace hoses as necessary.
Motor runs hot or makes
excessive noise during
operation.
Low oil level.
Check oil level in motor. Add oil as required to obtain proper level.
Improper lubrication.
page 19. 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 Disassemble and repair motor.
connecting rod.
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.
Motor may be damaged.
Remove and disassemble motor as described in the “MAINTENANCE”
parts.
Brake(s) not releasing.
Water in air supply.
Refer to brakes in “MAINTENANCE” section on page 26.
Install or drain air system moisture traps, moisture collecting air receivers
and compressor aftercoolers. After corrective action has been taken,
disconnect lines at winch inlet and purge with clean, dry air or nitrogen.
Throttle lever hard to actuate, Valve body sticking in
or lever does not spring return bushing.
to neutral.
Lubricate valve through grease fitting with recommended lubricant. Refer
Automatic Drum Brake:
Brake cylinder will not
release.
Drum brake out of adjustment. Adjust drum brake to maintain correct cylinder stroke.
Leaking cylinder seals.
If air is noticed escaping from cylinder breather when attempting to
release brake, replace or repair cylinder.
Dirty filter in air supply.
Faulty dump valve.
Clean or replace filter.
Check dump valve exhaust port. Air should exhaust when control valve
handle is in neutral. If no air escapes, replace dump valve.
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SYMPTOM
CAUSE
REMEDY
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.
Check for proper operation of winch controls.
Sticking brake piston.
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.
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MAINTENANCE
4. Rotate link stud (103) clockwise to increase brake torque.
5. Install pin (101) and check adjustment.
6. Brake should be adjusted until brake lever over center
position can be attained with 50 to 100 lb. (23 to 45 kg)
force on handle (104).
7. Install cotter pin (102) when adjustment is completed. Bend
ends of cotter pin over.
WARNING
• Never perform maintenance on winch while it is supporting a
load.
• Before performing maintenance, tag controls:
WARNING - DO NOT OPERATE -
EQUIPMENT BEING REPAIRED.
• Only allow service personnel trained in safety and service on
this winch to perform maintenance.
• After performing any maintenance on winch, test winch to
125% of its rated capacity before returning to service. Testing
to more than 125% of rated capacity may be required to
comply with standards outside the USA.
CAUTION
• When any part of brake lining measures 0.062 inch (2 mm)
or less, brake bands (128) or linings must be replaced.
• Shut off air system and depressurize air lines before
performing any maintenance.
Automatic Drum Brake Adjustment (optional feature)
Refer to Dwg. MHP0153 on page 48.
1. Remove cotter pin (102) and washer (129) at adjustment
clevis (107).
Maintenance Intervals
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
“INSPECTION” section for interval guidance.
2. Apply air to brake cylinder (110) and remove pin (106) and
second washer (129) to disconnect clevis from brake lever
(105).
3. Turn adjustment clevis (107) clockwise to increase cylinder
rod extension. Turn clevis counterclockwise to decrease
cylinder rod extension.
4. Assemble clevis (107) to brake lever (105) with washer
(129) and pin (106). Release air to brake cylinder (110).
5. Measure cylinder rod extension. Length should be 1 to 1-1/2
inches (25 to 37 mm). Readjust if necessary.
INTERVAL
MAINTENANCE CHECK
Start of each shift Make a thorough visual inspection of winch
for damage. Do not operate winch if
(Operator or
Maintenance
Personnel)
damaged.
6. Install cotter pin (102) and second washer (129) to secure
clevis to brake lever when adjustment is complete.
7. With brake “On”, adjust screw (127) to just touch arm (124).
Operate winch at low RPM in both
directions. Winch must operate smoothly
without sticking, binding or abnormal
noises. Check operation of brake(s)
Pilot Air Control Valve Adjustment (optional feature)
3 Months
(Maintenance
Personnel)
Inspect drum brake friction linings. Clean or
replace parts as required. Adjust drum brake
as necessary.
Refer to Dwg. MHP0141 on page 60.
If winch operating speeds differ from performance specifications
pilot air control valve may require adjustment. Loosen nut (271)
and adjust adjusting screw (270), located in valve end cap (268),
until drum speed for no-load haul-in equals drum speed for full
load payout. 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.
Yearly
Inspect winch gearing, shafts and bearings
for wear and damage. Repair or replace as
necessary.
(Maintenance
Personnel)
Check all supporting members, including
foundation, fasteners, nuts, sheaves and
rigging, etc. for indications of damage or
wear. Repair or replace as required.
Overload Valve Adjustment (optional feature)
Adjustments
new style
Refer to Dwg. MP2216 on page 27
5/16 in. or 8 mm open ended wrench required.
1. Adjust overload valve by turning adjustment screw located at
bottom of control valve.
Disc Brake Adjustment (optional feature)
Refer to Dwg. MHP0152 on page 46.
2. Rotating adjustment screw clockwise will increase pressure
required to activate overload valve.
Disc brake adjustment is not required. If disc brake does not hold
rated load disassemble and repair.
If brake assembly is removed or disassembled ensure breather (23)
is installed and located at top of brake housing during reassembly.
WARNING
Manual Drum Brake Adjustment
• This adjustment can cause overload device to NOT activate
before winch’s safety limit is exceeded. This procedure should
only be done by personnel trained in testing and servicing this
winch.
Refer to Dwg. MHP0153 on page 48.
1. Release wire rope tension on drum.
2. Raise handle (104) to free brake bands (128).
3. Remove cotter pin (102) and pin (101).
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3. Rotating adjustment screw counterclockwise will decrease
Overload Valve Adjustment (old style)
pressure required to activate overload valve.
Overload Valve Adjustment (new style)
(Dwg. MHP1678)
(Dwg. MHP2216)
Limit Switch Adjustment (optional feature)
Overload Valve Adjustment (optional feature)
old style
Refer to Dwg. MHP1678 on page 27.
Adjust overload valve by turning adjustment screw located at
bottom of valve.
Rotating screw clockwise will increase pressure required to
activate shutoff valve.
WARNING
(Dwg. MHP0607)
• This adjustment can cause overload device to NOT activate
before winch’s safety limit is exceeded. This procedure should
only be done by personnel trained in testing and servicing this
winch.
To set winch maximum wire rope payout limit switch:
1. Remove access plate from top of limit switch.
2. Loosen blue setscrew in center of limit switch, below access
cover.
3. Position winch wire rope at desired payout position.
4. Rotate left cam adjustment screw counterclockwise until it
fully activates cutoff valve, causing system air to vent. 2¾
turns of the cam adjustment screw are required for each full
cam revolution.
5. Hold cam adjustment screw in position (venting air) and
tighten blue setscrew to lock cam in place.
6. If required, adjust haul-in limit switch. Test winch set points
by operating winch through three complete cycles to ensure
consistent limit switch operation within +/- 2 feet (2/3 metre)
of set points.
Rotating adjustment screw counterclockwise will decrease
pressure required to activate shut off valve.
Checking Overload Valve Setting:
1. Attach load line to a load that is calibrated to 150% of the
maximum load for which winch is rated. Move control lever
to haul-in position. If winch lifts load, adjust screw as
described below.
Setting the Overload:
1. Attach load line to a load that is calibrated to 150% of winch
rated capacity.
2. When control lever is moved to haul-in position, overload
valve should activate shut off valve. Reset emergency stop
valve, valve is adjusted.
3. If winch lifts load, lower load. Turn adjustment screw
counterclockwise in ¼ turn increments until shut off valve is
activated. After each ¼ turn, retest winch.
7. Install access cover when final adjustments are complete.
To set winch maximum wire rope haul-in limit switch:
1. Remove access plate from top of limit switch.
2. Loosen red setscrew in center of limit switch, below access
cover.
3. Position winch wire rope at desired switch activation
position.
4. Rotate right cam adjustment screw clockwise until it fully
activates cutoff valve, causing system air to vent. 2¾ turns of
cam adjustment screw are required for each full cam
revolution.
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5. Hold cam adjustment screw in position (venting air) and
tighten red setscrew.
Disassembly
6. If required, adjust payout limit switch. Test winch set points
by operating winch through three complete cycles to ensure
consistent limit switch operation within +/- 2 feet (2/3 metre)
of set points.
General Disassembly Instructions
The following instructions provide necessary information to
disassemble, inspect, repair, and assemble winch. Parts drawings
are provided in parts section. If a winch is being completely
disassembled for any reason, follow the order of topics as they are
presented. It is recommended that all maintenance work on winch
be performed in a clean dust free work area.
In the process of disassembling winch, observe the following:
1. Never disassemble winch any further than is necessary to
accomplish needed repair. A good part can be damaged
during the course of disassembly.
7. Install access cover when final adjustments are complete.
Constant Tension Adjustment (optional feature)
Refer to Dwg. MHP1865 on page 12.
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.
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.
Regulator gauge and regulator are accessible through cover.
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.
WARNING
• When adjusting regulator, ensure winch control lever is
locked in neutral position and tension selector lever is in the
NORMAL position.
• Winch supply air is NOT shut off during regulator
adjustments. To prevent accidental winch operation, allow
only a single person, trained in safety, operation and
maintenance of this product, to conduct regulator
adjustments.
In general, winch is designed to permit easy disassembly and
assembly. The use of heat or excessive force should not be
required.
4. Keep work area as clean as practical, to prevent dirt and other
foreign matter from getting into bearings or other moving
parts.
5. All seals and ‘O’ rings should be discarded once they have
been removed. New seals and ‘O’ rings should be used when
assembling winch.
6. When grasping a part in a vise, always use leather-covered
or copper-covered vise jaws to protect the surface of part and
help prevent distortion. This is particularly true of threaded
members, machined surfaces and housings.
7. Do not remove any part which is a press fit in or on a
subassembly unless 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 bearing with a sleeve slightly smaller than outside
diameter of bearing. The end of sleeve or pipe which
contacts bearing must be square. Protect bearings from dirt
by keeping them wrapped in clean cloths.
Regulator Adjustment Procedure:
Refer to Dwg. MHP1865 on page 12.
1. Attach test load of desired weight to load line, or connect
load line to scale.
WARNING
• Ensure load line is connected to load and excessive slack is
taken up before activating auxiliary valve. When activated,
auxiliary valve will automatically engage and winch will
operate at full speed to set tension on load line.
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.
Winch Disassembly
Refer to Dwg. MHP0157 on page 40, MHP2093 on page 44 and
MHP0152 on page 46.
1. Remove wire rope from drum.
2. Operate winch to position reduction gear drain plug at it’s
lowest position.
Setting with scale:
3. Relieve pressure in air lines by operating winch control
several times after air supply has been turned off.
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.
WARNING
• Shut off, bleed down and disconnect air supply line before
performing any disassembly procedures.
4. Disconnect and tag air lines.
5. Remove winch from its mounting and take to a suitable work
area before beginning disassembly.
6. Remove lower case drain plug (225) on K5B motor housing
(217) and allow oil to drain into a suitable container. Loosen
fill cap (210) to vent motor housing.
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7. Drain oil from reduction gear assembly by removing one
plug (48) when positioned at it’s lowest point, and one plug
(48) from it’s highest point to vent. Refer to Dwg. MHP0140
on page 20 in “LUBRICATION” section. If winch is
equipped with a drum band brake elevate winch outboard
end (opposite from motor end) to prevent draining oil from
contaminating brake band lining.
8. For winches with a disc brake remove pipe plug (24) in
brake housing (21) to drain brake oil.
9. Remove drum band brake, drum guard and any other
externally mounted winch attachments.
To disassemble reduction gear refer to Reduction Gear
Disassembly section.
Manual or Automatic Drum Brake Disassembly
Refer to Dwg. MHP0153 on page 48.
1. Automatic Brake
a. Disconnect and remove hose, fittings and dump valve
(112) from cylinder (110).
b. Remove cotter pin (102) and pin (101) from link stud
(103) and brake band (128).
c. Remove cotter pin (102), washers (129) and pin (106).
Separate clevis (107) from brake lever (105).
d. Remove cotter pin (102) and pin (134). Remove
cylinder (110) from bracket (118).
WARNING
• The K5B air motor weighs approximately 260 lb. (118 kg).
Adequately support air motor before removing motor
mounting capscrews.
2. Manual Brake:
a. Remove cotter pin (102) and pin (101) from handle
(104) then remove handle (104) from brake band (128).
3. Remove capscrews (119), lockwashers (117) and stop plate
(126).
4. Use a hoist to raise winch approximately 6 inches (15 cm).
Separate brake band (128) halves and rotate brake band
assembly slowly until it can be removed from drum (80).
5. Remove cotter pins (102) and pins (121) so brake band
halves (128) can be removed from arm (124). Lower winch
when brake band assembly has been removed.
6. Refer to ‘Brake Lining Instruction Sheet’ (Form
MHD56142) for brake lining replacement procedures.
10. Remove capscrews (4) and lockwashers (3) securing motor
assembly to motor adapter (6). Using a hoist to support
motor, pull motor straight away from winch. Reference the
applicable Motor Disassembly section if motor disassembly
is required.
Instructions 11 through 17 apply only to winches with a disc
brake.
11. Alternately and evenly loosen eight capscrews (1) until brake
spring tension has been released. Remove capscrews and
motor adapter (6).
Reduction Gear Disassembly
12. Remove brake housing (21). If brake housing sticks, tap it
with a soft faced hammer until parts separate.
Refer to Dwg. MHP0157 on page 40.
Note position of all brake parts for reassembly.
NOTICE
13. Remove three friction plates (16) and two drive plates (17).
14. Remove springs (9) from brake piston (10).
15. Remove brake piston (10) from brake housing (21). Tap
lightly with a plastic mallet to separate parts if necessary.
16. Remove seals (11) and (12) from brake piston (10).
17. Loosen capscrew in collar (18) and slide collar from shaft
(35) with splined hub (19) and spacer (34) from shaft (35).
18. Remove retainer ring (36) from bore of drum shaft (41).
19. Pull shaft and bearing assembly from drum shaft (41).
20. Support drum (80) and remove capscrews (39) from drum
shaft (41). Pry drum shaft (41) from inboard upright (42).
21. Remove capscrews (85) and lockwashers (86) which secure
side rails (82) and (83) to inboard upright (42). Drive out
dowel pins (87).
22. Remove inboard upright (42).
23. Remove end cover (95), capscrews (97) and lockwashers
(96) from outboard upright (84).
24. Remove capscrews (93) and shaft retainer (92) from drum
(80).
25. Remove drum and reduction gear assembly.
26. Remove remaining capscrews (85) and lockwashers (86)
which attach side rails (82) and (83) to outboard upright
(84). Drive out dowel pins (87).
• It is important to maintain a clean work area when reduction
gear assembly is disassembled.
1. Place reduction gear assembly on a clean work bench such
that end containing bearing (49) is down.
2. Remove capscrews (75) and pry off cover (73).
3. Remove ring gear (72), planet assembly (67) and sun gear
(69).
4. Remove and discard ‘O’ rings (62) from ring gear (72).
5. Remove four pins (74) from between cover (73) and spacer
(71) and store in a safe place.
6. Remove spacer (71), ring gear (63) and sun gear (66).
7. If required, remove thrust plate (55) from sun gear (66).
Remove and discard ‘O’ rings (62) from ring gear (63).
8. Remove capscrews (60) from input housing (59). Separate
input housing from gear carrier (47).
9. Remove planet assembly (58).
10. Remove ring gear (53). Remove three dowel pins (52) from
between input housing (59) and gear carrier (47) and store in
a safe place.
11. Remove and discard ‘O’ rings (51) from ring gear (53).
12. Remove retainer ring (57) and sun gear (56). If required,
remove thrust plate (55) from sun gear.
13. Remove planet assembly (54).
14. Remove retainer ring (50) and bearing (49) from gear carrier
(47).
27. Remove bearing (49) and seal (99) from outboard upright
(84).
28. Remove capscrews (45) and lockwashers (46) securing gear
carrier (47) to drum (80).
29. Install two 3/4 inch - 10 NC x 3 inch long capscrews into
threaded holes in outer bolt pattern ring of gear carrier (47).
Use these capscrews to break seal. Remove reduction gear/
gear carrier assembly from drum (80).
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Control Valve Removal and Replacement
NOTICE
Refer to Dwg. MHP2036 on page 50 or MHP0165 on page 54.
Replacement of K5B control valve with K5C2 control valve.
1. Turn off air supply to valve and disconnect main air supply
line at motor.
2. Disconnect auxiliary air line(s) from fitting(s) located on
control valve.
3. Remove muffler and/or exhaust piping.
4. Remove capscrews (1) and (255), and washers (96) from
exhaust flange cap (254). Discard gasket (317).
5. Remove capscrews (257) and washers (96) from control
valve.
• Do not disassemble planetary gear assemblies (54), (58) and
(67).
K5B Motor Disassembly
Refer to Dwg. MHP2093 on page 44.
1. Remove five capscrews (1) from exhaust flange (253) or
(254). Do not remove the two capscrews (255) from throttle
valve assembly (260).
2. Remove rotary valve housing (247) by pulling it out of
motor housing (217) as an assembly with exhaust flange
(253) or (254).
6. Remove control valve from rotary housing and discard
gasket (248).
7. Install gaskets (946) and control valve assembly (900)
securing with capscrews (951) and washers (949).
8. Install gasket (970) and exhaust cap (971) to rotary housing
on motor.
9. Install fittings (957), (958) and muffler (959) on control
valve. These are optional parts.
CAUTION
• Do not remove the exhaust flange (254) until rotary valve
(250) has been removed from rotary valve housing (247).
3. Remove rotary valve (250) by pulling it out from assembly
through the motor housing end of rotary valve housing (247).
4. Remove exhaust flange (254) and throttle valve assembly
(260) by removing capscrews (255) and (257), respectively.
5. Remove each cylinder head (201) by removing four
capscrews (200). Remove head gasket (209).
K5C2 Control Valve Disassembly
Refer to Dwg. MHP2036 on page 50.
Handle Removal
6. Pull cylinder liner (208) straight out.
It is not recommended to disassemble handle.
1. Carefully pry off plug (935).
2. Remove capscrew (901) and tablock washer (909).
7. Position piston (204) at top of its stroke. In this position,
with cylinder liner pulled out in step 7, wrist pin (203) can
be removed. Remove one retainer ring (205) from either side
of piston (204). Push wrist pin (203) out by hand from one
side. If wrist pin is too tight it is acceptable to carefully heat
piston to 200° F (93° C) or less and then push wrist pin out.
NOTICE
• Observe spring (937) connection during disassembly. This
spring is under tension and is required to return handle to
neutral position.
NOTICE
3. Carefully pull handle assembly (930) from reverse valve
(943). Remove spring (937).
• If piston, wrist pin, connecting rod or cylinder liner are to be
re-assembled, number each set. Also add radial alignment
marks for each piston and cylinder liner to motor housing.
Reverse Valve Removal
8. Remove remaining cylinder liners and pistons as described in
steps 7 and 8. To remove crank assembly, all pistons and
cylinder liners must be removed.
9. Crank assembly (231) can now be removed with oil slinger
(230) by pulling straight out from motor housing (217). Use
care while guiding connecting rods (206) through inside of
motor housing.
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 (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).
4. Remove bushing (944) out exhaust flange side of housing.
Crankshaft Disassembly
1. Remove cotter pin (236) and pin nut (237).
2. Remove lock pin (235) by carefully driving it out of its
location. Use care not to damage pin threads.
NOTICE
3. Pull crankshaft valve end (231) off crankshaft.
4. Remove connecting rod rings (234), connecting rod bushing
(233), sleeve (232) and connecting rods (206). Record five
connecting rod (206) numbers and foot directions so they
can be re-installed in same order.
5. Oil slinger (230) does not have to be removed unless
damaged. If removal is required, heating of five screws (229)
may be necessary to loosen Loctite® connection.
• 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).
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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).
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.
4. Remove bushing (944) out exhaust flange side of housing.
NOTICE
• 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.
Pilot Valve Removal
Piston Removal
NOTICE
Follow disassembly instructions for K5C2 Control Valve.
• For easier removal it is recommended to use IR pilot valve
tool (920). This must be purchased separately.
Pilot Valve Removal
If pilot valve is not damaged it is not necessary to disassemble
completely.
Follow disassembly instructions for K5C2 Control Valve.
1. Remove plug (912).
2. Remove pilot valve assembly (910) as an assembly.
3. Discard and replace pilot valve assembly (910) if necessary.
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.
K5B Control Valve Disassembly (old style)
Refer to Dwg. MHP0165on page 54.
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.
NOTICE
• Match mark throttle valve parts to ensure proper re-
assembly.
1. Remove two capscrews (302) and lockwashers (96) that hold
the valve body retainer (305).
2. Mark square end on valve body (316) and handle (300) to
ensure correct orientation during reassembly.
3. Drive out pin (301) and remove handle (300).
4. Make note on how spring (303) is positioned before
removing it. Pull valve body (316) out of valve bushing
(314) while disconnecting spring (303).
NOTICE
• Cover (719) retains spring (718). To remove capscrews (901)
and washer (902) unscrew in a crisscross pattern.
4. Remove adjusting screw (720).
5. Remove seal rings (315) from valve body (316).
6. Check parts for score marks or wear.
Cleaning, Inspection and Repair
7. Measure clearance between valve bushing (314) and valve
body (316). Clearance between valve bushing and valve
body should not exceed 0.002 inch (0.05 mm) or excessive
air leakage will occur.
Clean all winch component parts in solvent (except drum brake
bands and disc brake friction plates). The use of a stiff bristle
brush will facilitate removal of accumulated dirt and sediments on
housings, frame and drum. If bushings have been removed it may
be necessary to scrape old Loctite® from bushing bores. Dry each
part using low pressure, filtered compressed air. Clean drum
brake band using a wire brush or emery cloth. Do not wash drum
brake band in solvent. If drum brake band lining is oil soaked, it
must be replaced.
K5C2-E Control Valve Disassembly
Refer to Dwg. MHP 2180 on page 52.
Handle Removal
Inspection
Follow disassembly instructions for K5C2 Control Valve.
All disassembled parts should be inspected to determine their
fitness for continued use. Pay particular attention to the
following:
Reverse Valve Removal
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 shaft.
4. Inspect all threaded items and replace those having damaged
threads.
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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5. Inspect drum band brake lining for oil, grease and glazing. If
drum band brake lining is oil-soaked replace brake bands as
a set. Remove glazed areas of band brake lining by sanding
lightly with a fine grit emery cloth.
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.
6. Measure thickness of drum band brake lining. If drum brake
band linings are less than 0.062 inch (2 mm) thick anywhere
along edges replace brake bands (128) as a set.
NOTICE
7. Inspect cylinder bores. Minor scratches in bore lining may
be repaired by lightly honing to remove. Refer to tolerances
listed below for acceptable clearances. Replace liner if deep
scratches or gouges are apparent. Measure inside diameter of
liner. If measurement is greater than 4.764 inches (121 mm)
replace liner. ‘Ring Gap’ may also be used to determine
wear; place compression ring into liner, using a piston, push
ring until approximately half way in liner and measure ‘Gap’
— 0.003 inch (0.076 mm) is normal; replace rings, or liner,
if ‘Gap’ exceeds 0.020 inch (0.51 mm).
• 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).
7. Secure exhaust flange (955) to valve housing with capscrews
(901) and washers (902).
Repair
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).
Actual repairs are limited to removal of small burrs and other
minor surface imperfections from gears and shafts. 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.
2. Inspect all remaining parts for evidence of damage. Replace
or repair any part which is in questionable condition. Cost of
the part is often minor in comparison with cost of redoing
job.
3. Smooth out all nicks, burrs, or galled spots on shafts, bores,
pins, or bushings.
Pilot Valve Assembly
NOTICE
• For easier installation it is recommended to use IR pilot valve
tool (920). This must be purchased separately.
4. Examine all gear teeth carefully, and remove nicks or burrs.
5. Polish edges of all shaft shoulders to remove small nicks
which may have been caused during handling.
6. Remove all nicks and burrs caused by lockwashers.
1. Install pilot valve assembly (910).
2. Apply thread sealant Loctite 567® to pilot valve assembly
(910), 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.
Assembly
3. Insert plug (912) and tighten.
General instructions
•
•
•
Use all new gaskets and seals.
Replace worn parts.
Piston Assembly
Assemble parts using match marks attached during
disassembly. Compare replacement parts with originals to
identify installation alignments.
Lubricate all internal parts with rust and oxidation inhibiting
lubricant, ISO VG 100 (SAE 30W).
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).
K5C2 Control Valve Assembly
Refer to Dwg. MHP2036 on page 50.
Reverse Valve Assembly
1. Insert reverse valve (943) into bushing (944) with ball slot
oriented UP, approximately 2-1/2 in. (64 mm).
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).
Handle Assembly
1. Place spring (937) over reverse valve handle end in seal
bracket.
3. Insert ball (916) onto reverse valve platform. With finger,
push ball (916) in housing until ball hits end of reverse
valve.
NOTICE
• Spring (937) will have to be ‘Cocked’ over stud in seal
bracket. This will ensure handle returns to neutral.
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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.
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.
Pilot Valve Assembly
Follow assembly instructions for K5C2 Control Valve.
Piston Assembly
Follow assembly instructions for K5C2 Control Valve.
Handle Assembly
Follow assembly instructions for K5C2 Control Valve.
K5B Control Valve Assembly (old style)
Refer to Dwg. MHP0165 on page 54.
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.
NOTICE
• During assembly align parts using match marks made
during disassembly.
• This valve is no longer available and should be replaced with
K5C2, if necessary.
5. Tighten adapter until snug, do not over tighten.
Overload Valve Assembly
1. Install seal rings (315) on each end of valve body (316).
2. Install valve body (316) into valve bushing (314).
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).
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).
NOTICE
• Valve bushing (314) is shown exploded for reference ONLY.
7. Replace gasket (714).
3. Install valve body retainer (305) with two capscrews (302)
and lockwashers (96). Torque capscrews to 25 ft lbs (34 Nm).
4. If removed, reinstall spring retaining stud (306) and torque
to 25 ft lbs (34 Nm).
NOTICE
5. Install spring (303) and handle (300) on square shaft of valve
body. Spring (303) ends must straddle spring retaining stud
on throttle handle. Install roll pin (301).
6. Check throttle handle moves fully left and right without
sticking or binding. Throttle handle should center, by spring
force, automatically when released.
• Cover (719) retains springs (718), adjustment nut (717) and
plate (715). Insert capscrews (902) and washers (901) in a
crisscross pattern until tightened evenly.
8. Insert adjusting screw (720), refer to ‘OPERATION’ section
for overload valve adjustment.
9. Secure Control Valve Assembly to intake manifold using
capscrews (951) and washers (949). Use new gaskets (946)
between control valve and manifold.
10. Test control valve for proper operation. Lift slide handle and
move handle all the way in one direction and release hand.
Control handle should return and lock in the neutral position.
Repeat for other direction.
K5C2-EX Control Valve Assembly
Refer to Dwg. MHP2180 on page 52.
Reverse Valve Assembly
11. Connect brake line.
12. Connect air supply line.
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).
4. Lubricate ‘O’ rings (942) and place in grooves in exhaust
flange (955).
K5B Motor Assembly
Refer to Dwg. MHP2093 on page 44.
1. Assemble throttle valve assembly (260), gasket (248) and
exhaust flange (254) to rotary valve housing (247) using four
capscrews (257) and lockwashers (223). Install two
capscrews (255) and lockwashers (223) that attach exhaust
flange (254) to throttle valve housing.
2. Tighten capscrews (255) and (257) to 25 ft lbs (34 Nm).
Throttle handle should move fully left and right without
sticking or binding, and should center (by spring force)
automatically when released.
5. Secure exhaust adapter with exhaust flange to valve housing
with capscrews (721) and washers (902).
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).
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3. 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 bearing inner race.
With rotary valve housing (247) exhaust flange down, install
rotary valve into housing.
4. Install ‘O’ ring (244) into motor housing (217).
5. Install rotary valve housing gasket (243) onto rotary valve
housing. With exhaust flange down on bench, install motor
housing (217) onto rotary valve housing. Check for any
evidence of damage to ‘O’ ring when rotary valve housing is
fully engaged. Install and tighten capscrews (1) to 50 ft lbs
(68 Nm).
6. If removed, press crank bearing (228) on crank assembly
(231). Apply pressure only on inner race of bearing.
7. Place crank assembly on a work bench with oil slinger (230)
down and slide the sleeve (232) (with tang up) on crankpin.
8. Slide connecting rod bushing (233) over sleeve (232) and
first connecting rod ring (234) with chamfer up.
9. Install connecting rods (206) in same order as removed, with
all feet pointing in same direction, using first connecting rod
ring (234) to hold one side of connecting rod feet.
10. Slide second connecting rod ring over other side of
connecting rod feet with chamfer on ring facing down
(toward stem of connecting rod).
NOTICE
• ‘O’ ring, item 5 listed in step 24 refers to part number 51459
as shown on winch assembly Dwg. MHP0157 on page 40. This
part must be placed between mounting flange (216) and motor
adapter (6).
25. Temporarily install capscrews and nuts finger tight to retain
motor adapter (6).
26. Install eye bolts (213) and vent cap assembly (210) in motor
housing.
27. Ensure oil drain and level plugs (225) are installed.
Reduction Gear Assembly
Refer to Dwg. MHP0157 on page 40.
NOTICE
• It is important to maintain a clean work area when reduction
assemblies are reassembled. During reassembly clean each
part thoroughly and lightly coat with appropriate lubricant as
“LUBRICATION” section.
11. Slide crank shaft valve end over crank pin while
simultaneously aligning tang on sleeve (232) with slot in
crank shaft.
1. Install bearing (49) and retainer ring (50) in gear carrier (47).
2. Lubricate and install ‘O’ rings (51) on ring gear (53).
3. Align capscrew holes and dowel pins with gear carrier (47)
and install ring gear (53). Ensure ‘O’ rings are not damaged
during installation.
12. Rotate and position crank shaft valve end relative to crank
pin to allow installation of lock pin (235).
13. Tap lock pin (235) in place and install pin nut (237). Torque
nut to 60 ft lbs (81 Nm).
14. Install cotter pin (236) and bend ends over.
15. Install roll pin (240) and bearing (228) into valve end of
crank shaft.
16. Check that all connecting rods move freely around crank.
Position crank assembly into motor housing (217). Ensure
bearing (228) is seated and connecting rods (206) are
centered in cylinder holes.
4. Install planet assembly (54).
5. Install thrust bearing (55) into sun gear (56). Install retainer
ring (57) on sun gear and locate in planet assembly (54).
6. Align capscrew and dowel holes and install input housing
(59). Apply a light coating of Loctite® 262 to capscrew (60)
threads and install by hand. Equally tighten capscrews in a
diametrically opposed pattern to allow for equal compression
of housing onto ring gear (53) and gear carrier (47). When
ring gear and input housing flanges are flush with gear
carrier torque capscrews to 95 ft lbs (128 Nm).
NOTICE
• Make certain roll pin (240) and three lugs on rotary valve
(250) line up with corresponding hole and lugs on crank shaft.
• Do not allow rotary valve to slide back in rotary valve
housing (247). If rotary valve slides in too far, seal ring (251)
will lock-up in internal grooves of rotary valve housing (247)
and restrict further assembly.
7. Install dowel pins (52) and tap into position until slightly
below input housing flange.
8. Install planet assembly (58) onto sun gear (56).
9. Lubricate and install ‘O’ rings (62) on ring gear (63).
10. Install dowel pins (70) in ring gear (63) so they extend an
equal distance on both sides of ring gear.
11. Align capscrew holes and dowel pins and install ring gear
(63) on input housing (59). Using a soft hammer or mallet,
carefully tap dowel pins and ring gear (63) onto input
housing until mating flanges are flush. Ensure ‘O’ rings are
not damaged during installation.
17. Rotate 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 connecting rod with wrist pin (203) and
retaining rings (205).
18. Install a new cylinder head gasket (209) before installing
cylinder liner (208).
12. Place thrust bearing (55) in sun gear (66) and install sun gear
into planet assembly (58).
19. Install cylinder liner over the piston by compressing both
piston rings and with a single band ring compressor.
20. Install cylinder head (201) over cylinder and secure cylinder
head to motor housing with four capscrews (200). Torque
capscrews to 60 ft lbs (81 Nm).
21. Repeat Steps 17 through 20 with remaining cylinders.
22. Rotate motor by hand. Motor should rotate without binding.
23. Install mounting flange (216) and gasket (226) on front of
motor housing. Make sure notches on both parts are aligned.
24. Lightly lubricate ‘O’ ring (5) and install in groove on motor
adapter (6).
13. Install planet assembly (67) onto sun gear (66).
14. Align capscrew holes and dowel pins and install spacer (71)
onto ring gear (63). Using a soft hammer or mallet, carefully
tap spacer onto ring gear until mating flanges are flush.
Ensure ‘O’ rings are not damaged during installation.
15. Lubricate and install ‘O’ rings (62) on ring gear (72).
16. Using a soft hammer or mallet, carefully tap ring gear (72)
onto spacer (71). Ensure ‘O’ rings are not damaged during
installation.
17. Install sun gear (69) in planet assembly (67).
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18. Align capscrew and dowel holes and install cover (73). Use a
soft hammer or mallet to carefully tap the cover until flush
with ring gear (72). Apply a light coating of Loctite® 242 to
capscrew (75) threads and install by hand. Equally tighten
the capscrews in a diametrically opposed pattern to allow for
equal compression of cover onto ring gear (72) and spacer
(71). When cover, ring gear and spacer flanges are flush
torque capscrews to 32 ft lbs (42 Nm).
19. Install dowel pins (74) and tap into position until slightly
below cover flange.
20. Place a bead of Loctite® 515 sealant on surface which mates
with gear carrier. Sealant location should be inside bolt
pattern.
14. Install one brake spring (9) in each brake spring holes.
15. Lubricate and install ‘O’ ring (33) in groove on brake
housing (21).
NOTICE
• ‘O’ ring, item 33 listed in step 15 refers to part number 51460
as shown on disc brake Dwg. MHP0152 on page 46. This part
must be placed between brake housing (21) and motor adapter
(6).
Brake Seal Installation
21. Align capscrew and dowel holes and install reduction gear
assembly into drum. Apply a light coating of Loctite® 242 to
capscrew (45) threads and install capscrews and lockwashers
(46). Torque capscrews to 255 ft lbs (346 Nm).
22. Install two dowel pins (87) and tap into position until
slightly below gear carrier flange.
23. Apply thin coat of Loctite® 609 to outside of seal (43) and,
with seal lip facing out, install in gear carrier (47).
Winch Assembly
Refer to Dwg. MHP0157 on page 40.
1. Clean both mating surfaces on inboard upright (42) and
install drum shaft (41) through bore aligning dowel pin
holes.
2. Install dowel pins (40) flush or slightly below surface of
drum shaft (41).
(Dwg. MHP0139)
3. Install eight capscrews (39). Lightly coat capscrew threads
with Loctite® 242 and torque to 80 ft lbs (108 Nm).
4. Press bearing (37) onto shaft (35). Lightly coat inner bearing
race bore with Loctite® 609. Install retainer ring (38).
5. Install shaft and bearing into drum shaft (41) so smaller
splined end enters first. Install retainer ring (36) in bore of
drum shaft (41).
17. Install brake reaction plate (8) in motor adapter.
18. Install seal adapter (15) in mounting flange (216), if
required.
19. Two threaded holes in motor adapter (6) are centered
between mounting bolt holes. Install motor adapter with
these two holes in 6 o’clock position.
20. Secure motor adapter with eight capscrews (1) using
Loctite® 242. Torque to 125 ft lbs (170 Nm). On winches
with a disc brake install capscrews evenly to compress brake
springs, and torque to 80 ft lbs (108 Nm). Do not allow plate
to become cocked. Evenly hand tighten all capscrews before
applying final torque.
21. On disc brake equipped winches install shaft extender (7) on
end of shaft (35). On winches without disc brake install seal
sleeve (14) on shaft (35).
Instructions 6 through 17 cover winches with a disc brake.
For winches without a disc brake skip to instruction 18.
6. Install spacer (34) on shaft (35). Install splined hub (19) so
splined side on outside diameter goes on first. Install
capscrew in locking ring (18) and place on shaft (35).
Maintain pressure on locking ring to keep it against splined
hub (19) and tighten capscrew in locking ring (18).
7. Lubricate and install ‘O’ ring (33) on hub of drum shaft.
8. Install brake housing (21) on drum shaft (41) being careful
not to damage ‘O’ ring (33).
9. Position brake housing so brake port is in the 2 o’clock
position (as viewed from the motor end). Install drain plug
(24) in brake housing at the 6 o’clock position.
10. Install fitting (22) and breather (23) in the top of the brake
housing.
22. Lubricate and install ‘O’ ring (5) in groove on motor adapter.
23. Ensure seal adapter (15) and oil seal (2) are installed in bore
of motor assembly. Seal lip must face into motor assembly.
WARNING
• The air motor weighs approximately 260 lb. (118 kg).
Adequately support air motor while installing motor
mounting capscrews.
11. Lubricate friction plates (16) with a light motor oil (refer to
“LUBRICATION” section). Install friction plates (16) and
drive plates (17) in brake housing. Begin with a friction plate
then alternate with drive plates between friction plates.
Ensure splined teeth mesh. Do not force plates into place
during installation.
24. If motor assembly is being mounted with winch in a vertical
position, install one short bolt and nut to keep motor
mounting flange from dropping off. Lower motor assembly
carefully onto the shaft. Position throttle assembly at the top.
Be careful not to damage oil seal (2). When correctly
positioned remove bolt and nut and lower motor assembly the
remaining distance.
12. Lubricate and install seals (11) and (12) in brake piston (10)
grooves so seal lips face each other. Do not overstretch seals
during this procedure. Refer to Dwg. MHP0139 on page 35.
13. Install brake piston assembly in brake housing so stepped
side enters first. Gently tap into position using a soft mallet
until seated.
MHD56037 - Edition 5
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25. Install the motor assembly to motor mounting plate using
capscrews (4) and lockwashers (3). Lightly coat capscrew
threads with Loctite® 242 and torque to 85 ft lbs (115 Nm).
26. On winches with a disc brake install fitting (31) in dump
valve (30) and screw into brake release port. Install vented
fitting (29) in dump valve (30). Install fitting (25) in valve
assembly (260) with elbow (26). Install steel tube (27)
between fitting on dump valve (30) and elbow (26).
9. Install stop plate (126) on inside of side rail (82) with
capscrew (119) and washer (117). Install adjusting screw
(127) and locknut (120) through side rail (82) and stop plate
(126) until it contacts arm (124). Refer to Dwg. MHP0173
on page 36.
FA5 Band Brake Components
Drum Assembly
1. Stand drum in an upright position. Align splines and
carefully lower inboard upright and drum shaft assembly
onto drum (80).
2. Using a ‘C’ clamp, secure inboard flange assembly to drum
flange and set complete assembly in a horizontal position.
3. Clean seal surface and install oil seal (99) in outboard
upright (84) with lip toward drum.
4. Pack bearing (49) with grease and install in outboard upright
(84).
5. Install outboard upright (84) on drum end. Ensure assembly
is kept centered on seal and journal during this step.
6. Install shaft retainer (92). Secure by installing three
capscrews (93). Lightly coat capscrew threads with Loctite®
242. Torque to 30 ft lbs (41 Nm).
(Dwg. MHP0173)
7. Install spacer (91).
NOTICE
8. Apply a light coat of Loctite® 515 sealant to mating surface
of outboard upright (84) and install end cover (95). Secure
using six capscrews (97) and lockwashers (96). Lightly coat
capscrew threads with Loctite® 242. Torque to 30 ft lbs (41
Nm).
9. Install pipe plug (98) in end cover (95).
10. Install side rails (82 and 83) to uprights (42 and 84) and
loosely secure using capscrews (85) and lockwashers (86).
11. Tap dowel pins (87) into position until flush with side rails.
12. Tighten eight capscrews (85) evenly. Torque to 140 ft lbs
(190 Nm).
• On FA5T winches install stop plate (126) at top edge of side
rail (82). Refer to Dwg. MHP0174 on page 36
in “MAINTENANCE” section.
FA5T Band Brake Components
13. Mount winch to foundation as described in ‘Mounting’.
Drum Brake Assembly
Ref. Dwg. MHP0153 on page 48.
1. Install pivot bracket (122) on end of arm (124) with pin (121)
and cotter pin (102). Recessed side of threaded hole must be
toward brake band side.
2. Install connecting link (125) on arm and secure in position
with pin (121), washer (123) and cotter pin (102). Bend ends
of cotter pin over to secure. Assemble connecting link so
curved surface matches contour of brake band.
3. Install halves of brake band (128) to connecting link and
secure with pins (101), (121) and cotter pins (102). Bend
ends of cotter pin over to secure.
4. Lift winch assembly, with a suitable hoist, approximately 6
inches (15 cm) off floor or work bench.
5. Position brake band subassembly around brake diameter on
drum (80) until arm lays at bottom. When positioned, lower
winch.
6. Mount pivot bracket on inside surface of side rail (83) and
secure in position with capscrews (116) and lockwashers
(117).
7. Screw link stud (103) into handle (104) and install handle
(104) in lug on end of brake band (128). Lubricate pivot
points being careful not to get grease on brake band lining.
8. Pull halves of brake band together and install pin (101)
through lug on band (128) and link stud (103) of handle
assembly.
(Dwg. MHP0174)
Automatic Drum Brake Actuator Assembly
1. Install bracket (118) on side rail (83) with capscrews (116)
and lockwashers (117).
2. Screw nut (108) and clevis (107) onto cylinder rod.
3. Attach brake lever (105) to brake band (128).
4. Install cylinder (110) so it connects with bracket (118) and
brake lever (105). Use pins (106) and (134), washers (129)
and cotter pins (102) to secure in position.
5. Install dump valve (112), fittings and hose (113) and (115) to
the cylinder (110).
page 26 in the “MAINTENANCE” section.
36
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Testing
Operational Test
Prior to initial use, all new 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
without load, in both directions, for 15 minutes at 100 - 200
RPM.
3. New Drum Brake Band Lining Run-in Procedure: All new
drum brake band linings require a ‘run-in’ period. Operate
the winch without load in the payout direction while
gradually applying the brake. Allow the brake to slip for
approximately one minute. Winch motor may stall as drum
brake band lining fully engages. Do not allow brake to
overheat.
4. Check operation of brakes. Adjust if necessary as described
in the “MAINTENANCE” section.
5. Check operation of limit switches, locking mechanisms and
all safety devices when equipped.
6. Check foundation mounting fasteners are secure.
7. Install drum guard when provided.
Load Test
Prior to initial use, all new or extensively repaired 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 winch. Test loads shall not be less than
100% of rated line pull and should not exceed 125% of rated line
pull. To test winch at 125% of rated load apply following load
with wire rope on the first layer of the drum:
FA5 Winch
FA5T Winch
19,970 lb. (9,058 kg)
19,970 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 of the USA.
Limit Switches
Operate winch through three complete cycles to ensure consistent
limit switch operation within +/- 2 feet (0.6 metre) of set points.
“MAINTENANCE” section to establish set points.
MHD56037 - Edition 5
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FA5 WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS
Description
Page No.
Drum, Base and Reduction Gear Assembly Drawing (Dwg. MHP0157) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drum, Base and Reduction Gear Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Drum, Base and Reduction Gear Assembly Parts List (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Muffler Assembly Drawing (Dwg. MHP2090) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
K5B Motor Assembly Drawing (Dwg. MHP2093) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
K5B Motor Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disc Brake Assembly Drawing (Dwg. MHP0152) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Disc Brake Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Drum Brake Assembly Drawing (Dwg. MHP0153) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Drum Brake Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
K5C2 Control Valve Assembly Drawing (Dwg. MHP2036) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
K5C2 Control Valve Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Emergency Stop and Overload K5C2-EX Valve Assembly Drawing (Dwg. MHP2180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Emergency Stop and Overload K5C2-EX Valve Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
K5B Control Valve Assembly Drawing (Dwg. MHP0165) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Full Flow Remote Control Valve Assembly Drawing (Dwg. MHP2092) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Remote Pilot Air Control (optional) Assembly Drawing (Dwg. MHP0167) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Remote Pilot Air Control (optional) Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Remote Pendant Assembly Drawings (Dwg. MHP2346 and MHP1677) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Remote Pendant Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Pilot Air Control Valve (optional) Assembly Drawing (Dwg. MHP0141) and Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Drum Locking Pin (optional) Assembly Drawing (Dwg. MHP0155) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Drum Guard Assembly Drawing (Dwg. MHP0154) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Emergency Stop Valve and Overload Assembly Drawing (Dwg. MHP1341) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pendant Control Assembly (optional) Drawing (Dwg. MHP0168) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Emergency Stop Overload Assembly Drawing (Dwg. MHP1488) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Emergency Stop Overload Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Limit Switch Assembly Drawing (Dwg. MHP2027) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Limit Switch Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Pilot Air Valve Plumbing Assembly Drawing (Dwg. MHP1679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Pilot Air Valve Plumbing Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Tensioning Manifold Assembly Drawing (Dwg. MHP2028) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Tensioning Manifold Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Air Preparation Assembly Drawing (Dwg. MHP0223) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Accessories Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Labels and Tags Replacement Drawing (Dwg. MHP1676) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
MHD56037 - Edition 5
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DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
Item
No.
Description
of Part
Total
Qty
Part
Number
•
•
2
3
Oil Seal
1
10
10
1
51873
50181
52379
51459
14227
10598
16354
51460
61
62
63
66
67
69
70
71
72
73
74
75
80
Plug
4
4
1
1
1
1
4
1
1
1
4
8
1
71068571
Order Item 34
See Note 1
Lockwasher
Capscrew
‘O’ Ring
4
Ring Gear
5
‘O’ Ring
Sun Gear
6
Motor Adapter
Sleeve (w/o Disc Brake)
Seal Adapter
‘O’ Ring
1
Planetary Assembly
Sun Gear
14
15
33
1
1
Dowel Pin
•
1
Spacer
Ring Gear
Reduction Gear Assembly
(includes items 35, 51-75)**
34
35
1
1
28744
Cover
10579
28738**
52298
Dowel Pin
Shaft, Drive †
Capscrew
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Retainer Ring
Bearing
1
1
Drum
51870
Wire Rope Anchors:
5/8 inch (16 mm)
3/4 inch (19 mm)
7/8 inch (22 mm)
Side Rail (Front - RH) †
Side Rail (Back - LH) †
Outboard Upright †
Capscrew
Retainer Ring
Capscrew
1
51872
52306
52000
81
8
52380
1
Pin, Dowel
2
52334
52308
Drum Shaft †
Upright, Inboard †
Seal
1
14020
82
83
84
85
86
87
88
89
91
92
93
94
95
96
97
98
99
---
---
1
1
1
8
8
10
1
4
1
1
3
8
1
6
6
1
1
1
1
see Note 1
see Note 1
see Note 1
50872
1
see Note 1
51464
•
1
Seal Sleeve*
Capscrew
2
51466
12
12
1
52829
Washer
50203
Lockwasher
Gear Carrier †
Plug, Fill and Drain
Bearing
51012
Dowel Pin
71266670
71106967-R
71028849
15458
15418
Nameplate
2
51467
Screw, Drive
Spacer
2
51455
Retainer Ring
‘O’ Ring
1
71018196
Shaft Retainer
Capscrew
15457
2
51086
Dowel Pin
3
Capscrew
50910
Ring Gear
1
End Cover
15459
Planetary Assembly
Thrust Bearing
Sun Gear
1
Lockwasher
Capscrew
50200
2
Order Item 34
71068605
51780
1
Plug
54292
Retainer Ring
Planetary Assembly
Input Housing
Capscrew
1
•
•
Seal
51463
1
Reduction Gear (old style)
‘O’ Ring Kit (includes 51 & 62)
51721
1
27347
12
•
Recommended spare for one winch, 2 years of normal operation.
* Seal sleeve, item 44 is no longer used and is not available as a replacement part. For units purchased with seal sleeves requiring
replacement contact your Ingersoll-Rand distributor or factory.
** Serial numbers A1480801 and above will have new reduction gear 28744, drive shaft 28738 and sun gear 28826. Winches with
Serial numbers below A1480801 needing reduction gear parts will have to purchase new reduction gear and drive shaft 28738.
Service kits are still available.
† These parts also come in a cold weather version. For winches with a -C in the model code, adding CH to the end of these part
numbers is required to retain winch certification. Example: Order Drive Shaft (item 35) part number 10579 as part number
10579CH.
Note 1 Refer to UPRIGHT ASSEMBLY PARTS LIST, DRUM ASSEMBLY PARTS LIST and SIDE RAIL ASSEMBLY PARTS
LIST for parts information. RH = Right Hand Side, LH = Left Hand Side as viewed from the winch motor end. Inboard is end
closest to motor; outboard is end farthest away from motor.
MHD56037 - Edition 5
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DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST (CONT’D)
UPRIGHT ASSEMBLY PARTS LIST
Inboard Upright
Total
Qty
Part
Number
Outboard Upright
(Item 84)
Total
Qty
Part
Number
(Item 42)
Standard Drum Flange (27 inch) †
Tall Drum Flange (35 inch) †
1
1
10789
10787
Standard Drum Flange (27 inch) †
Tall Drum Flange (35 inch) †
1
1
10790
10788
DRUM ASSEMBLY PARTS LIST
Drum (Item 80) With
Band Brake
Total
Qty
Part
Number
Drum (Item 80) Without
Band Brake
Total
Qty
Part
Number
Drum - Standard Flange Height (27 inches):
Drum (12 inches long) †
10860-2
10860-3
10860-5
10860-6
Drum (12 inches long) †
Drum (16 inches long) †
Drum (24 inches long) †
Drum (30 inches long) †
11378-2
11378-3
11378-5
11378-6
Drum (16 inches long) †
1
1
1
1
Drum (24 inches long) †
Drum (30 inches long) †
Drum - Tall Flange Height (35 inches):
Drum (12 inches long)
11043-2
11043-3
11043-5
11043-6
11043-9
Drum (12 inches long)
Drum (16 inches long)
Drum (24 inches long)
Drum (30 inches long)
Drum (36 inches long)
11380-2
11380-3
11380-5
11380-6
11380-9
Drum (16 inches long)
Drum (24 inches long)
Drum (30 inches long)
Drum (36 inches long)
SIDE RAIL PARTS LIST
Side Rail (Item 82)
Right Hand
Total
Qty
Part
Number
Side Rail (Item 83)
Left Hand
Total
Qty
Part
Number
Side Rail for drum with band brake:
with 12 inch Drum †
11381-2
11381-3
11381-5
11381-6
with 12 inch Drum †
with 16 inch Drum †
with 24 inch Drum †
with 30 inch Drum †
11385-2
11385-3
11385-5
11385-6
with 16 inch Drum †
1
1
1
1
with 24 inch Drum †
with 30 inch Drum †
Side Rail for drum without band brake:
with 12 inch Drum †
11386-2
11386-3
11386-5
11386-6
11386-9
with 12 inch Drum †
with 16 inch Drum †
with 24 inch Drum †
with 30 inch Drum †
with 36 inch Drum †
11386-2
11386-3
11386-5
11386-6
11386-9
with 16 inch Drum †
with 24 inch Drum †
with 30 inch Drum †
with 36 inch Drum †
†
These parts also come in a cold weather version. For winches with a —C in the model code, adding CH to the end of these part
numbers is required to retain winch certification. Example: Order Drum (12 inches long) (item 80) part number 10860-2 as part
number 10860-2CH.
42
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MUFFLER ASSEMBLY DRAWING AND PARTS LIST
K5C2 Control Valve
Muffler Assembly
K5B Motor Mufflers with Remote
Actuated Pilot Control Valve
163
355
173
172
957
958
165
169
959
171
170
K5B Motor Muffler with Round Exhaust
Manifold K5B Control Valve with Muffler
K5B Motor Muffler and K5B Control
Valve with Long Exhaust Manifold
162
161
165
169
165
169
171
171
170
170
(Dwg. MHP2090)
Item
No.
Description
of Part
Total
Qty
Part
Item
Description
Total
Part
Number
No.
172
173
355
957
958
959
of Part
Qty
Number
161
162
165
169
170
171
Pipe Elbow
Muffler
1
1
1
1
1
1
54513
71264360
71057459
71057434
50594
Pipe Elbow
Muffler
1
52103
52465
1
Reducer Bushing
Pipe Elbow
Muffler
Valve Assembly
Pipe Elbow
Pipe Nipple
Muffler
1
20993
1
71273676
71057483
52472
2
Pipe Nipple
51704
1
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K5B MOTOR ASSEMBLY DRAWING
200
201
216
2
15
202
204
205
228
205
203
202
205
206
204
203
207
208
206
200
213
210
209
213
201
214
207
229
205
208
951
900
949
209
K5C2 Valve
244
225
243
230
946
247
226
225
217
246
3
4
236
237
251
252
232
260
231
233
243
K5B Valve
234
235
251 250
240
257
96
317
231
228
253
96
1
248
255
254
1
(Dwg. MHP2093)
44
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K5B MOTOR ASSEMBLY PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
Motor Assembly
230 Oil Slinger
231 Crank Assembly
232 Sleeve
1
1
K5B-540
K5B-A516
K5B-519
K5B-511
K5B-510
HU-520
199 with Control Valve *
without Control Valve *
K5B-546M-S
K5B-546LM-S
51471
1
1
1
2
Capscrew
5
1
233 Bushing
1
Oil Seal †
51873
234 Connecting Rod Ring
235 Lock Pin
1
3
Lockwasher
Capscrew
10
10
1
50181
1
4
52379
236 Cotter Pin
1
53456
15
96
Seal Adapter †
Lockwasher
16354
237 Pin Nut
1
D02-394
54257
6
50200
240 Roll Pin
1
200 Capscrew
20
5
52317
243 Gasket
2
K5B-928
20A11CM248
53095
201 Cylinder Head
K5B-H505
K5B546-KRING
HU-514A
††
244 ‘O’ Ring
1
202
Compression Ring
1 Set
5
246 Grease Fitting
247 Rotary Valve Housing
248 Gasket
1
203 Wrist Pin
1
K5B-545
K5B-547
K5B-526EQ-RS
K5B-607A
50138
204 Piston
5
1
205 Retainer Ring
206 Connecting Rod
10
5
902A45-632
K5B-509
250 Rotary Valve Assembly
251 Seal Ring Assembly
252 Bearing
1
1 set
1
207
Oil Ring
Refer to Item 202
208 Cylinder Liner
209 Head Gasket
210 Vent Cap Assembly
213 Eye Bolt
5
K5B-L505-47
K5B-507-5
26604
253 Exhaust Flange Round
254 Exhaust Flange
255 Capscrew
1
KK5B-276M
K5B-276
54610
1 Set
1
1
2
1
1
1
3
1
2
5
2
KU-888
257 Capscrew
4
51766
214 Pipe Plug
71263297
K5B-502A
K5B-501A
54912
317
Gasket
1
K5B-275
216 Mounting Flange
217 Motor Housing
225 Pipe Plug (Drain)
226 Gasket
Not available
Order K5C2-X
Valve Assembly K5B
Valve Assembly K5C
900
1
K5C2-X
27115
K5B-592
51066
946 Gasket
949 Washer
951 Capscrew
1 set
228 Bearing
4
4
71376370
71369276
229 Button Head Screw
K5B-541
•
Recommended spare for one winch, 2 years of normal operation.
* K5B-546 with K5B-REMOTE valve includes items 1, 3, 4, 96, 200 through 252, 254, 255, 257, 260 and 317.
* K5B-546 with K5C valve includes items 1, 3, 4, 96, 200 through 253, 260 and 812.
* K5B-546L includes items 1, 3, 4, 200 through 247, 251, 252 and 253.
† When ordering Motor Assembly, also order Oil Seal (2) and Seal Adapter (15).
†† Parts not sold separately. Refer to “K5B Motor Assembly Kit List”
K5B Motor Assembly Kit List:
Item Description
Total
Qty
Part
No.
231
250
261
---
of Part
Number
Crank Assembly (Includes items 206 and 228 through 240)
Rotary Valve Assembly (includes items 251 and 252)
Piston Assembly (Includes items 202 through 205 and item 207)
Motor Gasket Kit (includes items 209, 226, 243, 244 and 248)
Air Motor Service Kit (includes items 3, 4, 200, 202, 207-209, 226, 243, 244, and 251
1
1
1
1
1
K5B-A516
K5B-526EQ-RS
K5B-A513-47
26823
•
---
71390181
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DISC BRAKE ASSEMBLY DRAWING
12
15
11
1
10
9
8
7
5
6
2
29
28
20
44
23
31
27
20
22
28
26
30
35
Note: Tee fitting for use
on units with Disc and
Auto Band Brake only.
33
36
21
19
24
16
18
17
(Dwg. MHP0152)
46
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DISC BRAKE ASSEMBLY PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
64
1
Brake Assembly (includes items 1, 7 through 32 and 44)
1
8
1
1
1
1
15
1
1
1
3
2
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
11366
51471
51873
14227
10594
10597
50751
15437
51461
51462
50772
50773
71039333
10600
55014
11322
51803
51857
51467
54688
71056972
52181
52520
55013
20770
50276
50859
51458
51460
10579
52298
18683
Capscrew (with Disc Brake)
Oil Seal
2
6
Motor Adapter
Shaft Extender
Brake Reaction Plate
Spring
7
8
9
10
11
12
16
17
18
19
20
21
22
23
24
25
Brake Piston
Seal
•
•
Seal
Friction Plate
Drive Plate
Collar
Splined Hub †
Fitting, Sleeve
Brake Housing
Fitting, Reducer Bushing
Breather
Pipe Plug
Fitting, Reducer Bushing
Fitting, Elbow
26
Fitting, Tee (for units with auto drum band brake and disc brake only)
27
28
29
30
31
32
33
35
36
44
Tubing
Fitting, Nut
Vented, Fitting
Dump Valve
Fitting, Nipple
‘O’ Ring
•
•
‘O’ Ring
Drive Shaft †
Retainer Ring
Spacer
•
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 to the end of these part
numbers is required to retain winch certification. Example: Order Drive Shaft (item 35) part number 10903 as part number
10903CH.
MHD56037 - Edition 5
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DRUM BRAKE ASSEMBLY DRAWING
(Dwg. MHP0153)
48
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DRUM BRAKE ASSEMBLY PARTS LIST
Part Number
Manual Brake Automatic Brake
Item Description
No. of Part
Total
Qty
80
82
83
Drum with band brake
1
Side Rail, Right Hand
Side Rail, Left Hand
1
Common Parts:
101 Pin †
2
4308-S
4308-S
102 Cotter Pin
103 Link Stud †
104 Brake Lever - Manual Brake †
105 Brake Lever - Automatic Brake
106 Pin
See ( )
51937 (5)
51937 (7)
1
4115
1
4127
- - -
- - -
1
21158
8609
1
- - -
107 Clevis
1
- - -
8586
108 Nut
1
- - -
50152
52384
8575
109 Breather
1
- - -
110 Cylinder
1
- - -
111
Fitting, Bushing
1
- - -
52006
51954
51029
54272
50923
52014
112 Dump Valve
113 Hose End
114 Fitting, Elbow
115 Hose (bulk)
116 Capscrew
117 Washer
1
- - -
2
- - -
1
- - -
As Req’d
- - -
3
- - -
See ( )
51008 (4)
- - -
71293005 (5)
11329
118 Bracket
1
119 Capscrew
120 Nut
See ( )
71128193 (4)
54661 (1)
71128193 (2)
54661 (2)
See ( )
121 Pin †
3
4307-S
10881
122 Pivot Bracket †
123 Washer
1
As Req’d
1
52915
Arm (27 inch Drum flange) †
Arm (35 inch Tall Drum flange)
10883
124
10884
125 Connecting Link †
126 Stop Plate
1
10882
1
1
10879
127 Screw, Adjusting
• 128 Brake Band †
129 Washer
71033104
382-29302
52914
1 Set
2
134 Pin
1
22442
•
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 to the end of these parts
is required to retain winch certification. Example: Pivot Bracket (item 122) part number 10881 should be ordered as part number
10881CH.
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K5C2 CONTROL VALVE ASSEMBLY DRAWING
903
902
904
901
955
905
Note: Brake
906
901
902
Fitting
956
907
912
910
917
947
950
962
940
918
919
902
942
901
944
916
943
960
921
922
923
954
924
951
925
949
948
945
942
935
941
946
939
938
937
920
930
909
901
957
Old Version
K5C Control Valve
Optional
958
959
0.720
New Style
Piston (922)
Shown From
Cap (906) End
(Dwg. MHP2036)
* Item 920 is not sold with any valve parts, must be purchased separately.
50
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K5C2 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
901 Capscrew
1
9
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
2
1
K5C2-X
71342034
71303408
26997
939 Seal Bracket (Note 3)
940 Tag, No FA2B
941 ‘O’ Ring
1
1
1
2
28733-S
71392757
71357198
51651
902 Washer
903 Cover, Poppet
904 Gasket, Poppet
905 Spring, Poppet
906 Cap, Poppet
907 Seal, Poppet
909 Washer, Tablock
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
71398091
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 IR Pilot Valve Tool
921 ‘O’ Ring
947 Rivet
71028849
71352777
71413355
71366348
71369276
71263297
26691
26999
948 Label, Throttle Direction
949 Washer
1
26998
4
28690
950 Plug
1
52537
951 Capscrew
4
922 Piston (Note 2)
923 ‘O’ Ring
28735-S
71355796
71271985
71348338
27239-1
71348962
26966
954 Plug
1
955 Exhaust Flange
956 Fitting
1
924 Washer
1
71367932
71273676
71057483
52472
925 Capscrew
957 Fitting, Elbow
958 Fitting, Nipple
959 Muffler
1
930 Handle Assembly
935 Plug
1
1
937 Spring
960 Label, Warning
962 Breather
1
71373229
51559
938 Buttonhead Screw
939 Seal Bracket (Note 3)
71394407
28733-S
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: For service kit descriptions and additional information on related publication(s) refer to Tables on page 76.
Note 2: Item 922 not sold separately, includes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
Note 3: Item 939 not sold separately, includes items (1) each of 901 and 909, items 924, 925, 935, 937, 938 and 941-942.
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EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE ASSEMBLY DRAWING
700
903
901
701
902
904
702
905
704
703
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
941
712
715
935
713
963
939
714
717
938
930
718
937
909
901
902
901
719
716
720
920
0.720
New Style
Piston (922)
Shown From
Cap (906) End
(Dwg. MHP2180)
52
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EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE PARTS LIST
Item Description
Total
Qty
Part
Item Description
Total
Qty
Part
No.
908
700
701
702
703
704
705
706
707
711
712
713
714
715
716
717
718
719
720
721
722
723
726
901
902
903
904
905
906
907
909
910
911
912
916
917
918
919
*
of Part
Number
No.
920
921
922
923
924
925
930
935
937
938
939
940
941
942
of Part
Number
Control Valve Assembly
Cap
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
2
1
1
1
1
1
K5C2-EX
27491
IR Pilot Valve Tool (MHP2036)
‘O’ Ring
1
1
1
1
2
2
1
1
1
2
1
1
1
3
26998
52537
Grommet
71365779
27490
Piston (Note 2)
‘O’ Ring
28735-S
71355796
71271985
71348338
27239-1
71348965
26966
Plunger
‘O’ Ring
71127039
95790099
71372601
27488
Washer
Label, Stop
Button, E-Stop
Adapter
Capscrew
Handle Assembly
Plug
Plunger
27489
Spring
Spring
71365787
27964
Buttonhead Screw
Seal Bracket (Note 3)
Tag, No FA2B
‘O’ Ring
71394407
28733-S
71392757
71357198
51651
Piston
‘O’ Ring
51768
Gasket
27493
Plate
27624
‘O’ Ring
‘O’ Ring
71365795
24374
Reverse Valve Kit (Normal)**
Reverse Valve (Reverse Bias)**
Reverse Valve (Unbiased)
Bushing (Normal)***
Bushing (Reverse Bias)***
Bushing (Unbiased)
Pin
27925-SX
28002
Adjustment Nut
Spring
943
944
1
1
71053730
27494
****
Cover
26686
Screw, Adjusting
Capscrew
‘O’ Ring
27571
27450
71365811
71138135
27540
****
945
946
947
948
949
951
954
955
956
1
71146674
27115
Adapter, Exhaust
Plug
Gasket
1 Set
27945
Rivet
2
1
4
4
1
1
1
71028849
71352777
71413355
71369276
71263297
26691
Capscrew
Washer
71342034
71303408
26997
Label, Throttle Direction
Washer
Cover, Poppet
Gasket, Poppet
Spring, Poppet
Cap, Poppet
Seal, Poppet
Washer, Tab Lock
Pilot Valve Assembly
‘O’ Ring
Capscrew
27064
Plug
71351068
28734
Exhaust Flange
Fitting
71367932
26991
Fitting, Elbow
(refer to Dwg. MHP2036)
957
958
959
1
1
1
71273676
71057483
52472
71398091
28696
Fitting, Nipple
(refer to Dwg. MHP2036)
71126825
71414817
D10-280
*
Plug
Muffler
(refer to Dwg. MHP2036)
Ball
Valve Housing
Gasket, Cover
Cover, Piston
960
963
Label, Warning
Plug
1
3
71373229
28628
26999
26998
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: For service kit descriptions and additional information on related publication(s) refer to Tables 75.
Note 2: Item 922 not sold separately, includes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
Note 3: Item 939 not sold separately, includes items (1) each of 901 and 909, items 924, 925, 935, 937, 938 and 941-942.
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K5B CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST
(old style)
(Dwg. MHP0165)
Item Description
No. of Part
Total
Qty
Part
Number
Not available; order
K5C2-X Valve
260 Valve Assembly (Includes item 96, 246 and 300 through 318)
1
96
Lockwasher
4
1
1
1
4
1
1
1
1
1
2
1
1
1
2
1
1
1
50200
53095
246 Grease Fitting
300 Handle
K5B-556
K5B-1115
71326110
K5B-412
K5B-1110A
K5B-553
K5B-869A
HLK-20
301 Roll Pin
302 Capscrew
303 Spring
305 Valve Body Retainer
306 Spring Retaining Stud
307 Latch
308 Roll Pin
309 Pipe Plug
E5UD-947
K5B-1101
25A13C92
K5B-1101
K5B-606
K5B-944
K5B-275
KK5B-276S
311 Valve Housing (matched set with item 314)
312 Roll Pin
314 Valve Bushing (matched set with item 311)
315 Seal Ring
316 Valve Body
317 Gasket
318 Flange
54
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FULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST
(Dwg. MHP2092)
Item Description
Total
Qty
Part
Number
No. of Part
1
Capscrew
5
51471
51029
113 Hose End
2
115 Hose (bulk)
243 Gasket
As Req’d
50923
1
K5B-928
KK5B-276M
K5C2-SBK
54270
253 Exhaust Cover
260 Control Valve Assembly
321 Fitting, Elbow
322 Hose End
1
1
4
4
As Req’d
1
54738
323 Hose (bulk)
819 Fitting, Elbow
54737
71018022
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REMOTE PILOT AIR CONTROL (OPTIONAL) ASSEMBLY DRAWING
113
343
324
115
324
340
113
115
552
To
Brake
552
324
324
113
324
115
97
115
96
355
335
348
358
334
333
Remote Pilot
Lever Throttle
Remote Pilot
Pendant Throttle
348
357
Old Style
Pendant Throttle
(Dwg. MHP0167)
56
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REMOTE PILOT AIR CONTROL (OPTIONAL) ASSEMBLY PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
96
97
Lockwasher
4
50200
51780
Capscrew
4
Fitting, Hose End – Disc Brake Only
Fitting, Hose End – Disc and Automatic Drum Brake
8
113
51029
10
115 Hose, Bulk
As Req’d
50923
K5B-547
52182
248 Gasket (item not illustrated)
324 Fitting, Elbow
1
6
333 Capscrew
4
54681
334 Lockwasher
4
50893
335 Manifold
1
13881
340 Fitting, Connector
343 Shuttle Valve
1
51814
1
Order item
352
346 Fitting, Connector
347 Quick Exhaust Valve Assembly
348 Fitting, Nipple
2
†
3 (6)
71048268
Order item 352
Order item 353
PHS2E
349 Hose Tie (3 for standard hose; 2 additional each 5 feet of hose)
352 Pendant Assembly*
353 Pendant Assembly
355 Valve Assembly
As Req’d
1
1
1
2
1
2
20993
357 Fitting, Elbow
51281
358 Pilot Lever Throttle Assembly
552 Fitting, Tee
71069561
54977
* Item 352 Pendant Assembly is no longer available.
† Hose length exceeding 50 feet (16 metres), contact factory.
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REMOTE PENDANT ASSEMBLY DRAWINGS
Pendant without Emergency Stop
440
444
448
453
447
445
446
449
456
470
451
455
454
443
452
457
458
(Dwg. MHP2346)
Pendant with Emergency Stop
440
442
443
444
448
453
447
446
445
446
443
456
451
441
455
449
443
454
443
452
451
452
457
458
(Dwg. MHP1677)
58
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REMOTE PENDANT ASSEMBLY PARTS LIST
Part
Item Description
No. of Part
Total
Qty
Number
With E-Stop
Without E-Stop
353 Pendant Assembly*
440 Lifting Eye
441 Emergency Stop Valve
442 Plug
1
1
PHS2E
PHS2E-U
64222332
1
95790108
95790106
- - -
1
• 443 ‘O’ Ring
444 Plug
2(5)
2(4)
2(4)
2(5)
1
58209229
54292
445 Spring
69128541
69401625
95790040
42008607
58235329
95790107
95790104
95790122
446 Ball
447 Pin
448 Setscrew
• 449 ‘O’ Ring
451 Protector
452 Valve
2
2(3)
2(3)
2(3)
2
453 Lever
454 Pendant Handle
455 Setscrew
456 Label Kit
457 Exhaust Washer
458 Retainer Ring
470 Plug
1
order item 500
71078158
95790111
3(5)
1
1
95790114
47713030
1
1
- - -
65129541
* Pendant Assembly includes items 440 to 449 and 451 to 458.
•
Recommended spare for one winch, 2 years of normal operation.
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PILOT AIR CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST
(Dwg. MHP0141)
Part Number
Item Description
No. of Part
Total
Qty
510 size
355 Valve Assembly (includes items 265 through 280)
1
1
2
1
1
8
1
2
1
1
1
1
1
1
1
1
1
20993
265 End Cap
71136725
266 Gasket
71136733
267 Valve Body
Not sold separately, order item 355
268 End Cap Assembly (includes items 270 and 271)
25591
71030118
53545
269 Capscrew
270 Adjusting Screw
271 Nut
50176
272 Shoulder Screw
54710
273 Guide
71136741
71136758
71136774
71136766
Order Kit
274 Spring
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.
60
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DRUM LOCKING PIN (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST
OLD STYLE
80
84
84
136
401
137
246
135
138
304
140
403
135
135
136
137
138
140
404
(Dwg. MHP0155)
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
27 inch Standard Flange Drum (old style)
12 inch with band brake
35 inch Tall Flange Drum (old style)
12 inch with band brake
10860–2
11378–2
10860–3
11378–3
10860–5
11378–5
10860–6
11378–6
14596–2
14596–3
14596–5
14596–6
14596–36
12 inch without band brake
16 inch with band brake
16 inch with band brake
24 inch with band brake
30 inch with band brake
36 inch with band brake
1
80
16 inch without band brake
80
1
24 inch with band brake
24 inch without band brake
30 inch with band brake
30 inch without band brake
For 12, 16, 24, 30 and 36 inch tall flange drums without
band brakes contact factory for information
Common Parts:
Outboard Upright
137 Spring
1
1
1
1
54453
16329
16310
53095
84
(27 inch Drum flange)
(35 inch Drum flange)
14946
14952
138 Gland
1
140 Pull Rod
246 Grease Fitting
135 Pin (Zinc pt.)
136 Lock Pin
2
1
71001135
16328
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DRUM GUARD ASSEMBLY DRAWING AND PARTS LIST
(Dwg. MHP0154)
Part Number
Item Description
No. of Part
Total
Qty
Standard Flange
Tall Flange
Drum Guard Assembly (includes items 3, 96 and 150 through 158)
12 inch long drum
16 inch long drum
24 inch long drum
30 inch long drum
36 inch long drum
Lockwasher
10925-2
10925-3
10925-5
10925-6
- - -
10927-2
10927-3
10927-5
10927-6
10927-9
149
1
3
4
6
6
6
2
50181
96
Lockwasher
50200
71126742
10399
150 Capscrew
151 Clamp
152 Support
10934
10935-2
10935-3
10935-5
10935-6
- - -
10931
Drum Guard (12 inch long drum)
10932-2
10932-3
10932-5
10932-6
10932-8
Drum Guard (16 inch long drum)
153 Drum Guard (24 inch long drum)
Drum Guard (30 inch long drum)
Drum Guard (36 inch long drum)
155 Nut
1
6
4
4
50198
50973
50171
156 Capscrew
158 Nut
62
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EMERGENCY STOP VALVE, OVERLOAD ASSEMBLY DRAWING AND PARTS LIST
(old style)
(Dwg. MHP1341)
Item Description
Total
Qty
Part
Item Description
Total
Qty
Part
No.
of Part
Number
No.
423
424
425
426
481
482
483
484
485
486
487
488
489
491
492
535
of Part
Number
96
Washer
2
50200
51029
50923
71057483
51704
51766
52182
51281
50177
50170
24491
51079
35790066
24490
53541
51676
Valve, Shut-off
Fitting, Nipple
Pilot Valve
1
1
1
1
1
1
1
9
1
1
7
1
2
1
1
1
25541
52191
113
115
163
171
257
324
357
412
413
414
417
418
419
421
422
Hose End
7
Hose (bulk)
Fitting, Nipple
Fitting, Nipple
Capscrew
As Req’d
71269039
24492
2
1
2
1
5
2
2
1
2
1
1
2
2
Rotary Housing
Breather
50595
Fitting, Elbow
Fitting, Tee
71034714
54081
Fitting, Elbow
Fitting, Elbow
Washer
Fitting, Elbow
Fitting, Pipe
Muffler
52179
71273676
52472
Nut
Bracket, Overload
Capscrew
Fitting, Connector
Fitting, Swivel-Tee
Capscrew
71078158
71067789
50848
Emergency Stop Valve
Bracket, E-Stop
Nut
Valve, Delta P
Fitting, Pipe
Pipe Bushing
36360002
71149355
51706
Washer
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PENDANT CONTROL ASSEMBLY DRAWING AND PARTS LIST
(old style)
(Dwg. MHP0168)
Item Description
No. of Part
Total
Qty
Part
Number
348 Fitting, Adapter
3
1
71048268
352 Pendant Assembly (includes items 370–381 and 383)
No longer available
Order item 353
370 Pendant Handle (only available as part of assembly item 352)
1
371 Throttle Valve
372 Throttle Valve Face
373 Spring
2
2
2
2
2
2
1
2
1
2
4
1
MLK-K264B
R000BR1C-283
MKL-51A
MLK-266A
MLK-504
374 Throttle Valve Cap
375 Valve Cap Gasket
376 Lever
MLK-273
377 Throttle Lever Pin
378 Pin Lock Washer
379 Support
DLC-120A
D02-138
MLK-450
380 Lockwasher
381 Handle Screw
383 Pipe Plug
H54U-352-10
HRE20A-68
54247
64
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SERVICE NOTES
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EMERGENCY STOP OVERLOAD ASSEMBLY DRAWING
(Dwg. MHP1488)
66
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EMERGENCY STOP OVERLOAD ASSEMBLY PARTS LIST
Item Description
Total
Qty
Part
Item Description
Total
Qty
Part
No.
of Part
Number
No.
486
487
488
491
515
529
531
535
537
543
548
605
616
618
620
621
625
640
of Part
Number
26
Fitting, Tee
1
52181
51029
Muffler
1
1
2
1
3
1
2
1
1
2
1
1
1
1
1
1
1
1
52472
71078158
71067789
36360002
71327316
26148
113
115
163
171
325
341
346
347
348
357
382
423
425
481
482
484
485
Hose End
26
Fitting, Connector
Fitting, Tee
Delta ‘P’ Valve
Fitting, Elbow
Bracket
Hose (bulk)
As Req’d
50923
Fitting, Nipple
Fitting, Nipple
Fitting, Elbow
Hose Assembly
Fitting, Connector
Valve, Exhaust *
Fitting, Connector
Fitting, Elbow
Fitting, Connector
Shut Off Valve
Pilot Valve
1
1
2
1
4
4
12
2
2
1
1
1
1
5
1
71057483
51704
52182
17073-6
71048284
20417
Capscrew
71327324
51706
Pipe Bushing
Fitting, Elbow
Capscrew
54237
71048268
51281
54240
Fitting, Connector
Plug
54679
52092
50860
25541
Fitting, Tee
Valve
K6U-926
54672
71269039
50595
Breather
Fitting, Elbow
Fitting, Connector
Breather
71063473
71110894
51559
Fitting, Elbow
Fitting, Elbow
Fitting, Elbow
71034714
52179
71273676
Pendant Assembly
PHS2E-U
* Must be installed at 20 foot (6 metre) intervals. Part number 20417 (item 347) includes items 113 (quantity 2), 346 and 348.
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(
LIMIT SWITCH ASSEMBLY PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
93
96
97
Capscrew
Lockwasher
Capscrew
3
51086
50200
6
6
51780
115 Hose
As Req’d
50923
357 Fitting, Elbow
484 Fitting, Elbow
4
7
1
8
2
1
4
4
1
51281
52179
501 Retainer (replaces Retainer, item 191, on standard winch)
11485
502 Washer
71372114
71393409
29102
503 Buttonhead Screw
504 Bracket, Limit Switch
505 Lockwasher
52909
506 Nut
54142
507 Coupling Assembly
52381
Limit Switch Assembly 357:1 (includes items 534, 536, 538 and 539)*
71402119
71402101
27306-3
71062475
2688
508 Limit Switch Assembly 120:1 (includes items 534, 536, 538 and 539)*
1
Limit Switch Assembly 20:1 (includes items 534, 536, 538 and 539)*
509 Capscrew
511 Plate
4
2
8
1
1
2
2
1
2
2
2
1
2
1
2
1
4
1
1
512 Capscrew
513 Block, Tall
514 Block, Short
516 Capscrew
519 Valve
71365126
27312
27311
53869
213-C
522 Access Plate
523 Lockwasher
524 Capscrew
527 Washer
3394-B
51801
71007009
50182
528 Plug
71027494
51559
532 Breather
533 Fitting, Tee
534 Lever Assembly
536 Gasket
53940
Order item 508
52382
538 Capscrew
539 Cover Plate
546 Seal
* Dash numbers 1, 2 and 3 indicate ratio for limit switch.
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PILOT AIR VALVE PLUMBING ASSEMBLY DRAWING
Note: This drawing is for Pilot Air Valve Assembly with Limit Switch. For Remote Pilot Air installation refer to Dwg. MHP0167 on page 56.
(Dwg. MHP1679)
70
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PILOT AIR VALVE PLUMBING ASSEMBLY PARTS LIST
Item Description
No. of Part
Total
Qty
Part
Number
96
97
Washer
4
4
50200
51780
Capscrew
113 Fitting, Hose End
115 Hose (bulk)
269 Capscrew
5
51029
As Req’d
50923
2
2
4
4
1
2
2
1
1
1
1
1
3
2
2
1
2
5
3
1
2
2
1
3
1
6
71030118
52182
324 Fitting, Elbow
333 Capscrew
54681
334 Washer
50893
335 Adapter Manifold
339 Fitting, Tee
340 Fitting, Connector
341 Tube Assembly
343 Valve, Shuttle
348 Fitting
13881
54678
51814
17073-6
50277
71048268
20993
355 Valve Assembly
358 Throttle Valve Assembly
360 Nut
71069561
54567
382 Fitting, Connector
482 Fitting, Elbow
484 Fitting, Elbow
525 Valve
52092
71034714
52179
51756
Fitting, Elbow (Remote Control Valve)
526
71098545
71062889
54273
Fitting, Elbow (Pendant Control)
537 Fitting, Elbow
548 Fitting, Nipple
551 Fitting, Connector
552 Fitting, Tee
554 Capscrew
54679
54274
54977
71002968
20231
555 Bracket
558 Washer
54785
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TENSIONING MANIFOLD ASSEMBLY DRAWING
(Dwg. MHP2028)
72
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TENSIONING MANIFOLD ASSEMBLY PARTS LIST
Item Description
Total
Qty
Part
Number
No.
113
115
248
260
343
701
702
703
704
705
706
707
708
709
711
712
713
714
715
716
717
718
719
721
725
726
727
728
729
732
733
734
735
736
737
738
739
741
742
743
744
745
746
753
of Part
Fitting, Hose End
Hose (bulk)
Gasket
3
As Req’d
2
51029
50923
K5B-547
K5B-REMOTE
50277
Control Valve Assembly
Shuttle Valve
Washer
1
1
4
71320964
71127054
50915
Capscrew
4
Rivet
6
Label, Tensioning Manifold
Gasket
1
26217
1
26216
Cover
1
26215
Fitting, Elbow
Fitting, Elbow
Fitting, Elbow
Capscrew
2
54869
5
52803
6
54243
3
71319073
71138051
71316434
71069017
51001
Handle Ball
Valve
1
1
Plug
2
Fitting, Elbow
Spacer
1
3
14998-8B
26149
Handle
1
Hose (bulk)
Fitting, Hose End
Washer
As Req’d
51003
4
4
1
2
1
2
1
1
1
1
1
4
4
3
1
1
1
1
1
1
1
4
51002
51581
Fitting, Bushing
Fitting, Nipple
Fitting, Elbow
Fitting, Nipple
Manifold, Control Valve
Union
51705
71308258
50928
50933
25874
71328330
71328314
71320915
71328249
51607
Fitting, Nipple
Check Valve
Fitting, Nipple
Washer
Capscrew
71320949
71069132
26095
Nut
Bracket
Fitting, Nipple
Fitting, Elbow
Regulator and Gauge *
Fitting, Connector
Fitting, Tube Extension
Fitting, Elbow
Capscrew
71320907
26057
71325047
54943
71325591
71149975
71328199
* Items not sold separately.
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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
Total
Qty
Part
No.
575
577
578
580
**
of Part
Number
Filter (1–1/2 FNPT)
Regulator (1–1/2 FNPT)
Pipe Nipple (1-1/2 FNPT*)
Lubricator (1–1/2 FNPT)
Liquidator (2 FNPT)
1
F35-0B-C28
R40-0B-G00
---
1
As Req’d
1
1
L40-0B-G00
8834-W1-000
Air preparation components for 1-1/2 inch FNPT system.
Length as required for installation.
*
** Item not illustrated.
ACCESSORIES
Description of Accessory
Lubricant
Accessory Part Number
LUBRI-LINK-GREEN®
74
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LABELS AND TAGS
(Dwg. MHP1676)
Item Description
No. of Part
Total
Qty
Part
Number
Item Description
No. of Part
Total
Qty
Part
Number
22261-4-S
Product Label 12-16 in. long drum
71111777
Label and Tag Kit *
654
1
Product Label 24 in. and longer
drum
22261-5-S
71109508
650
1
24305-4-S
24305-5-S
Warning Label
71060529
96180100
71043616
71042196
96180102
71046395
71107130
Label and Tag Kit -E *
Nameplate
655
1
Warning Label -E
656 Oil Level Label
1
1
1
1
1
Contact Fac-
tory
88
89
1
4
2
657 Exhaust Label
Drive Screw
71028849
71109516
96180103
658 Control Valve Operation -E
659 Air Supply Label
Winding Label
Winding Label -E
651
661 Warning Label (Only Non -E)
IR Logo Label 12-16 in. long
drum
71106272
662 Check Oil Level Label
1
1
71107148
71110068
652
1
1
IR Logo Label 24 in. and longer
drum
71109102
71153464
663 Underwound Direction Label
653 Label General -E
*
Kits depend on drum length. Numbers ending in -4 are for drums 12-16 inches long. Numbers ending in -5 are for drums 24 inches
or longer. -E kits contain all labels, EXCEPT item 661.
MHD56037 - Edition 5
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KITS
Description
of Kit
Part
Number
Automatic Brake Kit (converts manual band brake to automatic band brake). Refer to Dwg. MHP0153on
page 48; includes items 102, 105 through 115, 117 through 120, 129 and 134.
FA5-ABK
Disc Brake Kit (adds disc brake to winch). Refer to Dwgs. MHP0152on page 46 and MHP0157on page 40;
includes items 1, 7–12, 16–32, 34–38)
FA5-DBRK
Full Flow Remote Control Kit (converts winch live air control valve to remote control)
Refer to Dwgs. MHP2092on page 55 and MHP0165on page 54; includes items 113, 115, 253, 318, and 321–324.
with 10 feet (3.05 metres) hose
with 20 feet (6.1 metres) hose
19999-1S
19999-2S
Pendant Control Kit (converts winch live air control to pendant control). Refer to Dwg. MHP0167on page 56; includes all items, except
348, 357 and 358.
with 10 feet (3.05 metres) pendant hose
with 20 feet (6.1 metres) pendant hose
with 30 feet (9.15 metres) pendant hose
with 40 feet (12.1 metres) pendant hose
FA-PRC
FA-PRC-20
FA-PRC-30
FA-PRC-40
Limit Switch Kit (adds limit and controls to winch) Refer to Dwgs. MHP1679on page 70 and MHP2027on
page 68.
FA5-LSK
K5C2-X and K5C2-EX Control Valve Service Kits
Item
Total
Qty
Part
Number
Kit Description
No.
• 780 K5C2 Control Valve Service Kit (includes items 904, 907, 918, 921, 923, 941, 942 and 946)
1
1
1
1
1
1
27240
27239
930
784
Handle Assembly Kit (includes items 901, 902, 930 through 935)
Reverse Valve Kit (includes items 943 and 956)
27925-SX
27995-X
27994-X
28026
• 786 Overload Valve Service Kit †
• 788 Emergency Stop Service Kit*†
789
910
922
939
Emergency Stop Kit (Optional Feature)*†
Pilot Valve Assembly Kit
28696
Piston Kit
1
1
28735-S
28733-S
Seal Bracket Kit (includes items 901, 902, 924, 925, 935, 937-939, 941 and 942
•
Recommend spare for one winch, two years of normal service.
Kits can be installed to new style control valve.
*
Items not illustrated
†
76
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PARTS ORDERING INFORMATION
Use of other than Ingersoll Rand replacement parts may
adversely affect the safe operation and performance of this
product.
Return Goods Policy
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
NOTICE
2724 Sixth Avenue South
Seattle, WA 98134 USA
Phone: (206) 624-0466
Fax: (206) 624-6265
• 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.
or
• Sections of this manual may not apply to your winch.
• The use of other than genuine Ingersoll Rand replacement
parts may result in safety hazards, decreased performance
and increased maintenance and invalidate all warranties.
Ingersoll Rand
Douai Operations
529, Avenue Roger Salengro
59450 Sin Le Noble, France
Phone: (33) 3-27-93-08-08
Fax: (33) 3-27-93-08-00
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SERVICE NOTES
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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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