Air Powered Man Rider™

Winch
MR150K Series

y
Product Maintenance
Information

Save These Instructions

Form MHD56492
Edition B
May 2019
CCN 47512571
Only allow Ingersoll Rand trained technicians to perform maintenance on these products. For additional
information contact Ingersoll Rand or nearest Distributor.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased
performance, increased maintenance and will invalidate all warranties.
The original language of this manual is English. Other languages are translations of the original instructions.
Manuals can be downloaded from irmhdocs.skysite.com
Refer all communications to the nearest Ingersoll Rand Office or Distributor.
Table 1. Product Information Manuals
Publication Part/Document Number (CCN)

Product Safety Information Manual MHD56251 (71402606)

Product Information Manual MHD56490 (45957115)

Product Parts Information Manual MHD56489 (45957107)

2 MHD56492
Table of Contents
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Records and Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance Interval Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Inspection Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overload Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic Band Drum Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Disassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External Components Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powerhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drum Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Automatic Band Drum Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Limit Switch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Press Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Slack Line Device Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Winch Base and Drum Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disc Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reduction Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Function Emergency Stop Pendant Disassembly (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reduction Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disc Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Winch Base and Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Automatic Band Drum Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Limit Switches Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Slack Line Device Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Press Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Water Separator, Regulator, Filter, and Lubricator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drum Guard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Two Function Emergency Stop Pendant Assembly (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

MHD56492 3
Inspection
Frequent inspections must be performed on equipment in regular service. Refer to Product Information Manual.

Periodic Inspection
Refer to Table 3, p. 5 for suggested winch inspection classifications for Periodic Inspection intervals. Select
conditions most appropriate to application.
1. Siderails and Uprights: Check for deformed, cracked or corroded main components. Replace damaged parts.
2. Fasteners: Check retainer rings, 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.
c. Check wire rope anchor is secure in drum.
d. Verify wire rope diameter. Measure the diameter of the wire rope from crown-to-crown throughout the life of
the wire rope. Recording of the actual diameter should only be done with the wire rope under equivalent
loading and in the same operating section as accomplished during previous inspections. If the actual
diameter of the wire rope has decreased more than 1/64 inch (0.4 mm) a thorough examination of the wire
rope should be conducted by an experienced inspector to determine the suitability of the wire rope to
remain in service. Refer to Figure 1, p. 4.
e. Inspect rope for broken strands/wires: When broken wires are evident close to, or within, the termination,
even if few in number, are indicative of high stresses at this position and can be caused by incorrect fitting of
the termination. The cause of this deterioration shall be investigated and, where possible, the termination
shall be remade, shortening the rope if sufficient length remains for further use, otherwise the rope shall be
discarded. One valley break may indicate internal rope deterioration, requiring closer inspection of this
section of rope. When two or more valley breaks are found in one lay length, the rope should be considered
for discard. If a complete strand fracture occurs, the rope shall be immediately discarded. Where broken
wires are very close together, constituting a localized grouping of such breaks, the rope shall be discarded. If
the grouping of such breaks occurs in a length less than 6d or is concentrated in any one strand, it may be
necessary to discard the rope even if the number of wire breaks is smaller than the maximum number, refer
to Table 3, p. 5.
Table 2. Wire Rope

Number Broken Wires in rope over a Number Broken Wires in rope over a
Rope Construction Type
length 6x nominal diameter length 30x nominal diameter

6 x 19S-IWRC Single layer rope 3 6

6 x 37M-IWRC Single layer rope 10 19

Figure 1. MHP0056

A
Wire

B
Crown
to
Crown

C
Strand

One
Lay
D

4 MHD56492
 Inspection

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. Clean and replace components as necessary.
Adjustments can be made to the band brake to compensate for normal brake lining wear. Refer to
“Adjustments,” p. 10. 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,” p. 10.
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. 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 ft [+ / - 0.6 m]). Reset limit switch by operating winch in opposite
direction. Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.
10. Emergency Stop Valve: During winch operation verify the emergency stop 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.
12. Slack Line Detector: Inspect rollers for wear and grooves or ridges. Replace worn or grooved rollers. Check
arms move freely and activate sensor valve. Ensure rollers rotate freely. Check sensor valve plunger operation.
If damaged or stiff, replace sensor valve.
13. Press Roller: Inspect rollers for wear and grooves. Ensure rollers freely rotate. Replace rollers if worn or
grooved. Replace bearings if rotation is rough or stiff.
14. Emergency Lowering Device: Provide auxiliary supply air to emergency lowering power entry port and activate
valve. Verify winch operation.
15. Drum Guard: Verify fasteners are tight and in good condition. Ensure guard is in good condition and panels are
correctly positioned.
16. Operator Orientation Guard: Verify fasteners are tight and in good condition. Ensure guard is in good condition
and panels are correctly positioned.
17. Labels and Tags: Check for presence and legibility of labels. Replace if damaged or missing.

Inspection Classifications
Table 3. Inspection Classifications

Conditions Normal Heavy Severe

Typical Use (operating time) Infrequent Regular Continual/Constant

60% of Capacity 75% of Times 80% of Capacity 75% of Times 100% of Capacity 75% of Times
Load Range
Used Used Used

Installation Protected/Enclosed/Dry Not Sheltered/Exterior Full Exposure

Dirty/Non-Corrosive/ Dirty/Corrosive/Saltwater
Atmosphere Clean/Non-Corrosive
Freshwater Marine Marine

Wet/Moderate Temperature Wet/Severe Temperature

Climate Dry/Stable Temperature
Fluctuations Fluctuations

Records and Reports

Inspection records, listing all points requiring periodic inspection must be maintained for all load bearing
equipment. Written reports, based on severity of service, must be made on the condition of critical parts as a
method of documenting periodic inspections. These reports must be dated, signed by the inspector, and kept on file
where they are readily available for authorized review.

MHD56492 5
Inspection

Maintenance Interval Chart

Refer to Table 4, p. 6 for recommended maintenance schedule.

NOTICE
Winch Load Test!
Do an annual winch load test for all applications.

Table 4. Maintenance Interval Chart

Severe Application

The following work can be completed by owner maintenance personnel

System Air Filter Inspect system air filter every 30 days.

Water Separator Inspect system filter every 30 days.

Grease Fittings Lubricate grease fittings every 90 days.

Gearbox Oil Level Check oil level in gearbox every 90 days. Replace oil yearly.

It is recommended that the following work be completed by an Ingersoll Rand trained service technician or a Qualified
Person

Standard Components 1 year 2 years 3 years 4 years 5 years 6 years

Inspect Motor x x

Inspect Disc Brake x x

Inspect Gearbox x x

Replace Winch Anchor Bolts x x

Inspect Control Valve x x x x x x

Inspect Drum, Housings and Main Frames x x

Emergency Shut-off Valve x x x x x x

Drum Shaft x x

Overload Device x x x x x x

Limit Switches x x x x x x

Emergency Brake Release x x x x x x

Emergency Lowering x x x x x x

Automatic Band Brake (a) x x x x x x

(a) Do not disassemble Auto Band Brake Air Cylinder unless brake operation or visual inspection indicates a requirement.

NOTICE
!
• Annual Inspection and Load test shall be performed by an Ingersoll Rand Trained
Technicians unless directed otherwise by a *Qualified Person.
• Certification shall be done in every three years by an Ingersoll Rand Trained Technicians
unless directed otherwise by a *Qualified Person.

* Qualified Person: A person who, by possession of a recognized degree in an applicable field or certificate of
professional standing, or who by extensive knowledge, training, and experience has successfully demonstrated the
ability to solve or resolve problems relating to the subject matter and work.

6 MHD56492
Inspection Report
Make a photo copy of this form and use as an inspection record.

Ingersoll Rand MR150K Series Air Winches

Model Number: Date:

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection: (_____ Months _____ Years)

2. Discrepancy(s) noted during Frequent Inspection Operating Environment:
Normal ____ Heavy____ Severe ____
3. Discrepancy(s) noted during maintenance
4. Other: ___________________________

Refer to the Product Information Manual and Product Parts Information Manual and “Inspection,” p. for general inspection criteria. Also,
refer to appropriate National Standards and Codes of practice. If in doubt about an existing condition, contact the nearest Ingersoll Rand
Distributor or the factory for technical assistance.

Condition Corrective Action

Component Notes
Pass Fail Repair Replace

Uprights and Siderails

Drum Band Brake (125% Load Test)

Disc Brake (125% Load Test)

Drum Band Brake (Visual Inspection)

Disc Brake (Visual Inspection)

Motor

Controls

Limit Switches

Air System

Fasteners —

Emergency Stop Valve

Overload Device —

Reduction Gears

Labels and Tags —

Shafts

Winch Guard

Wire Rope Wedge —

Emergency Lowering Device —

Slack Line Device —

Press Roller

Wire Rope —

Other Components (list in Notes section)

Testing Pass Fail Notes

Operational (No Load)

Operational (10% Load)

Operational (Maximum Test Load (a) )

(a) 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.

MHD56492 7
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
Winch will not operate.
Load continues to move when
winch is stopped.
Winch hauls-in but does not
payout.
Winch does not lift load or does
not lift rated capacity. Winch
does not lift load.
Oil leak from motor end of
winch.
Throttle or pendant lever
moves but winch does not
operate.
8 MHD56492
Cause
Not sufficient or no air supply to
winch.
Winch is overloaded.
Disc brake does not release.
Drum brake does not release.
Emergency stop valve engaged.
Motor is damaged.
Air leak.
Overload device engaged.
Air lines freeze because of water in air
supply.
Brake is slipping.
Winch is overloaded.
Winch motor controls sticking.
Lower limit switch activated.
Slack line detector activated.
Motor is damaged.
No sufficient air supply.
Brake is not releasing.
Winch is overloaded.
Reduction assembly is leaking.
Motor is damaged.
No sufficient air supply.
Air leak.
Remedy
Examine air supply line connections and hoses.
Decrease load to within rated capacity.
Examine brake piston seals and replace if seals appear to be
leaking.
Refer to “Automatic Band Drum Brake ,” p. 11.
Reset emergency stop valve.
Disassemble and clean the motor and replace any broken or
damaged parts.
Examine hose and fitting for correct connections. Examine
hose(s) for breaks. Tighten fittings and repair or replace hoses
as necessary.
Decrease load to within rated capacity of winch. If you cannot
reset the overload device, contact factory.
Install or drain air system moisture traps, moisture collecting
air receivers and compressor aftercoolers. After corrective step
has been taken, disconnect lines at winch inlet and remove
with clean, dry air or nitrogen.
Examine brake friction discs and automatic band drum brake
for wear.
Decrease load to within rated capacity.
Make sure that the pendant/throttle levers spring return to
normal (neutral) position when released.
Raise the load and examine limit switch settings.
Find the cause of slack line and correct the problem.
Remove and disassemble motor as described in on “Motor
Disassembly,” p. 15. Examine all parts and replace any that are
worn or damaged.
Make sure that the air supply pressure and volume at winch
inlet meet the requirements listed in the “SPECIFICATIONS”
section in Product Instruction Manual. Clean air line filter.
Make sure that the brake release pilot hole is not blocked. Make
sure that the seals on cylinder piston are not damaged. Brake
will start to release at 50 psig (3.5 bar/350 kPa).
Decrease load to within rated capacity.
Disassemble winch and examine reduction assembly seals.
Disassemble, examine and clean motor. Replace any broken or
damaged parts.
Make sure that the minimum air pressure at winch inlet is 70 to
100 psig (5 to 7 bar) at rated volume. Clean air line filter.
Examine hose and fitting connections. Examine hose(s) for
breaks. Tighten fittings and repair or replace hoses as
necessary.

Symptom
Winch runs slow.
Air lines freeze.
Throttle or pendant lever
moves but winch does not
operate.
Automatic Band Brake:
Brake cylinder will not release.
Automatic Disc Brake:
Brake fails to release.
MHD56492
Cause
Improper hose or fitting sizes.
Motor is damaged.
Brake(s) not releasing.
No sufficient air supply.
Water in air supply.
Motor is damaged.
No sufficient air supply.
Band brake adjustment is not correct.
Leaking cylinder seals.
Dirty filter in air supply.
Low air supply pressure.
Leaking piston seals.
No release pressure at brake port.
Sticking brake piston.
Troubleshooting
Remedy
Examine fittings, connections and hoses for correct size and
length. Replace parts that decreases the air flow. Examine air
line filter.
Remove and disassemble motor as described in
“Maintenance,” p. 10. Examine all parts and replace all worn or
damaged parts.
Refer to brake sections.
Make sure that the air supply pressure and volume at winch
inlet meet the requirements. Refer to “SPECIFICATIONS”
section in Product Instruction Manual. Clean air line filter.
Install or drain air system moisture traps, moisture collecting
air receivers and compressor aftercoolers. After corrective step
has been taken, disconnect lines at winch inlet and remove
with clean, dry air or nitrogen.
Disassemble, examine and clean motor. Replace any broken or
damaged parts.
Make sure that the air pressure at winch inlet is between 70
and 100 psig (5 to 7 bar) at rated volume. Clean air line filter.
Adjust band brake to maintain correct cylinder stroke.
If you find air leak from cylinder breather when you try to
release brake, replace or repair cylinder.
Clean or replace filter.
Make sure that the minimum air pressure at inlet to disc brake
is 60 psig (3.4 bar/340 kPa).
Examine brake breather. If you find air leak from brake
breather when you try to release brake, replace brake seals.
Make sure that the operation of the winch control is correct.
Apply 60 psig (3.4 bar/340 kPa) to brake release port and do a
check for brake disc movement. (Brake discs can be seen
through brake breather hole.) If brake discs do not move,
disassemble and examine disc brake as described in
“Maintenance,” p. 10.
9
Maintenance
WARNING
General Maintenance!
• Do not perform maintenance on the winch while it is supporting a load.
• Before performing maintenance, tag controls:
• WARNING - DO NOT OPERATE, EQUIPMENT BEING REPAIRED.
• Only allow Ingersoll Rand trained Technicians to perform maintenance on this winch.
• Shut off air system and depressurize air lines before performing any maintenance.
• Do not use Trichloroethylene to clean parts.
• Use of other than genuine Ingersoll Rand parts may result in safety hazards, decreased
performance and increased maintenance and will invalidate all warranties.
• After performing any maintenance on the winch, test winch to 125% of its rated line pull at
mid drum before returning to service. (Testing to more than 125% of rated line pull may be
required to comply with standards and regulations set forth in areas outside the USA.)

NOTICE
!
Refer to Product Instruction and Safety Manuals for specific information.

General
The correct disassembly (to prevent loss or damage of good parts), repair, assembly, testing and adjusting are
necessary for proper winch operation. Maintenance procedures are technical in nature and necessitate training and
experience to do them correctly. Specialized equipment is necessary to do the repair and testing, that is not
typically found at the products mounting site.
Correct 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 lets you do
disassembly of components easily.
It is very important that anyone involved with maintaining the product must fully know the servicing procedures of
these products and is physically capable to do the procedures. These personnel must have skills that include:
1. Correct and safe use and application of mechanics’ common hand tools and special Ingersoll Rand or
recommended tools.
2. Safety procedures, precautions and work habits approved by accepted industry standards.
Ingersoll Rand cannot know of or give all the procedures by which product operations or repairs are done and the
hazards and/or results of each method. If operation or maintenance procedures not specifically recommended by
the manufacturer are done, make sure that product safety is not endangered by the actions taken. If not sure of an
operation or maintenance procedure or step, personnel must keep the product in a safe condition and refer all
communications to supervisors and/ or the factory for technical assistance.

NOTICE
Manual Drawings!
Refer to the Product Parts Information Manual for drawings unless specified elsewhere.

Adjustments
Limit Switch
Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.

Overload Device
WARNING
!
Overload is factory set and sealed with red paint and should not be adjusted without consulting
an Ingersoll Rand trained technician.

10 MHD56492
 Maintenance

A
Securing
Screw
Adjustment
B
Screw

1. Connect winch to an air supply.

2. Release securing screw and adjusting screw in order to increase or decrease the SWL (increase SWL by
tightening the adjusting screw). Adjustment must be made for an overload of 125% maximum of SWL.
3. Tighten securing screw.
4. Check winch operation at rated load. If necessary, repeat adjustment.

Automatic Band Drum Brake

Refer to Figure 2, p. 11.
1. Loosen locknut ‘B’.
2. Tighten the nut ‘A’ until you get the adjustment dimension between 0.43 and 0.51 inch (11 to 13 mm).
3. Tighten locknut ‘B’.
4. Examine the brake for correct operation.
Figure 2. Adjusting Band Brake
0.43-0.51 inch
11-13 mm

Nut ‘A’ Locknut ‘B’

Disc Brake
No brake adjustment is required. Refer to Figure 3, p. 12.
1. Remove motor as described in “Motor Disassembly,” p. 15.
2. Remove the reaction plate (57), splined hub (53), friction plates (55) and (58), and drive plates (56).
3. Examine the friction plates (55) and (58) for wear. If friction plate thickness is not equal on all the sides or less
than 0.047 in (1.2 mm), replace all friction plates.
No more disassembly is required, if only the brake friction discs are being inspected. Make sure that the friction and

MHD56492 11
Maintenance

drive plates are assembled in the correct order.

Figure 3. Disc Brake Assembly (MHP2849)

E
0.047 inch minimum
(1.2 mm minimum)

A Piston Friction
B Plate
Drive
C Plate

D
Reaction
Plate

NOTICE
!
Make sure that the original brake disc thickness is 0.059 in (1.5 mm).

Disassembly
General Disassembly Instructions
The instructions that follow gives necessary information to disassemble, inspect, repair, and assemble the product.
Parts drawings are provided in Product Parts Information Manual.
If a product is completely disassembled for any reason, follow the order of topics as they are presented. It is
recommended that all maintenance work on product be performed in a clean dust-free work area.
In the process of disassembling the product, obey the instructions that follow:
1. Do not disassemble the product any further than is necessary to accomplish needed repair. A good part can be
damaged during disassembly.
2. Do not use too much force when removing parts. Tapping lightly around the perimeter of a cover or housing
with a soft hammer, for example, is sufficient to break the seal.
3. Do not heat a part with a flame to free it for removal, unless part being heated is already worn or damaged and
cannot be repaired and no more damage will occur to other parts.
In general, products are designed to permit easy disassembly and assembly. The use of heat or too much force is
not necessary.
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, gaskets and ‘O’ rings must be discarded once they are removed. New seals and ‘O’ rings must be used
when assembling the product.
6. When holding 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, move out bearing with a sleeve slightly smaller than outside diameter of bearing. The end of sleeve or
pipe which touches bearing must be square. Protect bearings from dirt by keeping them wrapped in clean
cloths.

External Components Removal

Refer to component disassembly sections for further repair.
1. Stop the air supply and bleed down main air supply to winch.
2. Disconnect and tag all external air lines.

12 MHD56492
 Maintenance

3. Remove inboard and outboard guarding.

4. Remove tube guarding.
5. Remove water separator, regulator, filter, and lubricator assembly.
6. Remove press roller assembly from spacer. Refer to “Press Roller Disassembly,” p. 13.
7. Remove drum guards. Refer to “Drum Guard Removal,” p. 13.
8. Remove slack wire rope device from spacer. Refer to “Press Roller Disassembly,” p. 13.
9. Remove limit switch assembly. Refer to “Limit Switch Disassembly,” p. 13.

Powerhead Removal
Refer to Dwg. MHP3312 and MHP3375 in the Parts Information Manual.
1. Stop air supply and bleed down main air supply to winch.
2. Remove tube guarding. If necessary, remove operator orientation guarding.
3. Disconnect and tag air lines.
4. Hold winch in a vertical position, with the motor end up. Make sure that the winch is correctly held.
5. Remove four capscrews (86) and washers (2) that attach motor and control valve assembly to endframes (62).
6. Carefully pull motor assembly from winch.
7. Clean capscrews (86) and threaded holes with Loctite® 7063 or equivalent so they are free of Loctite®.
8. Keep motor in a clean area until necessary. If repair is necessary, refer to related disassembly sections.

Drum Guard Removal

Refer to Dwg. MHP3312 in the Parts Information Manual.
1. Remove capscrews (8) and lockwashers (64)that secure the drum guards (7 and 9) and bottom panels (406) to
endframes.
2. Remove drum guard (216), left panel (217) and right panel (218).

Automatic Band Drum Brake Disassembly

Refer to Dwg. MHP3298 in the Parts Information Manual.
1. Disconnect and tag the air lines.
2. Loosen the nut (151) until brake band (111) is slack on drum.
3. Remove one cotter pin (113) from each pin (112) and tap out pins (112) from brake band ends.
4. Remove brake band (111) and adjustment screw (149).
5. Remove capscrews (156) and lockwashers (64) that attach housing (147) to side rail (68).

Limit Switch Disassembly

Refer to Dwg. MHP3372 in the Parts Information Manual.

CAUTION
!
It is not recommended to disassemble limit switch. Contact factory if repair is required.

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

2. Remove nuts (262) from rods (263). Remove cover (505), gasket (490) and housing (486) from limit switch
adapter (450).
3. Remove capscrews (499) and pull spindle switch assembly (501) from limit switch adapter (450).
4. Store limit switch assembly in a clean, dry area until winch reassembly.

Press Roller Disassembly

Refer to Dwgs. MHP3313 in the Parts Information Manual.
1. Compress ends of springs (167) and (169) to disengage from spacer (66) and pin on press roller arm (163).

CAUTION
!
Use care when releasing springs (167) and (169) from press roller. Springs are under tension.

MHD56492 13
Maintenance

2. Remove capscrews (183) and lockwashers (73). Remove press roller assembly from spacer (66).
3. Remove capscrews (161) and washers (162) from both sides of roller arm (181). Remove frames (176) and
springs (169).
4. Remove capscrews (161) and washers (162) from both sides of roller arm (181). Remove press rollers (184).

Slack Line Device Disassembly

Refer to Dwgs. MHP3296 in the Parts Information Manual.
1. Remove and tag hose connections if not done.
2. Remove locknuts (301) and washers (307) from shoulder screws (310).
3. Remove spacers (308) and pull slack wire arm assembly.
4. Tap shoulder screws (310) from uprights (62) and remove bearings (309).
5. Remove capscrews (302) and lockwashers (73) from axle (304).
6. Remove locknuts (301) and lockwashers (73) from roller axle (305). Remove arms (303), rollers (306) and axles
(304) and (305).
7. Remove capscrews (324) and lockwashers (2) from protector (323).
8. Remove protector (323) and sensor valve (327) from upright (62).

Winch Base and Drum Disassembly

Refer to Dwgs. MHP3312 in the Parts Information Manual to remove motor assembly from the winch.
1. Remove external components. Refer to “External Components Removal,” p. 12.
2. Hold winch in a vertical position with motor end up.
3. Remove capscrews (86), and washers (125) that attach motor, reduction gear and brake assembly to drum end
cover (76). Set assembly to one side for more disassembly if necessary.
4. Remove capscrews (65) and (67), nuts (63) and lockwashers (64) to remove 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).
7. Remove capscrews (50) and lockwashers (73). Remove drum end cover assembly from upright (62).
8. Remove bearing (76) and oil seal (77) from drum (60) if not removed with drum end cover (78).
9. Carefully turn drum until limit switch end is up.
10. Remove upright (62) from drum (60).
11. Remove capscrews (50) and lockwashers (73) from drum end cover (78).
12. Remove drum end cover (78) from upright (62).
13. Remove bearing (76) and oil seal (77) from drum (60) if not removed with drum end cover (78).

Disc Brake Disassembly

Refer to Dwg. MHP3376 in the Parts Information Manual.
1. Make sure the disc brake is pulled from the motor and reducer assembly.
2. Remove capscrews (25) (black) to let brake and reducer assembly to be removed together.
3. Use the two threaded puller holes in the piston (51) to remove piston (51) and brake reaction plate (57) from
brake housing (41).
4. Remove drive plates (56), friction plates (55) and (58), spacer (54) and splined hub (53). Record the position for
future assembly.
5. Remove ‘O’ rings (16) and (52) from piston (51) and discard.

Reduction Gear Disassembly

Refer to Dwg. MHP3376 in the Parts Information Manual.
1. Remove disc brake assembly.
2. Remove fill plug (14) and drain oil from reduction gear into an applicable container.
3. Remove capscrews (24) and (25) to remove reduction gear assembly from brake housing (41).
4. Remove capscrews (22) and washers (23) that attach reduction gear end cover (15).
5. Remove retainer ring (12) from gear shaft (20).

14 MHD56492
 Maintenance

CAUTION
!
It may be necessary to use a small amount of air pressure in fill hole of reduction gear end cover
(15) to separate from housing (27).

6. Remove and discard ‘O’ ring (16) on reduction gear end cover (15).
7. It is not necessary to remove bearing (39) from reduction gear end cover (15) unless damaged. Replace as
necessary.
8. Remove bearing (13) and oil seal (17). Replace seal and bearing if necessary.
9. Remove bearing (21) and ring gear (19).
10. Hold end cover (15) and tap out shaft (20).
11. Remove retainer ring (36) from sun gear (34).
12. Hold reducer housing (27) and lightly tap out sun gear (34).
13. Tap out gear shafts (33) and remove planet gears (31), spacers (30), needle bearings (28) and bearing rings (29).
14. Remove retainer ring (49).
15. Remove sun gear (34).
16. Remove retainer ring (36) and bearing (35).
17. Remove and discard gasket (26) and ‘O’ ring (16) from brake housing (41).
18. Remove and replace bearing (38) if necessary.

Motor Disassembly
Refer to Dwg. MHP3375 in the Parts Information Manual.
1. Remove motor assembly, refer to “Reduction Gear Disassembly,” p. 14.
2. Remove control valve assembly (100) from motor assembly.
3. Remove capscrews (103) and emergency stop end cover (185).
4. Remove and discard gasket (101).
5. Remove capscrews (107) and remove motor cover (97) from motor housing (87).
6. Remove and discard ‘O’ rings (90).
7. Remove valves (105) and springs (96) from motor cover (97).
8. Remove ‘O’ rings (94) only if necessary. ‘O’ rings must be cut for removal.

NOTICE
Drive & Idle Gear Removal!
The two bearings (91) located in the motor housing (87) are bonded with Loctite® 603 or
equivalent. Remove idle gear (104) and drive gear (92) only if replacement is necessary; use a
bearing punch (IR pn: 96441232) or standard drift punch and a hammer. Refer to Dwg.
MHP2644.
9. To remove both bonded bearings (91) from motor housing (87), it is necessary to use a bearing punch and
hammer. Two or three strikes are sufficient.
10. If replacement is necessary, use an applicable bearing extractor and remove bearings (91) from drive gear (92)
and idle gear (104).
11. Remove check valve (83) and ball (84) from motor housing (87).
Emergency Stop End Cover:
1. Remove and discard ‘O’ rings (90).
2. Remove setscrew (180).
3. Remove ball (84).
4. Remove valve seat (186).
5. Remove seal (189) and axle (188).
6. Remove and discard ‘O’ rings (187).
7. Remove spring (193).
8. Remove clamping screw (102).
9. Remove regulating screw (192) and remove and discard ‘O’ ring (191).

MHD56492 15
Maintenance

10. Remove valve seat (205).

11. Remove spring (213).
12. Remove capscrews (214).
13. Remove caps (202) and (211), washers (208) and (206), sleeve (209) and diaphragm (212).
14. Remove seals (203) and (210).
15. Pull stop nut (194) and remove plunger (198) with diaphragm (196) from base plate (199).
16. Remove nut (194) and remove plunger (198) and washer (195).
17. Remove and discard ‘O’ ring (197) .
18. Install a screw (dia. M5) in threaded hole on base plate (199) and pull it from motor cover (97).

Control Valve Disassembly

Refer to Dwg. MHP3307 in the Parts Information Manual.
1. To remove control valve (100) from motor assembly, remove capscrews (137) and (168) with lockwashers (2).
2. Remove capscrews (118) and lockwashers (2) from stop plate (119). Remove stop plate.
3. Partially remove capscrew (126) just far enough to let emergency stop housing assembly to be removed. Keep
emergency stop housing assembly to one side for future disassembly.
4. Remove spools (142) from valve housing (135).
5. Fully remove capscrew (126) and lockwasher (125).
6. Remove lever assembly, coupling (124) and spring (116).
7. Do not disassemble handle unless repairs are necessary. To disassemble handle, tap out pin (120) and remove
cap (121). Remove handle spool (123) and spring (130).
8. Remove retainer (140), spindle shaft (131) and gear (138).
9. Remove retainer (140), spindle shaft (131) and gear cam (139).
10. Remove pins (132) from spindle shafts (115).
11. Remove bushings (133) and (141).
Emergency Stop:
Refer to Dwg. MHP3307 in the Parts Information Manual.
1. Remove emergency stop valve (164) from end cover (172).
2. Remove and discard ‘O’ rings (175).
3. Remove the valve (165) with ‘O’ ring (171), ‘O’ ring (166) and protector (170).
4. Remove retainer rings (178).
5. Remove springs (177) and balls (84).
6. Remove check valve (83) and remove ball (84).
7. Remove and discard ‘O’ rings (166).

2 Function Emergency Stop Pendant Disassembly (optional)

Refer to Dwg. MHP3039 in the Parts Information Manual.
1. Disconnect hoses from pendant assembly (600).
2. Remove fittings (152).
3. Remove lifting eye (617), if necessary.
4. Tap out pin (618) to remove the levers (619).
5. Loosen and remove check valve (83) and ball (84).
6. Remove setscrew (173) to remove the valve assemblies (165).
7. Remove protector (170), ‘O’ rings (166) and (171) from the valve (165).
8. Remove plugs (623) to remove the springs (177) and balls (84).
9. Remove emergency stop button (164).
10. Remove retainer ring (621) and exhaust washer (615) from handle (622).

16 MHD56492
 Maintenance

Cleaning, Inspection and Repair

Cleaning
1. Clean all the winch component parts in solvent (not the drum brake bands and disc brake friction plates).
Note: The use of a stiff bristle brush will help removal of collected dirt and sediments on the housings, frame
and drum.
2. If bushings are removed, carefully clean the Loctite® from the bushing bores.
3. Dry each part with low pressure, filtered compressed air.
4. Clean the drum brake band with a wire brush or emery cloth.
Note: Do not wash the drum brake band in solvent.
5. If the drum brake band lining is oil soaked, replace it.

Inspection
Examine all the disassembled parts for fitness for continued use. Do an inspection of the parts that follow:
1. Examine the gears for worn, cracked, or broken teeth. Replace if necessary.
2. Examine the bushings for wear, scoring or galling. Replace if necessary.
3. Examine the shafts for ridges caused by wear. If you can see ridges on the shafts, replace the shaft. Do an
inspection for scoring or galling.
4. Examine all threaded parts and replace the parts with damaged threads.
5. Examine drum band brake lining for oil, grease and glazing.
a. If band brake lining is oil soaked greasy or glazed, replace the brake band.
b. Remove small glazed areas of band brake lining by sanding lightly with a fine grit emery cloth.
c. Measure the thickness of drum band brake lining. If drum brake band lining is less than 0.062 inch (2 mm)
thick anywhere along edges, replace the brake band assembly.
6. Do an inspection of the motor housing gear bores for wear or scoring. Replace the motor housing if you see
scratches or the wear pattern is not equal.
7. Examine the motor gears (92) and (104) for:
a. ridges or more grooving on outside diameter of gears.
b. contact between gears and gear housing.
8. Examine slack wire device for:
a. wear, grooves or scoring of rollers. Replace if necessary.
b. free turn. Rollers must operate without binding and without more side-to-side play.
9. Examine bearings for:
a. loss of grease, and grit, dirt or other contaminants. All motor bearings are factory lubricated and sealed. If
dry or contaminated, replace the bearing.
b. damage. Do an inspection of the roller bearings (needle). If the bearings are damaged or you see any
contamination, replace the bearings.
10. Examine the disc brake for:
a. wear. Replace the brake discs if you do not see the grooving pattern or if discs are cracked or chipped.
b. thickness of disc. If it is less than 0.047 in (1.2 mm), replace.

Repair
There is only a small number of repairs that you can do to remove the small burrs and other imperfections on the
surface from the gears, shafts, housings and machined surfaces. Use a fine stone or emery cloth for this work.
1. Replace the worn or damaged parts. Refer to applicable parts listing for specific replacement parts information.
2. Examine all remaining parts for damage. Replace or repair any damaged part.
Note: The cost of the part is less when you compare with the cost of rework.
3. Remove all nicks, burrs or galled spots on shafts, bores, pins or bushings.
4. Carefully examine all gear teeth and remove nicks or burrs.
5. Polish the edges of all shaft shoulders to remove small nicks caused during handling.
6. Remove all nicks and burrs caused by lockwashers.

MHD56492 17
Maintenance

General Instructions
• Use all new gaskets and seals.
• Replace worn parts.
• Assemble parts using matchmarks attached during disassembly. Compare replacement parts with originals to
identify installation alignments.

Control Valve Assembly

Refer to Dwg. MHP3307 in the Parts Information Manual.
1. Install bushings (133) and (141) in valve housing (135).
2. Install pins (132) in spindle shafts (115), so they extend an equal amount on both sides.
3. Install retainer (140), spindle shaft (115), key (136) and gear cam (139) in valve housing.
4. Install retainer (140), spindle shaft (131), key (136) and gear (138) in valve housing. Ensure keys are vertically
aligned and gear teeth are meshed.
5. If handle was disassembled, install spring (130) and handle spool (123) in lever shaft (128). Align hole in handle
spool (123) with slot in lever shaft (128) and install pin (120) so it extends an equal amount on both sides. Install
ʽOʽ ring (122) on cap (121) and screw cap (121) into lever shaft (128).
6. Vertical Wire Rope Take-off Angle:
a. Install pin (134) in the top pin hole in valve housing (134).
b. Install lever assembly in coupling (124). Install spring (116) and coupling/ handle assembly on lower spindle
shaft (115). Align notch in coupling with pin in spindle shaft. Spring (116) ends will point up.
c. Install capscrew (126) and lockwasher (125) through coupling (124) and lower hole in lever shaft (128).
or
7. Horizontal Wire Rope Take-off Angle:
a. Install pin (134) in the lower pin hole in valve housing (134).
b. Install lever assembly in coupling (124). Install spring (116) and coupling/ handle assembly on top spindle
shaft (115). Align notch in coupling with pin in spindle shaft. Spring (116) ends will point down.
c. Install capscrew (126) and lockwasher (125) through coupling (124) and top hole in lever shaft (128).
8. Install spools (142) in valve housing (135).
9. Install emergency stop housing assembly to valve housing (135). Install shoulder screw (127). Tighten
capscrews (126) and (127) to secure emergency stop housing.
10. Install capscrews (118), lockwashers (2) and stop plate (119) on valve housing (135).
11. Check operation of control valve to ensure smooth movement and ability to spring return and lock in neutral.

Motor Assembly
Refer to Dwg. MHP3375 in the Parts Information Manual.
1. Clean the grease from bearings (91).
2. Clean interior and exterior diameter of bearings with Loctite® 7063 or equivalent.
3. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of bearing (91). Refer to Figure 4, p.
19.
4. Apply a continuous thin film of Loctite® 603 or equivalent on bearing diameter on drive gear (92) and install
bearing (91).
5. Install a second bearing (91), not bonded, on drive gear (92).
6. Apply a continuous thin film of Loctite® 603 or equivalent on interior diameter of bearing (91).
7. Apply a continuous thin film of Loctite® 603 or equivalent on bearing diameter on idle gear (104) and install
bearing (91).
8. Install a second bearing (91), not bonded, on idle gear (104).
9. Apply a continuous thin film of Loctite® 603 or equivalent on bore for bearings in the motor housing (87).
10. Install drive gear (92) and idle gear (104) into motor housing, ensure the drive gear and idle gear are completely
inside motor housing and leave the motor housing in a position as shown in Figure 4, p. 19, for 10 minutes.
11. Turn the gears with coupling and a tool. Check bearings do not rotate on bonded diameters and gears rotate
freely.
12. Install pins (88) in motor cover (97).
13. Install exhaust washer (99) with a drop of Loctite® 601 or equivalent on motor cover.

18 MHD56492
 Maintenance

14. Install ‘O’ rings (90) on motor cover (97).

15. Install motor cover (97) on motor housing and secure with capscrews (107).
16. Lubricate ‘O’ rings (85) on valves (94) and (105). One ‘O’ ring is mounted in a special groove. Ensure a good
assembly.
17. Install springs (96) and valve assemblies (94) and (104) in motor cover (97).
18. Lubricate and install ‘O’ rings (166) on check valve (83). Install ball (84) and check valve assembly in motor
housing (87).
19. Check to ensure motor gears turn smoothly in both directions.
Figure 4. MHP2644

(Dwg. MHP2644)

Motor Emergency Stop End Cover

Refer to Dwg. MHP3375 in the Parts Information Manual.
1. Lubricate and install ‘O’ ring (201) and seal (189) on base plate (199).
2. Lubricate and install ‘O’ ring (197) to plunger (198).
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.
4. Insert base plate (199) with plunger into motor cover (97).
5. Lubricate and install ‘O’ rings (204) on valve seat (205).
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). Apply a thin film of Loctite® 243 or equivalent to capscrew
threads. Do not over tighten capscrew.
7. Place seal (210) and cap (202) on capscrew (62). Place spring (213) on cap (202).
8. Install valve seat assembly into emergency stop end cover (185).

MHD56492 19
Maintenance

9. Lubricate and install ‘O’ ring (191) on regulating screw (192); insert into emergency stop end cover (185)
avoiding damage to the ‘O’ ring. Secure with screw (102). Install screw (102) with Loctite® 243 or equivalent.
10. Lubricate and install spring (193).
11. Install ‘O’ rings (187) to valve seat (186).
12. Insert axle (188) into valve seat (186) then install seals (189) on each end of axle (188).
13. Insert valve seat (186) into emergency stop end cover (185).
14. Insert ball (84) into emergency stop end cover (185).
15. Install gasket (101) on motor cover (97).
16. Install emergency stop end cover (185) on motor cover (97) and secure with capscrews (103).
17. Insert plug (182) if removed during disassembly.
18. Install setscrew (180) in emergency stop end cover (185).
19. Install ‘O’ rings (90) on emergency stop end cover (185).
20. Install control valve assembly.
21. If pendant adapter plate (605) or (613) was removed from motor cover (83), refer to pendant assemblies for
installation.

Reduction Gear Assembly

Refer to Dwg. MHP2807 in the Parts Information Manual.
1. Install oil seal (17) in the bore of the reduction gear end cover (15) so seal lip is toward the planet assembly side.
2. Lubricate and install ‘O’ ring (16) on outside diameter of reduction gear end cover (15). Install plug (14).
3. Press bearings (13) and (39) into the reduction gear end cover (15). Install retainer ring (12) on the gear shaft
(20).
4. Press gear shaft (20) into reduction gear end cover (15).
5. Install ring gear (19) and bearing (21) on gear shaft (20) and secure in position with retainer ring (94). Install
assembly in reducer housing (27).
6. Press bearing (35) onto the sun gear (34) and locate with retainer ring (36). Install sun gear (34) with bearing (35)
in the planet gear support (32) and secure with retainer ring (49).
7. Install two bearings (28) with a spacer (30) between in the bore of each planetary gear (31).
8. Install bearing rings (29) in each bearing (28).
9. Position each assembled planetary gear in the planet gear support (32) with the timing mark as shown on
drawing Figure 5, p. 20.

CAUTION
!
For assembly of planet gears, each planet gear must be positioned with the timing mark as shown
on Dwg. MHP1406

Figure 5. MHP1406

B
C

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

20 MHD56492
 Maintenance

Product Instruction Manual.

14. Install new gasket (20) on reducer housing (27).
15. Apply Loctite® 243 to capscrews. Refer to “Torque Chart,” p. 24.

Disc Brake Assembly

Refer to Dwg. MHP3376 in the Parts Information Manual.
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 assembly.
3. Assemble brake housing (41) to reducer assembly and secure with capscrew (24).
4. Ensure plug (14) is removed, then press piston assembly into brake housing (41). 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), drive plate (56) and finishing with friction plate with springs
(58).
6. Install plug (14).

Winch Base and Drum Assembly

Refer to Dwgs. MHP3312 in the Parts Information Manual.
1. Install oil seal (77) and rear bearing (76) on drum end cover (78). Oil seal lip must be toward the bearing
2. Install drum end cover assembly on upright (62) and secure with capscrews (50) and lockwashers (73).
3. Position the upright on several block of wood with the rear bearing (76) up.
4. Check that plate (72) is securely installed in the drum with countersunk screws (71).
5. Lubricate the outside diameter of oil seal (77) and install drum assembly on rear bearing.
6. Install oil seal (77) and front bearing (76) on drum end cover (78). Oil seal lip must be toward the bearing.
7. Install drum end cover assembly on front upright (62) and secure with capscrews (50) and lockwashers (73).
8. Lubricate the outside diameter of oil seal (77) and install front upright assembly on drum (60).
9. Rotate uprights so they are aligned and install spacers (66) and siderails (68) with capscrews (65) and (67), nuts
(63) and washers (64). Longer capscrews (65) are required to attach lifting lugs (69). Mount lifting lugs
diagonally opposite.
10. Check pin (79) is installed in drum end cover (78).
11. Install motor reducer assembly. Ensure gear shaft (20) meshes with splined bore in drum and secure with
capscrews (86) and lockwashers (125).
12. Return winch to a horizontal position.
13. Install remaining external assemblies.

Automatic Band Drum Brake Assembly

Refer to Dwg. MHP3298 in the Parts Information Manual. It is recommended that any brake cylinder service work be
conducted by an Ingersoll Rand trained technician.
1. Install ‘O’ ring (145) on the piston (146).
2. Install oil seal (114), ring (143) and ‘O’ ring (145) in the cover (117).
3. Install piston (146) and spring (144) in the housing (147).
4. Install cover (117) and close brake cylinder assembly with capscrews (302) and lockwashers (73). Before closing
the brake cylinder, fill the spring housing with about 1 oz. (25 ml) of SP 150 type oil.
Brake Band:
1. Thread nut (148) onto adjustment screw (149), then install adjustment screw (149) in brake cylinder assembly.
2. Install the brake cylinder assembly with capscrews (156) and lockwashers (64) on the siderail (68).
3. Install band brake (111) on drum (60). Anchor brake band ends to adjustment screw (149) and piston (146) with
pins (112) and cotter pins (113). Bend ends of cotter pins apart.
4. Install locknut (151) and washer (150) on adjustment screw (149).
5. Adjust brake band assembly. Refer to “Automatic Band Drum Brake ,” p. 11.

Limit Switches Assembly

Refer to Dwg. MHP3372 in the Parts Information Manual.

MHD56492 21
Maintenance

1. Install limit switch adapter (450) on drum end cover (78). Secure with capscrews (98) and lockwashers (73).
2. Install spindle switch assembly (501) on limit switch adapter (450). Secure with capscrews (499).
3. Install one gasket (490) on each end of housing (486).
4. Thread one nut (73) and washer (73) on each rod (502). Install four rods in limit switch adapter (450) and tighten
nut (73). Ensure full thread engagement of rod in limit switch adapter.
5. Install housing (486) and housing cover (505). Position housing with cap assembly (498) hole on top. Align
housing cover holes with rods.
6. Install nuts (504) on rods (502) to secure housing and housing cover.

Slack Line Device Assembly

Refer to Dwg. MHP3296 in the Parts Information Manual.
1. Attach valve support (325) to sensor valve (327) with capscrews (318).
2. Attach protector (322) to valve support (325) with capscrews (22) and washers (23).
3. Attach protector (323) and valve support (325) to upright (62) with capscrews (324) and lockwashers (2).
4. Install bearings (309) on the shoulder screws (310).
5. Install arms (303), rollers (306) and axles (304) and (305). Install nuts (301) and lockwashers (73) on roller axle
(305).
6. Install capscrews (302) and lockwashers (73) on axle (304).
7. Install spacers (308) and slack wire arm assembly. Tap shoulder screws (310) into uprights (62).
8. Install nuts (301) and washers (307) on shoulder screws (310).
9. Connect hoses.

Press Roller Assembly

Refer to Dwgs. MHP3313 in the Parts Information Manual.
1. Install press rollers (184) between roller arms (181) and secure with capscrews (161) and washers (162).
2. Install frames (176) and springs (169) on roller arms (181). Secure with capscrews (161) and washers (162).
3. Install press roller assembly in spacer (404). Secure with capscrews (183) and lockwashers (73).
4. Compress ends of springs (167) and (169) to engage with spacer (66) and pin on press roller arm (163).

Water Separator, Regulator, Filter, and Lubricator Assembly

Refer to Dwg. MHP3385 in the Parts Information Manual.
Horizontal Take-off Angle:
1. 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.
3. install hose connections and three way shut-off valve (407).
Vertical Take-off Angle:
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
!
Run winch in both directions with no load to ensure proper connections and no air leaks.

Drum Guard Assembly

Refer to Dwg. MHP3312 in the Parts Information Manual.

NOTICE
!
Install drum guard for proper take-off angle, refer to data (name) plate for model.

1. Install drum guard (216) and both side panel guards and secure with capscrew (161).

22 MHD56492
 Maintenance

Two Function Emergency Stop Pendant Assembly (optional)

Refer to Dwg. MHP2818 in the Parts Information Manual.
1. Install ‘O’ rings (166) and protector (170) on valves (165). Install valve assemblies in handle (514).
2. Install levers (503) in pendant handle (514) with pin (502). Stake pin in pendant handle at both ends to secure.
3. Install screws (504) in levers.
4. Install screws (173) in handle.
5. Install balls (84) and springs (177) in handle (514). Secure in position with plugs.
6. On pendants with emergency stop, install emergency stop button (164).
7. On pendants without emergency stop button, install plug (507).
8. Install exhaust washer (41) and secure in handle with retainer ring (512).
Adjustment:
1. Connect the inlet of the pendant to 100 psi (7 bar) air supply.
2. Connect a manometer at the outlet of the lever to be adjusted.
3. Apply a small amount of Loctite® 243 on the adjustment screw (521).
4. Tighten the adjustment setscrew to obtain a pressure of 15 psi (1 bar) without operating the lever.
5. Release the adjustment setscrew by a half turn (pressure must fall to zero).
6. Push the lever. Check that pressure reaches 93 +/-7 psi (6.5 +/- 0.5 bar). Check that there is no leak at the exhaust.
7. Release the lever; exhaust must occur and result in rapid pressure reduction.
8. Repeat steps 6 and 7. Do this 2 to 3 times.
9. Disconnect the manometer. Check to make sure that there are no leaks when the lever is not activated.
10. Repeat the steps from 2 thru’ 9 with each lever.

Testing
Operational Test
Before you use, all new, altered or repaired winches must be tested for correct operation.
1. Make sure that the guards are installed and tight.
2. Make sure that all winch mounting bolts are tight.
3. Operate winch in both directions with no load.
4. Do a check for the operation of brakes and emergency stop.
5. Do a check for the operation of the limit switches, slack line device, press roller and all safety devices when
installed.

Load Test
Before use, winches must be load tested by an Ingersoll Rand trained technician and make sure that the rating of
the winch agrees with the written report furnished. Make sure that the test loads are between 100 and 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:

NOTICE
Winch Load Test!
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.

MHD56492 23
Torque Chart
Standard Coarse Thread Torque
SAE Grade 5 SAE Grade 8
Size
Dry Lubricated PTFE Dry Lubricated PTFE
1/4-20 8-10 6-7 4 12-14 9-10 5-6
5/16-18 17-20 13-15 8-9 25-28 18-21 11-13
3/8-16 31-35 23-26 14-16 44-49 33-37 20-22
7/16-14 49-56 37-42 22-25 70-79 52-59 31-36
1/2-13 75-85 57-64 34-38 106-121 80-90 48-54
9/16-12 109-123 82-92 49-55 154-174 115-130 69-78
5/8-11 150-170 113-128 68-77 212-240 159-180 95-108
3/4-10 267-302 200-227 120-136 376-426 282-320 169-192
7/8-9 429-487 322-365 193-219 606-687 455-515 273-309
1-8 644-729 483-547 290-328 909-1030 681-772 409-463
1 1/8-7 794-900 596-675 357-405 1288-1460 966-1095 580-657
1 1/4-7 1121-1270 840-952 504-571 1817-2059 1363-1545 818-927
Standard Fine Thread Torque
SAE Grade 5 SAE Grade 8
Size
Dry Lubricated PTFE Dry Lubricated PTFE
1/4-20 10-11 7-8 4-5 14-15 10-12 6-7
5/16-24 19-22 14-16 9-10 27-31 20-23 12-14
3/8-24 35-40 26-30 16-18 49-56 37-42 22-25
7/16-20 55-63 41-47 25-28 78-88 58-66 35-40
1/2-20 85-96 64-72 38-43 120-136 90-102 54-61
9/16-18 121-137 91-103 55-62 171-194 128-146 77-87
5/8-18 170-193 127-144 76-87 240-272 180-204 108-122
3/4-16 297-337 223-253 134-152 420-476 315-357 189-214
7/8-14 474-537 355-403 213-242 669-758 502-568 301-341
1-12 704-798 528-599 317-359 995-1127 746-845 448-507
1 1/8-12 1023-1159 767-869 460-572 1444-1637 1083-1227 650-736
1 1/4-12 1425-1615 1069-1211 641-727 2012-2280 1509-1710 905-1026
Metric Coarse Thread Torque
Class 8.8 / 9.8 Class 10.9
Size
Dry Lubricated PTFE Dry Lubricated PTFE
M6x1 9-10 6-7 4 11-12 8-9 5-6
M8x1.25 21-23 16-18 9-11 26-30 20-22 12-13
M10x1.5 41-47 31-35 19-21 53-60 39-45 24-27
M12x1.75 71-81 54-61 32-36 91-103 68-77 41-46
M14x2 115-130 86-98 52-59 147-166 110-125 66-75
M16x2 165-187 124-140 74-84 227-257 170-193 102-116
M20x2.5 321-364 241-273 144-164 443-502 332-376 199-226
M22x2.5 439-497 329-373 197-224 605-686 454-514 272-309
M24x3 556-630 417-473 250-284 767-869 575-652 345-391
M30x3.5 1103-1250 827-938 496-563 1521-1724 1141-1293 685-776

24 MHD56492
 Torque Chart

Metric Fine Thread Torque

Class 8.8 / 9.8 Class 10.9
Size
Dry Lubricated PTFE Dry Lubricated PTFE
M8x1 22-25 17-19 10-11 28-32 21-24 13-14
M10x1.25 44-49 33-37 20-22 56-63 42-47 25-28
M12x1.25 78-89 59-67 35-40 100-113 75-85 45-51
M14x1.5 125-141 93-106 56-64 159-180 119-135 72-81
M16x1.5 176-200 132-150 79-90 243-276 183-207 110-124
M18x1.5 257-291 193-219 116-131 355-402 266-302 160-181
M20x1.5 358-406 268-304 161-183 494-559 370-420 222-252
M22x1.5 484-548 363-411 218-247 667-756 500-567 300-340
M24x2 609-690 456-517 274-310 839-951 630-713 378-428
M30x2 1227-1390 920-1043 552-626 1692-1918 1269-1438 761-863

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

MHD56492 25
Notes

MHD56492
 Notes

MHD56492
Ingersoll Rand (NYSE: IR) advances the quality of life by creating comfortable, sustainable and efficient
environments. Our people and our family of brands—including Club Car®, Ingersoll Rand®, Thermo King® and
Trane®—work together to enhance the quality and comfort of air in homes and buildings; transport and protect
food and perishables; and increase industrial productivity and efficiency. We are a global business committed
to a world of sustainable progress and enduring results.

ingersollrand.com

Ingersoll Rand has a policy of continuous product and product data improvements and reserves the right to change design and
specifications without notice.
We are committed to using environmentally conscious print practices.

MHD56492-EN 13 May 2019

Supersedes (New) ©2019 Ingersoll Rand