Ingersoll-Rand FH5i-DCOKER, Product Maintenance Information, Page: 7 / 12

The above recommendations are based on an open system equipped with micro-
air breathers. Open systems without micro-air breathers are not recommended.
Visual inspection cannot be used to determine cartridge replacement. Particles
below 40 microns are not visible to the human eye.
Before changing from one type of fluid to another (for example, from a petroleum-
base to a fire-resistant fluid) consult component and filter manufacturers on the
selection of the fluid and the filters that should be used. Follow recommended
flushing procedures when changing fluids. Also consult ANSI B93.5M-1979 “Practice
for the Use of Fire Resistant Fluids for Industrial Hydraulic Fluid Power Systems.”
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Disassembly
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General Disassembly Instructions
The following instructions provide necessary information to disassemble, inspect,
repair and assemble winch. Parts drawings are provided in Product Parts Information
Manual.
If winch is being completely disassembled for any reason, follow the order of topics
as they are presented. It is recommended that all maintenance work on winch be
performed in a clean dust free work area.
In the process of disassembling winch, observe the following:
1. Never disassemble winch 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, winch is 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, gaskets and ‘O’ rings should be used when assembling
winch.
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.
7. Do not remove any part that is a press fit in or on a subassembly unless removal
of that part is necessary for repairs or replacement.
8. When removing ball bearings from shafts, it is best to use a bearing puller. When
removing bearings from housings, drive out bearing with a sleeve slightly
smaller than outside diameter of bearing. The end of sleeve or pipe that contacts
bearing must be square. Protect bearings from dirt by keeping them wrapped
in clean cloths.
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Winch Disassembly
Refer to Dwgs. MHP2850, MHP2859, and MHP2674.
1. Remove wire rope from drum.
2. Operate winch to position reduction gear drain plug at its lowest position.
3. Relieve pressure in hydraulic lines by operating winch control several times after
hydraulic supply has been shut off.
WARNING
• Shut off, bleed down and disconnect hydraulic supply line before
performing any disassembly procedures.
4. Tag and disconnect hoses to motor and control valve.
5. Remove winch from its mounting and move to a suitable work area before
beginning disassembly.
6. Drain oil from reduction gear assembly by removing one plug (48) when
positioned at its lowest point, and one plug (48) from its highest point to vent.
Refer to Dwg. MHP1756 in Product Information Manual. If winch is equipped
with a drum band brake, elevate winch outboard end (opposite from motor end)
to prevent draining oil from contaminating brake band lining.
7. Remove drum band brake, winch guard and any other externally mounted winch
attachments.
8. Winch guard disassembly, refer to Dwgs. MHP2676 and MHP2850:a.Remove
panels (805) and (807), one section at a time, by removing locknuts (804) and
crossbars (806).b.Remove capscrews (90) and washers (98) securing lifting lugs
(83) to uprights.c.Remove capscrews (809) and washers (96) securing frames
(802) and (801) to uprights (42) and (84).
9. Remove nuts (8) and lockwashers (3) securing motor assembly to disc brake (20).
Support motor and pull motor straight away from winch. Refer to motor
manufacturer’s literature if motor disassembly and service is required.
10. Remove brake assembly (20). If brake assembly sticks, tap it with a soft faced
hammer until assembly separates.
11. Drive out pin (9) and remove coupling (14) from drive shaft (35).
12. Remove seal adapter (10) from brake adapter (6).
13. Remove ‘O’ ring (5) and oil seal (2) from seal adapter (10) if they require
replacement.
14. Remove capscrews (4) and pull brake adapter from drum shaft (41).
15. Remove ‘O’ ring (33).
16. Remove retainer ring (36) from bore of drum shaft (41).
17. Pull shaft and bearing assembly from drum shaft (41).
18. Support drum (80) and remove capscrews (39) from drum shaft (41). Pry drum
shaft (41) from inboard upright (42).
19. Remove capscrews (85) and lockwashers (98) that secure side rails (82) to inboard
upright (42). Drive out dowel pins (86).
20. Remove inboard upright (42).
21. Remove capscrews (97), lockwashers (96) and end cover (95) from outboard
upright (84).
22. Remove capscrews (94) and bearing retainer (92) from drum (80).
23. Remove drum and reduction gear assembly.
24. Remove remaining capscrews (85) and lockwashers (98) that attach siderails (82)
to outboard upright (84). Drive out dowel pins (86).
25. Remove bearing (87) from outboard upright (84).
26. Remove capscrews (45) and lockwashers (46) securing gear carrier (47) to drum
(80).
27. Install two 3/4 in. - 10 NC x 3 in. long capscrews into threaded holes in outer bolt
pattern ring of gear carrier (47). Use these capscrews to break seal. Remove
reduction gear assembly from drum (80).
28. Remove dowel pins (86) from gear carrier (47).
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Manual or Automatic Band Brake Disassembly
Refer to Dwg. MHP2852.
1.
Automatic Brake:
a. Disconnect and remove hose and fittings from cylinder (110).b.c.d.
b. Remove cotter pin (102) and pin (101) from link stud (103) and brake band
(128).
c. Remove cotter pin (102) and pin (106). Separate cylinder clevis from brake
lever (105).
d. Remove cotter pin (102) and pin (134). Remove cylinder (110) from bracket
(118).
2.
Manual Brake:
a. Remove cotter pin (102) and pin (101) from handle (104) then remove handle
(104) from brake band (128).
3. Remove capscrews (119), lockwashers (117), and stop plate (126).
4. Remove cotter pin (102) and pin (121) from pivot bracket (122).
5. Use a hoist to raise winch approximately 6 inches (15 cm). Separate brake band
(128) halves and rotate brake band assembly slowly until it can be removed from
drum (80).
6. Remove cotter pins (102) and pins (121) so brake band halves (128) can be
removed from arm (124). Lower winch when brake band assembly has been
removed.
7. Remove capscrews (116), washers (117), bracket (118), spacer (automatic brake
only) (107) and pivot bracket (122).
8. Remove cotter pin (102), pin (134) and hydraulic cylinder (110) from bracket
(118).
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Reduction Gear Disassembly
NOTICE
• It is important to maintain a clean work area when reduction gear assembly
is disassembled.
• Disassembly is not recommended, if it is unavoidable, use the following
steps.
Refer to Dwg. MHP2850.
1. Remove plug (48) from gear carrier (47). Rotate reduction gear to drain oil from
level plug hole.
2. Place reduction gear assembly on a clean work bench so that end containing
bearing (49) is down.
3. Remove capscrews (75) and pry off cover (73).
4. Remove ring gear (72), planetary assembly (67) and sun gear (69).
5. Remove and discard ‘O’ rings (62) from ring gear (72).
6. Remove four dowel pins (74) from between cover (73) and spacer (71) and store
in a safe place.
7. .Remove spacer (71), ring gear (63) and sun gear (66).
8. If required, remove thrust bearing (55) from sun gear (66). Remove and discard
‘O’ rings (62) from ring gear (63).
9. Remove capscrews (60) from input housing (59). Separate input housing from
gear carrier (47).
10. Remove planetary assembly (58).
11. Remove ring gear (53). Remove three dowel pins (52) from between input
housing (59) and gear carrier (47) and store in a safe place.
12. Remove and discard ‘O’ rings (51) from ring gear (53).
13. Remove retainer ring (57) and sun gear (56). If required, remove thrust bearing
(55) from sun gear.
14. Remove planetary assembly (54).
15. Remove retainer ring (50) and bearing (49) from gear carrier (47).
NOTICE
• Do not disassemble planetary gear assemblies (54), (58) and (67).
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Motor Disassembly
Refer to motor manufacturer’s literature for motor maintenance instructions. It is
not recommended that the motor be disassembled unless it is known that problems
exist.
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Disc Brake Disassembly
Refer to brake manufacturer’s literature for brake maintenance instructions . It is not
recommended that the brake be disassembled unless it is known that problems
exist.
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Press Roller Disassembly
Refer to Dwgs. MHP2695 and MHP2850.
1. Compress ends of springs (405) and (406) to disengage from side rail (82) and
pin on press roller arm (407).
CAUTION
• Springs are under tension. Use care when releasing springs (405) and (406)
from press roller.
2. Loosen collars (404).
Form MHD56375 Edition 2 7