Ingersoll-Rand FORCE5i FA2i-MRA Setup guide

Product

Maintenance

Information

Model FA2i-MRA (ANSI)

Save These Instructions

Form MHD56332

Edition 1

July 2010

71468144

2Form MHD56332 Edition 1

Only allow Ingersoll Rand trained Technicians to perform maintenance on this product. For additional information contact Ingersoll Rand

factory or nearest Distributor.

The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and may invalidate all

warranties.

For additional supporting documentation refer to Table 1 on page 2 for Product Information Manuals.

Manuals can be downloaded from www.winchandhoistsolutions.com

Refer all communications to the nearest Ingersoll Rand Office or Distributor.

The original language of this manual is English.

Table 1: Product Manuals

INSPECTION

Frequent inspections should be performed on equipment in regular service. Refer to

Product Information Manual. Periodic Inspection

Refer to Table 2: “Inspection Classifications” on page 2 for suggested winch

inspection classifications for Periodic Inspection intervals. Select conditions most

appropriate to application.

Table 2: Inspection Classifications

Maintain written records of periodic inspections to provide an accumulative basis for

continuing evaluation. Inspect all items listed in “Frequent Inspection.” Also inspect

the following at the suggested intervals recommended in Table 3: “Maintenance

Interval Chart” on page 3:

1. Siderails and Uprights. Check for deformed, cracked or corroded main

components. Replace damaged parts.

2. Fasteners. Check retainer rings, capscrews, nuts and other fasteners on winch,

including mounting bolts. Replace if missing or damaged and tighten if loose.

3. Drum and Sheaves. Check for cracks, wear or damage. Replace if necessary.

4. Wire Rope. In addition to “Frequent Inspection” requirements, also inspect for

the following:

a. Build-up of dirt and corrosion. Clean with steam or a stiff wire brush to

remove dirt and corrosion if necessary.

b. Loose or damaged end connection. Replace if loose or damaged.

c. Check wire rope anchor is secure in drum.

d. Verify wire rope diameter. Measure the diameter of the wire rope from

crown-to-crown throughout the life of the wire rope. Recording of the

actual diameter should only be done with the wire rope under equivalent

loading and in the same operating section as accomplished during previous

inspections. If the actual diameter of the wire rope has decreased more

than 1/64 inch (0.4 mm) a thorough examination of the wire rope should

be conducted by an experienced inspector to determine the suitability of

the wire rope to remain in service. Refer to Dwg. MHP0056 on page 2.

(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.

6. Brakes. Individually test brakes installed to ensure proper operation. Brakes

must hold a 125% rated load at mid drum without slipping. If indicated by poor

operation or visual damage, disassemble and repair brake(s). Check all brake

surfaces for wear, deformation or foreign deposits. Clean and replace components

as necessary. Adjustments can be made to the drum band brake to compensate

for normal brake lining wear. Refer to ‘Adjustments’ in the “MAINTENANCE”

section. If brake band cannot be adjusted to hold rated load, replace the brake

band assembly. Adjustments cannot be made to the disc brake. The disc brake

must be repaired as described in the “MAINTENANCE” section.

7. Foundation or Supporting Structure. Check for distortion, wear and continued

ability to support winch and rated load. Ensure winch is firmly mounted and that

fasteners are in good condition and tight.

8. Labels and Tags. Check for presence and legibility of labels. Replace if damaged

or missing.

9. Limit Switches. Operate winch in both directions to activate limit switches.

Limit switches should engage (stop winch operation) at established settings (+/

- 2 feet [+/- 0.6 meters]). Reset limit switch by operating winch in opposite

direction. Refer to ‘Limit Switch Adjustment’ in “MAINTENANCE” section.

10. Drum Guard. Verify fasteners are tight and in good condition. Ensure guard is in

good condition.

Records and Reports

Inspection records, listing all points requiring periodic inspection should be

maintained for all load bearing equipment. Written reports, based on severity of

service, should be made on the condition of critical parts as a method of

documenting periodic inspections. These reports should be dated, signed by the

person who performed the inspection, and kept on file where they are readily

available for review.

Maintenance Intervals

Refer to “Periodic Inspection” and Table 2: “Inspection Classifications” on page 2 for

maintenance interval guidance.

Publication Part/Document Number Publication Part/Document Number

Product Safety Manual (Man Rider) MHD56251 Product Parts Information Manual MHD56302

Product Information Manual MHD56331

Conditions Normal Heavy Severe

Typical Use (operating time) Infrequent Regular Continual/Constant

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

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

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

Climate Dry/Stable Temperature Wet/Moderate Temperature Fluctuations Wet/Severe Temperature Fluctuations

Form MHD56332 Edition 1 3

Table 3: Maintenance Interval Chart

Normal Application

The following work can be completed by owner maintenance personnel

System Air Filter Inspect system air filter every 45 days or 125 hours.

Grease Fittings Lubricate grease fittings every 180 days or 500 hours.

Gearbox Oil Level Check oil level in gearbox every 180 days or 500 hours. Replace oil yearly.

It is recommended that the following work be completed by an Ingersoll-Rand trained service technician.

Standard Components 1 Year or

1,000 hrs

2 years or

2,000 hrs

3 years or

3,000 hrs

4 years or

4,000 hrs

5 years or

5,000 hrs

6 years or

6,000 hrs

8 years or

8,000 hrs

Inspect Motor X X X

InspectManualBandBrake XXXXXXX

Inspect Disc Brake X

Inspect Gearbox X

Replace Winch Anchor Bolts X

Inspect Control Valve X X X

Inspect Drum, Housings and Main Frames X X X

Line Speed Monitor and Overspeed Alarm X X X X

LimitSwitches XXXXXXX

Automatic Band Brake * X X X X

Heavy Application

The following work can be completed by owner maintenance personnel

System Air Filter Inspect system air filter every 30 days or 100 hours.

Grease Fittings Lubricate grease fittings every 90 days or 250 hours.

Gearbox Oil Level Check oil level in gearbox every 180 days or 500 hours. Replace oil yearly.

It is recommended that the following work be completed by an Ingersoll-Rand trained service technician.

Standard Components 1 Year or

1,000 hrs

2 years or

2,000 hrs

3 years or

3,000 hrs

4 years or

4,000 hrs

5 years or

5,000 hrs

6 years or

6,000 hrs

Inspect Motor X X

InspectManualBandBrake XXXXXX

Inspect Disc Brake X

Inspect Gearbox X

Replace Winch Anchor Bolts X

Inspect Control Valve X

Inspect Drum, Housings and Main Frames X X

Line Speed Monitor and Overspeed Alarm X X X

LimitSwitches XXXXXX

Automatic Band Brake * X X X

Severe Application

The following work can be completed by owner maintenance personnel

System Air Filter Inspect system air filter every 30 days or 100 hours.

Grease Fittings Lubricate grease fittings every 90 days or 250 hours.

Gearbox Oil Level Check oil level in gearbox every 90 days or 250 hours. Replace oil yearly.

Drum Band Brake Check drum band brake adjustment every 90 days or 250 hours.

It is recommended that the following work be completed by an Ingersoll-Rand trained service technician.

Standard Components 1 Year or

1,000 hrs

2 years or

2,000 hrs

3 years or

3,000 hrs

4 years or

4,000 hrs

5 years or

5,000 hrs

6 years or

6,000 hrs

8 years or

8,000 hrs

Inspect Motor X XXX

Inspect Manual Band Brake X X X XXXX

Inspect Disc Brake X X

Inspect Gearbox X X

Replace Winch Anchor Bolts X X

Inspect Control Valve X XXX

Inspect Drum, Housings and Main Frames X XXX

Line Speed Monitor and Overspeed Alarm X XXX

Limit Switches X X X XXXX

Automatic Band Brake * X XXX

Note: Hours are for actual winch drum rotation. Perform an annual winch load test for all applications.

* Do not disassemble band brake air cylinder unless brake operation or visual inspection indicates a requirement.

Recommend complete general overhaul.

4Form MHD56332 Edition 1

INSPECTION REPORT

Ingersoll Rand Force 5 Infinity Series Models FA2i, FA2.5i, FA5i or FA5Ti Air Winches

Model Number: Date:

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection:

(_____ Months _____ Years)

Operating Environment:

Normal: ___ Heavy: ___ Severe: ___

2. Discrepancy(s) noted during Frequent Inspection

3. Discrepancy(s) noted during maintenance

4. Other: ___________________________

Refer to the Product Information and Parts Information Manual and “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.

COMPONENT CONDITION CORRECTIVE

ACTION NOTES

Pass Fail Repair Replace

Uprights and

Siderails

Drum Band Brake

(125% Load Test)

Drum Locking Pin

Disc Brake

(125% Load Test)

Drum Band Brake

(Visual Inspection)

Disc Brake

(Visual Inspection)

Motor

Limit Switches

Controls

Air System

Fasteners

Reduction Gears

Labels and Tags ---

Shafts

Drum Guard

Wire Rope Wedge ---

Line Speed Monitor and Overspeed

Alarm

Other Components

(list in NOTES section)

TESTING Pass Fail NOTES

Operational (No Load)

Operational (10% Load)

Operational (Maximum Test Load*)

* Maximum test load is 125% of rated line pull. Testing to more than 125% of rated load may be required to set overload device or comply with standards and regulations

set forth in areas outside the USA.

This form may be photo copied and used as an inspection record.

Form MHD56332 Edition 1 5

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 operate. Insufficient or no air supply to winch. Check air supply line connections and hoses.

Winch is overloaded. Reduce load to within rated capacity.

Disc brake does not release. Pressurize disc brake release port and check for leakage. Replace brake piston seals if

leakage is found. Ensure air pressure at inlet to disc brake is at least 45 psig (3.1 bar/

310 kPa). Inspect brake piston seals and replace if seals appear to be leaking.

Shipping plugs may still be in place. Remove shipping plugs in valve and motor exhaust ports.

Drum brake does not release. Disengage manual drum brake, or refer to ‘Automatic Band Brake Adjustment’ on page 6.

Motor may be damaged. Disassemble and clean the motor and replace any broken or damaged parts.

Air leak. Check hose and fitting connections. Inspect hose(s) for breaks. Tighten fittings and

repair or replace hoses as necessary.

Air lines frozen due to 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.

Load continues to move when winch

is stopped.

Brake is slipping. Check ‘Automatic Band Brake Adjustment’ on page 6 and brake band lining wear.

Check brake friction disc wear.

Winch is overloaded. Reduce load to within rated capacity.

Winch motor controls sticking. Check pendant/throttle levers spring return to normal (neutral) position when released.

Winch does not lift load or does not

lift rated capacity.

Winch does not lift/pull load.

Motor may be damaged. Remove and disassemble motor as described in the “MAINTENANCE” section on page 8.

Examine all parts and replace any that are worn or damaged.

Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements listed in the

“SPECIFICATIONS” section in Product Information Manual. Clean air line filter.

Brake is not releasing. Check brake release pilot hole is not restricted. Check seals on cylinder piston are not

damaged. Brake should be released at 45 psig (3.1 bar/310 kPa).

Winch is overloaded. Reduce load to within rated capacity.

Oil leak from motor end of winch. Reduction assembly is leaking. Disassemble winch and inspect reduction assembly seals.

Throttle or pendant lever moves but

winch does not operate.

Motor may be damaged. Disassemble and clean motor and replace any broken or damaged parts.

Insufficient air supply. Ensure air pressure at winch inlet is at least 90 psig (6.3 bar/630 kPa) at rated volume.

Clean air line filter.

Air leak. Check hose and fitting connections. Inspect hose(s) for breaks. Tighten fittings and

repair or replace hoses as necessary.

Motor does not run smoothly or

makes excessive noise during

operation.

Damaged or broken piston or connecting

rod.

Disassemble and repair motor.

Motor runs hot or makes excessive

noise during operation.

Low oil level. Check oil level in motor. Add oil as required to obtain proper level.

Improper lubrication. Replace oil with type recommended in “LUBRICATION” section in Product Information

Manual. Set lubricator to provide 6 to 9 drops of oil per minute at maximum winch

operating capacity.

Water in oil. Drain and refill with recommended oil. Operate winch with no load slowly, in both

directions. If noise still exists or motor overheats disassemble and repair motor.

Damaged or broken piston or connecting

rod.

Disassemble and repair motor.

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 as described in the “MAINTENANCE” section on page 8.

Inspect all parts and replace all worn or damaged parts.

Brake(s) not releasing. Refer to brakes in “MAINTENANCE” section on page 8.

Insufficient air supply. Verify air supply pressure and volume at winch inlet meets the requirements. Refer to

“SPECIFICATIONS” section in Product Information Manual. Clean air line filter.

Throttle lever hard to actuate, or

lever does not spring return to

neutral.

Reverse valve sticking in bushing. Remove and disassemble control valve. Clean control valve parts and check clearance

between reverse valve and bushing.

Winch does not operate in one

direction.

Limit switch engaged. Operate winch in opposite direction. Adjust limit switch settings to required travel limits.

Line Speed Monitor does not show

feet per minute indication.

Low Battery. Charge battery.

Sensor maybe damaged or obstructed. Clean capscrew heads and sensor. Verify 0.2 inches (+/- 0.1 inches) [5 mm (+/- 2.5 mm)]

clearance between sensor and capscrew heads.

6Form MHD56332 Edition 1

MAINTENANCE

WARNING

• Never perform maintenance on winch while it is supporting a load.

• Before performing maintenance, tag controls:

WARNING - DO NOT OPERATE -

EQUIPMENT BEING REPAIRED

• Only allow Ingersoll Rand trained Service Technicians to perform

maintenance on this winch.

• After performing any maintenance on 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 will invalidate all

warranties.

General

Correct disassembly (to prevent loss or damage of good parts), repair, assembly,

testing and adjusting are critical to proper winch 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 winch-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 winch be

familiar with the servicing procedures of these winches 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.

Adjustments

Drum Guard

Refer to Dwg. MHP2676.

Drum guard panels must be adjusted to suit wire rope departure angle. Adjust per

procedures in Product Information Manual.

Disc Brake

Refer to Dwg. MHP2786.

Disc brake adjustment is not required. If disc brake does not hold rated load

disassemble and repair. If brake assembly is removed or disassembled ensure breather

(29) is installed and located at top of brake housing during reassembly.

Manual Drum Band Brake

Refer to Dwg. MHP0209.

1. Release wire rope tension on drum.

2. Raise handle (104) to free brake bands (128).

3. Remove cotter pin (102) and pin (101).

4. Rotate link stud (103) clockwise to increase brake torque.

5. Install pin (101) and check adjustment.

6. Brake should be adjusted until brake lever over center position can be attained

with 50 to 100 lb (23 to 45 kg) force on handle (104).

7. Install cotter pin (102) when adjustment is completed. Bend ends of cotter pin

over.

CAUTION

• When any part of brake lining measures 0.062 inch (2 mm) or less, brake

bands (128) or linings must be replaced.

Automatic Band Brake

Refer to Dwg. MHP0209.

1. Remove cotter pin (102) at adjustment clevis (107).

2. Apply air to brake cylinder (110) and remove pin (106) to disconnect clevis from

brake lever (105).

3. Turn adjustment clevis (107) clockwise to increase cylinder rod extension. Turn

clevis counterclockwise to decrease cylinder rod extension.

4. Assemble clevis (107) to brake lever (105) with pin (106). Release air to brake

cylinder (110).

5. Measure cylinder rod extension. Length should be 1 to 1-1/2 inches (25 to 37

mm). Re-adjust if necessary.

6. Install cotter pin (102) to secure clevis to brake lever when adjustment is

complete. Bend ends of cotter pin over.

7. With brake on, adjust screw (127) to just touch arm (124).

Pilot Air Control Valve (optional feature)

Not shown in Product Parts Information manual.

If winch operating speeds differ from performance specifications, pilot air control

valve may require adjustment.

1. Loosen nut (271) and adjust adjusting screw (270), located in valve end

cap(268), until drum speed for no-load haul-in equals drum speed for full load

payout.

2. Rotate screw (270) ‘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.

3. Tighten nut (271) after adjustment.

Automatic Band Brake:

Brake cylinder will not release. Band brake out of adjustment. Adjust band brake to maintain correct cylinder stroke.

Leaking cylinder seals. If air is noticed escaping from cylinder breather when attempting to release brake,

replace or repair cylinder.

Dirty filter in air supply. Clean or replace filter.

Faulty dump valve. Check dump valve exhaust port. Air should exhaust when control valve handle is in

neutral. If no air escapes, replace dump valve.

Automatic Disc Brake:

Brake fails to release. Low air supply pressure. Ensure air pressure at inlet to disc brake is at least 60 psig (3.4 bar/340 kPa).

Leaking piston seals. Inspect brake breather. If air escapes from brake breather when attempting to release

brake, replace brake seals.

No release pressure at brake port. Check for proper operation of winch controls.

Sticking brake piston. Apply 60 psig (3.4 bar/340 kPa) to brake release port and check for brake disc

movement. (Brake discs can be viewed through brake breather hole.) If brake discs do

not move, disassemble and inspect disc brake as described in “MAINTENANCE” section on

page 6.

SYMPTOM CAUSE REMEDY

Form MHD56332 Edition 1 7

Limit Switch

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

Wire Rope Line Speed Monitor and Overspeed Alarm Adjustment

Line speed monitor adjustments are limited to placement of sensor. Adjustments to

indicator set points established at factory should not be attempted. To change line

speed monitor set points contact your nearest Ingersoll Rand distributor or the

factory.

1. The sensor attaches to assembly bracket and faces the drum reduction gear

mounting capscrews.

2. Install sensor and adjust to ensure a clearance of 0.2 inch (+/- 0.1 inch) [5 mm

(+/- 2.5 mm)] between sensor and drum reduction gear mounting capscrew

heads. Refer to Dwg. MHP0602 on page 7.

(Dwg. MHP0602)

Disassembly

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 a 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.

NOTICE

• 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 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 which is a press fit in or on a subassembly unless

removal of that part is necessary for repairs or replacement.

8. When removing ball bearings from shafts, it is best to use a bearing puller. When

removing bearings from housings, drive out bearing with a sleeve slightly smaller

than outside diameter of bearing. The end of sleeve or pipe which contacts

bearing must be square. Protect bearings from dirt by keeping them wrapped in

clean cloths.

Winch Disassembly

Refer to Dwgs. MHP0210 and MHP2773.

1. Remove wire rope from drum.

2. Operate winch to position reduction gear drain plug at its lowest position.

3. Relieve pressure in air lines by operating winch control several times after air

supply has been turned off.

WARNING

• Shut off, bleed down and disconnect air supply line before performing any

disassembly procedures.

4. Disconnect and tag the air lines.

5. Remove winch from its mounting and take to a suitable work area before

beginning disassembly.

6. Remove lower case drain plug (464) in motor housing (463) and allow oil to

drain into a suitable container. Loosen fill cap (462) to vent motor housing.

7. Drain oil from gear reduction assembly by removing pipe plug (48) when

positioned at its lowest point.

8. Remove pipe plug (25) in brake housing (17) to drain brake oil. If winch is

equipped with a drum band brake the winch outboard end (opposite motor end)

must be elevated to prevent draining oil from contaminating brake band lining.

WARNING

• The motor weighs approximately 117 lbs. (53 kg). Adequately support motor

before removing motor mounting capscrews.

9. Remove drum guard. Refer to ‘Drum Guard’ disassembly on page 6.

10. Remove drum band brake and any other externally mounted winch attachments.

11. Remove capscrews (97) and lockwashers (96) securing motor assembly to the

motor adapter (6). Using a hoist to support the motor, pull motor straight away

from winch. Reference applicable ‘Motor Disassembly’ section if motor

disassembly is required.

12. Alternately and evenly loosen capscrews (93). Remove capscrews and motor

adapter (6).

13. Remove brake housing (17). If brake housing sticks, tap it with a brass hammer

until pieces separate. Note position of all brake pieces for reassembly.

14. Remove friction plates (19) and drive plates (18).

15. Remove springs (9) from brake piston (10).

16. Remove brake piston (10) from brake housing (17). Tap lightly with a plastic

mallet to separate parts if necessary.

17. Remove seals (11) and (12) from brake piston (10).

18. Remove gear (21) from shaft (35).

19. Remove retainer ring (36) from bore of drum shaft (41).

20. Pull shaft and bearing assembly from drum shaft (41).

21. Support drum (80) and remove capscrews (39) from drum shaft (41). Pry drum

shaft (41) from inboard upright (42).

22. Remove capscrews (85) and lockwashers (98) which secure siderails (82) to

inboard upright (42) and drive out dowel pins (86).

23. Remove inboard upright (42).

24. Remove end cover (95), capscrews (97) and lockwashers (96) from outboard

upright (84).

25. Remove capscrews (94) and bearing retainer (92) from drum (80).

26. Remove drum and reduction gear assembly.

27. Remove remaining capscrews (85) and lockwashers (98) that attach siderails

(82) to outboard upright (84)and drive out dowel pins (86).

28. Remove bearing (86) and seal (99) from outboard upright (84).

29. Remove capscrews (45) and lockwashers (46) from gear carrier (47). Lift

reduction gear assembly from drum (80). To disassemble reduction gear refer to

“Reduction Gear” disassembly section on page 9.

Drum Guard

Refer to Dwg. MHP2676.

1. Remove capscrews (90) and washers (91) securing lifting lugs (83) to uprights.

2. Remove panels (805) one section at a time, by removing nuts (804) and

crossbars(806).

3. Remove capscrews (809) and washers (96) that secure frames to winch uprights.

4. Remove frames.

Motor

Refer to Dwg. MHP0210.

1. Remove capscrews (364), lockwashers (96) and exhaust cover (469). Pull out

rotary valve (467) and rotary valve bushing (466). Remove adapter valve (468).

2. Remove capscrews (451), lockwashers (452) and cylinders (453) from motor

housing (463).

3. Rotate crankshaft assembly (473) to bring each wrist pin (457) above the motor

housing (463), then push out wrist pin (457) and remove piston (455). Plugs

(456) pressed into ends of wrist pins (457) should not be removed. To avoid

breakage use extreme care when removing compression rings (454).

4. Pull crankshaft assembly (473) with attached connecting rods (459) out of

motor housing (463) by shifting connecting rods (459) to clear cylinder holes.

Connecting rods (459) are joined through a common journal on the crankshaft

and are held in place by connecting rod rings (474) on each side of main rib.

Reduction Gear

Assembly

Capscrew

Head

Inboard

Upright

Maintain Clearance o

0.2 inch (+/- 0.1 inch)

[5 mm (+/- 2.5 mm]

bewteen sensor and

capscrew head

Overspeed Indicator Sensor Clearance

Drum

8Form MHD56332 Edition 1

5. To remove connecting rods (459) from crankshaft (473), take out setscrew (478)

and drive out taper pin (479) securing counterbalance to crankshaft.

6. Loosen capscrew (480), remove counterbalance, then pull off connecting rod

rings (474), connecting rods (459), bushing (476) and sleeve (475).

Live Air Throttle Valve

Refer to Dwg. MHP0203.

Match mark throttle valve parts to ensure proper reassembly.

1. Remove pins (428) and tap out pin (429) from handle bracket (426).

2. Mark the square end on valve body (441) and handle (426) to ensure correct

orientation during reassembly. Remove handle assembly.

3. Make note on how spring (427) is positioned before removing it. Remove

capscrews (444), lockwashers (443) and exhaust cover (442) from housing

(438).

4. Remove pipe plug (434), spring (422), poppet valve (436) and ball (421) from

housing (438). Pull valve (441) out of valve bushing (440).

5. Check parts for score marks or wear. Clearance between valve bushing (440)and

valve (441) should not exceed 0.002 in. (0.05 mm) or excessive air leakage will

occur.

Manual or Automatic Band Brake

Refer to Dwg. MHP0209.

1. Automatic Brake:

a. Disconnect and remove hose, fittings and dump valve (112) from cylinder

(110).

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 clevis (107) from brake

lever (105).

d. Remove cotter pin (102) and pin (117). 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 (45), lockwashers (119) and stop plate (126). Ensure pivot

bracket (122) is no longer secured to siderail.

4. 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).

5. 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.

6. Refer to Product Parts Information Manual to order replacement parts.

Reduction Gear

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. MHP2773.

1. Place the reduction gear assembly on a clean work bench such that the end

containing seal (43) is down.

2. Remove capscrews (75) and pry off cover (73).

3. Remove four pins (74) from between cover (73) and spacer (71) and store in a

safe place.

4. Remove ring gear (72), sun gear (69) and planet assembly (67).

5. Remove ring gear (63) and spacer (71). Remove and discard ‘O’ rings (51) and

(62) from ring gears (63) and (72).

6. Remove capscrews (60) from the input housing (59).

7. Lift off input housing (59) and remove sun gear (66) from planet assembly (67).

8. If required, remove thrust plate (55) from sun gear (66).

9. Remove planet assembly (58) and sun gear (56).

10. Remove planet assembly (54) and ring gear (53).

11. Remove three dowel pins (52) from gear carrier (47) and store in a safe place.

12. Remove and discard ‘O’ rings (51) from ring gear (53).

13. Remove retainer ring (50) and bearing (49) from gear carrier (47).

Cleaning, Inspection and Repair

Cleaning

Clean all winch component parts in solvent (except drum brake bands and disc brake

friction plates). The use of a stiff bristle brush will facilitate removal of accumulated

dirt and sediments in the reduction assembly, on housings, frame and drum. If drum

bushings have been removed it may be necessary to scrape old Loctite® from drum

bushing bores. Dry each part using low pressure, filtered compressed air. Clean drum

brake band using a wire brush or emery cloth. Do not wash drum brake band in

solvent. If drum brake band lining is oil soaked, it must be replaced.

Inspection

All disassembled parts should be inspected to determine their fitness for continued

use. Pay particular attention to the following:

1. Inspect all gears for worn, cracked, or broken teeth.

2. Inspect all bushings for wear, scoring, or galling.

3. Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent

on shafts, replace shaft. Inspect all surfaces on which oil seal lips seat.

4. Inspect all bearings for play, distorted races, pitting and roller or ball wear or

damage. Inspect bearings for freedom of rotation.

5. Inspect all threaded items and replace those having damaged threads.

6. Inspect drum band brake lining for oil, grease and glazing. If drum band brake

lining is oil-soaked replace brake bands as a set. Remove glazed areas of band

brake lining by sanding lightly with a fine grit emery cloth.

7. Measure thickness of band brake lining. If brake band linings are less than 0.062

inch (2 mm) thick anywhere along edges replace brake bands (128) as a set.

8. Inspect cylinder bores. Minor scratches in bore lining may be repaired by lightly

honing to remove. Refer to tolerances listed below for acceptable clearances.

Replace liner if deep scratches or gouges are apparent. Measure inside diameter

of liner. If measurement is greater than 4.764 inches (121 mm) replace liner.

‘Ring Gap’ may also be used to determine wear; place compression ring into liner,

using a piston, push ring until approximately half way in liner and measure

‘Gap’— 0.003 inch (0.076 mm) is normal; replace rings, or liner, if ‘Gap’ exceeds

0.020 inch (0.51 mm).

9. Inspect drive plates for warpage or other damage, and replace damaged parts as

necessary. Replace input pinion shaft oil seal.

10. Measure thickness of brake friction disc. Friction disc must show an even wear

pattern. If friction disc is 0.076 in. (1.93 mm) or less, replace disc.

Repair

Actual repairs are limited to removal of small burrs and other minor surface

imperfections from gears and shafts. Use a fine stone or emery cloth for this work.

Do not use steel wool.

1. Worn or damaged parts must be replaced. Refer to the applicable Parts Listing for

specific replacement parts information.

2. Inspect all remaining parts for evidence of damage. Replace or repair any part

which is in questionable condition. Cost of the part is often minor in comparison

with cost of redoing the job.

3. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings.

4. Examine all gear teeth carefully, and remove nicks or burrs.

5. Polish edges of all shaft shoulders to remove small nicks which may have been

caused during handling.

6. Remove all nicks and burrs caused by lockwashers.

7. Replace all gaskets, oil seals, and ‘O’ rings removed during winch disassembly.

Assembly

General Instructions

-Use all new gaskets and seals.

-Replace worn parts.

-Assemble parts using match marks attached during disassembly. Compare

replacement parts with originals to identify installation alignments.

-Lubricate all internal parts with rust and oxidation inhibiting lubricant, ISO

VG100 (SAE 30W).

-Apply a light coat of Loctite® 243 to all threaded components prior to

assembly, unless otherwise specified.

Live Air Throttle Valve

Refer to Dwg. MHP0203.

NOTICE

During assembly align parts using match marks made during disassembly.

1. Install valve (441) and valve bushing (440) into the housing (438).

2. Install ball (421), poppet valve (436), spring (422) and pipe plug (434) in

housing(438).

3. If screws (430) were removed during disassembly, reinstall in housing (438) and

handle bracket (426).

4. Place spring (422) and ball (421) in handle bracket (426).

5. Depress spring and ball with handle (420) and install pin (425) with washers

(424)and pins (423). Bend pin (423) apart.

6. Install spring (427) and handle assembly on square shaft of valve (441) taking

note of the match marks put on during disassembly. The ends of the spring

(427)must straddle the screw (430) on handle bracket (426). Secure handle

assembly to valve with pins (429) and (428). Install sleeves (432) and capscrews

(431) on housing (438). Attach exhaust cover (442) to housing (438) with

capscrews (444)and lockwashers (443).

7. Check throttle handle moves fully left and right without sticking or binding.

Throttle handle should center, by spring force, automatically when released.

Motor

Refer to Dwg. MHP0210.

1. Press bearing (465) onto crankshaft counterbalance. Place connecting rods (459)

on bushing (476) and hold them in place with the two connecting rod rings

Form MHD56332 Edition 1 9

(474). Install connecting rod rings (474) so chamfered side is next to

connecting rod (459).

2. Place sleeve (475) on crankshaft (473), then install the connecting rod (459)

assembly on the crankshaft (473).

3. Secure crankshaft counterbalance to the crankshaft with taper pin (479) and

tighten capscrew (480).

4. Install rotary bushing (466) and attach adapter valve (468) and valve cover

(469) to motor housing (463) with at least two capscrews. This is necessary to

correctly locate bearing (465) when installing crankshaft in motor housing

(463), shifting it as necessary so each connecting rod (459) end will project

through a cylinder hole.

5. Align bearing (465) in bore of motor housing (463) and tap crankshaft assembly

in place until bearing (465) bottoms on the rotary bushing.

6. Check fit of each compression and oil ring by placing one ring at a time in the

cylinder, making sure that it is not canted or tilted in relation to the cylinder

wall. With a feeler gauge, measure the ring gap.

7. Make sure that compression rings, oil rings, and pistons are absolutely clean.

Carefully place oil rings (458) and compression rings (454) in their respective

grooves on the pistons (455).

NOTICE

• Do not interchange the compression and oil rings. The plain compression

ring (454) must be placed nearest the head of the piston (455). The oil ring

(458) (identified by several oil channel grooves) must be placed nearest the

skirt of the piston (455).

8. Compression and oil ring joints (gaps) should be staggered and positioned so

that joints (gaps) do not coincide with wrist pin (457) openings. Refer to Dwg.

MHP0224.

(Dwg. MHP0224)

9. Rotate crankshaft so each connecting rod (459) in succession will project

enough beyond the motor housing (463) to permit inserting wrist pin (457)

through the piston (455) and connecting rod (459).

10. After each piston (455) is assembled to its connecting rod (459), install a gasket

(460) and cylinder (453).

11. Slide each cylinder (453) over the piston (455), guiding it carefully over the

compression and oil rings.

NOTICE

• the cylinder has four tapered ears around the skirt of the piston which serve

as ring compressors to aid in installation. The cylinder should go into place by

tapping lightly. If force is required, there maybe an alignment problem which

must be corrected before continuing.

12. Secure cylinders (453) to motor housing (463) by uniformly tightening

capscrews (451) and lockwashers (452).

13. Remove exhaust cap (469). Install rotary valve (467) in adapter valve (468).

Align the drive pins on the rotary valve (467) with the end of the crank shaft

(473). The three drive pins on the crank shaft end of the rotary valve should fit

in the holes in the crank shaft without appreciable play. If holes in crank shaft

are elongated, crank shaft should be replaced. The drive pins are located so the

rotary valve will always be returned to the correct position.

14. Replace exhaust cap (469) and secure in position with capscrews (364) and

lockwashers (96).

Reduction Gear

NOTICE

• It is important to maintain a clean work area when reduction assemblies are

reassembled. During reassembly clean each part thoroughly and lightly coat

with appropriate lubricant as described in ‘Recommended Lubricants’ in the

“LUBRICATION” section of the Product Information Manual.

Refer to Dwg. MHP2773.

1. Lubricate and install ‘0’ rings (62) on ring gear (72). Assemble ring gear (72),

cover (73) and spacer (71). Check dowel and capscrew holes are aligned.

2. Drive dowels (74) into assembly so they are flush with the cover (73).

3. Position assembled parts vertically with the cover (73) down. Install planet

assembly (67) and gear (69) into ring gear (72).

4. Press bushing (55) into sun gear (66) and install sun gear (66) into planet

assembly (67).

5. Lubricate and install ‘0’ rings (51) on ring gear (63). Install ring gear on spacer

(71) being careful not to damage ‘0’ ring. Align dowel and capscrew holes.

6. Tap dowels (52) into ring gear (63) and spacer (71). Leave approximately 0.37

inch (9 mm) exposed for engagement with input housing (59).

7. Install planet assembly (58) so planet gear teeth mesh in the ring gear (63) and

with the sun gear (66).

8. Carefully install input housing (59) so it locates on dowels (70). Tilt assembly on

work bench and install capscrews (75) with Loctite® 242 and torque to 21 ft-lbs

(28 Nm).

9. Return assembly to vertical position. Install bushing (55) and on sun gear (56)

and install sun gear (56) in planet assembly (58).

10. Lubricate and install ‘0’ ring (51) on ring gear (53). Line up dowel and capscrew

holes and install ring gear (53) on input housing (59) being careful not to

damage ‘0 ring (51).

11. Install planet assembly (54) so planet gear teeth mesh with ring gear and sun

gear.

12. Lubricate and install ‘0’ ring (51) on ring gear (53).

13. Install oil plugs (61) in input housing (59).

14. .Press bearing (49) into bore of gear carrier (47). Install retainer ring (50).

15. Install gear carrier (47) on ring gear (53) being careful not to damage ‘0’ ring

(51). Check capscrew and dowel holes are lined up. Install capscrews (60) with

Loctite® 262. Torque capscrews (60) to 33 ft-lbs (44.7 Nm).

16. Tap dowels (52) through ring gear (53), input housing (59) and gear carrier (47)

until they are just below flange surface of gear carrier (47).

Drum

Refer to Dwg. MHP2773.

1. Clean surfaces of drum (80) and gear carrier (47). Apply Loctite® 515 gasket

sealant to drum mating surface. Lower reduction gear assembly into drum (80) so

capscrew and dowel pin holes are aligned. On 8 inch long drums ensure a spacer

is used between drum and gear carrier flange.

2. Install capscrews (45) and lockwashers (46) with Loctite® 242 and torque to 61

ft-lbs (82 Nm).

3. Install dowel pins (44) so they are flush with gear carrier (47).

4. Install fill/drain plugs (48) in gear carrier (47).

5. Apply a thin coat of Loctite® 609 to the outside of seal (43) and install in gear

carrier (47).

6. Place drum in an upright position.

Winch Assembly

Refer to Dwgs. MHP2773 and MHP2786.

1. Clean both mating surfaces on inboard upright (42) and install drum shaft

(41)through bore aligning dowel pin holes.

2. Install dowel pins (40) flush or slightly below surface of drum shaft (41).

3. Install eight capscrews (39). Lightly coat capscrew threads with Loctite® 242

and torque to 35 ft lbs (47 Nm).

4. Press bearing (37) onto drive shaft (35). Lightly coat inner bearing race bore

with Loctite 609.

5. Install shaft and bearing into drum shaft (41) so smaller splined end enters

first.Install retainer ring (36) in bore of drum shaft (41).

6. Carefully lower inboard assembly into the drum (80) making sure splines on

shaft(35) and drum shaft (41) mesh in the drum and reduction gear assembly.

7. Using a ‘C’ clamp, secure inboard flange assembly to drum flange and position

complete assembly in a horizontal position.

8. Clean seal surface and install oil seal (99) in outboard upright (84) with lip

toward the drum. Pack bearing (87) with grease and install in outboard upright

(84).

9. Install outboard upright (84) on drum end. Ensure assembly is kept centered on

journal during this step.

10. Install bearing retainer (92). Secure by installing two capscrews (94). Lightly

coat capscrew threads with Loctite® 242. Torque to 35 ft lbs (47 Nm).

11. Apply a light coat of Loctite® 515 sealant to mating surface of outboard

upright(84) and install end cover (95). Secure using four capscrews (97) and

lockwashers(96). Lightly coat capscrew threads with Loctite® 242. Torque to 25

ft lbs (34Nm).

12. Install siderails (82) to uprights (42) and (84) and loosely secure using

capscrews(85) and lockwashers (98).

13. Tap dowel pins (86) into position until flush with siderails.

14. Tighten eight capscrews (85) evenly. Torque to 61 ft lbs (82 Nm)

Piston Head

Wrist pin opening

Install one compression

ring on either side of oil ring

Ends of compression rings

must be staggered to avoid

alignment with wrist pin

opening and ends of oil ring

Colored ends of oil ring

must butt together,

and must not overlap

Compression Ring Groove

10 Form MHD56332 Edition 1

15. Install splined hub (21) so splined side on outside diameter goes on first. Install

capscrew in collar (13) and place on shaft (35). Maintain pressure on collar to

keep it against splined hub (21) and tighten capscrew in collar (13).

16. Lubricate and install ‘O’ ring (26) on drum shaft (41).

17. Install brake housing (17) on drum shaft (41).

18. Position brake housing so brake port is in the 2 o’clock position (as viewed from

the motor end). Install drain plug (25) in brake housing at the 6 o’clock

position.

19. Install reducer fitting (28) and breather (29) in the top of the brake housing

(17).

20. Lubricate friction plates (19) with a light motor oil (refer to ‘Recommended

Lubricants’ in Product Information Manual). Install friction plates (19) and drive

plates (18) in brake housing (17). Begin with a friction plate then alternate with

drive plates between friction plates. Ensure splined teeth mesh. Do not force

plates into place during installation.

21. Lubricate and install seals (11) and (12) in brake piston (10) grooves so seal lips

face each other. Do not overstretch seals during this procedure. Refer to

Dwg.MHP0139 on page 10.

22. Install brake piston assembly in brake housing so stepped side enters first.

Gently tap into position using a soft mallet until seated.

23. Install one brake spring (9) in each brake spring hole.

24. Lubricate and install ‘O’ ring (5) in groove on brake housing (17).

NOTICE

• ‘O’ ring, item (5) listed in step 24 refers to part number 51484 as shown on

disc brake Dwg. MHP2786. This part must be placed between brake housing(17)

and motor adapter (6).

(Dwg. MHP0139)

25. Install brake reaction plate (8) over springs (9).

26. Two threaded holes in motor adapter (6) are centered between mounting bolt

holes. Install motor adapter with these two holes as close as possible to the

6o’clock position.

27. Secure motor adapter (6) with five capscrews (4) using Loctite® 242. Torque

to35 ft lbs (47 Nm). On winches with a disc brake install capscrews (93) evenly

to compress brake springs. Do not allow mounting adapter to become cocked.

Evenly hand tighten all capscrews before applying final torque.

28. On disc brake equipped winches, install shaft (7) on end of drive shaft (35).

29. Lubricate and install ‘O’ ring (5) in groove on motor adapter (6).

30. Ensure oil seal (2) is installed in bore of motor assembly. Seal lip must face into

motor assembly.

31. Place gasket (470) on mounting flange (216) and align holes.

WARNING

• The air motor weighs approximately 117 lb. (53 kg). Adequately support air

motor while installing motor mounting capscrews.

32. Position winch in a horizontal position. Using suitable lifting equipment

carefully slide motor assembly onto the drive shaft (35). Position throttle

assembly at the top. Be careful not to damage oil seal (2).

33. Install the motor assembly to motor adapter (6) with capscrews (97) and

lockwashers (96). Lightly coat capscrew threads with Loctite® 242 and torque to

25 ft-lbs (34 Nm).

34. On winches with a disc brake install fitting (31) and dump valve (30) into brake

release port. Install vented fitting (27) in dump valve (26) between dump

valve(26) and hose assembly (44) or tubing assembly (64).

Manual and Automatic Band Brake

Refer to Dwg. MHP0209.

1. Install pivot bracket (122) on the end of arm (124) with pin (121), washer

(123)and cotter pin (102). Recessed side of the threaded hole must be toward

the band side.

2. Install connecting link (125) on the arm (124) and secure in position with

pin(121), washer (123) and cotter pin (121). Assemble connecting link (125) so

curved surface matches contour of the brake band.

3. Install halves of brake band (128) to the connecting link (125) and secure with

pins (101), (121) and cotter pins (102).

4. Lift the winch assembly, with a suitable hoist, approximately 6 inches (15 cm)

off the floor or work bench.

5. Position the brake band sub-assembly around the brake diameter on the

drum(80) so the arm (124) lays at the bottom. When positioned, lower the

winch.

6. Mount pivot bracket (122) on the inside surface of the siderail (130) and secure

in position with capscrews (116) and lockwashers (117).

7. Screw link stud into handle and install the handle (104) in the lug on the end of

the brake band (128). Lubricate the pivot points being careful not to get grease

on the brake band lining.

8. Pull the halves of the brake band together and install pin (101) through the lug

on band (128) and the adjusting screw (103) of the handle assembly.

9. Install stop plate (126) on the inside of the siderail (131) with capscrews

(119)and washers (117). Install adjusting screw (127) and locknut (120)

through the siderail (131) and stop plate (126) until it contacts the arm (124).

10. Adjust brake as described at the start of the “MAINTENANCE” section.

Automatic Band Brake Actuator

11. Install bracket (118) on siderail (139) with capscrews (116) and

lockwashers(117).

12. Screw nut (108) and clevis (107) onto cylinder rod.

13. Attach brake lever (105) to brake band (128).

14. Install cylinder (110) so it connects with bracket (118) and brake lever (105).

Use pins (106), washers (129) and cotter pins (102) to secure in position.

15. Install dump valve (112) fittings and hose (115) to the cylinder (110). Adjust

automatic brake as described at the start of the “MAINTENANCE” section. Install

pipe plug (98) in end cover (95).

Drum Guard

Refer to Dwg. MHP2676.

1. Secure frames (802) and (801) to uprights (42) and (84) with capscrews

(809)and washers (96). Secure lifting lugs (83) to uprights with capscrews (90)

and washers (91).

2. Install panels (805) and (807) one at a time, beginning with either the

upper(807) or lower (805) panel.

3. Install first crossbar (806) with nuts (804).

4. Attach panel to crossbar (806).

5. Hold second panel (805) in place and install second crossbar (806) by sliding

through [hooked] edges of the two panels.

6. Secure crossbar (806) with nuts (804).

7. Continue until all panels are in place.

8. Tighten all fasteners and check drum guard is secure. Ensure wire rope does not

interfere with drum guard during winch operation.

Limit Switch Assembly (optional feature)

Refer to Dwgs. MHP2670.

1. Secure limit switch assembly to upright (84) with capscrews (97) and washers

(96).

2. Install hose connections. Refer to label 71459929.

Press Roller

Refer to Dwg. MHP2695.

Two people are recommended when installing press roller assembly.

1. If shaft collars (404) have been removed, replace and install in uprights (42)

and(84), and in both ends of arm (407). Grease bushings (404) for ease of

installation.

2. Install rollers (402) on smaller ends of press roller arm (407) and secure with

capscrews (408) and washers (409). Apply a small amount of Loctite® 242 to

threads of capscrews.

3. Install springs (405) and (406) so that the shorter end of springs are towards the

inner portion of the arm (407) where the tabs are located.

4. One person positions press roller so the top of arm (407) is curved up towards

the under side of the drum (80), and holds press roller in place while the other

person completes installation.

5. Adjust both springs (405) and (406) so that the long end of springs are on the

inside of siderail (82).

NOTICE

• Do not engage shorter end of spring behind tabs of arm (407) until after

shaft (403) has been installed and secured, and press roller assembly adjusted

to center of drum.

6. Install shaft (403) through hole in leg of upright (42) only.

7. Install one collar (410) on end of shaft (403) between upright and press roller

assembly. Do not tighten collar (410) until steps 10 and 11 have been

completed.

8. Install shaft (403) through press roller assembly (400).

9. Install second collar (410) and slide shaft through hole in leg of upright

(84).Ensure that the long end springs (405) and (406) are still between the

siderail(82) and drum (80). Do not tighten collar (410) until steps 10 and 11

have been completed.

10. Secure shaft (403) to uprights using capscrews (408) and washers (409). Apply a

small amount of Loctite® 242 to threads of capscrews.

11. Adjust press roller assembly so that it is centered between the drum flanges, and

tighten collars (410).

Seal Lip

Seal Brake

Piston

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