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MHD56305 Ed3
MHD56305 Ed3
Information
Form MHD56305
Edition 3
April 2013
71455570
© 2013 Ingersoll-Rand
Only allow Ingersoll Rand trained technicians to perform maintenance on this product. For additional information contact Ingersoll Rand factory or nearest
Distributor.
For additional supporting documentation refer to Table 1 ‘Product Information Manuals’ on page 2.
Manuals can be downloaded from http://www.ingersollrandproducts.com.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate all
warranties.
Original instructions are in English. Other languages are a translation of the original instructions.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
INSPECTION
Frequent inspections should be performed on equipment in regular service. Refer
to Product Information Manual.
n Periodic Inspection
Refer to Table 2 ‘Inspection Classifications’ on page 2 for suggested winch
inspection classifications for Periodic Inspection intervals. Select conditions most
appropriate to application.
Maintain written records of periodic inspections to provide an accumulative basis e. Inspect rope for broken strands/wires: When broken wires are evident close
for continuing evaluation. Inspect all items listed in the ‘Frequent Inspection’ section to, or within, the termination, even if few in number, are indicative of high
of the Product Information Manual. Also inspect the following at the suggested stresses at this position and can be caused by incorrect fitting of the
intervals recommended in Table 4 ‘Maintenance Interval Chart’ on page 3: termination. The cause of this deterioration shall be investigated and, where
possible, the termination shall be remade, shortening the rope if sufficient
1. Siderails and Uprights. Check for deformed, cracked or corroded main length remains for further use, otherwise the rope shall be discarded. One
components. Replace damaged parts. valley break may indicate internal rope deterioration, requiring closer
2. Fasteners. Check retainer rings, capscrews, nuts and other fasteners on winch, inspection of this section of rope. When two or more valley breaks are found
including mounting bolts. Replace if missing or damaged and tighten if loose. in one lay length, the rope should be considered for discard. If a complete
3. Drum and Sheaves. Check for cracks, wear or damage. Replace if necessary. strand fracture occurs, the rope shall be immediately discarded. Where
4. Wire Rope. In addition to ‘Frequent Inspection’ requirements, also inspect for broken wires are very close together, constituting a localized grouping of
the following: such breaks, the rope shall be discarded. If the grouping of such breaks
a. Build-up of dirt and corrosion. Clean with steam or a stiff wire brush to occurs in a length less than 6d or is concentrated in any one strand, it may
remove dirt and corrosion if necessary. be necessary to discard the rope even if the number of wire breaks is smaller
b. Loose or damaged end connection. Replace if loose or damaged. than the maximum number, refer to table on page 2
c. Check wire rope anchor is secure in drum.
d. Verify wire rope diameter. Measure the diameter of the wire rope from Table 3: Wire Rope
crown-to-crown throughout the life of the wire rope. Recording of the actual Number Broken Wires Number Broken Wires
diameter should only be done with the wire rope under equivalent loading Rope Construction in rope over a length in rope over a length
and in the same operating section as accomplished during previous Type 6x nominal diameter 30x nominal diameter
inspections. If the actual diameter of the wire rope has decreased more than
1/64 inch (0.4 mm) a thorough examination of the wire rope should be 6 x 19S-IWRC Single- 3 6
conducted by an experienced inspector to determine the suitability of the layer rope
wire rope to remain in service. Refer to Dwg. MHP0056 on page 2. 6 x 37M-IWRC Single- 10 19
layer rope
A 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
B operation or visual damage, disassemble and repair brake(s). Check all brake
surfaces for wear, deformation or foreign deposits. Clean and replace
components as necessary. Adjustments can be made to the band brake to
compensate for normal brake lining wear. Refer to
ʽAdjustmentsʽon page 7. If brake band cannot be adjusted to hold rated load,
replace the brake band assembly. Adjustments cannot be made to the disc brake.
The disc brake must be repaired as described in “MAINTENANCE”
sectionon page 7.
7. Foundation or Supporting Structure. Check for distortion, wear and continued
C ability to support winch and rated load. Ensure winch is firmly mounted and that
fasteners are in good condition and tight.
8. Control Valve. Check control valve operation. Ensure control valve handle
moves freely in both directions without sticking and automatically returns to
neutral when released. Ensure locking button moves freely and locks control
handle in neutral when not depressed.
9. Limit Switches. 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.
D Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.
10. Emergency Stop Valve . During winch operation verify the emergency stop
(Dwg. MHP0056) valve operation. Valve must stop winch operation quickly. Valve must reset
properly. Refer to ‘Emergency Stop Valve’ in the “OPERATION” section in Product
Information Manual for procedures.
11. Overload Device. Ensure overload device is properly set to stop the winch when
loads exceed 150% (+/- 25%) of winch rated capacity. If winch does not shut
down, contact your distributor or the factory for repair information.
Inspect Gearbox X X
Inspect Output Shaft X X X X X X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Press Roller X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X
* Maximum test load is 125% of rated line pull. Testing to more than 125% of rated load may be required to set overload device or comply with standards and regulations
set forth in areas outside the USA.
This form may be photo copied and used as an inspection record.
WARNING
n Adjustments
• Never perform maintenance on the winch while it is supporting a load.
• Before performing maintenance, tag controls: n Limit Switches
Refer to ʽLimit Switchesʽ section in Product Information Manual.
WARNING - DO NOT OPERATE, EQUIPMENT BEING REPAIRED.
n Disc Brake
• Only allow Ingersoll Rand trained Technicians to perform maintenance on
this winch. No brake adjustment is required. Refer to Dwg. MHP2849 on page 7, A. Piston;
• Shut off air system and depressurize air lines before performing any B. Friction Plate; C. Drive Plate; D. Reaction Plate; E. 0.047 inch minimum (1.2 mm
maintenance. minimum).
• Do not use Trichloroethylene to clean parts.
• Use of other than genuine Ingersoll Rand parts may result in safety hazards, 1. Remove motor as described in ‘Motor Removal’ section on page 8.
decreased performance and increased maintenance and may invalidate all 2. Remove the reaction plate (57), splined hub (53), friction plates (55) and (58),
warranties. and drive plates (56).
• After performing any maintenance on the winch, test winch to 125% of its 3. Inspect the friction plates (55) and (58) for wear. If friction plate thickness is
rated line pull at mid drum before returning to service. (Testing to more uneven or is less than 0.047 in (1.2 mm), replace all friction plates.
than 125% of rated line pull may be required to comply with standards and
regulations set forth in areas outside the USA.) No further disassembly is required, if only the brake friction discs are being inspected.
Ensure friction and drive plates are assembled in the correct order. Refer to ‘Disc
Brake Assembly’ on page 9.
NOTICE
• Refer to Product Information and Safety Manuals for specific information.
n General
E
Correct disassembly (to prevent loss or damage of good parts), repair, assembly, 0.047 inch minimum
testing and adjusting are critical to proper winch operation. Maintenance
procedures are technical in nature and require training and experience to (1.2 mm minimum)
accomplish correctly. In addition, repair and testing require specialized equipment
that is not typically found at the products mounting site.
Proper use, inspections and maintenance increase the life and usefulness of your
Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and
all machined threads with applicable lubricants. Use of anti-seize compound and/
or thread lubricant on capscrew and nut threaded areas prevents corrosion and
allows for easy disassembly of components. A Piston Friction
B Plate
It is extremely important that anyone involved with maintaining the product be Drive
familiar with the servicing procedures of these products and be physically capable C Plate
of conducting the procedures. These personnel shall have skills that include:
D
1. Proper and safe use and application of mechanics’ common hand tools as well Reaction
as special Ingersoll Rand or recommended tools.
2. Safety procedures, precautions and work habits established by accepted Plate
industry standards. (Dwg. MHP2849)
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 NOTICE
method. If operation or maintenance procedures not specifically recommended by
the manufacturer are conducted, it must be ensured that product safety is not • Original brake disc thickness is 0.059 in (1.5 mm)
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 n Overload Device
contact supervisors and/or the factory for technical assistance.
NOTICE WARNING
• Refer to the Product Parts Information Manual for drawings unless • Overload is factory set and sealed with red paint and should not be adjusted
specified elsewhere. without consulting an Ingersoll Rand trained technician.
MHP2728 4
MHP2729 10
MHP2730 16
MHP2731 13
MHP2732 14
MHP2807 6 A
MHP2811 12 Securing
MHP2812 8 Screw
MHP2817 4 Adjustment
Screw B
MHP2818 18
MHP3100 20
(Dwg. MHP2683)
1. Loosen locknut ‘B’. 1. Shut off and bleed down main air supply to winch.
2. Tighten nut ‘A’ until the adjustment dimension 0.43 to 0.51 inch (11 to 13 mm) 2. Disconnect and tag air lines.
is achieved. 3. Stand winch in a vertical position, with the motor end up. Ensure winch is
3. Tighten locknut ‘B’. properly supported.
4. Check brake operation. 4. Remove four capscrews (86) and washers (125) that secure motor and control
valve assembly to upright (62).
5. Carefully pull motor assembly from winch.
6. Clean capscrews (86) and threaded holes with Loctite® 7063 or equivalent so
they are free of Loctite® residue.
7. Store motor in a clean area until needed. If repair is required refer to specific
disassembly sections.
CAUTION
• It is not recommended to disassemble limit switch. Contact factory if repair
is required.
Nut ‘A’ Locknut ‘B’ 1. Remove and tag hose connections if not already done.
2. Remove nuts (504) from rods (502). Remove cover (505), gasket (490) and
(Dwg. MHP2880) housing (486) from limit switch adapter (450).
3. Remove capscrews (499) and pull spindle switch assembly (501) from limit switch
adapter (450).
n Disassembly 4. Store limit switch assembly in a clean, dry area until winch reassembly.
4. Keep work area as clean as practical, to prevent dirt and other foreign matter Refer to Dwgs. MHP2732.
from getting into bearings or other moving parts.
5. All seals, gaskets and ‘O’ rings should be discarded once they have been 1. Remove and tag hose connections if not already done.
removed. New seals and ‘O’ rings should be used when assembling product. 2. Remove locknuts (301) and washers (307) from shoulder screws (310).
6. When grasping a part in a vise, always use leather-covered or copper-covered 3. Remove spacers (308) and lift off slack wire arm assembly.
vise jaws to protect the surface of part and help prevent distortion. This is 4. Tap shoulder screws (310) from uprights (62) and remove bearings (309).
particularly true of threaded members, machined surfaces and housings. 5. Remove capscrews (302) and lockwashers (73) from axle (304).
7. Do not remove any part which is a press fit in or on a subassembly unless removal 6. Remove locknuts (301) and lockwashers (73) from roller axle (305). Separate arms
of that part is necessary for repairs or replacement. (303), rollers (306) and axles (304) and (305).
8. When removing ball bearings from shafts, it is best to use a bearing puller. When 7. Remove capscrews (324) and lockwashers (2) from protector (323).
removing bearings from housings, drive out bearing with a sleeve slightly 8. Remove protector (323) and sensor valve (327) from upright (62).
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 n Winch Base and Drum Disassembly
wrapped in clean cloths.
Refer to Dwgs. MHP2728, MHP2807 and MHP2812. Refer to ‘Motor and Reduction
n External Components Removal Gear Removal’ section on page 8 to remove motor assembly from the winch.
Refer to component disassembly sections for further repair. 1. Remove external components. Refer to ‘External Components Removal’ section
on page 8.
1. Disconnect and tag all external air lines. 2. Stand winch in a vertical position with motor end up.
2. Remove filter, regulator and lubricator (FRL) assembly from spacer (66). 3. Remove capscrews (86), and washers (125) that secure motor, reduction gear
3. Remove drum guards. Refer to drum guard disassembly. and brake assembly to drum end cover (76). Set assembly to one side for further
4. Remove press roller assembly from spacer. Refer to press roller disassembly. disassembly if needed.
5. Remove slack wire rope device from spacer. Refer to press roller disassembly. 4. Remove capscrews (65) and (67), nuts (63) and lockwashers (64) to remove
6. Remove limit switch assembly. Refer to limit switch disassembly. spacers (66) and lifting lugs (69).
5. Remove capscrews (67), nuts (63) and lockwashers (64) to remove siderails (68).
6. Remove upright (62) and tube (70).
n Repair
Actual repairs are limited to the removal of small burrs and other minor surface
imperfections from gears, shafts, housings and machined surfaces. Use a fine stone
or emery cloth for this work. Note: position
of coupling,
1. Worn or damaged parts must be replaced. Refer to applicable parts listing for shoulder screw
specific replacement parts information. and spring.
2. Inspect all remaining parts for evidence of damage. Replace or repair any part
which is in questionable condition. The cost of the part is often minor in
comparison with the cost of redoing the job.
3. Smooth out all nicks, burrs or galled spots on shafts, bores, pins or bushings.
4. Examine all gear teeth carefully and remove nicks or burrs.
5. Polish edges of all shaft shoulders to remove small nicks which may have been
caused during handling.
6. Remove all nicks and burrs caused by lockwashers.
n Assembly Horizontal
Refer to the Product Parts Information Manual for drawings unless specified
elsewhere.
General instructions:
CAUTION
• For assembly of planet gears, each planet gear must be positioned with the
timing mark as shown on Dwg. MHP1406.
B
C
(Dwg. MHP1406)
10. Install planetary gear assembly in the reducer housing (27).
11. Install ball bearing (38) on the planet gear support (32). Check planet gears, sun
gear and ring gear teeth mesh smoothly.
12. Place the reduction gear assembly in a vertical position with the planetary gear
end up.
13. Fill the gear assembly to within 1 in. (25 mm) of the top with clean oil. Refer to
“LUBRICATION” section in Product Information Manual.
14. Install new gasket (20) on reducer housing (27).
15. Apply Loctite® 243 to capscrews. Refer to “TORQUE CHART” on page 13.
1. Lubricate and install ‘O’ rings (16) and (52) on piston (51).
2. Install new gasket (26) on reducer housing (27) if not done during reduction gear
(Dwg. MHP2644) assembly.
3. Assemble brake housing (41) to reducer assembly and secure with capscrew (24).
Motor Emergency Stop End Cover: 4. Ensure plug (14) is removed, then press piston assembly into brake housing (41).
Refer to Dwg. MHP2812. Puller screw holes must face out.
5. Install spacer (54) and splined hub (53). Start with friction plate (55) followed by
drive plate (56), friction plate with springs (58), drive plate (56), friction plate (55),
1. Lubricate and install ‘O’ ring (201) and seal (189) on base plate (199). drive plate (56) and finishing with friction plate with springs (58).
2. Lubricate and install ‘O’ ring (197) to plunger (198). 6. Install plug (14).
3. Install diaphragm (196) and washer (195) with stop nut (194) on plunger (198)
and insert into base plate (199). Ensure plunger assembly moves freely in bore
of base plate. n Winch Base and Drum Assembly
4. Insert base plate (199) with plunger into motor cover (97).
5. Lubricate and install ‘O’ rings (204) on valve seat (205). Refer to Dwgs. MHP2728, MHP2807 and MHP2812.
6. Place washer (206), diaphragm (212), cap (211), seal (203), sleeve (209) and
washers (206) and (208) onto capscrew (214) and insert into valve seat (205). 1. Install oil seal (77) and rear bearing (76) on drum end cover (78). Oil seal lip must
Apply a thin film of Loctite® 243 or equivalent to capscrew threads. Do not over be toward the bearing.
tighten capscrew. 2. Install drum end cover assembly on upright (62) and secure with capscrews (50)
7. Place seal (210) and cap (202) on capscrew (62). Place spring (213) on cap (202). and lockwashers (73).
8. Install valve seat assembly into emergency stop end cover (185). 3. Position the upright on several block of wood with the rear bearing (76) up.
9. Lubricate and install ‘O’ ring (191) on regulating screw (192); insert into 4. Check that plate (72) is securely installed in the drum with countersunk screws
emergency stop end cover (185) avoiding damage to the ‘O’ ring. Secure with (71).
screw (102). Install screw (102) with Loctite® 243 or equivalent. 5. Lubricate the outside diameter of oil seal (77) and install drum assembly on rear
10. Lubricate and install spring (193). bearing.
11. Install ‘O’ rings (187) to valve seat (186). 6. Install oil seal (77) and front bearing (76) on drum end cover (78). Oil seal lip must
12. Insert axle (188) into valve seat (186) then install seals (189) on each end of axle be toward the bearing.
(188). 7. Install drum end cover assembly on front upright (62) and secure with capscrews
13. Insert valve seat (186) into emergency stop end cover (185). (50) and lockwashers (73).
14. Insert ball (84) into emergency stop end cover (185). 8. Lubricate the outside diameter of oil seal (77) and install front upright assembly
15. Install gasket (101) on motor cover (97). on drum (60).
16. Install emergency stop end cover (185) on motor cover (97) and secure with 9. Rotate uprights so they are aligned and install spacers (66) and siderails (68) with
capscrews (103). capscrews (65) and (67), nuts (63) and washers (64). Longer capscrews (65) are
17. Insert plug (182) if removed during disassembly. required to attach lifting lugs (69). Mount lifting lugs diagonally opposite.
18. Install setscrew (180) in emergency stop end cover (185). 10. Check pin (79) is installed in drum end cover (78).
19. Install ‘O’ rings (90) on emergency stop end cover (185). 11. Install motor reducer assembly. Ensure gear shaft (20) meshes with splined bore
20. Install control valve assembly. in drum and secure with capscrews (86) and lockwashers (125).
21. If pendant adapter plate (605) or (613) was removed from motor cover (83), refer 12. Return winch to a horizontal position.
to pendant assemblies for installation. 13. Install remaining external assemblies.
1. Install press rollers (184) between roller arms (181) and secure with capscrews 1. Check guards are installed and secure.
(161) and washers (162). 2. Check all winch mounting bolts are secure.
2. Install frames (176) and springs (169) on roller arms (181). Secure with capscrews 3. Operate winch in both directions with no load.
(161) and washers (162). 4. Check operation of brakes and emergency stop.
3. Install press roller assembly in spacer (404). Secure with capscrews (183) and 5. Check operation of limit switches, slack line device, press roller and other safety
lockwashers (73). devices when provided.
4. Compress ends of springs (167) and (169) to engage with spacer (66) and pin on
press roller arm (163). n Load Test
n Filter, Lubricator and Regulator Assembly Prior to initial use, all new, extensively repaired, or altered winches shall be load
tested by or under the direction of an Ingersoll Rand trained technician and a
Refer to Dwg. MHP3100. written report furnished confirming the rating of the winch. Test loads shall not be
Horizontal Take-off Angle: 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
1. layer of the drum:
Install FRL assembly (400) to bracket (401) with capscrews (402), washers (404)
and locknut (403).
2. Install bracket (401) to spacer (66) on press roller side of winch. NOTICE
3. install hose connections and three way shut-off valve (407).
Vertical Take-off Angle: • 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.
1. Install FLR assembly (400) to spacer (66), opposite press roller side, with bracket
(418) and secure with capscrews (420) and washers (419).
2. Install hose connections and three way shut-off valve (407).
NOTICE
Notes:
1. Definitions:
DRY: Cadmium plate, zinc plate, and oiled fasteners.
LUBRICATED: Molysulfide paste, carnaba wax, molysulfide grease and
copper-based anti-seize coated fasteners.
PTFE: 2% minimum PTFE (teflon) coated fasteners.
2. All torque values foot-pounds unless noted.
3. SAE grade 5 equivalent to ASTM A325 Type 2 and ASTM A449.
4. SAE grade 8 equivalent to ASTM A354 Grade BD, ASTM A490 Type 1.
5. If mixing fasteners use lowest torque value.
6. Torque values 75 to 85% of fastener proof load ref.