Form MHD56298

IMPORTANT INFORMATION:
• A copy of our “Safe Operating Practices” Manuals are always available free of charge either by downloading it from our
Technical Publications website @ www.airwinch.com or by contacting the Factory at (800) 866-5457 for North America and
(206) 624-0466 for International. The Safe Operating Practices manual must be read prior to anyone operating a
Ingersoll-Rand winch or hoist. The manual form numbers are as follows:
“Safe Operating Practices Non-Man Rider™ Winches” Manual, Form No. MHD56250
“Safe Operating Practices for Man Rider™ Winches” Manual, Form No. MHD56251
“Safe Operating Practices for Pneumatic, Hydraulic and Electric Hoists” Manual, Form No. MHD56295

• Available winch options may require additional supplements to the basic winch manual.

• For Man Rider™ winches ensure a copy of the Man Rider™ supplement is made available to the operator prior to winch
operation.
Winch Man Rider™ Supplements:
Model: Publication No. Model: Publication No.
FA2, FA2.5, LS500RLP SAM0011
MHD56046
FH2, FH2.5 LS1000RLP SAM0012
MHD56042 and LS150RLP SAM0082
FA5
MHD56220 LS150RLP/500/
SAM0115
FA10 MHD56252 1000
FA2.5A MHD56236 LS150RLP and
SAM0120
LS150PLP-PH
FA2B and
MHD56207
HU40A LS500RLP-E SAM0122
FH10MR MHD56212 LS150RLP-
SAM0184
Fulcrum Electric MHD56277 DP5M-F

LS500HLP/ LS150HLP SAM0222

SAM0004
LS1000HLP

• We strongly recommend that ALL maintenance on Ingersoll-Rand equipment be carried out by personnel certified by
Ingersoll-Rand, or by Ingersoll-Rand Authorized Service Centers.

• Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions.

• Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist.

• ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested
prior to being placed into service:
* Winches - ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
* Hoists - ANSI / ASME B30.16 (OVERHEAD HOISTS - UNDERHUNG) Refer to section 16.2.2 - Testing.

Form MHD56298
Edition 2
November 2004
71441844
© 2004 Ingersoll-Rand Company
 Form MHD56244

PARTS, OPERATION AND MAINTENANCE MANUAL

MODEL FA150KGMR-RC MAN RIDER ®

(Dwg. MHP2374)

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.
This manual applies only to FA150KGMR-RC winches designed by Ingersoll-Rand that
are identified for personnel lifting by a permanent nameplate attached to the winch at the
factory.
Always operate, inspect and maintain this winch in accordance with European Security
Rules and any other applicable safety codes and regulations.

Form MHD56244
Edition 1
December 2001
71396907
© 2001 Ingersoll-Rand Company
 CONTENTS

Description Page No.

Safety Information
Danger, Warning, Caution and Notice .................................................................................................................................................................3
Safety Summary...................................................................................................................................................................................................3

General Information
Operating Limitations ..........................................................................................................................................................................................4
Traceability ..........................................................................................................................................................................................................4

Winch Operating Instructions

Man Rider Operating Instructions.......................................................................................................................................................................5

Warning Labels ..................................................................................................................................................................................................6

Specifications
Description...........................................................................................................................................................................................................7

Installation
Mounting............................................................................................................................................................................................................10
Wire Rope ..........................................................................................................................................................................................................10
Air Supply..........................................................................................................................................................................................................13
Initial Winch Operating Checks.........................................................................................................................................................................14

Operation
Training..............................................................................................................................................................................................................17
Winch Controls ..................................................................................................................................................................................................18
Winch Brakes .....................................................................................................................................................................................................19
Slack Line Detector ...........................................................................................................................................................................................20
Press Roller ........................................................................................................................................................................................................20
Limit Switches ...................................................................................................................................................................................................20
Emergency Lowering .........................................................................................................................................................................................20

Inspection
Records and Reports ..........................................................................................................................................................................................21
Frequent Inspection............................................................................................................................................................................................21
Periodic Inspection ............................................................................................................................................................................................22
Winches Not in Regular Use..............................................................................................................................................................................22

Inspection and Maintenance Report ..............................................................................................................................................................23

Troubleshooting................................................................................................................................................................................................24

Lubrication
Reduction Gear and Disc Brake Lubrication .....................................................................................................................................................30
Air Line Lubricator ............................................................................................................................................................................................30
Wire Rope ..........................................................................................................................................................................................................30
Seals and Bearings .............................................................................................................................................................................................30

Maintenance
Adjustments .......................................................................................................................................................................................................31
Disassembly .......................................................................................................................................................................................................31
Cleaning, Inspection and Repair ........................................................................................................................................................................33
Assembly ...........................................................................................................................................................................................................34
Testing................................................................................................................................................................................................................36

Parts Section
Parts Drawings and Parts Lists Table of Contents .............................................................................................................................................38
Winch Parts Drawings and Parts Lists ..........................................................................................................................................................40-67
Parts Ordering Information ................................................................................................................................................................................70

2 MHD56244 - Edition 1
 SAFETY INFORMATION

This manual provides important information for all personnel The National Safety Council, Accident Prevention Manual for
involved with the safe installation, operation and proper Industrial Operations, Eighth Edition and other recognized safety
maintenance of this product. Even if you feel you are familiar with sources make a common point: Employees who work near
this or similar equipment, you should read this manual before suspended loads or assist in hooking on or arranging a load should
operating the winch. 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
Danger, Warning, Caution and Notice
failure, no personnel would be injured. This means keep out from
Throughout this manual there are steps and procedures which, if under a raised load and keep out of the intended path of any load.
not followed, may result in a hazard. The following signal words
are used to identify the level of potential hazard. The Occupational Safety and Health Act of 1970 generally places
the burden of compliance with the user, not the manufacturer.
Danger is used to indicate the presence Many OSHA requirements are not concerned or connected with
of a hazard which will cause severe
the manufactured product but are, rather, associated with the final
injury, death, or substantial property
installation. It is the owner’s and user’s responsibility to determine
damage if the warning is ignored.
the suitability of a product for any particular use. It is
Warning is used to indicate the presence recommended that all applicable industry, trade association,
of a hazard which can cause severe federal, state and local regulations be checked. Read all operating
injury, death, or substantial property instructions and warnings before operation.
damage if the warning is ignored.
Rigging: It is the responsibility of the operator to exercise caution,
Caution is used to indicate the presence use common sense and be familiar with proper rigging techniques.
of a hazard which will or can cause Refer to ASME B30.9 for rigging information, American National
injury or property damage if the warning Standards Institute, 1430 Broadway, New York, NY 10018.
is ignored.
Notice is used to notify people of This manual has been produced by Ingersoll-Rand to provide
installation, operation, or maintenance dealers, mechanics, operators and company personnel with
information which is important but not information required to install, operate, maintain and repair the
hazard-related. products described herein.

It is extremely important that mechanics and operators be familiar

with servicing procedures of these products, or like or similar
Safety Summary 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
• Be sure to check all regulations, local, state, federal and hand tools as well as special Ingersoll-Rand or
country, that may apply to the use of a winch or winch system recommended tools.
for lifting and lowering people before using a Man Riding 2. Safety procedures, precautions and work habits established
winch. by accepted industry standards.
• The supporting structures and load-attaching devices used in
conjunction with this winch must provide an adequate safety Ingersoll-Rand cannot know of, or provide all the procedures by
factor to handle the rated load, plus the weight of the winch which product operations or repairs may be conducted and the
and attached equipment. This is the customer’s responsibility. hazards and/or results of each method. If operation or maintenance
If in doubt, consult a registered structural engineer. procedures not specifically recommended by the manufacturer are
conducted, it must be ensured that product safety is not
Ingersoll-Rand winches are manufactured in accordance with endangered by the actions taken. If unsure of an operation or
European Security Rules and Regulations. maintenance procedure or step, personnel should place the product
in a safe condition and contact supervisors and/or the factory for
technical assistance.

MHD56244 - Edition 1 3
 GENERAL INFORMATION

Ingersoll-Rand offers, in its winch product line, a limited number 7. The personnel platform shall be designed by a registered
of models referred to as Man Rider which are designed and engineer competent in this area.
manufactured to standards and specifications based on the
recommendations of various regulatory bodies for the purpose of
lifting people.
• Lifting personnel with this winch is STRICTLY LIMITED to
Man Rider winches are type-approved and/or certified to meet the off-shore marine applications specifically approved by
requirements of the Offshore Oil Industry by one or more of the maritime regulatory bodies. Suitable use is determined by
following regulatory bodies: regulatory bodies, not the manufacturer. DO NOT USE FOR
American Bureau of Shipping (ABS), Lloyd’s Register of personnel lifting applications not specifically approved by
Shipping (LRS) or Det Norske Veritas (DNV) to comply with regulatory bodies.
the UK Health and Safety Executive (HSE), UK Department of
Energy (DEn), the Norwegian Maritime Directorate (NMD) or the
Norwegian Petroleum Directorate (NPD). Traceability
In furnishing customers Man Rider winches, I-R does not warrant Load bearing parts are documented to provide traceability.
the suitability of these winches for any particular use. It is the Documentation includes chemical and physical properties of raw
owner’s and user’s responsibility to determine the suitability of a material, heat treating, hardening, tensile and charpy tests as
Man Rider winch for a particular application. Further, it is the required for the part.
owner’s and user’s responsibility to check and satisfy all local,
state, federal and country requirements pertaining to lifting and Winches with M1, M2 or M3 in the model code have traceable
lowering people. load bearing components.

M1–Material Traceability certificates according to EN 10204

(Ex DIN 50049) 2.2 on load bearing parts. Conformity documents
• Many agencies require on winches additional redundant affirm (by the manufacturer) that parts are in compliance with the
safety devices that I-R does not furnish. Additional devices are
requirements of the order based on non-specific inspection and
often required to bring the system up to elevator code testing (i.e., results are typical material properties for these parts).
standards.
M2–Material Traceability certificates according to EN 10204
Operating Limitations (Ex DIN 50049) 3.1b on load bearing parts. Conformity
documents affirm (by a department independent of the
Man Rider winches manufactured by I-R to ABS, LRS and/or manufacturing department) that the actual parts are in compliance
DNV requirements are furnished with limitations; approval for use with the requirements of the order based on specific inspection
in personnel-lifting applications automatically terminates for any and testing (i.e., results are actual material properties for these
of the following reasons: parts).
1. Winch does not meet other applicable codes or standards.
2. Winch is not part of an approved system. M3–Material Traceability certificates according to EN 10204
3. Winch is not properly maintained in an “as new” condition (Ex DIN 50049) 3.1b on load bearing parts. Conformity
with all parts intact and properly adjusted. documents affirm (by a department independent of the
4. Winch is used in applications not approved by codes and manufacturing department) that the actual parts used in the
regulations, or is used in applications inconsistent with product are in compliance with the order based on specific
manufacturer’s operation and maintenance manual. inspection and testing (i.e., results are actual material properties
5. Changes in any of the standards or regulations after for these parts in a finished, as delivered condition).
Ingersoll-Rand’s initial shipment of the product.
6. More than one winch is used to attach to a common load. Components with part numbers ending in CH are charpy parts for
use under extreme cold conditions. Traceability requirements must
be stated when reordering these parts for continued certification.

• Before using a Man Rider winch, be sure to check all

regulations: local, state, federal and country, that may apply to
the use of a winch or winch system for lifting and lowering
people.

4 MHD56244 - Edition 1
 OPERATING INSTRUCTIONS

Man Rider Operating Instructions General Operating Instructions

The following warnings and operating instructions have been
adapted in part from American National (Safety) Standard ASME
B30.7 and are intended to avoid unsafe operating practices which
• Failure to follow these instructions may result in termination might lead to injury or property damage.
of all applicable warranties. Ingersoll-Rand assumes no
liability for any loss or damage resulting from operation of Ingersoll-Rand recognizes that most companies who use winches
Man Rider winches if these operating instructions are not have a safety program in force at their facility. In the event that
followed. some conflict exists between a rule set forth in this publication and
a similar rule already set by an individual company, the more
1. Winch operator must maintain visual or signalmen contact stringent of the two should take precedence.
with personnel being lifted or lowered at all times.
2. Personnel operating the winch or being transferred are to Safe Operating Instructions are provided to make an operator
have sufficient instruction/training concerning that operation aware of dangerous practices to avoid and are not necessarily
before any movement takes place. limited to the following list. Refer to specific sections in the
3. Winch installation must be arranged to conform to statutory manual for additional safety information.
regulations covering personnel handling.
4. Prior to any personnel movement, winch shall be inspected to 1. Only allow people trained in safety and operation of this
ensure safe operation. product to operate and maintain this winch.
5. Lifting apparatus (basket, etc.) shall be inspected and 2. Only operate a winch if you are physically fit to do so.
certified for personnel lifting prior to use. 3. When a “DO NOT OPERATE” sign is placed on the winch,
6. Winch shall not be overloaded. or controls, do not operate the winch until the sign has been
7. Do not operate without testing. Refer to “INSPECTION” and removed by designated personnel.
“TESTING” procedures. 4. Before each shift, the operator should inspect the winch for
8. Do not operate winch in a damaged condition. wear and damage. Never use a winch that inspection
9. Do not operate winch in an improperly equipped or indicates is worn or damaged.
maintained condition. 5. Never lift a load greater than the rated capacity of the winch.
10. Do not attach winch to an unsafe foundation. All bolts and Refer to nameplate attached to winch or to
foundations should have a higher load carrying capacity than “SPECIFICATIONS” section on page 7.
the wire rope on winch. 6. Keep hands, clothing, etc., clear of moving parts.
11. Do not operate winch if any personnel are near the line of 7. Never place your hand in the throat area of a hook or near
force or where they are likely to come into contact with wire rope spooling onto or off of the winch drum.
moving parts. 8. Always rig loads properly and carefully.
12. All signs and warning notices must be permanently posted on 9. Be certain load is properly seated in the saddle of the hook.
winch. Do not support the load on the tip of the hook.
13. Always maintain three or more wraps of wire rope on winch 10. Do not “side pull” or “yard”.
drum. 11. Always ensure that you, and all other people, are clear of the
14. Never leave an unattended load suspended. path of the load. Do not lift a load over people.
15. Wire rope must spool off drum from the top away from the 12. Ease slack out of wire rope when starting a lift or pull. Do not
operator. jerk the load.
13. Do not swing a suspended load.
14. Do not leave a suspended load unattended.
15. Never operate a winch with twisted, kinked or damaged wire
rope.
16. Pay attention to load at all times when operating winch.
17. Never use wire rope as a sling.
18. After use, or when in a non-operational mode, the winch
should be secured against unauthorized and unwarranted use.

MHD56244 - Edition 1 5
 WARNING LABELS

Each unit is shipped from the factory with warning labels shown.
If labels are not attached to your unit, order new labels and install.
Refer to parts list for part numbers. Labels are shown smaller than
actual size.
Failure to follow these
warnings can result in
severe injury, death or
property damage:
• Do not operate this
TM winch before
reading operation
Personnel lifting with this winch is STRICTLY LIMITED to off-shore and maintenance
manual.
marine applications specifically approved by maritime regulatory
bodies. Regulatory bodies, not the manufacturer, have determined
suitable use. Use for man-lifting ONLY IN APPLICATIONS • Do not lift people except as
SPECIFICALLY APPROVED by regulatory bodies. allowed by maritime regulatory
bodies for people lifting
71108856/A applications.

• Do not lift loads over people.

• Do not lift more than rated load
as specified on name plate.

• Do not allow less than three

wraps of wire rope to remain
on drum at all times.

• Do not operate a damaged or

malfunctioning winch.

• Do not remove or obscure

warning labels.

Comply with third party maritime regulations

for man-lifting and material handling applications.
P/N 71124887
for Offshore Man Rider™
winches

WARNING
- NEVER ACTIVATE THE BALANCING SYSTEM WHEN THERE IS NO LOAD.
BALANCING POINT ADJUSTMENT PROCEDURE:
select STANDARD WINCH mode
(Green indicator will come on to indicate standard winch mode working)
I) PERSON MUST HAVE THE SAFETY HARNESS FITTED.
II) ADJUST PRESSURE REGULATOR KNOB TO APPROX 1 BAR.
III) RAISE MAN 0.5 METER ABOVE FLOOR WITH MAIN CONTROL LEVER
Select Balancing Mode
(Green indicator will come on to indicate balancing mode working)
SLOWLY ADJUST PRESSURE REGULATOR KNOB TO OBTAIN BALANCING POINT.
— CLOCKWISE WILL INCREASE PRESSURE AND TEND TO LOWER MAN.
— ANTICLOCKWISE WILL DECREASE PRESSURE AND THE ABILITY TO LOWER MAN.
(At this point it is recommended than additionnal person is present to increase the load
when required for balancing purposes)
USE CONTROL LEVER TO RAISE PERSON TO WORKING POSITION WHEN JOB
IS COMPLETED, AND PERSON IS BACK ON THE FLOOR, SELECT STANDARD
MODE BEFORE TAKING THE SAFETY HARNESS OFF
IMPORTANT
- THE BALANCING MODE MUST ALWAYS BE SELECTED WHEN LIFTING A
PERSON TO WORKING POSITION.
96150447

6 MHD56244 - Edition 1
 SPECIFICATIONS

Output from the externally mounted gear air motor is transmitted

Description
through a disc brake to the planetary reduction gear assembly.
FA150KGMR-RC winches are air powered, planetary geared The output from the planetary reduction gear assembly is
units designed for transporting personnel. FA150KGMR-RC connected to the wire rope drum through the drum carrier.
winches are supplied with an internal automatic disc brake and The disc brake is automatically applied when winch is in neutral.
automatic drum band brake. The drum band brake operates by applying a friction force
between the drum band and winch drum.
Model Code Explanation

Example: FA150KGMR12-RC-60-C-E FA 150KG MR 12 - RC - 60 - C - E

Series
FA = Force 5 Air Powered
Capacity: (based on wire rope at full drum)
150KG = 330 lb [150 kg] Man Rider Rating
Man Rider Designation:
MR = Man Rider
Drum Length:
8 = 8 inches (203 mm)
12 = 12 inches (305 mm)
16 = 16 inches (406 mm)
24 = 24 inches (610 mm)
Control:
1 = Winch mounted lever throttle (Standard)
3XX = Remote pilot pendant throttle (XX = Specify hose length (feet). Maximum 50 ft (15 metres))
includes automatic band brake
RC = Winch with remote “float” control console includes automatic band brake
Wire Rope Take-off Range:
Blank = 75° - 90°
60 = 60° - 75°
45 = 45° - 60°
0 = 0° - 45°, where 0° is horizontal
Design Temperature:
Blank = 32° F (0° C) or warmer
C = -4° F (-20° C)
Options:
M1 = Typical Material Certificates (2.2)*
M2 = As-received traceability*
M3 = As-shipped traceability*
N = Type approval (specify ABS or DNV) ††
Q = Special Paint ††
W = Witness Testing ††
X = Testing ††
-E = Compliance with European Machinery Directive (includes emergency stop and overload protection)
Notes:
* Refer to ‘Traceability’ on page 4 for a description of the differences between M1, M2 and M3.
†† If N, Q, W or X are entered, the details must be specified in the text of the sales order.

MHD56244 - Edition 1 7
 Air Rated Operating Pressure 75 psig (5.8 bar/580 kPa)
System Air Consumption (at rated pressure and load) 75 scfm 2.1 cu.m/min
Rated Performance (at Full Drum Line Pull 330 lbs 150 kg
rated pressure/volume) (1) Full Drum Line Speed 78 fpm 23.8 mpm
Sound Pressure Level (dBA) (2, 3) 89 dBA
Sound Power Level (dBA) (2) 103 dBA
Winch Overload Device Setting (4) 610 lbs 276 kg
Winch Net Weight
(without wire rope) 12 in. (305 mm) long drum 620 lbs 281 kg

Air Motor Port Inlet Size 3/4 in. NPT

Minimum Air System Hose Size 0.75 in. 19 mm
Wire Rope Size 10 mm
Maximum Foundation Anchor Shear Force at One Capscrew (5) 75 lbs 334 N
Drum Barrel Diameter 10.75 in. 273 mm
Drum Flange Diameter 19 in. 483 mm

Notes:
1. Performance based on 84 psig (5.8 bar/580 kPa) operating pressure.
2. Sound measurements have been made in accordance with ISO 11201, ISO 3744-3746 and ISO 4871 test specifications for sound from
pneumatic equipment. Readings shown are based on the average noise level of each winch configuration, proportionate to the utilized time
in a regular cycle.
3. Lpc (Peak Sound Pressure) does not exceed 130 dB.
4. Winch Overload Device is factory preset at 125% (+/- 10%) of the winch capacity at top layer.
5. Occurs when wire rope take-off from drum equals zero degree angle of inclination. Values based on wire rope at third layer and rated
line pull.

Wire Rope Storage Capacity

Line Speed @
330 lb (150 kg)
Load 8 in. (203 mm) 12 in. (305 mm) 16 in. (406 mm) 24 in. (610 mm)
Layer Drum Drum Drum Drum

fpm mpm ft m ft m ft m ft m

1 72 21.9 56 17 86 26 116 35 175 53

2 74 22.6 116 35 178 54 239 73 361 110

3 75 22.9 180 55 275 84 370 113 560 171

4 76 23.2 248 76 378 115 509 155 770 235

5 77 23.5 319 97 487 148 655 200 991 302

6 78 23.8 395 120 602 183 810 247 1225 373

7 78 23.8 474 144 723 220 972 296 1470 448

8 78 23.8 556 169 849 259 1142 348 1727 526

* Operate winch at speeds as slow as practical to ensure personnel safety.

** Wire rope storage capacity based on DNV and NMD standards of 2.5 times wire rope diameter below drum flange. Wire rope storage
capacities listed may vary from figures stated elsewhere.

8 MHD56244 - Edition 1
Performance Graph
409 900 76 2.15

74 2.06
363 800
1st Layer 72 2.04

318 700 70 1.98

Half Drum
68 1.93

Air Consumption (m³/min)

272 600

Air Consumption (scfm)

66 1.87
Line Pull (lbs)
Line Pull (kg)

227 500
64 1.81

62 1.75
181 400

Full Drum 60 1.69

136 300
58 1.64
Half Drum
91 200 56 1.58

1st Layer Full Drum 54 1.53

45 100
52 1.47

0 0 50 1.42
0 14 28 42 56 70 84 98 112 126 140 154 168 182 196 210 224
Line Speed (ft/min)
0 4.8 9.6 14.3 19.0 23.9 28.6 33.4 38.2 42.9 47.7 52.5 57.3 62.0 66.8 71.6 76.3
Line Speed (m/min)
(Dwg. MHP2395)

MHD56244 - Edition 1 9
 INSTALLATION

Prior to installing winch, carefully inspect it for possible shipping Winch Bolt Hole Mounting Dimensions
damage.
B B
Winch gearbox and disc brake are supplied fully lubricated from
factory. Refer to “LUBRICATION” section on page 30 for C
recommended oils.

• Owners and users are advised to examine specific, local or Drum A

other regulations, including American National Standards
Institute and/or OSHA Regulations which may apply to a
particular type of use of this product before installing or
putting winch to use.
(Dwg. MHP2288)
Mounting
Table 1: Mounting Bolt Hole Dimensions
Refer to Dwg. MHP2288 on page 10 and Table 1 on page 10. Drum Length (inches)
Care must be taken when moving, positioning or mounting winch. Dimension
Winch has lifting eyes welded to both uprights to assist in moving 8 12 16 24
the unit. Attach hooks or a suitable sling to these eyes when in. 20
moving winch. Refer to “SPECIFICATIONS” section on page 7 to “A”
mm 508
determine winch weight.
in. 7 9 7.5* 10*
“B”
Mount winch so drum axis is horizontal and motor control valve mm 178 229 190* 254*
pad is not more than 15 degrees off top vertical center. If winch is in. 0.69
to be mounted in an inverted position, the motor case must be “C”
rotated to position control valve pad at the top and adequate mm 18
clearance must be provided for control valve operation. Position * 4 mounting bolt holes in each side.
winch to provide unrestricted access to winch control valve. Do
not mount winch in a vertical position, with motor up or down.
Reduction gear box lubrication is not designed for this type of Wire Rope
installation.

1. Winch mounting surface must be flat and of sufficient

strength to handle rated load plus the weight of the winch and • Maintain at least 3 tight wraps of wire rope on drum at all
attached equipment. An inadequate foundation may cause times. Refer to Dwg. MHP0498 on page 12.
distortion or twisting of the winch uprights and side rails
resulting in winch damage. Install winch so that wire rope, when at take-off angle limits,
2. Make sure mounting surface is flat to within 1/16 in. shown in Dwg. MHP2269 on page 11, does not contact mounting
(1.6 mm). Shim if necessary. surface.
3. Mounting bolts must be 5/8 in. NC (16 mm) Grade 8 or
better. Use self-locking nuts or nuts with lockwashers. Install winch with single part wire rope reeving only.
4. Tighten mounting bolts evenly and torque to 220 ft lbs
(298 Nm) for dry thread fasteners. If fasteners are plated,
lubricated or a thread-locking compound is used, torque to
170 ft lbs (231 Nm).
5. Maintain a fleet angle between the lead sheave and winch of
no more than 1-1/2 degrees. The lead sheave must be on a
center line with the drum and, for every inch (25 mm) of
drum length, be at least 1.6 ft (0.5 m) from the drum. Refer to
Dwg. MHP0498 on page 12.

10 MHD56244 - Edition 1
Wire Rope Take-off Angles Sleeve
Wire

End Strands
75˚-90˚
60˚-75˚ Core Strand

45˚-60˚
Arm configuration
will vary depending
on wire rope take
off angle. Split Wedge
(Dwg. MHP0166)

3. Wrap wire rope with wire a distance from the end 2-5/8 in.
(60.3 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.
View From End
7. Pull wire rope anchor into position in drum anchor pocket.
Opposite Motor
(Dwg. MHP2269) Spooling Wire Rope onto Winch Drum

Wire Rope Selection

Consult a reputable wire rope manufacturer or distributor for CORRECT

assistance in selecting the appropriate type and size of wire rope
and, where necessary, a protective coating. Use a wire rope that
provides an adequate safety factor to handle the actual working
load and that meets all applicable industry, trade association,
federal, state and local regulations. Wire Rope
Spooling
When considering wire rope requirements the actual working load
must include not only the static or dead load but also loads
resulting from acceleration, retardation and shock load.
Consideration must also be given to the size of the winch wire
INCORRECT
rope drum, sheaves and method of reeving. Wire rope construction
must be 10 mm EIPS 6 X 19 IWRC with a minimum breaking
strength of 15,690 lbs (69.8 kN) right lay to assist spooling. Refer
to Table 2.
Table 2: Wire Rope Size Wire Rope
Spooling
Wire Rope Anchor Size
Part No.
(Dwg. MHP2294)
71387781 10 mm

Installing Wire Rope • Install wire rope to come off drum in an overwind position.
Improper installation of wire rope can result in failure of disc
brake to hold load and prevent overload device operation.
Refer to Dwg. MHP2269 and Dwg. MHP2294 on page 11.
• 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.
• Make sure the first wrap of wire rope is tight and lies flush
Refer to Dwg. MHP0166 on page 11. against drum flange.
1. Cut wire rope to length in accordance with wire rope • Ensure correct wire rope anchor is used.
manufacturer’s instructions.
2. Feed end of wire rope into wire rope anchor hole in drum and Safe Wire Rope Handling Procedures
pull through approximately 1 ft (305 mm) of wire rope.
1. Always use gloves when handling wire rope.
2. Never use wire rope which is frayed or kinked.

MHD56244 - Edition 1 11
3. Never use wire rope as a sling. Connection of the Control Console to the Winch
4. Always ensure wire rope is correctly spooled and the first
layer is tight against the drum. To connect the supply hoses to the control console, unions are
5. Always follow wire rope manufacturer’s recommendations placed so as to avoid any possible reversal during assembly. To
on use and maintenance of wire rope. connect supply hoses to control box on winch, refer to the marking
with color codes (blue, white, no color).
Wire Rope Spooling Twelve pipes numbered from 1 to 12 must also be connected to the
control box. Refer to Dwg. MHP2355 on page 63.
To compensate for uneven spooling and the decrease in line pull
capacity as the drum fills up, use as short a wire rope as practical.
When winding, apply tension to the end of the wire rope to
eliminate line slack. This helps achieve level winding and tight • Winches and control console are matched components, their
spooling. identification plates bear the same serial number. Under no
circumstances should the console change without having a
complete test of the winch-console assembly performed by a
certified maintenance person.
• Do not feed wire rope through slack wire roller for spooling
operation. This may cause damage to slack line arm. Test and adjustment procedure
1. Supply compressed air to the system.
Wire Rope and Fleet Angle Installation Drawing 2. Make sure the emergency stop button is unlocked.
3. Make sure the standard mode is selected.
4. Press button “ON”.
5. Static pressure 80 psi (5.5 0/+0.3 bar) adjust the manometer-
relief valve of the filter-regulator -lubricator if necessary,
then lock it or seal it. For correct performance, a dynamic
pressure of 75 psi (5.2 bar) minimum is necessary.
6. Check the standard mode, set the button mode to the standard
position.

Indicators
❍
------- Green ------- -------
Press button “ON”,

Indicators

❍
-Green Green ------- -------
Press the emergency stop button

(Dwg. MHP0498) Indicators

❍
Notes: ------- Green ------- -------
1. Maintain a minimum of 3 tight wraps of wire rope on drum at Power shut-off (manometer on left side of console is to 0
all times. + warning device is heard for a brief moment)
2. Ensure wire rope does not exceed top layer requirement.
Refer to “SPECIFICATIONS” section on page 7. Set the Mode button to the “balancing” position
3. For correct fleet angle maintain a minimum of 1.6 ft (0.5 m) The “failure” indicator comes on
per inch of drum length. Example: for 12 in. (305 mm) drum Set the button back to the “standard” mode
length locate lead sheave at least 19.2 ft (6 m) from drum. The “failure” indicator goes off
“A” = 1.6 feet (.05 metre) per inch of drum length: The “standard” mode is validated
“A” = 12.8 feet (3.9 metres) for 8 inch long drum.
“A” = 19.2 feet (5.8 metres) for 12 inch long drum.
“A” = 26.0 feet (7.9 metres) for 16 inch long drum.
“A” = 38.4 feet (11.7 metres) for 24 inch long drum. • If winch fails test, refer to “Troubleshooting” section on page
24.
Installation of the Control Console 7. CHECK OF NO LOAD SPEED
Speed in the lifting direction to 120 ft/min (37 m/min)
There are four holes of 1/2 inch (13 mm) diameter to attach the minimum
console. Speed in the lowering direction to 80 ft/min (24 m/min)
minimum.

• The position of the control console is very important for the

safety of the person attached to the harness. The operator
must be able to see the person at any time.

12 MHD56244 - Edition 1
 Adjustment in Balancing Mode To set for maximum wire rope haul-in:
1. Remove access plate (477) from top of limit switch (462).
This adjustment is done at factory. If adjustments need to be made 2. Loosen red setscrew in center of limit switch, below access
contact factory. cover.
3. Position winch wire rope at desired haul-in position.
4. Rotate right cam adjustment screw clockwise until it fully
Slack Line Detector activates cutoff valve, causing system air to vent. 2.75 turns
of cam adjustment screw are required for each full cam
Refer to Dwg. MHP2266 on page 50. revolution.
Before adjusting slack line detector remove one shoulder screw 5. Hold cam adjustment screw in position (venting air) and
(524) from outboard stop bracket (507). Store in threaded hole on tighten red setscrew.
opposite side of winch on the inboard support bracket (508). 6. If required, adjust payout limit switch. Test winch setpoints
by operating winch through three complete cycles to ensure
consistent limit switch operation within +/- 2 ft (0.7 m) of
setpoints.
• To avoid damage to limit valve (513), use shoulder screw
7. Install access cover when final adjustments are complete.
(524) to lock slack line detector for shipping, maintenance and
storage purposes.
Rigging
To adjust slack line detector, with wire rope installed on drum:
1. Loosen capscrew (514) on actuator bracket (505). Make sure all wire rope blocks, tackle and fasteners have a safety
2. Feed wire rope end between take-off rollers (501), and margin sufficient to handle the required load under all conditions.
remove slack from wire rope. Do not allow wire rope to contact sharp edges or make sharp
3. Rotate actuator bracket (505) until it contacts the limit switch bends which will cause damage to wire rope. Use a sheave. Refer
(481). Tighten capscrew (514). to wire rope manufacturer’s handbook for proper sizing, use and
care of wire rope.
Limit Switch
Safe Installation Procedures
Refer to Dwgs. MHP2278 on page 54 and MHP0607 on page 13.
Operate winch in both directions to activate limit switches. Limit 1. Do not use wire rope as a ground (earth) for welding.
switches should engage at established setting +/- 2 ft (0.7 m), and 2. Do not attach a welding electrode to winch or wire rope.
prevent winch operation until reset by shifting winch operating 3. Never run the wire rope over a sharp edge. Use a correctly
direction. sized sheave.
4. When a lead sheave is used, it must be aligned with the center
To set for maximum wire rope payout: of the drum. The diameter of the lead sheave must be at least
1. Remove cover plate (475) from top of limit switch (462). 18 times the diameter of the wire rope. Refer to Dwg.
2. Loosen blue setscrew in center of limit switch, below access MHP0498 on page 12.
cover. 5. Always maintain at least 3 full, tight wraps of wire rope on
3. Position winch wire rope at desired payout position. the drum.
4. Rotate left cam adjustment screw counterclockwise until it
fully activates cutoff valve, causing system air to vent. 2.75 Air Supply
turns of the cam adjustment screw are required for each full
cam revolution. Air supply must be clean, free from moisture and lubricated to
5. Hold cam adjustment screw in position (venting air) and ensure optimum motor performance. Foreign particles, moisture
tighten blue setscrew to lock cam in place. and lack of lubrication are primary causes of premature motor
6. If required, adjust haul-in limit switch. Test winch setpoints wear and breakdown. Using an air filter, lubricator and moisture
by operating winch through three complete cycles to ensure separator will improve overall winch performance and reduce
consistent limit switch operation within +/- 2 ft (0.7 m) of unscheduled downtime.
setpoints.
7. Install access cover when final adjustments are complete. Air consumption is 75 scfm (2.1 cu.m/min) at rated operating
pressure of 84 psig (5.8 bar/580 kPa) at the control console gauge.
Limit Switch Adjustment If air supply varies from what is recommended, winch
performance will change.
Cam Adjustment Screw
Exceeding 84 psi (5.8 bar/580 kPa) may cause inadvertent
Payout Haul-In activation of the overload device.
Turn Screw Turn Screw
Counter- Clockwise
clockwise to Adjust
• The whole equipment is delivered with 16 ft (5 meters) of
to Adjust
hose. Do not modify the length without informing
Ingersoll-Rand.
BLUE RED
Setscrew Setscrew Air Lines
(Dwg. MHP0607)
The inside diameter of the winch air supply lines must not be less
than the size shown in Table 3 on page 14. Prior to making final

MHD56244 - Edition 1 13
connections, all air supply lines should be purged with clean,
Initial Winch Operating Checks
moisture free air or nitrogen before connecting to winch inlet.
Supply lines should be as short and straight as installation Winches are tested for proper operation prior to leaving factory.
conditions will permit. Long transmission lines and excessive use Before winch is placed into service the following initial operating
of fittings, elbows, tees, globe valves, etc. cause a reduction in checks should be performed.
pressure due to restrictions and surface friction in the lines. 1. When first running motor, inject light oil into inlet
Table 3 connection to provide initial lubrication.
2. When first operating the winch, it is recommended that motor
Minimum Allowable Air Supply Line Sizes be driven slowly in both directions for a few minutes.
Model inch mm 3. Check Emergency Stop operation. Refer to “OPERATION”
section on page 17.
FA150KGMR-RC 3/4 19
4. Check Limit Switch operation. Refer to “OPERATION”
section on page 17.
Air Line Lubricator
For winches that have been in storage the following start-up
Always use an air line lubricator with these motors. Lubricator procedures are required.
must have an inlet and outlet at least as large as the inlet on motor. 1. Give winch an inspection conforming to the requirements of
The air line lubricator is mounted to the winch frame. ‘Winches Not in Regular Use’ in “INSPECTION” section on
page 21.
2. Pour a small amount of SAE 10W (ISO VG 32) oil in motor
inlet port.
• Shut off air supply before filling air line lubricator. 3. Operate motor for 10 seconds in both directions to flush out
any impurities.
Air line lubricator should be replenished daily and set to provide 2 4. Check to ensure oil levels are “full.”
to 3 drops per minute of SAE 10W (ISO VG 32) oil. A fine mist 5. The winch is now ready for normal use.
will be exhausted from the throttle control valve when the air line
lubricator is functioning properly.

Air Line Filter

The air line strainer/filter is mounted to the winch frame to prevent

dirt from entering motor. Strainer/filter should provide 20 micron
filtration and include a moisture trap. Clean strainer/ filter
periodically to maintain its operating efficiency.

Air Pressure Regulator

An air pressure regulator is installed between lubricator and filter.

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 the motor, an aftercooler at the compressor that cools the
air to condense and collect moisture prior to distribution through
the supply lines are also helpful.

Motor

For optimum performance provide an air supply of 84 psig at

75 scfm (5.8 bar/580 kPa at 2.1 cu.m/min) for FA150KGMR-RC
winches. Winch should be installed as near as possible to the
compressor or air receiver. Recommended pressures and volumes
are measured at the point of entry to emergency stop valve.

Mufflers

Ensure mufflers are installed in exhaust port of motor. Check

mufflers periodically to ensure they are functioning correctly.

14 MHD56244 - Edition 1
 Switches

(Dwg. MHP2353)
Bottom Slack Wire
System

MHD56244 - Edition 1
Top Limit Limit

S
Down

DFR
Up

FH FB Torque
Ø
PU Limiter
3/4"
Regulation
L2R Air Control for
Air Control Valve Balancing
L std Valve Ø3/4" Mode
Ø3/4"
Ø3/4" Ø3/4"

R1
Ø3/4" Ø3/4"
A
P1

L2A L2P Ø3/4"

Ø3/4" L1A
P=5.5Bar
Ø3/4" A
Ø3/4"

P1
R1
2 4
L1P
SYSTEM SCHEMATIC

AV
2 Balancing 2 4
Ø3/4" Mode
Y Up

Down
A 1 3 5
3 1 Y
X Ve A
Regulation for
VeA Standard Winch Ve,Dc Standard X

A
Winch
Mode 2
On
A 1
Reset
Y
ADVe Secondary
Power Source

15
16
1 Ø6
1 Input Number
Ø6
2
Ø6 Ø6 Ø6

(Dwg. MHP2365)
3 3-Way
Valve
&

Filter
16 14
Enter
2
4
Module
& & & & & & & >1 & >1 3 15
No Cell
&

11
& And Cell

5
>1 Or Cell
4

& >1 >1 >1 & & & & >1 & & & >1
A
R 4 Step
P Sequencer
12
9
6 Leak
7 Detector

A
R t3 0
>1 >1 >1 >1 & >1 & >1 >1
Timer
P
SEQUENCER SCHEMATIC

Ø6
24

Interlock
31 5

15
Ø6 14 4 2

5/2 Distribution
18 3 Valve
1
22 17 13 24 23 t3 0 t4 0 5
& >1 >1 &
20 14 4 2 14 4 2 14 4 2 14 4 2 14 4 2
19
5 5
Y
1 1
21 3 3 8 10
5
Ø4
1

3
Plug
Ø6

Ø4
Ø6 Reducer
Ø6

MHD56244 - Edition 1
 OPERATION

It is recommended that the user and owner check all appropriate 9. Rider suspension devices shall be in accordance with all
and applicable regulations before placing this product into use. applicable codes and regulations.
10. Bridles and associated hardware for the man riding device
The four most important aspects of winch operation are: shall not be used for any other service.
1. Follow all safety instructions when operating the winch. 11. If a slack wire rope condition occurs the hoisting mechanisms
2. Allow only people trained in safety and operation of this shall be inspected to assure wire rope is properly spooled
winch to operate this equipment. onto drum and through sheaves. When slack wire has been
3. Subject each winch to a regular inspection and maintenance detected, operator must determine and rectify problem prior
procedure. to resuming operation.
4. Be aware of winch capacity and weight of load at all times.
Training

• Do not lift loads over people. Program

The employer shall provide and implement a training program for

all supervisors and employees engaged in the operation of raising,
• Verify limit switch operation to ensure man riding device lowering or suspending personnel platforms from a winch load
does not contact sheave. line so that they are familiar with the requirements of the hoisting
system and are able to recognize the associated hazards and take
Operators must be physically competent. Operators must not have appropriate measures. Records of training programs shall be
a health condition which might affect their ability to act, and they maintained.
must have good hearing, vision and depth perception. The winch
operator must be carefully instructed in his duties and must Planning Meeting
understand the operation of the winch, including a study of the
manufacturer’s literature. The operator must thoroughly A meeting attended by the winch operator, signal persons,
understand proper methods of hitching loads and must have a persons to be lifted and the person in charge of the task to be
good attitude regarding safety. It is the operator’s responsibility to performed is required to be held to plan and review the
refuse to operate the winch under unsafe conditions. procedures to be followed, including procedures for entering and
leaving the man riding device, the use of safety equipment,
1. Lifting and lowering speeds are operator controlled and signals, and the lift chart information.
should be as slow as practical. Ingersoll-Rand recommends
that you do not exceed 100 ft (30 m) per minute. Any
applicable codes and standards should be followed.
2. Personnel being lifted or lowered must be alert to obstacles • This meeting shall be held prior to the beginning of
and hazards during movement. personnel hoisting operations at each new work location and
3. If a personnel platform is used and is not landed on a solid thereafter for any new employees assigned to the operation.
surface, it shall be tied to the structure before personnel get
off or on.
4. Tag lines shall be used where practical.
5. The winch operator shall remain at the controls at all times
when handling personnel.
6. Handling of personnel shall be discontinued upon indication
of any impending danger.

• Maintain at least 3 wraps of wire rope on the drum at all

times.

7. The man riding device shall be hoisted approximately 1 ft

(30 cm) and inspected to ensure that it is secure prior to
personnel occupancy. Before raising or lowering personnel,
the following conditions shall exist:
a. Wire rope shall be free of kinks.
b. Winch shall be reeved for single part line which avoids
obstructions and interference.
c. The primary point of wire rope attachment shall be
centered over the man riding device to reduce tilting and
swinging the suspended person.
8. When personnel are suspended, a signal person must be
provided unless operator has line of sight. Signals must be
visible to the operator at all times.

MHD56244 - Edition 1 17
Control Console Layout

Lever
Control Failure
On Line Standard Winch Valve Balancing
Indicator Mode Indicator Indicator Mode Indicator
(424) (423)
(422) (422) (422)

Balancing
Network Air Pressure
Pressure Guage
Guage (426)
(425)

Balancing
Pressure
Control
Regulator
(430)

Emergency On
Stop Button Lockout Selector
Button (428) Key Switch
(427) (431) (429)
(Dwg. MHP2354)

Winch Controls Standard Winch Mode Indicator

Refer to Dwg. MHP2354 on page 18. This indicator is green when the “standard” mode is selected.

On Line Indicator Lever Control Valve

This indicator is green when the “ON” button is actuated, To spool the wire rope, pull the lever.
compressed air is available, the console is operational. To spool out the wire rope, push the lever.
Move the lever slowly and progressively.
Network Air Pressure Gauge
On Button
• Indicates static pressure preset to 80 psi (5.5 0/+0.3 bar).
• For correct performance, a dynamic pressure of 75 psi (5.2 bar) When this button is actuated, air is supplied to the pilot circuit and
minimum is necessary. to the power circuit; the console is thus operational.
• Indicates null pressure when the button “ON” is not actuated or This button is disabled in the “balancing” mode; ensure “standard”
when the emergency stop button is actuated. mode is selected.

Emergency Stop Button Failure Indicator

If this button is actuated in “standard” mode, the compressed air

supply is stopped.
If this button is actuated in “balancing” mode, a warning device is •

heard. • DO NOT use the system when this indicator is red.

• Ensure lifted person is safe before repairing the failure.

18 MHD56244 - Edition 1
When selecting a mode or even permanently, the control box 4. Raise person 18 inch (0.5 meter) above floor with main
monitors those functions which might be dangerous to the lifted control lever.
person such as: 5. Select balancing mode.
a. Brake opening through the band detector.
b. The connection distributor that switches the winch Green indicator will come on to indicate balancing mode working.
controls either to the “standard” mode or to the
“balancing” mode. 6. Slowly adjust pressure regulator knob to obtain balancing
c. The safety valve that enables rapid air escape from the point.
motor in case of an overload in “balancing” mode but - Clockwise will increase pressure and tend to lower person.
that must be inactive in “standard” mode. - Anticlockwise will decrease pressure and the ability to
d. The torque limiter that is calibrated differently lower person.
according to the selected mode.
e. The emergency stop which must be in the correct At this point it is recommended that an additional person is present
position according to the selected mode. to increase the load when required for balancing purposes.

When an anomaly is detected, a red indicator comes on the control 7. Use control lever to raise person to working position.
box which automatically starts the warning device. 8. When job is completed, and person is back on the floor,
select standard mode before taking the safety harness off.

• The indicator also becomes red for a short while when WARNING

selecting a mode, this is normal and will last only during the • Never activate the balancing system when there is no load.
time necessary to check the parameters. The same applies in
“balancing” mode, when the operator actuates the control Overload Device
lever.
An overload device is required on all Man Rider winches.
When a failure is detected in “balancing” mode, it is necessary to
switch to the “standard” mode, even if the anomaly has been The overload device is integrated into the winch air motor and
solved. prevents the winch from lifting a load greater than the overload
value listed in the specifications chart. If an overload is detected,
Selector Switch -Standard Winch Mode or Balancing Mode the winch automatically switches to the “balancing” mode
whatever the operating mode, “standard” or “balancing”.
Button used for mode selection.

CAUTION

WARNING
• To avoid damage to the rigging, the structure supporting the
• The balancing mode must always be selected when lifting a rigging and the winch, do not use the wire rope with multi
person to working position. reeving arrangement.

Balancing Mode Indicator Winch Brakes

The indicator is green when the “balancing” mode is selected,
Automatic Disc Brake
even if this mode is validated after testing the control box and after
the red indicator “failure” went off. The automatic disc brake is a spring applied, air released brake.
When the winch is in the neutral position the brake air is vented
Balancing Pressure Gauge and the brake springs apply the brake. The springs, acting on the
pressure plate, compress the brake’s friction and steel discs and
It indicates the air pressure supplied in the lowering direction in engage the brake to prevent drum rotation.
order to balance the person in the “balancing” mode.
Disc brake adjustment is not required. If disc brake does not
Balancing Pressure Control Regulator operate properly it must be disassembled, inspected and repaired.

It allows adjustment of the supplied air pressure in the lowering Automatic Drum Brake (Remote Control)
direction in order to balance the person in the “balancing” mode.
A pressure of 22 psi (1.5 bar) is necessary to balance an equipped Refer to Dwg. MHP2265 on page 46.
person of approximately 225 lbs (100 daN). 14.5 psi (1 bar) is The automatic drum brake is a spring applied, air released,
necessary for 337 lbs (150 daN). externally mounted brake which uses an air actuated, spring
loaded cylinder to disengage the brake when the motor is operated
Balancing Point Adjustment Procedure in either the haul-in or payout directions. Air pressure directed to
the cylinder overcomes spring force to release brake and allow
1. Select Standard Winch mode. drum to rotate.
(Green indicator will come on to indicate standard winch When the control valve is placed in the neutral position, air in the
mode working.) cylinder is vented which allows the cylinder spring to engage
2. Person must have the safety harness fitted. brake and prevent drum rotation.
3. Adjust pressure regulator knob to approximately 14.5 psi Adjustments to the cylinder clevis can be made to compensate for
(1 bar). normal brake lining wear. The drum brake must be kept properly

MHD56244 - Edition 1 19
adjusted to hold the required load. Refer to ‘Adjustments’ on page Emergency Lowering Precautions
31, in the “MAINTENANCE” section. If brake band cannot be
adjusted to hold rated load, the brake must be disassembled, 1. Emergency lowering operations must be performed by a
inspected and repaired. minimum of two personnel trained in the operation of the
winch.
Slack Line Detector 2. Communication must be established between lifted person
and winch operators. Operators should be able to visually
monitor lifted person until landed.
3. If line of sight between operators and lifted person is not
possible, signals must be conveyed to the operators.
• Slack line detector and limit switch functions are not operable 4. The winch must be isolated from the supply air system during
when emergency release valve is activated. emergency lowering operations.
5. In the event of supply failure, operate the three way valve
Refer to Dwg. MHP2266 on page 50. from normal air supply to the emergency inlet.
If slack line exists between winch and sheave, slack line detector 6. Open the emergency power source. Ensure that downstream
limit switch valve stops wire rope payout. When slack wire has pressure is 72 to 101 psi (5 to 7 bar).
been detected, operator must determine and rectify problem prior 7. Operate the winch slowly to open the brakes and lower the
to resuming operation. person the shortest way to safety.
Slack Line Detector arms may vary in design depending on
required take-off angle. Ensure correct arms are used for desired
take-off angle. Normal
Inlet

• Operator and signal persons must watch for any conditions Three Way
Valve To the
that allow slack wire rope to exist between sheave and lifted
Winch
person which may not be sensed by the slack wire detector. If
slack wire condition is noticed, all winch operations must cease
until problem is rectified.

Press Roller
Emergency
Refer to Dwg. MHP2268 on page 52. Outlet
The press roller, positioned between drum flanges, assists proper
spooling of wire rope onto the drum and maintains tight wraps (Dwg. MHP2372)
when winch is not in operation. Ensure wire rope is always
trapped between press roller and drum barrel. Press roller
adjustments are not required.
• For the emergency power source, 13 gallon (50 litre) nitrogen
bottles can be used.
Limit Switches
Pre-set limit switch settings prevent winch wire rope payout and WARNING

haul-in by stopping air flow to the winch motor when a set point • After each use of emergency lowering device, return the
has been reached. It is the owner’s and operator’s responsibility to three-way valve to the main air inlet and check the secondary
adjust winch operating limits prior to using the winch to transport power source is in proper working condition and able to fulfill
personnel. To adjust the limit switch set points refer to the its task.
“INSTALLATION” section on page 13.

Emergency Lowering
The following information is provided to allow for emergency
lowering of a person if air supply is lost to the winch. These
procedures should be used if no other method of safely lowering
personnel is available.

1. In the event of supply failure, operate the three way valve

from normal air supply to the emergency inlet Open the
emergency power source. Ensure that downstream pressure is
72 to 101 psi (5 to 7 bar). Operate the winch slowly to open
the brakes to lower the person the shortest way to safety.

• After each use of emergency lowering device, return the three

valve to the main air inlet and check the secondary power
source is in proper working condition and able to fulfill its
task.

20 MHD56244 - Edition 1
 INSPECTION

Inspection information is based in part on American National 1. WINCH. Prior to operation, visually inspect winch housings,
Standards Institute Safety Codes (ASME B30.7). controls, brakes, side rails, uprights and drum for indications
of damage. Do not operate unless the wire rope feeds onto the
drum smoothly. Any discrepancies noted must be reviewed
and inspected further by authorized personnel instructed in
• All new or repaired equipment should be inspected and the operation, safety and maintenance of this winch.
tested by personnel instructed in safety, operation and 2. WIRE ROPE. Visually inspect all wire rope which can be
maintenance of this equipment to ensure safe operation at expected to be in use during the day’s operations. Inspect for
rated specifications before placing equipment in service. wear and damage indicated by distortion of wire rope such as
• Never use a winch that inspection indicates is damaged. kinking, “birdcaging,” core protrusion, main strand
displacement, corrosion, broken or cut strands. If damage is
Frequent and periodic inspections should be performed on evident, do not operate winch until the discrepancies have
equipment in regular service. Frequent inspections are visual been reviewed and inspected further by personnel
examinations performed by operators or personnel trained in knowledgeable on wire rope safety and maintenance
safety and operation of this equipment and include observations procedures.
made during routine equipment operation. Periodic inspections are
thorough inspections conducted by personnel trained in the safety,
operation and maintenance of this equipment.
ASME B30.7 states inspection intervals depend upon the nature of • The full extent of wire rope wear cannot be determined by
the critical components of the equipment and the severity of usage. visual inspection. At any indication of wear inspect wire rope
The inspection intervals recommended in this manual are based on in accordance with instructions in ‘Periodic Inspection.’
intermittent operation of the winch eight hours each day, five days
per week, in an environment relatively free of dust, moisture, and 3. AIR SYSTEM. Visually inspect all connections, fittings,
corrosive fumes. If the winch is operated almost continuously or hoses and components for indication of air leaks. Repair any
more than eight hours each day, more frequent inspections will be leaks or damage.
required. 4. MANUAL THROTTLE LEVER. Ensure operation of
Careful inspection on a regular basis will reveal potentially manual throttle lever is smooth and winch is responsive to
dangerous conditions while still in the early stages, allowing lever movement. Lever must return to neutral. If winch
corrective action to be taken before condition becomes dangerous. responds slowly or controls stick, do not operate winch until
Deficiencies revealed through inspection, or noted during all problems have been corrected.
operation, must be reported to designated personnel instructed in 5. BRAKES. During winch operation test brakes. Brakes must
safety, operation and maintenance of this equipment. A hold load without slipping. Automatic brakes must release
determination as to whether a condition constitutes a safety hazard when winch motor throttle is operated. If brakes do not hold
must be decided, and the correction of noted safety hazards load, or do not release properly, brakes must be adjusted or
accomplished and documented by written report before placing repaired.
the equipment in service. 6. WIRE ROPE REEVING. Check reeving and ensure wire
rope is properly secured to the drum. Do not operate winch
unless wire rope feeds onto drum smoothly.
Records and Reports
7. LUBRICATION. Refer to “LUBRICATION” section on
Inspection records, listing all points requiring periodic inspection page 30 for recommended procedures and lubricants.
should be maintained for all load bearing equipment. Written 8. LIMIT SWITCHES. Ensure limit switches engage and
reports, based on severity of service, should be made on the prevent operation at the required set point and with drum
condition of critical parts as a method of documenting periodic rotating in correct direction. Ensure limit switch properly
inspections. These reports should be dated, signed by the person resets.
who performed the inspection, and kept on file where they are 9. MOTOR. During operation check motor housing for excess
readily available for authorized review. heat build up. Housing should not be hot to touch. Listen for
grinding or knocking noises. Ensure lubricated air supply
provides 2 to 3 drops per minute of SAE 10W (ISO VG 46)
Wire Rope Report oil when winch is operated at rated capacity. Operate winch
slowly in both directions to verify operation.
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.

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).

MHD56244 - Edition 1 21
 6. BRAKES. Brakes must hold a 125% rated load at mid-drum
Periodic Inspection
without slipping. If indicated by poor operation or visible
Winch periodic inspection intervals vary depending on the damage, disassemble and repair brake(s). Check all brake
conditions listed below: surfaces for wear, deformation or foreign deposits. Clean and
replace components as necessary. Adjustments can be made
NORMAL HEAVY SEVERE to the drum band brake to compensate for normal brake
yearly semiannually quarterly lining wear. Refer to ‘Adjustments’ in “MAINTENANCE”
section on page 31. If brake band cannot be adjusted to hold
rated load, replace brake band assembly. Adjustments cannot
Disassembly may be required as a result of frequent inspection
be made to disc brake. The disc brake must be repaired as
findings or in order to properly inspect individual components.
described in “MAINTENANCE” section.
Disassembly steps are described in “MAINTENANCE” section.
7. FOUNDATION or SUPPORTING STRUCTURE. Check for
Maintain written records of periodic inspections to provide an
distortion, wear and continued ability to support winch and
accumulative basis for continuing evaluation. Inspect all items
rated load. Ensure winch is firmly mounted and that fasteners
listed in ‘Frequent Inspection’on page 21. Also inspect the
are in good condition and tight.
following:
8. LABELS AND TAGS. Check for presence and legibility of
1. SIDE RAILS and UPRIGHTS. Check for deformed, cracked
labels. Replace if damaged or missing.
or corroded main components. Replace damaged parts.
9. DRUM GUARD. Verify fasteners are tight and in good
2. FASTENERS. Check retainer rings, split pins, capscrews,
condition. Ensure guard is in good condition.
nuts and other fasteners on winch, including mounting bolts.
10. LIMIT SWITCH. Operate winch in both directions to
Replace if missing or damaged and tighten if loose.
activate limit switch. Limit switch must activate (stop winch
3. DRUM and SHEAVES. Check for cracks, wear or damage.
operation) at established settings +/- 2 ft (+/- 0.6 m). Reset
Replace if necessary.
limit switch by operating winch in opposite direction. Refer
4. WIRE ROPE. In addition to “Frequent Inspection”
to ‘Limit Switch’ in “INSTALLATION” section on page 10
requirements, also inspect for the following:
for adjustment procedures.
a. Buildup of dirt and corrosion. Clean with steam or a stiff
11. EMERGENCY STOP BUTTON. During winch operation
wire brush to remove dirt and corrosion if necessary.
verify emergency shut-off valve operation. Valve must stop
b. Loose or damaged end connection. Replace if loose or
winch operation quickly. Valve must reset properly. For
damaged.
procedures, refer to ‘Emergency Stop Button’ in the
c. Check wire rope anchor is secure in drum.
“OPERATION” section on page 18.
d. Verify wire rope diameter. Measure diameter of wire
12. OVERLOAD DEVICE. The overload device is an intrical
rope from crown-to-crown throughout the life of wire
part of the motor. Ensure overload device is properly set to
rope. Recording of actual diameter should only be done
stop winch when load exceeds 125% (+/-10%) of winch rated
with wire rope under equivalent loading and in the same
capacity. If winch does not shut down, contact your
operating section as accomplished during previous
distributor or factory for repair information.
inspections. If actual diameter of wire rope has
13. PRESS ROLLER. Inspect rollers for wear and grooves.
decreased more than 1/64 in. (0.4 mm) a thorough
Ensure rollers freely rotate. Replace rollers if worn or
examination of wire rope should be conducted by an
grooved. Replace bearings if rotation is rough or stiff.
experienced inspector to determine the suitability of
14. SLACK LINE DETECTOR. Inspect rollers for wear and
wire rope to remain in service. Refer to Dwg. MHP0056
grooves. Ensure rollers freely rotate. Replace worn or
on page 22.
grooved rollers.

Wire
Winches Not in Regular Use
1. Equipment which has been idle for a period of one month or
Crown more, but less than six months, shall be given an inspection
to conforming to the requirements of ‘Frequent Inspection’on
Crown page 21 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’on page 22 before being
Wire Strand placed in service.
3. Standby equipment shall be inspected at least semiannually
in accordance with requirements of ‘Frequent Inspection’on
One page 21. In abnormal operating conditions equipment should
Lay be inspected at shorter intervals.
(Dwg. MHP0056)

5. ALL COMPONENTS. Inspect for wear, damage, distortion,

deformation and cleanliness. If external evidence indicates
damage, disassemble as required to conduct a detailed
inspection. Inspect gears, shafts, bearings, sheaves, springs
and covers. Replace worn or damaged parts. Clean, lubricate
and reassemble.

22 MHD56244 - Edition 1
 INSPECTION AND MAINTENANCE REPORT

Ingersoll-Rand FA150KGMR-RC Winch

Model Number: Date:
Serial Number: Inspected By:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection:
______ Quarterly ______ Semiannually ______ Yearly Operating Environment:
2. Discrepancies noted during Frequent Inspection
3. Discrepancies noted during Maintenance Normal _____ Heavy _____ Severe _____

4. Other:___________________________________________
Refer to 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.
CONDITION CORRECTIVE ACTION
COMPONENT NOTES
Pass Fail Repair Replace

Uprights and Side Rails

Drum Band Brake

(125% Load Test)
Automatic Disc Brake
(125% Load Test)
Drum Band Brake
(Visual Inspection)
Disc Brake
(Visual Inspection)

Motor

Hoses, Controls and Valves

Fasteners ---

Shafts and Gears

Labels and Tags ---

Slack Line Detector

Guard

Wire Rope and Anchor ---

Press Roller

TESTING Pass Fail NOTES

Operational (No Load)

Operational (10%)

Operational (Maximum Test Load *)

* Maximum test load is 125% of rated line pull at full drum.

This page may be copied and used as an Inspection/Maintenance Record.

MHD56244 - Edition 1 23
 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 No air supply to winch. Check air supply line connections and hoses.
operate. Winch is overloaded. Reduce load to within rated capacity. Verify overload settings.
Shipping plugs may still be in Remove shipping plugs in control valve.
place.
Drum brake not released. Refer to ‘Automatic Drum Brake’ below.
Load continues to Brake(s) slipping. Check brake band adjustment and brake band lining wear. Disassemble and
move when winch inspect disc brake.
is stopped. Winch motor controls sticking. Check throttle levers return to normal (neutral) positions when released.
Disassemble, inspect and repair the pilot air control valve. Verify spool
adjustment.
Winch does not Motor may be damaged. Remove and disassemble motor. Examine all parts and replace any that are worn
lift load. or damaged.
Insufficient air supply. Verify air supply pressure and volume at winch inlet meets requirements.
Refer to “SPECIFICATIONS” section on page 7. Clean air line filter.
Upper limit switch activated. Lower load and check limit switch settings.
Winch hauls in Lower limit switch activated. Raise load and check limit switch settings.
but does not Slack line detector activated. Determine cause of slack line and rectify problem.
payout.
Throttle moves Motor may be damaged. Disassemble and clean the motor and replace any worn or damaged parts.
but winch does Insufficient air supply. Ensure air pressure at the winch inlet is at least 84 psig (5.8 bar/580 kPa) at rated
not operate. volume. Clean air line filter.
Air leak. Check hose connections. Check hose lines for wear or damage. Replace worn or
damaged hoses and fittings.
Winch runs slow. Improper hose or fitting sizes. Check fittings, connections and hoses for correct size and length. Replace parts
that may cause restricted air flow. Inspect air line filter.
Motor may be damaged. Remove and disassemble motor. Inspect all parts and replace all worn or
damaged parts.
Brake(s) may not be releasing. Refer to brake sections below.
Ice in exhaust ports and/or air Check aftercoolers and traps. Add airline antifreeze to air supply.
lines.
Air lines freeze. Water in air supply. Install or drain air system moisture traps, moisture collecting air receivers and
compressor aftercoolers. After corrective action has been taken, disconnect lines
at winch inlet and purge with clean, dry air or nitrogen.
Air Motor:
Motor runs hot or Damaged or broken motor internal Disassemble and repair motor.
makes excessive parts.
noise during
operation.
Automatic Band Brake:
Brake will not Damaged or leaking cylinder seals. If air is noticed escaping from around the cylinder cover when attempting to
release. release the brake, disassemble and inspect cylinders. Replace all seals and repair
or replace worn or damaged parts.
Dirty filter in air supply. Clean or replace filter.
Brake does not set Hole in exhaust valve restricted or Remove and inspect exhaust valve. Clean hole or replace damaged exhaust
when controls are exhaust valve damaged. valve.
released.

24 MHD56244 - Edition 1
SYMPTOM CAUSE REMEDY
Control Box:
Indicator’s Status Start up Failure: Check the on information at input 18, if not present check hoses
On Line Off Refer to Dwg. MHP2367 on between input 18 and on button.
Standard winch mode On page 27. Check the on information at output 19, if not present exchange
Failure Off command block.
Balancing mode Off
Indicator’s Status Standard Mode Failure: Check test points A, B, C, D and E.
On Line On
Standard winch mode On A, B, C, D and E points must be high level.
Failure On
Balancing mode Off
Point A at a low level: Check input 14, high level required.
If the level is high, use the interlock adjustment procedure, if the
adjustment does not correct the problem exchange the command
block, contact Ingersoll-Rand customer service.
If the input 14 is at a low-level, check output 23, a high level is
required.
If the level is high, check the hoses between output 23 and exhaust
valve.
If the level is low, check the input 24, high level is required.
If the level is high, exchange the command block.
If the level is low, check the output 13, a high level is required.
If the level is high, check the hoses between output 13, input 24
and exhaust valve.
If the level is low, exchange the command block.
Point B at a low level: Exchange the command block.
Point C at a low level: Check the input 15, high level required.
If the level is high, exchange the command block.
If the level is low, check the hose between the brake detector and
input 15, check the detector.
Point D at a low level: Exchange the command block.

Point E at a low level: Check the input 8, low level required.

If the level is high, check the hose between the brake detector and
input 15, check the detector.
If the level is low, exchange the command block.
Indicator’s Status Standard Mode Problems Check the output signal 16, each time you move the main control
On Line On Without Failure Signal: handle you have a pulse of about 1 second.
On Refer to Dwg. MHP2368 on
Standard Winch Mode
page 27.
Failure Off
Balancing Mode Off
No pulse: Check limit switches: slack and bottom input 12 (high) top input
10 (high).
Check up 11 and down 12 inputs, high when moved.
If these inputs are right, verify setting of the temporisation A, set
between the 0 and A.
If right, exchange command block.
Indicator’s Status Floating Mode Failure Check test points A, B, C, D, E and F.
On Line Off Refer to Dwg. MHP2369 on Check points A, B, C, D and F must be at a low level.
Standard Winch Mode Off page 28. Check point E must be at a high level for 10 seconds after
Failure On switching to the floating mode. After this time it will be at a low
level.
Balancing Mode Off

MHD56244 - Edition 1 25
SYMPTOM CAUSE REMEDY
Point A at a high level: Check input 19, high level required.
If the level is high, exchange the command block.
If input 19 is at a low level, check the hose between input 19 and
the emergency stop.
Point B at a high level: Exchange the command block.
Point C at a high level: Check input 14, a level of about 29 psi (2 bar) is required.
If the level is 29 psi (2 bar) use the interlock adjustment
procedure; if the adjustment does not correct the problem
exchange the command block.
If input 14 is at a high level, check output 23, a low level is
required.
If the level is low, check the hoses between output 23 and exhaust
valve.
If the level is high, check input 24, low level is required.
If the level is low, exchange the command block.
If the level is high, check output 13, a low level is required.
If the level is low, check the hose between plug 13, 24 and exhaust
valve.
If the level is high, exchange the command block.
Point D at a high level: Refer to Check input 15, low level required.
View Two of Dwg. MHP2370 If the level is low, exchange the command block.
on page 28.
If the level is high, check output 13, a low level is required.
If the level is low, check the hoses between output 13 and
connection distributor.
If the level is high, exchange the command block.
When switching to balancing Verify setting of the temporisation B, set to D. If right exchange
mode you must have a high level the command block.
at point E during 10 second if
wrong:
Point F at a high level: Check input 8, high level is required.
If the level is low, check the hose between the brake detector and
input 15, check the detector.
If the level is high, exchange the command block.
No Switching Between the Two Check input 11 and 12, low level is required.
Modes. If high level, check hoses between inputs 11 and 12 and main
control detectors, check detectors.
If low level, check inputs 4 and 5:
In standard mode 4 is low 5 is high
In floating mode 4 is high 5 is low
If right, exchange command block.

26 MHD56244 - Edition 1
Standard Mode Failure

A
B
C
D

(Dwg. MHP2367)

Standard Mode Problems Without Failure Signal

(Dwg. MHP2368)

MHD56244 - Edition 1 27
Floating Mode Failure: View One

A
B
C
D

(Dwg. MHP2369)

Floating Mode Failure: View Two

(Dwg. MHP2370)

28 MHD56244 - Edition 1
Interlock Adjustment Procedure

Test Point
A

Interlock
Adjustment
Screw
(Dwg. MHP2371)

1. Disconnect input 14, close the hose coming from the winch;
connect an adjustable regulator to the input.
2. Supply air to the winch.
3. Adjust the pressure to 44 psi (3 bar).
4. Unscrew the nut on the interlock and then unscrew the screw
until you have a low level on test point A.
5. Then adjust the screw until you have a high level on test point
A, secure the screw with the locknut.
6. Set the pressure to 29 psi (2 bar). You must have a low level
on test point A.
7. Set the pressure to at least 72 psi (5 bar). You must have a
high level on test point.
8. Shut-off the air, reconnect hose and test the winch.

MHD56244 - Edition 1 29
 LUBRICATION

To ensure continued satisfactory operation of winch, all points Replace the oil in the reduction housing every year. If the winch is
requiring lubrication must be serviced with the correct lubricant at used at a normal frequency, the oil in the reduction housing is
the proper time interval as indicated for each assembly. suitable for one years operation without changing. However, when
the winch is used at a high frequency, the oil may need to be
The lubrication intervals recommended in this manual are based changed on a more frequent basis.
on intermittent operation of winch eight hours each day, five days To ensure correct performance, highest efficiency and long life, it
per week. If winch is operated almost continuously or more than is essential that the lubricating oil be maintained at the correct
eight hours each day, more frequent lubrication will be required. level. The recommended grade of oil must be used at all times
Also, lubricant types and change intervals are based on operation since the use of unsuitable oil may result in excessive temperature
in an environment relatively free of dust, moisture, and corrosive rise, loss of efficiency and possible damage of the gears
fumes. Use only those lubricants recommended. Other lubricants
may affect winch performance. Approval for the use of other The reduction gear assembly is filled and shipped with oil from
lubricants must be obtained from your Ingersoll-Rand distributor. the factory. Oil capacity is approximately 0.25 pt (0.12 ltr). Use
Failure to observe this precaution may result in damage to winch only high quality lubricants in the reduction gear assembly.
and/or its associated components. Recommended lubricant: SYNTHETIC OIL MOBIL SHC 626.
INTERVAL LUBRICATION CHECKS
Start of each shift Check flow and level of air line lubricator
(approximately 2 to 3 drops per minute • Do not overfill. Excess oil will reduce operating efficiency
required at maximum motor speed). and increase oil temperature.
• The use of unsuitable oil may result in excessive temperature
Check mufflers for damage. Clean or
rise, loss of efficiency and possible damage to the gears. Use
replace if necessary.
only high quality rust and oxidation inhibiting lubricant.
Monthly Lubricate components supplied by grease
fittings
Air Line Lubricator
Inspect and clean or replace air line filter.
An air line lubricator is mounted to the winch frame. Use SAE
Half Yearly Replace mufflers.
10W (ISO VG 46) oil in lubricator. Adjust lubricator to provide 2
Yearly Disassemble winch and refill winch to 3 drops per minute at maximum motor speed.
reduction gear oil.
Inspect disc brake. Clean or replace as Wire Rope
necessary.
Follow wire rope manufacturer’s instructions. At a minimum,
Note: Intervals are based on winch operation in a normal observe the following guidelines.
environment as described in the “INSPECTION” section on page 1. Clean with a brush or steam to remove dirt, rock dust or other
21. In ‘Heavy’ or ‘Severe’ operating conditions adjust lubrication foreign material on wire rope surface.
intervals accordingly.

Reduction Gear and Disc Brake Lubrication • Do not use an acid-based solvent. Only use cleaning fluids
specified by the wire rope manufacturer.
The reduction gear is filled with oil from the factory.
Reduction gear components are splash lubricated by oil in the 2. Apply a wire rope lubricant, Ingersoll-Rand
housings and have no other means of lubrication. It is therefore LUBRI-LINK-GREEN or 30W SAE (ISO VG 100)
important to use high quality, Extreme Pressure (EP) rust and lubricant.
oxidation inhibited gear oils to ensure maximum performance and 3. Brush, drip or spray lubricant weekly, or more frequently,
minimum downtime for repairs. depending on severity of service.

Initial Reduction Gear Assembly Oil Change Seals and Bearings

1. Always inspect removed oil for evidence of internal damage If winch is disassembled, clean all parts thoroughly and coat
or contamination (metal shavings, dirt, water, etc.). If bearings and seals with clean grease. Refer to ‘Recommended
indications of damage are noticed, investigate and correct Grease’ table on page 30. Use sufficient grease to provide a good
before returning winch to service. protective coat.
2. After winch operation, allow oil to settle before topping off.
3. Always collect lubricants in suitable containers and dispose Recommended Grease
of in an environmentally safe manner.
Temperature Grease Type
-20° to 50° F EP 1 multipurpose
Reduction Gear Fill/Drain Procedures
(-30° to 10° C) lithium based grease
Refer to Dwg. MHP2358 on page 44. 30° to 120° F EP 2 multipurpose
Disassemble reduction gear to replace oil. (-1° to 49° C) lithium based grease

30 MHD56244 - Edition 1
 MAINTENANCE

3. Turn adjustment clevis (358) clockwise to increase cylinder

rod extension. Turn clevis counterclockwise to decrease
cylinder rod extension.
• Never perform maintenance on the winch while it is 4. Assemble clevis (358) to brake lever (355) using pin (357).
supporting a load. Release air to brake cylinder (362).
• Before performing maintenance, tag controls: 5. Brake should hold rated load (refer to “INSPECTION”
WARNING - DO NOT OPERATE - section on page 21) when cylinder (362) is retracted. Brake
EQUIPMENT BEING REPAIRED. band should not drag on drum when cylinder is extended.
• Only allow personnel trained in safety and service on this 6. Install cotter pin (352) and washer (385) to secure clevis to
winch to perform maintenance. brake lever when adjustment is complete.
• 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 Directional Air Control Valve
required to comply with standards and regulations set forth in
areas outside the USA.) Refer to Dwg. MHP2275 on page 54.
• Turn off air system and depressurize air lines before Directional control valve adjustment is not required. If control
performing any maintenance. valve is not functioning properly contact factory.

INTERVAL MAINTENANCE CHECK Disassembly

Start of each Make a thorough visual inspection of the
shift winch for damage. Do not operate the winch if General Disassembly Instructions
(Operator or damaged.
Maintenance Operate the winch at low RPM in both The following instructions provide the necessary information to
Personnel) directions. Winch must operate smoothly disassemble, inspect, repair, and assemble the winch. Parts
without sticking, binding or abnormal noises. drawings are provided in the Parts Sectionon page 38.
Check the operation of the brake(s). If a winch is being completely disassembled for any reason, follow
the order of the topics as they are presented.
3 Months Inspect drum brake friction linings. Clean or
It is recommended that all maintenance work on the winch be
(Maintenance replace parts as required. Adjust drum brake as
performed in a clean, dust-free work area.
Personnel) necessary.
In the process of disassembling the winch, observe the following:
Yearly Inspect winch gearing, shafts and bearings for 1. Never disassemble winch any further than is necessary to
(Maintenance wear and damage. Repair or replace as accomplish needed repair. A good part can be damaged
Personnel) necessary. during the course of disassembly.
Check all supporting members, including the 2. Never use excessive force when removing parts. Tapping
foundation, fasteners, nuts, sheaves and gently around the perimeter of a cover or housing with a soft
rigging, etc. for indications of damage or wear. hammer, for example, is sufficient to break the seal.
Repair or replace as required. 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
Adjustments and no additional damage will occur to other parts.

Refer to “INSTALLATION” section for Slack Wire Rope Detector In general, the winch is designed to permit easy disassembly and
and Limit Switch Adjustments. assembly. The use of heat or excessive force should not be
required.
Disc Brake 4. Keep work area as clean as practical, to prevent dirt and other
foreign matter from getting into bearings or other moving
Refer to Dwg. MHP2259 on page 44.
parts.
Brake adjustment is not required. If disc brake does not hold
5. All seals, gaskets and ‘O’ rings should be discarded once they
125% of rated load at mid drum, disassemble and repair.
have been removed. New seals, gaskets and ‘O’ rings should
be used when assembling the winch.
Automatic Drum Band Brake 6. When grasping a part in a vise, always use leather-covered or
copper-covered vise jaws to protect surface of part and help
Refer to Dwg. MHP2265 on page 46. 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
• If brake band cannot be adjusted to hold rated load, replace repairs or replacement.
the brake band assembly. 8. When removing ball bearings from shafts, it is best to use a
bearing puller. When removing bearings from housings, drive
1. Remove cotter pin (352) and washer (385) at adjustment out bearing with a sleeve slightly smaller than the outside
clevis (358). bearing diameter. The end of the sleeve or pipe which
2. Apply air to the brake cylinder (362) and remove pin (357) to contacts the bearing must be square. Protect bearings from
disconnect clevis from brake lever (355). dirt by keeping them wrapped in clean cloths.

MHD56244 - Edition 1 31
 Winch Disassembly 5. Immobilize the motor rotors with a bar between the teeth and
remove nuts (131 and 136).
Refer to Dwg. MHP2376 on page 40 and MHP2375 on page 42. 6. Remove the drive gear (135), the idle gear (149), the retainer
1. Remove wire rope from drum (31). ring (146) and internal ring.
2. Relieve pressure in air lines by operating winch control
several times after air supply has been turned off.
• Take all necessary precautions to avoid damaging the rotors.
Use a mallet to disengage the rotors
• Shut off, bleed down and disconnect air supply line before
performing any disassembly procedures. 7. Remove the screw (133) and washer (132).
8. Remove ball bearings (130 and 134).
3. Disconnect and tag all air lines. 9. Remove the selector stop (153), ball (154) and ‘O’ ring (155).
4. Remove winch from its mounting and take to a suitable work
area before beginning disassembly. Disc Brake and Reduction Gear Disassembly
5. Remove capscrews (45), washers (46) and locknuts (47) from
control box assembly (44). It is not recommended to Refer to Dwg. MHP2358 on page 44.
disassembly control box assembly (44). Refer to Winch Disassembly section to begin brake gear
6. Remove capscrews (49), washers (50) and locknuts (51) that disassembly.
secure brackets (48) to side rails (32) and (33). 1. Stand reduction gear assembly in a vertical position so output
7. Disconnect and remove lubricator assembly and brackets shaft (85) is down.
from slack arm assembly (500). 2. Remove ‘O’ ring (108).
8. Remove slack arm assembly (500) from winch, refer to slack 3. Remove capscrews (107).
arm disassembly section. 4. Remove flange (112), ‘O’ ring (110) and springs (103).
9. Remove press roller assembly (400) from side rail (32) as an 5. Remove washer (102) and the brake discs (97 and 98).
assembly. Refer to press roller disassembly section to further 6. Remove coupling sleeve (104).
disassemble component. 7. Supply compressed air through the supply hole in the housing
10. Remove capscrews (10) that secure motor and brake of the brake piston (100) so as to remove it.
assembly to inboard upright (17). 8. Remove ‘O’ rings (99 and 101).
9. Remove retainer ring (84).
10. Put a drain pan under the assembly to collect oil from the
reducer.
• The air motor weights approximately 45 lbs (21 kg). 11. Hold reducer by the casing (91) and knock on the output shaft
Adequately support air motor before removing motor with a mallet to separate gear housing (91) from brake body
mounting capscrews. (111).
12. Remove planet pinion cage assembly and input shaft.
11. Refer to motor and brake disassembly sections for any further 13. After removing the axles from the planet gears (92), remove
disassembly of these components. the planet gears (92), the needle roller cage (89) and the
12. Support drum (31), and remove capscrews (36), lockwashers spacer (90).
(25) and dowel pins (37) that secure side rails (32) and (33) to 14. Remove the retainer ring (106) and remove the input shaft
inboard upright (17). (116).
13. Carefully pry inboard upright from drum carrier assembly 15. Remove the sun gear (113) and the bearing (115).
(23). 16. Remove ring gear (93), gasket (114), pins (95), bearing (94)
14. Remove capscrews (24) and lockwashers (25) that secure and oil seal (105).
drum carrier assembly (23) to drum (31). 17. Remove outer retainer ring (86) and then remove bearing (87)
15. Remove drum carrier assembly (23). and the output gear (80).
16. It is not necessary to disassemble drum carrier assembly (23), 18. Remove bearings (81), (83) and the oil seal (82).
unless worn or damaged.
17. Remove capscrews (41) and lockwashers (40) from end cover
Automatic Drum Brake
(74).
18. Remove capscrews (13) from retainer (72).
Refer to Dwg. MHP2373 on page 46.
19. Remove bearing (71) and seals (69) and (454) from outboard
Actuator Disassembly:
upright. Replace if necessary.
1. Automatic Brake
20. Remove capscrews (36), lockwashers (25) and dowel pins
a. Disconnect and remove hose, fittings and dump valve
(37) that secure side rails (32) and (33) to outboard upright
(364) from the cylinder (362).
(34).
b. Remove cotter pin (352), washer (385) and pin (351)
from the link stud (353) and brake band (384).
Motor Disassembly c. Remove cotter pin (352), washer (385) and pin (357).
Separate the clevis (358) from brake lever (355).
Refer to. Dwg. MHP2357 on page 42. d. Remove cylinder (362) from bracket (372).
1. Remove the capscrews (144) and lockwashers (143) to
remove the motor assembly from the motor housing (140). Brake Disassembly:
2. Remove the ‘O’ ring (137). 1. Remove capscrews (21) and (383), lockwashers (22) and
3. Remove capscrews (150). (374) and stop plate (382).
4. Remove the motor cover (142) and gasket (152). If necessary, 2. Use a hoist to raise the winch approximately 6 in. (15 cm).
remove bearings (145, 148), spool front stop (147) and pins Separate the brake band (384) halves and rotate the brake
(138). band assembly slowly until it can be removed from the

32 MHD56244 - Edition 1
 drum (60). 4. Remove bushing (415) from end of spacer (416), remove
3. Remove cotter pins (352) and pins (375) so brake band halves spacer and springs (409) and (411) from base.
(384) can be removed from the arm (379). Lower winch 5. From both ends of roller shaft (403), remove retainer ring
when brake band assembly has been removed. (405) and (404). Pull bearing (407) from both ends of shaft,
and remove short rollers (401) and spacers (408).
Torque Limiter Assembly Disassembly 6. Slide arms (412) off ends of roller shaft. Remove spacers
(408) and bearings (407) from ends of shaft, then slide long
Refer to Dwg. MHP2386 on page 48. press roller (402) off roller shaft (403).
1. Disconnect hoses.
2. Remove capscrews (179) with seal washer (181) to remove Slack Line Detector Disassembly
torque limiter assembly from motor.
3. Remove ‘O’ rings (180 and 178) if necessary. Refer to Dwg. MHP2266 on page 50.
4. Remove screw (176) and joint (177). 1. Slide rollers (501) off shafts (502). Remove capscrews (509)
5. Remove 4 capscrews (161) to remove cover (162). and washers (385) from shafts (502) and inboard arm (503).
6. Remove valve (165) and ‘O’ ring (163). 2. Remove capscrew (514) and washer (519) from threaded hole
7. Remove spacing piece (170), washer (167) and diaphragm in outboard arm (503) and the actuator bracket’s (505) slot.
(166). 3. Remove shoulder screw (517), bushing (521), and bushing
8. Remove 4 capscrews (161) to remove cover (175). (515), and detach actuator bracket (505) from outboard arm
9. Remove valve (174), ‘O’ ring (173) and spring (171). (503). Remove outboard arm from stop bracket (507).
10. Remove nut (172) and washer (167) to remove diaphragm 4. Remove capscrews (522) and washers (520) and detach limit
(166). valve (481) from stop bracket (507).
5. Remove elbow fittings (482) and breather (460) from limit
Directional Control Valve Disassembly valve (481).
6. Remove shoulder screw (523) and bushing (515). Detach
Refer to Dwg. MHP2361on page 57. inboard arm (503) from support bracket (508).
After disconnecting the hoses and pipes and after removing the 7. Remove capscrews (21) and washers (519) from stop bracket
capscrews (197), remove the connection distributor. (507). Detach stop bracket from outboard
1. Remove cover (205) and plug (202). upright (64).
2. Remove capscrew (192), washer (193), and cover (190). 8. Remove capscrews (21) and washers (519) from support
3. Remove plug (202), joint (199), and spring (200). bracket (508). Detach support bracket from inboard
4. Insert a drift punch in the hole of the piston (196) to prevent upright (17).
its rotation and release the capscrew (191).
5. Remove washer (194) and diaphragm (195). Drum Guard Disassembly
6. Remove piston (196).
7. Remove screw (203). Refer to Dwg. MHP2281on page 66.
8. Remove spacing piece (201). 1. Remove capscrews (701), nuts (707), lockwashers (705) and
9. If necessary, remove joint (199). clamps (702) from drum guard.
2. Lift drum guard (704) from between the two supports (703).
Lever Control Valve Disassembly 3. Remove capscrews (708) and washers (709).
4. Remove supports (703) from winch side rails.
Refer to Dwg. MHP2362 on page 58.
1. Disconnect all air hoses. Cleaning, Inspection and Repair
2. Remove capscrews (625) with lockwashers (626).
3. Remove valve assembly and base plate (632) from support
Cleaning
(622).
4. Remove capscrews (634) with lockwashers (610). Clean all winch component parts in solvent (except drum brake
5. Remove angle bracket (614) and directional valves (606) bands and disc brake friction plates). The use of a stiff bristle
from base plate (632). brush will facilitate removal of accumulated dirt and sediments on
6. Remove ‘O’ ring (630). housings, frame and drum. If bushings have been removed it may
7. Remove screw (628). be necessary to carefully remove old Loctite® from bushing bores.
8. Carefully slide out the rotary valve (629) with stop (619), Dry each part using low pressure, filtered compressed air. Clean
spring (637) and control lever (618) (check position of this drum brake band using a wire brush or emery cloth. Do not wash
rotary valve). drum brake band in solvent. If drum brake band lining is oil
9. Tap out pin (636) and extract control lever (618). soaked, it must be replaced.
10. Remove stop (619), spring (637) and ‘O’ ring (627).

Inspection
Press Roller Disassembly
All disassembled parts should be inspected to determine their
Refer to Dwg. MHP2268 on page 52. fitness for continued use. Pay particular attention to the following:
1. Compress the ends of the springs (409) and (411) and remove 1. Inspect gears for:
shoulder screw (413) from arms (412). a. worn, cracked or broken teeth. Replace if necessary.
2. Unfasten capscrews (418) and washers (419), and remove 2. Inspect bushings for:
base (421) from side rail (63). a. wear, scoring or galling. Replace if necessary.
3. Remove retainer ring (417) from either end of pivot shaft 3. Inspect shafts for:
(414) and slide shaft out of arm (412) base holes (421). a. ridges caused by wear. Replace if necessary.
Remove arms (412) from base (421). b. scoring or galling.

MHD56244 - Edition 1 33
4. Inspect all threaded items for: 6. Immobilize the motor rotors with an bar between the teeth
a. damaged threads. Replace if necessary. and install nuts (131 and 136) secured with Loctite® 243.
5. Inspect drum band brake lining for: 7. Install bearings (145 and 148), stops (147) and pins (138) in
a. oil, grease and glazing. If drum band brake lining is oil- motor cover (142).
soaked, excessively greasy or overly glazed replace 8. Install motor cover (142) on motor housing. Ensure pins
brake band. Remove small glazed areas of band brake (138) are fully aligned and engaged. Install capscrew (150)
lining by sanding lightly with a fine grit emery cloth. secured with Loctite® 243.
b. thickness of drum band brake lining. If drum brake band 9. Check that ‘O’ ring (137) is correctly installing in motor
lining is less than 0.062 in. (2 mm) thick anywhere housing (140).
along the edges replace brake band assembly. 10. Install motor assembly with gasket (152) in motor housing
6. Inspect motor housing bores for: and secure with capscrews (144) and lockwashers (143).
a. wear. Bores can be lightly honed. For any large 11. Check to ensure drive gear turns smoothly in both directions.
scratches or wear patterns, replace motor housing.
7. Inspect bearings for: Automatic Drum Brake Assembly
a. free smooth rotation. Inspect for evidence of grit, dirt or
other contaminants. If dry or contaminated, replace the Refer to Dwg. MHP2265 on page 46.
bearing. 1. Install bracket (372) on side rail (62) with capscrews (65) and
b. inspect roller bearings (needle). At any indication of lockwashers (22).
damage, or contamination replace bearings. 2. Screw nut (359) and clevis (358) onto cylinder rod.
8. Inspect the brake steel discs and friction discs for oil. If the 3. Attach brake lever (355) to brake band (384).
friction discs have become oil-soaked, replace them. If the 4. Install cylinder (362) so it connects with bracket (372) and
steel discs have become glazed, sand them lightly using fine brake lever (355). Use pins (357), washers (385) and cotter
emery cloth and a flat surface as backing. Inspect the pins (352) to secure in position.
remaining brake parts for warpage or other damage, and 5. Install dump valve (364) fittings and hose (368) to the
replace damaged parts as necessary. Replace the input pinion cylinder (362).
shaft oil seal 6. Adjust automatic brake as described at the start of the
“MAINTENANCE” section on page 31.
Repair
Disc Brake and Reduction Gear Assembly
Actual repairs are limited to the removal of small burrs and other
minor surface imperfections from gears, shafts, housings and Refer to Dwg. MHP2358 on page 44.
machined surfaces. Use a fine stone or emery cloth for this work. 1. Install oil seal (82) in the bore of gear housing (91) so seal lip
1. Worn or damaged parts must be replaced. Refer to applicable is toward the planet assembly side.
parts listing for specific replacement parts information. 2. Press bearings (81 and 83) into gear housing (91).
2. Inspect all remaining parts for evidence of damage. Replace 3. Install retainer ring (84) on output shaft (85) and press output
or repair any part which is in questionable condition. The shaft into gear housing.
cost of the part is often minor in comparison with the cost of 4. Install ring gear (80) and bearing (87) on output shaft and
redoing the job. secure in position with retainer ring (86).
3. Smooth out all nicks, burrs, or galled spots on shafts, bores, 5. Press bearing (115) onto sun gear (116) and locate with
pins, or bushings. retainer ring (113). Install sun gear (116) with bearing (115)
4. Examine all gear teeth carefully, and remove nicks or burrs. in the planet support (117) and secure with retainer ring
5. Polish edges of all shaft shoulders to remove small nicks (106).
which may have been caused during handling. 6. Install two bearings (89) with a spacer (90) between in the
6. Remove all nicks and burrs caused by lockwashers. bore of each planetary gear (92).
7. Position each assembled planetary gear in the planet support
Assembly (117) with timing marks correctly positioned and carefully
install planet axles (88). Refer to drawing Dwg. MHP2364 on
General instructions page 35.
• use new gaskets and seals.
• replace worn parts.
• assemble parts using match marks applied during
disassembly. Compare replacement parts with originals to
identify installation alignments.

Motor Assembly

Refer to Dwg. MHP2357 on page 42.

1. Install the selector stop (153), ball (154) and ‘O’ ring (155) in
the motor housing (141).
2. Lubricate ball bearings (130 and 134) with grade 2 grease
and install in motor housing (141).
3. Install screw (133) with washer (132).
4. Install internal ring of bearing and retainer ring (146) on
drive gear (135).
5. Install rotors in motor housing (141).

34 MHD56244 - Edition 1
 CAUTION

• When installing the motor on reducer-brake, be careful not

to damage the lip of the oil seal (105). Refer to Dwg. MHP2358
on page 44.

Torque Limiter Assembly

Refer to Dwg. MHP2386 on page 48.

1. Install diaphragm (166), washer (167) and nut (172).
2. Install spring (171), ‘O’ ring (173) and valve (174).
3. Install cover (175) and 4 capscrews (161).
4. Install diaphragm (166), washer (167) and spacing piece
(170).
5. Install ‘O’ ring (163) and valve (165).
6. Install cover (162) and the 4 screws (161).
7. Install joint (177) and screw (176).
8. Install ‘O’ rings (180 and 178).
9. Install torque limiter assembly with seal rings (181) and 2
capscrews (179).
10. Reconnect hoses.

(Dwg. MHP2364) Lever Control Valve Assembly

Refer to Dwg. MHP2362 on page 58.

1. Lubricate and install ‘O’ ring (627) on rotary valve (629).
• For assembly of planet gears, each planet gear must be 2. Lubricate and carefully install rotary valve in valve housing
positioned with the timing mark as shown on drawing (620).
MHP2364 on page 35. 3. Lubricate and install spring (637) on rotary valve. Ensure pin
(638) is installed in valve housing (620).
8. Install planetary gear assembly and ring gear (93) in gear 4. Install bracket stop (619). Apply a small amount of
housing (91). LOCTITE® 243 to threads of screws (628) and install.
9. Install ball bearing (94) on the planet support (117). 5. Install control lever (618) on rotary valve and align pin hole.
10. Place the reduction gear assembly in a vertical position with Install pin (638) to secure control lever.
the planetary gear end up. 6. Lubricate and install ‘O’ rings (630) on base plate (632).
7. Install angle bracket (614) with capscrews (634) and
Fill the gear assembly with clean oil SYNTHETIC OIL MOBIL lockwashers (610).
SHC 626. 8. Install the directional valve (606) on the angle bracket with
the capscrews (611) and lockwashers (612).
9. Install control valve and base plate on console with capscews
(625) and lockwasher (626).
• Capacity of gear box: 1 qt (0.94 Litres). 10. Install lever and bellows (641).
11. Install oil seal (105) and pins (95) in the brake body (111) (so
seal lip is toward planetary gear side). Winch Assembly
12. Install brake piston (100) with ‘O’ rings (99 and 101).
13. Install the friction discs (97), steel discs (98) and coupling Refer to Dwg. MHP2376 on page 40 and Dwg. MHP2358 on page
sleeve (104). Alternate discs placement, friction disc first 44.
then steel disc, ending with friction disc. Ensure steel disc 1. Assemble disc brake and reduction gear assembly using
between each pair of friction discs. assembly text in “MAINTENANCE” section.
14. Install washer (102) on the brake piston (100). Supply 2. Install motor assembly (20) to flange (112) using capscrews
compressed air through the supply hole of the housing of the (151). Apply small amount of Loctite® and torque to 20 ft
brake piston (100) to ensure that the piston moves correctly lbs (27 Nm).
(do the operation several times). 3. Stand drum (30) in a vertical position with large bore up.
15. Install oil seal (105) (seal lip is toward air gear motor side) 4. Clean surface of drum and install drum carrier assembly (23)
and retainer ring (106) in the flange (112). with hub side of carrier in drum and secure using capscrews
16. Install pins (96), ‘O’ ring (110) (hold seal in its housing by (24) and washers (25). Apply small amount of Loctite® 242
applying a small quantity of grease) and the springs (103) and torque to 57 ft lbs (81 Nm).
(hold the springs in their housings by applying a small 5. Clean surface and install oil seal (69) in outboard upright (34)
quantity of grease) on the flange (112). with lip toward the bearing (71).
17. Install flange (112) on the brake body. Install capscrews 6. Pack bearing (71) with grease and install in outboard upright
(107) secure with Loctite® 243 (34).
18. Install ‘O’ ring (108). 7. Support drum (30) in a horizontal position and install
outboard upright (34) to drum (30). Ensure assembly is kept
centered during this step to avoid seal or bearing damage
8. Install shaft retainer (72) using capscrews (13) with Loctite®
242. Torque to 35 ft lbs (41 Nm).

MHD56244 - Edition 1 35
9. Install oil seal (454) in end cover with lip toward the bearing. 4. Push spacer (416) through one of the holes in base (421), and
10. Apply a light coat of Loctite® 515 to the mating surface of slide springs (409) and (411) onto spacer.
outboard upright (64) and install end cover (74) using
capscrews (70) and lockwashers (5). Apply a small amount of
Loctite® 242 to capscrew (70) threads and torque to
25 ft lbs (34 Nm). • Long ends of springs (409 and 411) should be side by side in
11. Install side rails to uprights and loosely secure using center of spacer, and in front of base (421).
capscrews (65) and lockwashers (22).
12. Apply Loctite® 242 to capscrews (65) and torque to 65 ft lbs 5. Push spacer through other hole in base (421). Install bushings
(88 Nm). (415) to ends of spacer.
13. Install dowel pins (19). 6. Fit arms (412) over base (421) and line up holes. Slide pivot
14. Install disc brake, reduction gear and motor assembly on shaft (414) through holes in arms and base, then install
inboard upright. Apply Loctite® 243 to capscrew threads, retainer ring (417) to either end of pivot shaft.
secure with capscrews (10) torque to approximately 49-56 ft 7. Bolt base (421) to side rail (63) with capscrews (418) and
lbs (70-80 Ng). washers (419).
8. Compress short ends of springs (409) and (411) and install
shoulder screw (413) in arms (412) behind them. Short ends
Slack Line Detector Assembly
of springs (409) and (411) should press against the insides of
the screws.
Refer to Dwg. MHP2366 on page 50.
1. Install support bracket (508) to outside of inboard upright
(17) with capscrews (21) and washers (519). Drum Guard Assembly
2. Install stop bracket (507) to outside of outboard upright (64)
with capscrews (21) and washers (519). Refer to Dwg. MHP2281 on page 66.
3. Attach inboard arm (503) to support bracket (508) with 1. Place supports (703) over winch drum assembly and loosely
shoulder screw (523) and bushing (515). secure to side rails with washers (709) and capscrews (708).
4. Slip washers (510) over capscrews (509). Push capscrews 2. Position drum guard (704) between supports (703).
(509) though holes at other end of inboard arm (503). Attach 3. Secure drum guard to supports with clamps (702), capscrews
shafts (502) to inboard arm (503) with capscrews (509). Slide (701), lockwashers (705) and nuts (707).
rollers (501) over shafts (502). 4. Tighten all fasteners and check drum guard is secure. Ensure
5. Attach elbow fittings (482) and breather (460) to limit wire rope does not interfere with drum guard during winch
valve (481). operation.
6. Bolt limit valve to stop bracket (507) with capscrews (522)
and washers (520). Testing
7. With shoulder screw (517), bushing (521), and bushing (515),
attach actuator bracket (505) to lower end of outboard arm
(503), and outboard arm to stop bracket (507). Operational Test
8. Attach outboard ends of shafts (502) and rollers (501) to
Prior to initial use, all new or repaired winches shall be tested to
outboard arm (503) with capscrews (509) and washers (385).
ensure proper operation.
9. Insert capscrew (514) with washer (519) in the actuator
1. To initially ‘break in’ new or overhauled motors, operate
bracket’s (505) slot, and thread into hole in outboard arm
winch without load, in both directions, for 5 minutes at 100-
(503). For arm tension adjustment, refer to instructions in the
200 RPM.
“INSTALLATION” section on page 10.
2. Check operation of brakes. Adjust if necessary as described
in “MAINTENANCE” section on page 31.
3. Check foundation mounting fasteners are secure.
• Shoulder screw (524) fits in threaded hole in the stop bracket 4. Check drum guard is installed.
(507) and is used during shipping and storage to lock and 5. Check limit switches and slack line detector are correctly
protect the roller arm assembly. When not in use, this screw is adjusted. Refer to “INSTALLATION” section on page 10.
stored in threaded hole in support bracket (508).
Load Test
Press Roller Assembly
Prior to initial use, all new, extensively repaired, or altered
Refer to Dwg. MHP2268 on page 52. winches shall be load tested by or under the direction of a person
1. Slide long press roller (402) onto roller shaft (403), and trained in safety and operation of this winch and a written report
install bearings (407) inside roller on both ends of shaft. furnished confirming the rating of the winch. Test loads shall not
2. Slip spacers (408) over both ends of roller shaft (403) and be less than 100% of rated line pull at mid drum and should not
insert one end of shaft through small hole in arm (412). Over exceed 125% of the rated line pull at mid drum.
shaft end, slip spacer (408), short press roller (401), and To test the winch at 125% of the rated load at mid drum apply the
bearing (407). Install internal retainer ring (404) to hold following load:
bearing (407) to roller, then install external retainer ring
(405) to hold bearing (407) to roller shaft (403). FA150KGMR-RC Winch 125% Test Load 412 lb (187 kg)
3. Over opposite end of roller shaft (403), slip small hole of mid-drum
other arm (412), then spacer (408), short press roller (401),
and bearing (407). Install internal retainer ring (404) to hold
bearing to roller, then install external retainer ring (405) to
hold bearing to roller shaft (403).

36 MHD56244 - Edition 1
• 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.

Limit Switch

Operate winch through three complete cycles to ensure consistent

limit switch operation within +/- 2 ft (+/- 0.6 m) of setpoints.
Refer to ‘Limit Switch’ on page 13 in “INSTALLATION” section
to establish setpoints.

MHD56244 - Edition 1 37
 PARTS DRAWINGS AND PARTS LISTS TABLE OF CONTENTS

Description Page

Drum, Base Assembly Drawing (MHP2376) ...................................................................................................................................................40

Drum, Base Assembly Parts List .......................................................................................................................................................................41
Motor Assembly Drawing (MHP2357) and Parts List......................................................................................................................................42
Disc Brake and Gear Assembly Drawing (MHP2358) and Parts List ..............................................................................................................44
Drum Brake Assembly Drawing (MHP2373)...................................................................................................................................................46
Drum Brake Assembly Parts List ......................................................................................................................................................................47
Torque Limiter Assembly Drawing (MHP2386) and Parts List .......................................................................................................................48
Slack Line Detector Assembly Drawing (MHP2366).......................................................................................................................................50
Slack Line Detector Assembly Parts List ..........................................................................................................................................................51
Press Roller Assembly Drawing (MHP2268) ...................................................................................................................................................52
Press Roller Assembly Parts List.......................................................................................................................................................................53
Limit Switch Assembly Drawing (MHP2375)..................................................................................................................................................54
Limit Switch Assembly Parts List .....................................................................................................................................................................55
Control Console View (MHP2354) and Parts List............................................................................................................................................56
Directional Control Valve Assembly Drawing (MHP2361) and Parts List ......................................................................................................58
Lever Control Valve Assembly Drawing (MHP2362) and Parts List ...............................................................................................................58
Sequencer and Winch Assembly View (MHP2360) .........................................................................................................................................61
Control Box and Sequencer View (MHP2359).................................................................................................................................................60
Control Box and Sequencer Parts List ...............................................................................................................................................................61
Connecting Flange Piping and Hoses Legend Drawing (MHP2363) ...............................................................................................................62
Connecting Flange Piping and Hoses Legend Drawing (MHP2355) ...............................................................................................................63
Connecting Flange Legend ................................................................................................................................................................................64
Control Flange Legend ......................................................................................................................................................................................65
Drum Guard Assembly Drawing (MHP2281) and Parts List ...........................................................................................................................66
Winch Label/Tag Location Drawing (MHP2270) and Parts List......................................................................................................................67

38 MHD56244 - Edition 1
 SERVICE NOTES

MHD56244 - Edition 1 39
 DRUM AND BASE ASSEMBLY DRAWING

20

17 44
31 10
30

25
27 24

28
41 47
23 48
40 26
46
45
74
13
454 72
71
69

39
38
37 34 32

33

36 25

51

50
49
(Dwg. MHP2376)

40 MHD56244 - Edition 1
 DRUM AND BASE ASSEMBLY PARTS LIST

Item Description Qty. Part Item Description Qty. Part

No. of Part Total Number No. of Part Total Number
10 Capscrew 10 54133 34 Outboard Upright 1 28310
13 Capscrew 2 51766 36 Capscrew 8 50183
17 Inboard Upright 1 28300 37 Dowel Pin 8 52334
20 Motor Assembly 1 76157549 38 Nameplate 1 71106967-R
Drum Carrier Assembly 39 Rivet 4 71028849
23 1 28917
(incl’s items 27 and 28)
40 Lockwasher 4 50200
24 Capscrew 12 50973
41 Capscrew 4 51780
25 Lockwasher 20 50181
44 Control Box Assembly 1 76150491
26 Breather 4 51892
45 Capscrew 4 51712
27 Capscrew 8 Order item 23
46 Washer 8 50177
28 Hub 1 Order item 23
47 Locknut 4 50170
30 Wire Rope Anchor* 1 71387781
48 Bracket 2 28836
Drum 8 in. long (203 mm) Contact factory
49 Capscrew 4 71324743
Drum 12 in. long (305 mm) 11354-2
31 1 50 Washer 8 71064844
Drum 16 in. long (406 mm) Contact factory
51 Locknut 4 51750
Drum 24 in. long (610 mm) Contact factory
69 Seal 1 51474
Side Rail (8 in. long drum) Contact factory
71 Bearing 1 51797
Side Rail (12 in. long drum) 28837-2
32 1 72 Retainer 1 19232
Side Rail (16 in. long drum) Contact factory
74 End Cover 1 19233
Side Rail (24 in. long drum) Contact factory
454 Seal 1 71054688
Side Rail (8 in. long drum) Contact factory
Side Rail (12 in. long drum) 28852-2
33 1
Side Rail (16 in. long drum) Contact factory
Side Rail (24 in. long drum) Contact factory

• Recommended Spare for one winch, 2 years at normal operation.

* Wire rope anchors are for use with 6 X 19 or 6 X 37 IWRC right lay construction wire rope only.

† These parts also come in a cold weather version. For winches with a -C in the model code, adding CH (DNV) or CHA (ABS) to the end
of these part numbers is required to retain winch certification. Example: Order Drum (12 in. long) (item 60) part number 11354-2 as part
number 11354-2CH or 11354-2CHA.
Certification Type Example Part Number To Order
ABS --- 11354-2CHA
DNV 11354-2CH ---

MHD56244 - Edition 1 41
 MOTOR ASSEMBLY DRAWING AND PARTS LIST

153 154 155 140 141 138 142 143 144

139

138 145

137 146

136 147

135 148

134 149

133 150

132 151

131 143

130 152

(Dwg. MHP2357)

Item Description Qty. Part Item Description Qty. Part

No. of Part Total Number No. of Part Total Number
129 Motor Assembly 1 Contact factory 143 Lockwasher 9 4520-1006
130 Ball Bearing 1 50600004 144 Capscrew 5 41019001
131 Slotted Nut 1 57000004 145 Needle Bearing 1 56462813
132 Washer 1 96310054 • 146 Retainer Ring 1 47836732
133 Screw 1 41103403 • 147 Spool Front Stop 2 96200069
134 Ball Bearing 1 50600003 148 Needle Bearing 1 56492213
135 Drive Gear 1 96200094 149 Idle Gear 1 96200095
136 Slotted Nut 1 57000003 150 Capscrew 4 41321506
• 137 ‘O’ Ring 1 58221729 151 Screw 4 41020301
• 138 Pin 6 46000416 • 152 Gasket 1 96310118
• 139 Gasket 1 96310045 153 Selector Stop 1 96090223
140 Motor Housing 1 96310078 154 Ball 1 69401625
141 Motor Housing 1 96150361 • 155 ‘O’ Ring 1 58212229
142 Motor Cover 1 96150344 581 Fitting, Pipe 2 51281

• Recommended Spare for one winch, 2 years at normal service.

42 MHD56244 - Edition 1
 SERVICE NOTES

MHD56244 - Edition 1 43
 DISC BRAKE AND REDUCTION GEAR ASSEMBLY DRAWING

117 116 115 114 106 113 105 112

80 111

81 110

82 109

83 108

84 107

85 106

105
86

87 104

88 103

89 102

90

91

92
93 94 95 97 98 99 100 101
(Dwg. MHP2358)

44 MHD56244 - Edition 1
 DISC BRAKE AND REDUCTION GEAR ASSEMBLY PARTS LIST

Item Description Qty. Part Item Description Qty. Part

No. of Part Total Number No. of Part Total Number
80 Ouput Ring Gear 1 96090094 100 Brake Piston 1 96180126
81 Ball Bearing 1 50800006 • 101 ‘O’ Ring 1 58235229
• 82 Oil Seal 1 58017530 102 Washer 1 96150479
83 Ball Bearing 1 50050006 103 Spring 4 69165532
• 84 Retainer Ring for Shaft 1 47700029 104 Coupling Sleeve 1 96180128
85 Output Shaft 1 96187061 • 105 Oil Seal 2 58020330
• 86 Retainer Ring 1 47802139 • 106 Retainer Ring for Bore 2 47703032
87 Ball Bearing 1 50800005 107 Capscrew 4 41331306
88 Planet Axle 3 96090039 • 108 ‘O’ Ring 1 58218129
89 Needle Bearing 6 56501513 • 109 Capscrew 4 41322506
90 Spacer 3 96090095 • 110 ‘O’ Ring 1 58212529
91 Gear Housing 1 96180005 111 Brake Body 1 96150359
92 Planet Gear 3 96090096 112 Flange 1 96150550
93 Ring Gear 1 96090038 113 Retainer Ring for Sun Gear 1 47700015
94 Ball Bearing 1 50800009 • 114 Gasket 1 96180042
95 Pin 2 46001116 115 Ball Bearing 1 50000002
• 97 Friction Disc 5 63028241 116 Sun Gear 1 96157360
• 98 Steel Disc 4 63028341 117 Planet Support 1 96180041
• 99 ‘O’ Ring 1 58235129

• Recommended Spare for one winch, 2 years at normal operation.

MHD56244 - Edition 1 45
 DRUM BRAKE ASSEMBLY DRAWING

60
355
353
352
351
352 358
359

361

362
357 385

367 363
365

377

368 384
352
364 381
351
65
352
22
372 375 22
62 352
378
378 21
375
352

375
378

379
382
63
374
383
(Dwg. MHP2373)

46 MHD56244 - Edition 1
 DRUM BRAKE ASSEMBLY PARTS LIST

Item Description Qty. Part Number

No. of Part Total
21 Capscrew 1 50973
22 Lockwasher 3 50181
60 Drum (8 in. [203 mm] long)† Contact factory
Drum (12 in. [305 mm] long)† 11354-2
1
Drum (16 in. [406 mm] long)†
Contact factory
Drum (24 in. [610 mm] long)†
62 Side Rail (8 in. [203 mm] long drum)† Contact factory
Side Rail (12 in. [305 mm] long drum)† 28347-2
1
Side Rail (16 in. [406 mm] long drum)†
Contact factory
Side Rail (24 in. [610 mm] long drum)†
63 Side Rail (8 in. [203 mm] long drum)† Contact factory
Side Rail (12 in. [305 mm] long drum)† 28332-2
1
Side Rail (16 in. [406 mm] long drum)†
Contact factory
Side Rail (24 in. [610 mm] long drum)†
65 Capscrew 2 50183
351 Pin 2 4303-S
352 Cotter Pin 7 51937 (7)
353 Link Stud 1 2448
355 Brake Lever 1 11498
357 Pin 2 8609
358 Clevis 1 6237-2
359 Nut 1 50159
361 Breather 1 52384
362 Cylinder 1 4575-1
363 Fitting, Nipple 1 52006
• 364 Dump Valve 1 51954
365 Fitting, Hose End 2 52385
367 Fitting, Elbow 1 52182
368 Hose, Bulk 1 50923
372 Bracket† 1 11493
374 Locknut 2 50171 (2)
375 Pin 3 3704-S
377 Pivot Bracket† 1 11146
378 Washer As Req’d 50890
379 Arm 1 11147
381 Connecting Link† 1 11144
382 Stop Plate 1 11145
383 Setscrew 1 52226
Brake Band† 1 Set 28570-SET
• 384
Brake Band Lining Kit 1 Kit 28570-BLK
385 Washer 4 52914
• Recommended Spare for one winch, 2 years at normal operation.

† These parts also come in a cold weather version. For winches with a -C in the model code, adding CH (DNV) or CHA (ABS) to the end
of these part numbers is required to retain winch certification. Example: Order Drum (12 in. long) (item 60) part number 11354-2 as part
number 11354-2CH or 11354-2CHA.
Certification Type Example Part Number To Order
ABS --- 11354-2CHA
DNV 11354-2CH ---

MHD56244 - Edition 1 47
 TORQUE LIMITER ASSEMBLY DRAWING AND PARTS LIST

163 165
161 164
162 166

167

168

169

167
170

166
171

172

173

174
181 161 180 179 178 176
177
175
(Dwg. MHP2386)
Item Description Qty. Part
No. of Part Total Number
160 Torque Limiter Assembly --- 76360045
(Includes items 161 through 181)
161 Capscrew 8 41327406
162 Cover 1 96360041
• 163 ‘O’ Ring 1 58222329
164 Screw 1 42007307
165 Valve 1 96360017
• 166 Diaphragm 2 96360020
167 Washer 2 96360019
168 Body 1 96360038
169 Screw 1 42007807
170 Spacing Piece 1 96360044
171 Compression Spring 1 69154541
172 Nut 1 43001111
• 173 ‘O’ Ring 1 58214029
174 Valve 1 96360040
175 Cover 1 96360039
176 Screw 1 96360018
• 177 Joint 1 96360042
• 178 ‘O’ Ring 2 58209229
179 Capscrew 2 96360022
• 180 ‘O’ Ring 2 58210729
• 181 Seal Washer 2 58409731

• Recommended Spare for one winch, 2 years at normal operation.

48 MHD56244 - Edition 1
 SERVICE NOTES

MHD56244 - Edition 1 49
 SLACK LINE DETECTOR ASSEMBLY DRAWING

501

503

502
385
509

523

503
507
482

481 519
508 515
482
505
520
519
522
514
581

21 521
517

(Dwg. MHP2366)

50 MHD56244 - Edition 1
 SLACK LINE DETECTOR ASSEMBLY PARTS LIST

Item Description Qty. Part

No. of Part Total Number
Slack Line Detector Assembly
500 1 28281
(Incl’s items 21, 385, 460, 481, 482, and 501-523)
21 Capscrew 5 50973
385 Washer 4 52914
460 Breather 1 51559
481 Limit Valve 1 71356430
482 Fitting, Plug 2 54292
Roller 8 in. (203 mm) long drum Contact factory
Roller 12 in. (305 mm) long drum 28301
501 2
Roller 16 in. (406 mm) long drum
Contact factory
Roller 24 in. (610 mm) long drum
Shaft 8 in. (203 mm) long drum Contact factory
Shaft 12 in. (305 mm) long drum 28299
502 2
Shaft 16 in. (406 mm) long drum
Contact factory
Shaft 24 in. (610 mm) long drum
Arm (75°-90°) 28294
503 Arm (60°-75°) 2
Contact factory
Arm (45°-60°)
505 Actuator Bracket 1 28431
507 Stop Bracket, Outboard 1 28292
508 Support Bracket, Inboard 1 28289
509 Capscrew 4 71387278
514 Capscrew 1 51086
515 Bushing 2 71386577
517 Shoulder Screw 1 71386650
519 Washer 6 71064844
520 Washer 2 71352462
521 Bushing 1 71386569
522 Capscrew 2 71386585
523 Shoulder Screw 1 71386643
524 Shoulder Screw* 1 71383368

* Item not illustrated, required for transportation and storage

MHD56244 - Edition 1 51
 PRESS ROLLER ASSEMBLY DRAWING

402

403
407

410
413 408
401
407
404

405
412

414
410
409

416
417

411

415

421

418
385

(Dwg. MHP2268)

52 MHD56244 - Edition 1
 PRESS ROLLER ASSEMBLY PARTS LIST

Item Description Qty. Part

No. of Part Total Number
400 Press Roller Assembly (Incl’s items 385 and 401-421) 1 71383780
385 Washer 4 52914
401 Press Roller, Short 2 71383764
Press Roller 8 in. (203 mm) long drum Contact factory
Press Roller 12 in. (305 mm) long drum 71383772
402 1
Press Roller 16 in. (406 mm) long drum
Contact factory
Press Roller 24 in. (610 mm) long drum
Roller Shaft 8 in. (203 mm) long drum Contact factory
Roller Shaft 12 in. (305 mm) long drum 71383756
403 1
Roller Shaft 16 in. (406 mm) long drum
Contact factory
Roller Shaft 24 in. (610 mm) long drum
404 Retainer Ring 2 71069322
405 Retainer Ring 2 53050
407 Bearing 4 71053649
408 Spacer 4 71383798
409 Spring 1 71383657
410 Bushing 2 Order item 412
411 Spring 1 71383665
412 Arm Assembly (Incl’s item 410) 2 71383723
413 Shoulder Screw 2 71061634
414 Pivot Shaft 1 71383749
415 Bushing 2 71337091
416 Spacer 1 28416
417 Retainer Ring 2 71053581
418 Capscrew 4 71371652
Base 8 in. (203 mm) long drum Contact factory
Base 12 in. (305 mm) long drum 71383715
421 1
Base 16 in. (406 mm) long drum
Contact factory
Base 24 in. (610 mm) long drum

MHD56244 - Edition 1 53
 LIMIT SWITCH ASSEMBLY DRAWING

Hose Routing
Limit
Switch
Air Motor
581
and
Control Valve

460

481
Rear
452
453
456 472 368
468 479
464 469
477
467
474
464 471 475

465

463
464 473
472

462

461

77
5 455
457

458
74
459

73
454
69

72

71

(Dwg. MHP2375)

54 MHD56244 - Edition 1
 LIMIT SWITCH ASSEMBLY PARTS LIST

Item Description Qty. Part

No. of Part Total Number
Limit Switch Assembly (Incl’s items 5, 13, 71-72, 74, 77, 452-
50 1 27306-1
469, 471-479, 481, and 482)
5 Lockwasher 3 50200
69 Seal 1 51474
71 Bearing 1 51797
72 Retainer 1 19232
73 Capscrew 2 71030787
74 End Cover 1 19233
77 Capscrew 3 51769
Specify
368 Hose, Bulk Length in 50923
Feet
452 Fitting, Tee 1 53940
453 Fitting, Hose End 7 52179
454 Seal 1 71054688
455 Spacer 3 14998-7
456 Hose Sleeve 1 28449
457 Bracket, Limit Switch 1 11501
458 Lockwasher 4 52909
459 Nut 4 54142
460 Breather 2 51559
461 Coupling Assembly 1 52381
462 Limit Switch 1 19578-1
463 Capscrew 4 54493
464 Lever Assembly 2
465 Plate 2
467 Screw 8
468 Block, Tall 1
469 Block, Short 1
471 Screw 2
472 Locking Ring 2 Order item 462
473 Gasket 1
474 Screw 4
475 Cover Plate 1
477 Access Plate 1
478 Lockwasher 2
479 Screw 2
481 Valve 2 71356430
482 Fitting, Plug 4 51281

MHD56244 - Edition 1 55
 CONTROL CONSOLE VIEW AND PARTS LIST

Lever
Control Failure
On Line Standard Winch Valve Balancing
Indicator Mode Indicator Indicator Mode Indicator
(424) (423)
(422) (422) (422)

Balancing
Network Air Pressure
Pressure Guage
Guage (426)
(425)

Balancing
Pressure
Control
Regulator
(430)

Emergency On
Stop Button Lockout Selector
Button (428) Key Switch
(427) (431) (429)
(Dwg. MHP2354)

Item Description Qty. Part

No. of Part Total Number
422 Pneumatic Green Indicator 3 60932841
423 Pneumatic Red Indicator 1 60932941
424 Lever Control Valve Assembly 1 76150489
425 Pressure Gauge (0-10 bar) 1 67750241
426 Pressure Gauge (0-2.5 bar) 1 67750341
427 Directional Valve 1 68531241
428 Directional Valve 1 68531441
429 Directional Valve 1 68550041
430 Pressure Regulator 2 67780141
431 Lockout Key 1 Contact factory

56 MHD56244 - Edition 1
 DIRECTIONAL CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST

205

204

203
190

202
191

201
192

200
193

194 195 196 197 198 199

(Dwg. MHP2361)
Item Description Qty. Part
No. of Part Total Number
Directional Control Valve Assembly
606 2 68553441
(Refer to Dwg. MHP2362 on page 58)
190 Cover 1 96150378
191 Capscrew 1 41326306
192 Capscrew 4 41322306
193 Lockwasher 4 45201006
194 Washer 1 45700005
• 195 Diaphragm 1 96360020
196 Piston 1 96150376
197 Capscrew 4 41331306
198 Directional Control Valve Body 1 96150377
• 199 Joint 2 96150383
200 Spring 1 69158732
201 Spacing Piece 1 96150382
202 Plug 1 96150375
203 Screw 1 42008307
204 Plug 1 65160932
205 Cover 1 96150374

• Recommended Spare for one winch, 2 years at normal operation.

MHD56244 - Edition 1 57
 LEVER CONTROL VALVE ASSEMBLY DRAWING

623

624

622

621
620

600 619

601 618

602 617

603 603

604
605
606
606
643
605 607 616
609 611 614 613 606
604 642
610 612 635
641
613
625 622
635
626 640
627 626
628
621
619
639
629 638

630 637
636
631
618
617
609
632
610
603 611
607
613 612
616 610 634 635 614 606
(Dwg. MHP2362)

58 MHD56244 - Edition 1
 LEVER CONTROL VALVE PARTS LIST

Item Description Qty. Part

No. of Part Total Number
600 Fitting, Nipple 1/2-3/4 in 1 61331032
601 Female, Elbow 3/4 in 1 61331232
602 Fitting, 3/4 in 1 61645232
603 Fitting, Elbow 3/4 in 2 61330932
604 Elbow 1/8 in 2 68143628
605 Pipe 2m 68045428
606 Directional Control Valve Assembly 2 68553441
607 Sleeve 2 61045128
609 Capscrew 2 41311006
610 Lockwasher 4 45000104
611 Capscrew 2 41322106
612 Washer 2 45000105
613 Washer 2 45700005
614 Angle Bracket 1 96150423
615 Fitting 3 68246128
616 Hose 5m 16810656
617 Muffler 1 68497432
618 Control Lever 1 96150406
619 Stop 1 96180034
620 Valve Housing 1 96180145
621 Console 1 96150416
622 Lever Control Valve Support 1 96150368
623 Handle 1 57426232
624 Axle 1 96150394
625 Capscrew 4 41322506
626 Lockwasher 7 45201006
• 627 ‘O’ Ring 1 58217629
628 Screw 2 41105103
629 Rotary Valve 1 96180146
• 630 ‘O’ Ring 3 58220929
631 Elbow 1/2 in 1 61330832
632 Base Plate 1 96180110
633 Pipe 2m 102U0401
634 Capscrew 2 41313606
635 Stop Nut 2 43707211
• 636 Pin 1 46507220
637 Spring 1 96180035
• 638 Straight Pin 2 46001216
639 Stop Nut 3 43707611
640 Screw 3 41020301
641 Bellows with Clamping Collar 1 68952341
642 Nut 1 43003511
643 Washer 2 45701008

• Recommended Spare one winch, 2 years at normal operation.

MHD56244 - Edition 1 59
 CONTROL BOX AND SEQUENCER VIEWS

700 710 701

705 711 702

709

704

709

708 706
707

709

(Dwg. MHP2359)

60 MHD56244 - Edition 1
 CONTROL BOX AND SEQUENCER PARTS LIST

Item Description Qty. Part

No. of Part Total Number
700 Sequencer Assembly 1 76150490
701 Control Box Assembly 1 76150491
702 Connecting Flange 1 96150408
704 High Precision Pressure Regulator 1 67750141
705 Regulator 3/4 in 2 67730541
706 Servo Pressure Regulator 1/4 in 1 67730741
707 Pressure Regulator 1/4 in 1 67730841
708 Shut-Off Valve 3/4 in 1 76170123
709 Shut-Off Valve 3/4 in 4 76170122
710 Control Flange 1 96150411
711 Air Filter 1 68551941
712 Check Valve 1 63801741
713 Outlet Valve 1 67730441
714 Fitting, ‘Y’ 1/8 in 2 68245928
715 Muffler 3 68497432

SEQUENCER AND WINCH ASSEMBLY VIEW

712

715

715
714 713
(Dwg. MHP2360)

MHD56244 - Edition 1 61
62
Descent Pressure Climb Climb Pressure
Control Valve Pressure Regulator Control Valve

Standard Limiter
R37 R34 Pressure Regulator

(Dwg. MHP2363)
R28

To Descent R35 To Control To Climb

Motor Orifice Consol Motor Orifice

1 2
R32 R32
3
R36 Nozzle 0.8 R32 Control Flange
R33 R29
Descent
Limiter Descent Climb
Valve Valve Valve Emergency Pressure Regulator
Stop
1 2 1 2 Valve
R31 R31 R30 R30
N1 N2 N3
R22

R17
R22 N4 N5 N6
R15 N19
N16 N2 N23 B13
N9 N10 N7 N8 N9
R28
R29 M166 M14
R36 N13 N24 N10 N11 N12
B5
P5
N7
R34 N21 M21 M22 N5 N13 N14 N15
P9
R35 N20 P1
3 N15 N17
R32
N16 N17 N18
M26 M199 M23 P6 N4
P10
2 Nozzle 0.8 P2
B20
R30 N8 N12 N18 N19 N20 N21

M20 M24 N22

P11 P7
2 M27 P3 N22 N23 N24
N14
R31
N6 N11 R37
N25 N26 N27
CONNECTING FLANGE PIPING AND HOSES LEGEND

Nozzle 0.5
R33 M25 P12 P8 P4
N1 B18
N3
N/A (empty)

BX B= Interconnected blue hoses

RX R= Red hoses to the air equipment

MHD56244 - Edition 1
 CONNECTING FLANGE PIPING AND HOSES LEGEND

C12 C8 C4

C11 C7 C3

C10 C6 C2
Muffler
C9 C5 C1

C = Hoses from the Control Console

Viewed from beneath Control Box
(Dwg. MHP2355)

MHD56244 - Edition 1 63
 CONNECTING FLANGE LEGEND

B13 VeA: Port A of Exhaust Valve

B18 Piloting Pressure
M14 FH: Top Limit Switch
M16 FB + S: Bottom Limit Switch + Slack
M19 DFR: Brake Detection
M20-B20 ADFR: Brake Detection Supply
M21 L2a: Port A of Torque Limiter Control Valve Floating
M22-R22 Dc: Signal to Directional Control Valve
M23 E Dc: Directional Control Valve Inlet
M24 Ve: Signal to Exhaust Valve
M25 EVe: Exhaust Valve Inlet
M26 Torque Limiter Exhaust
M27 Piloting Pressure
P1 Standard Mode Information
P2 Balancing Mode Information
P3 L2r: Signal to Floating Torque Limiter (Port R)
P4 Signal to Lowering Pressure Valve
P5-B5 Downstream Connection to Emergency Valve
P6 Upstream Connection to Emergency Valve
P7 Connection to Pilot Pressure of Emergency Stop Valve
P8 UP
P9 Failure Indicator
P10 Warning Buzzer
P11 DOWN
P12 Floating Indicator
R15 Ve, Dc: Exhaust Valve, Directional Valve
R17 RESET
R28 Signal to Pressure Regulator Lifting Side
R29 Signal to Exhaust Valve Pressure Regulator
R30 Signal to Lifting Valve
R31 Signal to Lowering Valve
R32 Signal to Main Air Shut Off Valve
R33 Lowering Regulator
R34 Standard Limiter Regulating Inlet
R35 Standard Limiter Regulating Outlet
R36 Torque Limiter Supply
R37 Lowering Pressure Regulating Valve

B Interconnected Blue Hoses

M Hoses to the Air Winch
P Hoses from the Control Console
R Red Hoses to Air Equipment

64 MHD56244 - Edition 1
 CONTROL FLANGE LEGEND

N1 PA: Inlet Pressure

N2 PP: Piloting Pressure
N3 PU: Working Pressure
N4 FLT: Floating Mode
N5 STD: Standard Mode
N6 VF: Floating Indicator
N7 VA: Failure Indicator
N8 DFR: Brake Detector
N9 FB: Bottom Limit Switch
N10 FH: Top Limit Switch
N11 UP: Lifting
N12 DW: Lowering
N13 OUTLET Ve, Dc: Exhaust Valve Outlet, Directional Valve Outlet
N14 INLET Ve: Exhaust Valve Inlet
N15 INLET Dc: Directional Valve Inlet
N16 RESET
N17 AV: Warning Buzzer
N18 INLET L1p: Emergency Stop Valve Inlet (Port P)
N19 OUTLET L1a: Emergency Stop Valve Outlet (Port A)
N20 INLET L2p: Floating Torque Limiter Inlet (Port P)
N21 OUTLET L2a: Floating Torque Limiter Outlet (Port A)
N22 INLET L2r: Floating Torque Limiter Inlet (Port R)
N23 OUTLET VeA: Exhaust Valve Outlet (Port A)
N24 ADVe: Exhaust Valve Supply
N25 empty
N26 empty
N27 empty

Refer to Dwg. MHP2363 on page 62.

MHD56244 - Edition 1 65
 DRUM GUARD ASSEMBLY DRAWING AND PARTS LIST

704

701
702

703
705
707

709
708
(Dwg. MHP2281)
Item Description Qty. Part
No. of Part Total Number
700 Drum Guard Assembly* (8 in. [203 mm] long drum) Contact factory
Drum Guard Assembly* (12 in. [305 mm] long drum) 11283-2
1
Drum Guard Assembly* (16 in. [406 mm] long drum)
Contact factory
Drum Guard Assembly* (24 in. [610 mm] long drum)
701 Capscrew 4 71126742
702 Clamp 4 10399
703 Support 2 10400
704 Drum Guard (8 in. [203 mm] long drum) Contact factory
Drum Guard (12 in. [305 mm] long drum) 11259-2
1
Drum Guard (16 in. [406 mm] long drum)
Contact factory
Drum Guard (24 in. [610 mm] long drum)
705 Lockwasher 4 51581
707 Nut 4 51440
708 Capscrew 4 71324743
709 Washer 4 50182

* Drum Guard Assemblies include items 701–709.

66 MHD56244 - Edition 1
 WINCH LABEL/TAG LOCATION DRAWING AND PARTS LIST

Item Description Qty. Part

No. of Part Total Number
67 Nameplate 1 Contact factory
68 Rivet 8 71028849
902 Notice, Man Rider (Refer to Label on page 6) 1 71108856
903 Label, Throttle Direction 1 96180102
904 Label, Warning (Refer to Label on page 6) 1 71124887
905 Label, Overwind Cable 2 96180103
906 Label, Limit Switch 1 71149454
908 Label, Ingersoll-Rand Logo 2 71106256
909 Label, Product 1 71111793
910 Label Sheet 1 71295240
911 Label, Open Book 1 96180098
912 Label, CE 1 96180096
914 Warning 1 96150447

Contact factory for label locations.

MHD56244 - Edition 1 67
 SERVICE NOTES

68 MHD56244 - Edition 1
 SERVICE NOTES

MHD56244 - Edition 1 69
 PARTS ORDERING INFORMATION

The use of other than Ingersoll-Rand replacement parts may

Return Goods Policy
adversely affect the safe operation and performance of this
product. Ingersoll-Rand will not accept any returned goods for warranty
For your convenience and future reference it is recommended that or service work unless prior arrangements have been made and
the following information be recorded. written authorization has been provided from the location where
the goods were purchased.
Model Number _______________________________________ Winches that have been modified without Ingersoll-Rand
approval, mishandled or overloaded will not be repaired or
Serial Number ________________________________________ replaced under warranty. A printed copy of the warranty which
applies to this winch is provided inside the back cover of this
Date Purchased _______________________________________ manual.
When ordering replacement parts, please specify the following:
1. Complete model number and serial number as it appears on Disposal
the nameplate.
2. Part number(s) and part description as shown in this manual. When the life of the winch has expired, it is recommended that the
3. Quantity required. winch 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
• Continuing improvement and advancement of design may P.O. Box 24046
cause changes to this equipment which are not included in this 2724 Sixth Avenue South
manual. Manuals are periodically revised to incorporate Seattle, WA 98124-0046 USA
changes. Always check the manual edition number on the Phone: (206) 624-0466
front cover for the latest issue. Fax: (206) 624-6265
• Sections of this manual may not apply to your winch.
or
Refer all communications to the nearest Ingersoll-Rand Office or
Distributor. Ingersoll-Rand
Douai Operations
111, avenue Roger Salengro
59450 Sin Le Noble, France
Phone: (33) 3-27-93-08-08
Fax: (33) 3-27-93-08-00

70 MHD56244 - Edition 1
 WARRANTY

LIMITED WARRANTY
Ingersoll-Rand Company (I-R) warrants to the original user its I-R makes no other warranty, and all implied warranties
Products to be free of defects in material and workmanship for a including any warranty of merchantability or fitness for a
period of one year from the date of purchase. I-R will repair, particular purpose are limited to the duration of the expressed
without cost, any Product found to be defective, including parts warranty period as set forth above. I-R’s maximum liability is
and labor charges, or at its option, will replace such Products or limited to the purchase price of the Product and in no event
refund the purchase price less a reasonable allowance for shall I-R be liable for any consequential, indirect, incidental,
depreciation, in exchange for the Product. Repairs or replacements or special damages of any nature rising from the sale or use of
are warranted for the remainder of the original warranty period. the Product, whether based on contract, tort, or otherwise.

If any Product proves defective within its original one year Note: Some states do not allow limitations on incidental or
warranty period, it should be returned to any Authorized Hoist and consequential damages or how long an implied warranty lasts so
Winch Service Distributor, transportation prepaid with proof of that the above limitations may not apply to you.
purchase or warranty card.
This warranty gives you specific legal rights and you may also
This warranty does not apply to Products which I-R has have other rights which may vary from state to state.
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
This shipment has been thoroughly checked, packed and inspected You must file claims for damage with the carrier. It is the
before leaving our plant and receipt for it in good condition has transportation company’s responsibility to reimburse you for
been received from the carrier. Any loss or damage which occurs repair or replacement of goods damaged in shipment. Claims for
to this shipment while en route is not due to any action or conduct loss or damage in shipment must not be deducted from the
of the manufacturer. Ingersoll-Rand invoice, nor should payment of Ingersoll-Rand
invoice be withheld awaiting adjustment of such claims as the
Visible Loss or Damage carrier guarantees safe delivery.
If any of the goods called for on the bill of lading or express You may return products damaged in shipment to us for repair,
receipt are damaged or the quantity is short, do not accept them which services will be for your account and form your basis for
until the freight or express agent makes an appropriate notation on claim against the carrier.
your freight bill or express receipt.

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.

MHD56244 - Edition 1 71
 United States Office Locations International Office Locations

For Order Entry and Order Regional Sales Offices Offices and distributors in Latin America Operations
Status principal cities throughout the Ingersoll-Rand
Annandale, NJ world. Contact the nearest Production Equipment Group
Technical Support P.O. Box 970 Ingersoll-Rand office for the 730 N.W. 107 Avenue
1467 Route 31 South name and address of the Suite 300, Miami, FL
Ingersoll-Rand Annandale, NJ 08801 distributor in your country or 33172-3107 USA
P.O. Box 24046 Phone: (908) 238-7000 write/fax to: Phone: (305) 559-0500
2724 Sixth Avenue South Fax: (908) 238-7048 Fax: (305) 222-0864
Seattle, WA 98124-0046 USA Canada
Phone: (206) 624-0466 Detroit, MI National Sales Office Europe, Middle East and
Fax: (206) 624-6265 1872 Enterprise Drive Regional Warehouse Africa
Rochester, MI 48309 Toronto, Ontario Ingersoll-Rand
Ingersoll-Rand Phone: (248) 293-5700 51 Worcester Road Douai Operations
Distribution Center Fax: (248) 293-5800 Rexdale, Ontario 111, avenue Roger Salengro
P.O. Box 618 M9W 4K2 59450 Sin Le Noble, France
510 Hester Drive Houston, TX Phone: (416) 213-4500 Phone: (33) 3-27-93-08-08
White House, TN 37188 USA 450 Gears Road Fax: (416) 213-4510 Fax: (33) 3-27-93-08-00
Phone: (615) 672-0321 Suite 210 Order Desk
Fax: (615) 672-0801 Houston, TX 77067-4516 Fax: (416) 213-4506 Asia Pacific Operations
Phone: (281) 872-6800 Ingersoll-Rand
Web Site: Fax: (281) 872-6807 Regional Sales Offices 23/F., 625 King’s Road
www.irco.com Edmonton, Alberta North Point, Hong Kong
Los Angeles, CA 5608 - 94 A Street Phone: (852) 2527 0183
13107 Lakeland Road Edmonton, Alberta Fax: (852) 2529 5976
Santa Fe Springs, CA T6E 3E4
90670-0525 Phone: (780) 438-5039 Russia
Phone: (562) 777-0808 Fax: (780) 430-4500 Ingersoll-Rand
Fax: (562) 777-0818 Kuznetsky Most 21/5
Montreal, Quebec Entrance 3
3501 St. Charles Blvd., Moscow 103895
Suite 104 Russia
Kirkland, Quebec Phone: (7) 501 923 9134
H9H 4S3 Fax: (7) 501 924 4625
Phone: (514) 695-9040
Fax: (514) 695-0963 Australia
Ingersoll-Rand Aust
British Columbia 1 Hartnett Drive
1200 Cliveden Avenue Seaford, Vic 3198
Delta, B. C. Australia
V3M 6G4 Phone: 61 3 95541642
Phone: (604) 523-0803 Fax: 61 3 95541607
Fax: (604) 523-0801

Printed in USA