MAINTENANCE
WARNING
•
Never perform maintenance on the winch while it is supporting a load.
•
Before performing maintenance, tag controls:
WARNING - DO NOT OPERATE, EQUIPMENT BEING REPAIRED.
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Only allow Ingersoll Rand trained Technicians to perform maintenance on
this winch.
•
After performing any maintenance on the winch, test winch to 125% of its
rated line pull at mid drum before returning to service. (Testing to more
than 125% of rated line pull may be required to comply with standards and
regulations set forth in areas outside the USA.)
•
Shut off air system and depressurize air lines before performing any
maintenance.
•
Do not use Trichloroethylene to clean parts.
•
Use of other than genuine Ingersoll Rand parts may result in safety hazards,
decreased performance and increased maintenance and may invalidate all
warranties.
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General
Correct disassembly (to prevent loss or damage of good parts), repair, assembly,
testing and adjusting are critical to proper product operation. Maintenance
procedures are technical in nature and require training and experience to
accomplish correctly. In addition, repair and testing require specialized equipment
that is not typically found at the product-mounting site.
Proper use, inspections and maintenance increase the life and usefulness of your
Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and
all machined threads with applicable lubricants. Use of antiseize compound and/or
thread lubricant on capscrew and nut threaded areas prevents corrosion and allows
for easy disassembly of components.
It is extremely important that anyone involved with maintaining the product be
familiar with the servicing procedures of these products and be physically capable
of conducting the procedures. These personnel shall have skills that include:
1. Proper and safe use and application of mechanics’ common hand tools as well
as special Ingersoll Rand or recommended tools.
2. Safety procedures, precautions and work habits established by accepted
industry standards.
Ingersoll Rand cannot know of or provide all the procedures by which product
operations or repairs may be conducted and the hazards and/or results of each
method. If operation or maintenance procedures not specifically recommended by
the manufacturer are conducted, it must be ensured that product safety is not
endangered by the actions taken. If unsure of an operation or maintenance
procedure or step, personnel should place the product in a safe condition and
contact supervisors and/or the factory for technical assistance.
NOTICE
•
Refer to the Product Parts Information Manual for drawings unless
specified elsewhere.
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Maintenance Intervals
Refer to Table 3 ‘Maintenance Interval Chart’ on page 3 for recommended
maintenance schedule.
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Adjustments
CAUTION
•
Before adjusting brake, remove any load from load line to prevent injury
or property damage.
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Adjusting Manual Brake
Keep brake adjusted so that considerable pressure is required to force lever past the
high point. Never adjust the brake so tight that lever cannot be moved to the locked
position.
If brake does not hold rated load, disassemble and repair.
1. Lift up brake lever (55) to remove tension on brake band.
2. Remove brake lever screws, separate halves and set aside.
3. Spread brake band apart and measure thickness of metal band and lining
together. When brake band and lining together measure less than 0.203 inches
(5.2 mm) in any location, the brake band assembly (61) must be replaced.
4. Rotate brake trunnion (56) half a turn clockwise when facing the gear end of the
winch.
5. Insert brake trunnion into brake lever and assemble with screws. Place brake
lever halves into brake band bracket.
6. Press lever down. This should be difficult until lever goes “over center” and locks.
7. Actuate throttle lever in both directions. Drum should not rotate.
8. If drum rotates, remove brake lever, tighten trunnion clockwise another half turn
and test again. Repeat until drum does not rotate when lever is locked and
throttle is activated.
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Adjusting Automatic Brake
Refer to Dwg. MHP1210 in the Product Parts Information Manual.
If the brake assembly is removed or repaired, ensure that the breather is installed
and located at the top of the brake cylinder during reassembly.
The automatic brake is spring actuated in the brake “ON” position with no air. The
brake cylinder must be energized to affect any adjustments. The use of a brake-
pressurizing tool is recommended when adjusting the automatic brake. This tool
consists of: 3/8 NPT pipe nipple, ball valve and a quick disconnect fitting (to connect
to shop air supply).
1. Remove capscrews (131) from brake lever, separate halves and set aside.
2. Spread brake band apart and measure thickness of metal band and lining
together. When brake band and lining together measure less than 0.203 inches
(5.2 mm) in any location, the brake band assembly (61) must be replaced.
3. Rotate brake trunnion (56) half a turn clockwise when facing gear end of winch.
4. Place brake trunnion between brake lever halves and assemble with capscrews.
5. Align lever with air cylinder clevis and insert brake pin. Retain with cotter pin,
bend ends apart.
6. Attach test load to load line and lift load 6 to 9 inches (150 to 220 mm). When
throttle lever is in neutral position (centered), the load should not move.
7. Brake is correctly adjusted when 1/4 to 1/2 in. (13 to 19 mm) of piston rod is
exposed. Refer to Dwg. MHP1211 on page 6, A. Brake is correctly adjusted
when 1/4 to 1/2 in. (13-19 mm) of piston rod is exposed. If load does move,
tighten trunnion a further half turn and test again. Repeat until load does not
move when throttle lever is in neutral position.
A
(Dwg. MHP1211)
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Adjusting Remote Control Valve
Refer to Dwg. MHP0415 in the Product Parts Information Manual.
If winch operating speeds differ from performance specifications, pilot air control
valve may require adjustment. Loosen nut (640) and adjust adjusting screw (639),
located in valve end cap (632), until drum speed for no-load haul-in equals drum
speed for full load payout. Rotate adjusting screw (639) ‘out’ to increase drum speed
and ‘in’ to decrease drum speed. It is suggested that a chalk mark be placed on drum
flange so that drum rpm can be accurately counted.
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Winch Guard
1. Install drum guard (301) on base (87) with capscrews (302) and nuts (303).
2. Remove minimum amount of mesh from the drum guard to provide clearance
for wire rope departure.
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Disassembly
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General Disassembly Instructions
The following instructions provide necessary information to disassemble, inspect,
repair, and assemble product. Parts drawings are provided in Product Parts
Information Manual.
If a product is being completely disassembled for any reason, follow the order of
topics as they are presented. It is recommended that all maintenance work on
product be performed in a clean dust-free work area.
In the process of disassembling product, observe the following:
1. Never disassemble product any further than is necessary to accomplish needed
repair. A good part can be damaged during the course of disassembly.
2. Never use excessive force when removing parts. Tapping gently around
perimeter of a cover or housing with a soft hammer, for example, is sufficient to
break the seal.
3. Do not heat a part with a flame to free it for removal, unless part being heated
is already worn or damaged beyond repair and no additional damage will occur
to other parts.
In general, products are designed to permit easy disassembly and assembly. The
use of heat or excessive force should not be required.
4. Keep work area as clean as practical, to prevent dirt and other foreign matter
from getting into bearings or other moving parts.
5. All seals, gaskets and ‘O’ rings should be discarded once they have been
removed. New seals and ‘O’ rings should be used when assembling product.
6. When grasping a part in a vise, always use leather-covered or copper-covered
vise jaws to protect the surface of part and help prevent distortion. This is
particularly true of threaded members, machined surfaces and housings.
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Form MHD56461 Edition 2
