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Automatic Brake Assembly
Refer to Dwg. MHP1210.
1. Apply sealant to the exhaust elbow (135) and install into top port in brake
cylinder (136).
2. Apply sealant to the elbow fitting (228) and install into lower port in brake
cylinder.
3. Mount the brake cylinder to the brake cylinder mounting bracket (139) by
reinstalling the pin (138) and retainer rings (137).
4. Screw the brake trunnion (56) onto the brake adjusting screw (57) until 3 or 4
threads are exposed.
5. Insert the eye end of the brake adjusting screw into the brake band (61).
6. Insert the brake band pin (59) through the brake band and the adjusting screw
eye.
7. Insert retainer ring (58) into the groove in the brake band pin. Press the retainer
ring until fully seated.
8. Position each half of the brake lever (130) around the brake trunnion.
9. Secure brake lever halves together with capscrews (131) and tighten. Refer to
‘Torque Chart’ on page 11 for torque requirements.
10. Pressurize brake cylinder. Refer to ‘Adjusting Automatic Brake‘ on page 6 for
adjusting brake.
11. Using pin (133) and cotter pin (92) attach the lever assembly to the brake cylinder
rod end. Bend cotter pin ends apart.
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Shuttle Valve Chest Assembly (optional feature)
Refer to Dwg. MHP1209.
1. Clean the shuttle valve bushing (203) and bore with electrical contact cleaner
and blow dry with shop air.
2. Clean the brake valve bushing (202) and bore with electrical contact cleaner and
blow dry with shop air.
3. With the machined surface of the valve chest case (200) on a work bench and
pendant ports up, insert the shuttle valve (212) so that the threaded stud/small
ground surface is on the left.
4. Insert the shuttle valve washers (215) in both ports.
5. Insert the shuttle valve springs (216) into both ports.
6. Place shuttle valve gasket (214) onto the shuttle valve cap (213).
7. Screw the shuttle valve caps with shuttle valve gaskets in and HAND TIGHTEN.
8. Clean the brake valve (208) with electric contact cleaner.
9. Insert the brake valve into the brake valve bushing (202).
10. Screw the brake valve seats (209) into the valve chest. Tighten.
11. Place brake valve cap gasket (211) onto the brake valve cap (210).
12. Screw the brake valve cap with brake valve cap gasket into the valve chest. HAND
TIGHTEN - DO NOT deform the valve cap gasket.
13. Apply thread sealant to the air inlet plug (207), insert into the left port and HAND
TIGHTEN.
14. Apply thread sealant to the two-connector fittings (236) and install in the outside
ports. Hand tight.
15. Apply thread sealant to the brake elbow (225) and hand tighten.
16. Place a thrust washer (13) into the valve chest and tap with a hammer until
seated.
17. Insert capscrews (222) and lockwashers (223) through the valve chest sides.
18. Place the gasket (217) over the capscrew threads and hold in position.
19. Loosely secure the valve chest to the motor housing by tightening both
capscrews.
20. Insert the 3rd capscrew (221) and lockwasher (223) through the top mounting
hole. Tighten capscrews.
21. Apply thread sealant to the 3rd fitting (236) and insert it into the middle air port.
Tighten all fittings.
22. Tighten both brake valve and shuttle valve caps.
23. Apply thread sealant to both pipe plugs (205) and tighten.
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Two Function Pendant Assembly (optional feature)
Refer to Dwg. MHP2346.
1. Install ‘O’ rings (443) and (449) along with protector (451) on valves (452). Install
valve assemblies in handle (454).
2. Install levers (453) in pendant handle (454) with pin (447). Stake pin in pendant
handle at both ends to secure.
3. Install screws (448) in levers.
4. Install balls (446) and springs (445) in handle (454). Secure in position with plugs
(444).
5. On pendants with emergency stop, install emergency stop button (441). On
pendants without emergency stop, install plug (470).
6. Install exhaust washer (457) and secure in handle with retainer ring (458).
7. Attach hoses to fittings located on top of pendant handle. Locate hoses to fittings
as shown in Dwg. MHP2398 in Product Information Manual.
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Testing
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Operational Test
Prior to initial use, all new, altered or repaired winches shall be tested to ensure
proper operation.
a. Check oil level in motor and grease in gear assembly are correct.
b. To initially ‘break in’ new or overhauled motors, operate without load, in
both directions, for 15 minutes at 100 - 200 RPM.
c. New Brake Band Lining Run-in Procedure: All new brake band linings require
a ‘run-in’ period.
d. Operate the winch without load in the payout direction while gradually
applying the brake. Allow the brake to slip for approximately one minute.
Winch motor may stall as brake band lining fully engages. Do not allow brake
to overheat.
e. Check operation of brake. Adjust if necessary as described in the
“MAINTENANCE” section.
f. Check foundation mounting fasteners are secure.
g. Install winch guard.
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Load Test
Prior to initial use, all extensively repaired winches shall be load tested by or under
the direction of an Ingersoll Rand trained Technician and a written report furnished
confirming the rating of winch. Test loads shall not be less than 100% of rated line
pull and should not exceed 125% of rated line pull. To test winch at 125% of rated
load apply following load with wire rope on the first layer of the drum:
BU7A winch 125% Test Load = 1250 lbs (567 kg).
NOTICE
•
Testing to more than 125% of rated line pull may be required to comply
with standards and regulations set forth in areas outside the USA.
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Form MHD56461 Edition 2