Ingersoll-Rand FA5, FA5T User Manual

Form MHD56037

WARNING

PARTS, OPERATION AND MAINTENANCE MANUAL

MODEL FA5 AND FA5T

(Dwg. MHP2107)

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.

Do not use this winch for lifting, supporting, or transporting people unless winch is
approved for Man RiderTM applications. Do not lift or support loads over people.

Always operate, inspect and maintain this winch in accordance with American Society of
Mechanical Engineers Standards Safety Code (ASME B30.7) and any other applicable
safety codes and regulations.

Form MHD56037
Edition 5
May 2006
71062103

© 2006 Ingersoll Rand Company

TABLE OF CONTENTS

Description Page No.

Safety Information

Danger, Caution, Warning and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safe Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Specifications

Model Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Performance Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation

Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Air Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Constant Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Initial Operating Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation

Winch Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Underwound Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Emergency Stop and Overload System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Overload Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Winch Overload Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Constant Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Winch Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Drum Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Lubrication

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Component Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Inspection

Records and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Winches not in Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

Troubleshooting

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance

Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

K5C2 Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Cleaning, Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

K5C2 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

K5C2E Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Parts Information

FA5 Winch Assembly Drawings Reference Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

FA5 Winch Drawings and Parts Lists Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

FA5 Winch Drawings and Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-76

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2 MHD56037 - Edition 5

SAFETY INFORMATION

f

DANGER

G

N

E

WARNING

This manual provides important information for all personnel
involved with the safe installation, operation and proper
maintenance of this product. Even if you feel you are familiar
with this or similar equipment, you should read this manual
before operating the winch.

Danger, Warning, Caution and Notice

Throughout this manual there are steps and procedures which, if
not followed, may result in a hazard. The following signal words
are used to identify the level of potential hazard.

Danger is used to indicate the presence of
a hazard which will cause severe injury,
death, or substantial property damage if
the warning is ignored.

WWAARRNNIINNG

CCAAUUTTIIOON

NNOOTTIICCE

Warning is used to indicate the presence
of a hazard which can cause severe injury,
death, or substantial property damage if
the warning is ignored.

Caution is used to indicate the presence o
a hazard which will or can cause injury or
property damage if the warning is
ignored.

Notice is used to notify people of
installation, operation, or maintenance
information which is important but not
hazard-related.

Safety Summary

• Do not use this winch for lifting, supporting, or transporting
people unless winch is approved for Man Rider
applications. Do not lift or support loads over people.

• The supporting structures and load-attaching devices used in
conjunction with this winch must provide an adequate safety
factor to handle the rated load, plus the weight of the winch
and attached equipment. This is the customer’s responsibili ty.
If in doubt, consult a registered structural engineer.

TM

The Occupational Safety and Health Act of 1970 generally places
the burden of compliance with the user, not the manufacturer.
Many OSHA requirements are not concerned or connected with
the manufactured product but are, rather, associated with the final
installation. It is the owner’s and user’s responsibility to
determine the suitability of a product for any particular use. It is
recommended that all applicable industry, trade association,
federal, state and local regulations be check ed. Read all operating
instructions and warnings before operation.

Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper rigging
techniques. Refer to ASME B30.9 for rigging information,
American Society of Mechanical Engineers, Three Park Avenue,
New York, NY 10015.

This manual has been produced by Ingersoll Rand to provide
dealers, mechanics, operators and company personnel with
information required to install, operate, maintain and repair the
products described herein.

It is extremely important that mechanics and operators be familiar
with servicing procedures of these products, or like or similar
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

hand tools as well as special Ingersoll
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.

Rand or

Ingersoll Rand winches are manufactured in accordance with the

latest ASME B30.7 standards.

The National Safety Council, Accident Prevention Manual for
Industrial Operations, Eighth Edition and other recognized safety
sources make a common point: Employees who work near
suspended loads or assist in hooking on or arranging a load
should 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 failure, no personnel would be injured. This means
keep out from under a raised load and keep out of the intended
path of any load.

MHD56037 - Edition 5 3

SAFE OPERATING INSTRUCTIONS

The following warnings and operating instructions have been
adapted in part from American Society of Mechanical Engineers
(Safety) Standard ASME B30.7 and are intended to avoid unsafe
operating practices which might lead to injury or property
damage.

Ingersoll Rand recognizes that most companies who use winches
have a safety program in force at their facility. In the event that
some conflict exists between a rule set forth in this publication
and a similar rule already set by an individual company, the more
stringent of the two should take precedence.

Safe Operating Instructions are provided to make an operator
aware of dangerous practices to avoid and are not necessarily
limited to the following list. Refer to specific sections in the
manual for additional safety information.

1. Only allow personnel trained in safety and operation of this
product to operate and maintain this winch.

2. Only operate a winch if you are physically fit to do so.

3. When a “DO NOT OPERATE” sign is placed on winch, or
controls, do not operate winch until sign has been removed
by designated personnel.

4. Before each shift, check winch for wear and damage. Never
use a winch that inspection indicates is worn or damaged.

WARNING LABEL

5. Never lift a load greater than rated capacity of the winch.
Refer to labels attached to winch or to “SPECIFICATIONS”
section.

6. Keep hands, clothing, etc., clear of moving parts.

7. Never place your hand in the throat area of a hook or near
wire rope spooling onto or off of winch drum.

8. Always rig loads properly and carefully.

9. Be certain the load is properly seated in saddle of hook. Do
not support load on tip of hook.

10. Do not “side pull” or “yard”.

11. Always ensure that you, and all other people, are clear of the
path of the load. Do not lift a load over people.

12. Never use the winch for lifting or lowering people, and never
allow anyone to stand on a suspended load.

13. Ease slack out of wire rope when starting a lift or pull. Do
not jerk the load.

14. Do not swing a suspended load.

15. Do not leave a suspended load unattended.

16. Never operate a winch with twisted, kinked or damaged wire
rope.

17. Pay attention to the load at all times when operating the
winch.

18. Never use the winch wire rope as a sling.

19. After use, or when in a non-operational mode, winch should
be secured against unauthorized and unwarranted use.

Each unit is shipped from the factory with warning label shown.
If the label is not attached to your unit, order a new label and
install it. Refer to the parts list for part number. Label is shown
smaller than actual size.

(Dwg. 71060529)

4 MHD56037 - Edition 5

SPECIFICATIONS

Model Code Explanation

Example: FA5-24MK320P FA5 - 24 M K 320 P

Series (Capacity)

FA5 = Air Powered Winch (5 metric ton / 11,000 lbs.)

Drum Flange Height or Man Rider®:

- = Standard flange: 27 inch (660 mm) diameter

T = Tall flange: 35 inch (890 mm) diameter

MR =

Drum Length (Distance between drum flanges):

12 = 12 inch (306 mm)
16 = 16 inch (406 mm)

24 = 24 inch (610 mm) (Standard)

30 = 30 inch (760 mm)
36 = 36 inch (915 mm) Tall Flange Winch only

Drum Brake:

A = Automatic Drum Brake

M = Manual Drum Brake

X = None

Disc Brake:

K = Automatic Disc Brake

X = None

Control:

1 = Winch mounted lever throttle. (Standard)

* 2XX = Remote full flow lever throttle (XX = Specify hose length (feet). Maximum 20 ft. (6 metres))
* 3XX = Remote pilot pendant throttle (XX = Specify hose length (feet). Maximum 50 ft. (15 metres))
* 4XX = Remote pilot lever throttle (XX = Specify length (feet). Maximum 50 ft. (15 metres))
* 5XX = Remote electric over air throttle†

Options: **

7 = Drum Grooving (Number = wire rope size in sixteenths, e.g. 7/16 inch) †

** C = Low Temperature Components; specify -10° C (14° F) or -20° C (-4° F)

D = Drum Divider Flange and additional wire rope anchor †

E = Construction Cage†

G = Drum Guard

L = Drum Locking Pin

** M1 = Material Traceability (typical material results) ††
** M2 = Material Traceability (actual material results) ††
** M3 = Material Traceability (actual material results for these parts in finished, as-delivered condition) ††

N =

P = Marine Grade Corrosion Preventative Finish

Q = Special paint U = Underwound wire rope operation †

S = Limit Switch (upper and lower) V = Press Roller
T = Tensioning Manifold W = Witness; please specify **
Z = Sandblast and Carbozinc Primer X = Testing; please specify

-E = Compliance with European Machinery Directive (includes Emergency Stop and Overload Protection)

Notes: * Remote throttles are provided with 10 feet (3 metres) of hose. Specify hose lengths greater than 10 feet. For lengths

Man RiderTM (Refer to FA5 Man RiderTM Supplement Form #MHD56042)

Type Approval – Specify:
A = American Bureau of Shipping (ABS); N = Det Norske Veritas (DNV); R = Lloyd’s Register of Shipping (LRS)

greater than 20 ft. (6 metres) with the Remote Full Flow Throttle, or 50 ft. (15 metres) with the Remote Pilot Lever and
Remote Pilot Pendant Throttles contact your Ingersoll
lengths are provided for reference only, order lengths in feet.

** Documentation, witness testing and material traceability available; must be requested at time of order . Specify option s or

contact the factory or your nearest Ingersoll Rand distributor for information.

† Not covered in this manual.

†† Refer to ‘Traceability’on page 8 for a description of the dif f erences between M1, M2 and M3.

Rand distributor or the factory for control acceptability. Metric

MHD56037 - Edition 5 5

Performance Graphs

FA5 Winch

(Dwg. MHP1890)

FA5T Winch

(Dwg. MHP1891)

6 MHD56037 - Edition 5

General Specifications:

Rated Operating Pressure 90 psig (6.3 bar)

Air System

Rated Performance

(at rated pressure / volume)

Air Motor Pipe Inlet Size 1.25 inch 32 mm 1.25 inch 32 mm

Minimum Air System Hose Size 1.5 inch 38 mm 1.5 inch 38 mm

Drum Barrel Diameter 15 inches 381 mm 15 inches 381mm

Drum Flange Diameter 27.25 inches 692 mm 35.25 inches 895 mm

* Drum Wire Rope

Storage Capacity

(feet / metres)

* Wire rope storage capacity based on wire rope top layer located a minimum of 1/2 inch (13 mm) below drum flange and meets ASME

B30.7. The wire rope storage capacities listed may vary from figures stated elsewhere.

Air Consumption

(at rated pressure and load)

Full Drum Line Pull 11,000 lbs 4,490 kgs 8,400 lbs 3,810 kgs

Mid Drum Line Speed 65 fpm 20 m/min. 80 fpm 24 m/min.
Max Stall Pull - 1st Layer 24,000 lbs 10,886 kgs 24,000 lbs 10,886 kgs
F A 5-24MX1 Ship Weight 1,920 lbs 873 kgs - - - - - -

F A 5T-24MX1 Ship Weight - - - - - - 2,115 lbs 961 kgs

Drum Length (inches)

12 874 ft 266 m
16 1181 ft 360 m

24 (Standard) 1795 ft 547 m

30 2256 ft 688 m

12 550 ft 168 m 1240 ft 378 m
16 746 ft 227 m 1681 ft 512 m

24 (Standard) 1138 ft 347 m 2564 ft 782 m

30 1431 ft 436 m 3225 ft 983 m

36 (Tall flange only) - - - - - - 3887 ft 1185 m

12 400 ft 122 m 886 ft 270 m
16 544 ft 166 m 1204 ft 367 m

24 (Standard) 832 ft 254 m 1841 ft 561 m

30 1047 ft 319 m 2318 ft 706 m

36 (Tall flange only) - - - - - - 2796 ft 852 m

700 scfm 20 cu.m/min. 700 scfm 20 cu.m/min.

0.625 inch 16 mm

0.75 inch 18 mm 0.75 inch 18 mm

0.875 inch 20 mm 0.875 inch 20 mm

FA5 FA5T

Model

Wire Rope Diameter

0.625 inch (16 mm) diameter

wire rope not recommended for

use on FA5T winch es.

Description of Operation

FA5 winches are air powered, planetary geared units designed for

lifting and pulling applications. FA5 winches are available with
either an internal automatic disc brake, a manual or automatic
band brake, or a combination of both.

The output from an externally mounted piston air motor is
transmitted through a coupling and shaft to the planetary
reduction gear assembly.

The output from planetary reduction gear assembly is connected
to the wire rope drum through the output shaft.

MHD56037 - Edition 5 7

FA5 winches can be provided with an optional disc brake
assembly consisting of friction plates splined to a hub which in
turn is connected to the drive shaft from the air motor. Brake
friction plates are clamped to the drum shaft through a spring
applied piston. The brake remains applied until the winch control
valve is operated and winch payout or haul-in occurs. Air is
introduced into the brake piston chamber, which is formed
between brake piston and brake housing, causing the brake piston
to react, compressing brake springs and releasing friction plates
allowing motor shaft to rotate. A power failure or sudden loss of
air will immediately cause the spring applied brake to engage.

The drum band brake operates by applying a friction force
between drum brake band and winch drum. The manual brake
requires an operator to engage and disengage brake using a lever
located on top of brake band. The automatic drum band brake
operation is similar to disc brake operation; they are both fully
disengaged in the haul-in and payout direction.

Traceability

CAUTION

Load bearing parts are documented to provide traceability. The
documentation includes chemical and physical properties of raw
material, heat treating, hardening, tensile and charpy tests as
required for the part.

M2–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 3.1b on load bearing parts. Conformity documents
affirm (by a department independent of the manufacturing
department) that the actual parts are in compliance with the
requirements of the order based on specific inspection and testing
(i.e. results are actual material properties for these parts).

Units with M1, M2 or M3 in the model code have traceable load
bearing components.

M1–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 2.2 on load bearing parts. Conformity documents
affirm (by manufacturer) that parts are in compliance with
requirements of order based on non-specific inspection and
testing (i.e. results are typical material properties for these parts).

INSTALLATION

Prior to installing winch, carefully inspect it for possible shipping
damage.
Winches are supplied fully lubricated from the factory. Before
operation check oil levels and adjust as necessary. Use the proper
type of oil as recommended in “LUBRICATION” section.

• Owners and users are advised to examine specific, local or
other regulations, including American Society of Mechanical
Engineers Standards and/or OSHA Regulations which may
apply to a particular type of use of this product before
installing or putting winch to use.

Mounting

Refer to Dwg. MHP0133 and Table 1 on page 8, and Table 2 on
page 9.
Care must be taken when moving, positioning or mounting the
winch. In most cases, lifting lugs have been provided to assist in
handling the winch. If lug locations are improper for your specific
installation, great care should be taken to ensure that winch, when
lifted, will be properly balanced. Determine weight of your winch
by referring to “SPECIFICATIONS” section. Lift winch 3 to 4
inches (75 to 100 mm) off ground.
Verify winch is balanced and secure before continuing lift.
Mount winch so axis of drum is horizontal and that motor vent cap
is not more than 15° off top vertical center. If winch is to be
mounted in an inverted position, motor case must be rotated to
position vent cap at top.

1. The winch mounting surface must be flat and of sufficient
strength to handle rated load plus weight of winch and
attached equipment. An inadequate foundation may cause
distortion or twisting of winch uprights and side rails
resulting in winch damage.

2. Make sure mounting surface is flat to within 0.005 inch
(0.127 mm) per inch of drum length. Shim if necessary.
Refer to Table 1.

3. Mounting bolts must be 3/4 inch (18 mm) Grade 8 or better.
Use self-locking nuts or nuts with lockwashers.

M3–Material Traceability certificates according to EN 10204 (Ex
DIN 50049) 3.1b on load bearing parts. Conformity documents
affirm (by a department independent of the manufacturing
department) that the actual parts used in the product are in
compliance with the order based on specific inspection and
testing (i.e. results are actual material properties for these parts in
a finished, as delivered condition).

Components with part numbers ending in CH or CHA are charpy
parts for use under extreme cold conditions. Traceability
requirements must be stated when reordering these parts for
continued certification.

4. Tighten 3/4 inch (18 mm) mounting bolts evenly and torque
to 380 ft lbs (515 Nm) for dry thread fasteners. If fasteners
are plated, lubricated or a thread locking compound is used,
torque to 280 ft lbs (380 Nm).

5. Maintain a fleet angle between sheave and winch of no more
than 1-1/2°. The lead sheave must be on a center line with
drum and, for every inch (25 mm) of drum length, be at least

1.6 feet (0.5 metre) from the drum. Refer to Dwg. MHP2123
on page 9.

6. Do not weld any part of winch.

Table 1–Mounting Surface Tolerance

Drum

Length

12 0.06 1.52
16 0.08 2.03
24 0.12 3.05
30 0.15 3.81
36 0.18 4.57

Winch Bolt Hole Mounting Dimension Drawing

(Dwg. MHP0133)

Mounting Surface Minimum Flatness

inch mm

8 MHD56037 - Edition 5

Table 2–Winch Bolt Hole Mounting Dimensions

CAUTION

NOTICE

Dimension

“A” FA5

“A” FA5T

“B” (with

Drum Brake)

“B” (without

Drum Brake)

“C”

Bolt Hole Qty each

Side Rail

* 36 inch drum length applies to FA5T (tall flange) only.

inch 31.25

mm 794

inch 34.25

mm 870

inch 7.5 9 10.5 10 11.5

mm 190 229 267 254 292

inch 6 6.25 9 12 14

mm 152 159 229 305 356

inch 13/16

mm 20

Drum Length (inches)

12 16 24 30 36*

4 5

- - -

Wire Rope

• Maintain at least 3 tight wraps of wire rope on drum at all
times.

• Install wire rope to come off drum for overwind operation.
(normal application.) Refer to Dwg. MHP2124

(Dwg. MHP2124)

on page 9.

(Dwg. MHP2123)

‘A’ = 1.6 feet (0.5 metre) per inch of drum length:

‘A’ = 19.2 feet (5.85 metres) for 12 inch drum.
‘A’ = 25.6 feet (7.80 metres) for 16 inch drum.
‘A’ = 38.4 feet (11.7 metres) for 24 inch drum.
‘A’ = 48.0 feet (14.6 metres) for 30 inch drum.
‘A’ = 57.6 feet (17.5 metres) for 36 inch drum.

Notes:

1. Maintain a minimum of 3 tight wraps of wire rope on drum at
all times.

2. Ensure wire rope does not exceed top layer requirement.
Refer to “SPECIFICATIONS” section.

• For underwound applications order the “U” option or
contact factory prior to operation.

Wire Rope Selection

Consult a reputable wire rope manufacturer or distributor for
assistance in selecting appropriate type and size of wire rope and,
where necessary, a protective coating. Use a wire rope which
provides an adequate safety factor to handle actual working load
and that meets all applicable industry, trade association, federal,
state and local regulations.

When considering wire rope requirements the actual working load
must include not only static or dead load but also loads resulting
from acceleration, retardation and shock load. Consideration must
also be given to the size of winch wire rope drum, sheaves and
method of reeving. Wire rope construction should be 6 X 19 or 6
X 37 IWRC EIPS right regular lay. Refer to Table 3
minimum and maximum recommended wire rope sizes.

Table 3–Minimum and Maximum Wire Rope Size

Model

FA5 5/8 16

FA5T 3/4 20

Note: Maximum wire rope diameter is limited by size of wire
rope anchor hole. Refer to parts list for correct wire rope anchor
part numbers.

Minimum Maximum

inch mm inch mm

on page 9 for

7/8 22

MHD56037 - Edition 5 9

Installing Wire Rope

CAUTION

CAUTION

• 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.

Refer to Dwg. MHP0166 on page 10.

1. Cut wire rope to length in accordance with wire rope
manufacturer’s instructions.

2. Feed end of wire rope into wire rope anchor hole in drum
and pull through approximately one foot (305 mm) of wire
rope.

(Dwg. MHP0166)

3. Wrap wire rope with wire a distance from the end equal to
wedge length plus one inch (25 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.

7. Pull wire rope anchor into position in drum anchor pocket.

• Make sure first wrap of wire rope is tight and lays flush

against drum flange.

Support wire rope spool and have wire rope come off top of spool
and over top of winch drum. This will prevent damage to wire
rope.

Spooling Wire Rope onto Winch Drum

(Dwg. MHP2125)

Rigging

Make sure all wire rope blocks, tackle and fasteners have a
sufficient safety margin to handle required load under all
conditions. Do not allow wire rope to contact sharp edges or
make sharp bends which will cause damage to wire rope, use a
sheave. Refer to wire rope manufacturer’s handbook for proper
sizing, use and care of wire rope.

Safe Installation Procedures

1. Do not use wire rope as a ground (earth) for welding.

2. Do not attach a welding electrode to winch or wire rope.

3. Never run wire rope over a sharp edge. Use a correctly sized
sheave.

4. When a lead sheave is used, it must be aligned with center of
drum. The diameter of lead sheave must be at least 18 times
diameter of wire rope. Refer to Dwg. MHP2123

5. Always maintain at least three full, tight wraps of wire rope
on drum.

on page 9.

Safe Wire Rope Handling Procedures

1. Always use gloves when handling wire rope.

2. Never use wire rope which is frayed or kinked.

3. Never use wire rope as a sling.

4. Always ensure wire rope is correctly spooled and the first
layer is tight against drum.

5. Always follow wire rope manufacturers’ recommendation on
use and maintenance of wire rope.

Wire Rope Spooling

Refer to Dwg. MHP2125 on page 10.
To compensate for uneven spooling and decrease in line pull
capacity as drum fills up, use as short a wire rope as practical.
When rewinding apply tension to the end of wire rope to eliminate
slack. This helps achieve level winding and tight spooling.

10 MHD56037 - Edition 5

The air supply must be clean, free from moisture and lubricated to
ensure optimum motor performance. Foreign particles, moisture
and lack of lubrication are the primary causes of premature motor
wear and breakdown. Using an air filter, lubricator and moisture
separator will improve overall winch performance and reduce
unscheduled down time.

Air consumption for the FA5 and FA5T air motor is 700 scfm (20
cu. m/min.) at rated operating pressure of 90 psig (6.3 bar) at
winch motor inlet. If air supply varies from recommended, then
winch performance will change.

Air Supply

Air Lines

CAUTION

CAUTION

Air Pressure Regulator

Inside diameter of winch air supply lines must not be less than
sizes shown in Tab le 4
connections, all air supply lines should be purged with clean,
moisture free air or nitrogen before connecting to winch inlet.
Supply lines should be as short and straight as installation
conditions will permit. Long transmission lines and excessive use
of fittings, elbows, tees, globe valves etc. cause a reduction in
pressure due to restrictions and surface friction in lines.

Table 4–Minimum Allowable Air Supply Line Sizes

Model inch mm

FA5

FA5T

Air Line Lubricator

Refer to Dwg. MHP0191 on page 11.
Always use an air line lubricator with these motors. T he lubricator
must have an inlet and outlet at least as large as inlet on motor.
Install air line lubricator as close to air inlet on motor as possible.

• Lubricator must be located no more than 10 ft. (3 m) from
motor.

• Shut off air supply before filling air line lubricator.

The air line lubricator should be replenished daily and set to
provide 6 to 9 drops per minute of ISO VG 32 (SAE 10W) oil. A
fine mist will be exhausted from throttle control valve when air
line lubricator is functioning properly.

Air Line Filter

Refer to Dwg. MHP0191 on page 11.
It is recommended that an air line strainer/filter be installed as
close as practical to motor air inlet port, but before lubricator, to
prevent dirt from entering valve and motor. The strainer/filter
should provide 20 micron filtration and include a moisture trap.
Clean the strainer/filter periodically to maintain its operati ng
efficiency.

Air Out

on page 11. Before making final

1-1/2 38

Regulator

Air In

If an air pressure regulator is used, install between lubricator and
filter. Refer to Dwg. MHP0191

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

Mufflers

Make sure mufflers are installed in winch exhaust manifold and
control valve exhaust port. An additional muffler is used on
winches equipped with an emergency stop and overload device.
Check mufflers periodically to ensure they are functioning
correctly.

on page 11.

Motor

For optimum performance and maximum durability of parts,
provide an air supply of 90 psig at 700 scfm (6.3 bar/630 kPa at
20 cu. m/m) as measured at motor inlet. The air motor should be
installed as near as possible to compressor or air receiver.

Emergency Stop and Overload System (optional feature)

Refer to Dwg. MHP1492 on page 12.

old style

The air supply line is connected to the shutoff valve which is
connected to the air control valve. When Emergency Stop valve is
activated, a pilot signal is sent to the shut off pilot valve which
directs shutoff valve to cut off air to winch, immediately stopping
all winch movement.

• If winch continues to move (payout load) after shutoff valve
activates, brake(s) are not holding load and need to be
adjusted or repaired.

The overload system also activates shutoff valve. When Delta-P
valve senses a preset pressure difference between the two ports,
located on rotary housing, it directs a pilot signal to shutoff pilot
valve activating the shutoff valve. Refer to Dwg. MHP1491
page 12.

on

(Dwg. MHP0191)

MHD56037 - Edition 5 11

Lubricator

Filter

Emergency Stop and Overload System Components

CAUTION

(old style)

(Dwg. MHP1492)

Constant Tension (optional feature)

Refer to Dwg. MHP1865 on page 12 and Dwg. MHP1176 on
page 12.

The air supply line is connected to one of the two top ports on the
control valve. This will allow air to supply either the normal
control valve or the auxiliary valve.

• Use only one control valve to operate winch at any time.
Attempting to OVER-RIDE one control valve with the other
will result in total loss of winch control.

Air Schematic–Constant Tension Winches

Air Schematic–Emergency Stop and Overload System
(old style)

(Dwg. MHP1176)

Constant T ension Components

(Dwg. MHP1491)

(Dwg. MHP1865)

12 MHD56037 - Edition 5

Initial Operating Checks

CAUTION

WARNING

Winches are tested for proper operation prior to leaving factory.
Before winch is placed into service the following initial operating
checks should be performed.

1. When first running motor inject some light oil into inlet

connection to provide initial lubrication.

2. When first operating winch it is recommended that motor be

operated slowly in both directions for a few minutes.

OPERATION

For winches that have been in storage the following start-up
procedures are required.

1. Give the winch an inspection conforming to requirements of
“Winches Not in Regular Use” in the “INSPECTION”
section.

2. Pour a small amount of ISO VG 32 (SAE 10W) oil in motor
inlet port.

3. Operate motor for 10 seconds in both directions to flush out
any impurities.

4. The winch is now ready for normal use.

The four most important aspects of winch operation are:

1. Follow all safety instructions when operating winch.

2. Allow only people trained in safety and operation of this
winch to operate this equipment.

3. Subject each winch to a regular inspection and maintenance
procedure.

4. Be aware of winch capacity and weight of load at all times.

• To avoid damage to rigging, the structure supporting rigging

and winch, do not “two-block” the end of wire rope.

* Two blocking occurs when winch wire rope is multi-reeved
using two separate sheave blocks which are allowed to come into
contact with each other during winch operation. When this occurs
extreme forces are exerted on wire rope and sheave blocks which
may result in equipment and or rigging failure.

Operators must be physically competent. Operators must have no
health condition which might affect their ability to act, and they
must have good hearing, vision and depth perception. The winch
operator must be carefully instructed in his duties and must
understand the operation of winch, including a study of the
manufacturers’ literature. The operator must thoroughly
understand proper methods of hitching loads and must have a
good attitude regarding safety. It is the operator’s responsibility to
refuse to operate winch under unsafe conditions.

To operate control valve, place palm of hand on control knob and
wrap fingers around flange of sliding handle. Squeeze fingers,
lifting sliding handle up to unlock control lever . Shift control lever
in desired direction to payout or haul-in wire rope.
As viewed from the air motor end, move the control throttle
handle to the right (clockwise) to payout wire rope and to the left
(counterclockwise) to haul-in wire rope. A void sudden movements
of the control valve to ensure smooth operation of the winch.
When released, handle will return to the neutral or center position.
The sliding handle will drop down to engage and lock the control
handle in place.

Winch Mounted Throttle Control Valve Operation

Lift Slider

Handle

UP to

Unlock

Haul-In

Payout

Air Inlet Port

1-1/4 NPT

Brake Release Port

1/4 NPT

• Winch is not designed or suitable for lifting, lowering or

moving persons. Never lift loads over people.

The spring loaded, motor mounted, live air manual throttle
control valve is supplied as a standard feature on this winch.
Optional remote throttle controls are available. Reference model
code on the winch nameplate and compare it to the
“SPECIFICATIONS” section,
determine your configuration. The throttle controls provide
operator control of motor speed and direction of drum rotation.

New Style

Refer to Dwg. MHP1809 on page 13.
The spring loaded, live air, manual control throttle valve mounts
to the rotary housing.

MHD56037 - Edition 5 13

Winch Controls

on page 5 of this manual, to

Winch Mounted Air Throttle (standard feature)

Exhaust Port

1-1/2 NPT

(Dwg. MHP1809)

old style

Refer to Dwgs. MHP0165 on page 54 and MHP0566 on page 14.
The spring loaded, live air, manual control throttle valve mounts
to air motor.
As viewed from air motor end, move control throttle handle to the
right (clockwise) to payout wire rope and to the left
(counterclockwise) to haul-in wire rope. A void sudden movements
of control valve to ensure smooth operation of winch.
When winch is not in use, engage latch to prevent inadvertent
movement of control throttle.

Winch Mounted Thro ttle Control Valve Operation
(old style)

(Dwg. MHP2043)

Remote Pilot Pendant Throttle (optional feature)

Refer to Dwg. MHP2233 on page 14 and MHP1311 on page 15.
Provides for remote winch control at distances of up to 50* feet
(15 metres) away from winch. The pendant pilot control throttle is
a two lever movable control station for winch operation. Pilot
pressure from pendant pilot control throttle activates winch
control valve. The winch control valve, located on winch motor,
controls motor speed and direction of drum rotation. Direction of
rotation is determined by the pendant lever depressed.

Dwg. MHP0566)

Underwound Operation (optional feature)

Underwound operation is where wire rope haul-in or payout is off
the bottom of drum. This is a special operation and requires a
winch specifically designed for this usage.

Underwound operation requires a reverse bias valve installed in
the control valve.

Control valve operation will be opposite as shown in Dwg.
MHP1809
handle up to unlock control lever. Move control throttle handle to
the left (counterclockwise) to payout, and to the right (clockwise)
to haul-in.

Remote Live Air Throttle (optional feature)

Refer to Dwgs. MHP2043 on page 14.
Provides for remote mounting of winch control at a fixed location
at up to 20 feet (6 metres) away from winch motor. Air hoses
connect throttle to winch motor to provide winch operation.

Move control throttle handle to the right (clockwise) to payout
wire rope and to the left (counterclockwise) to haul-in wire rope.
Avoid sudden movements of control valve to ensure smooth
operation of winch.

on page 13. As viewed from air motor end, lift slider

Pendant Hose and Operating Levers (new style)

Red

Yellow

Green

Haul-In

Load
Payout
Load

(Dwg. MHP2233)

14 MHD56037 - Edition 5

Pendant Hose and Operating Levers (old style)

CAUTION

NOTICE

(Dwg. MHP1311)

* For distances greater than 50 feet (15 metres) contact

Ingersoll

Rand Technical Sales for control suitability.

Emergency Stop Operation

(Dwg. MHP2047)

Remote Pilot Lever Throttle (optional feature)

Refer to Dwg. MHP0167 on page 56, item 358.
Provides for remote winch control at distances of up to 50* feet
(15 metres) away from winch. The lever pilot control throttle is a
fixed mount lever control station for winch operation. Pilot
pressure from lever pilot control throttle activates winch control
valve. The winch control valve, located on winch motor, controls
motor speed and direction of drum rotation. Direction of rotation
is determined by direction in which lever is shifted.

* For distances greater than 50 feet (15 metres) contact

Ingersoll

Rand Technical Sales for control suitability.

Emergency Stop and Overload System

Refer to Dwg. MHP2180 on page 52.
Air supply line is connected to air control valve. When emergency
stop or overload valve is activated, all winch movement will stop.

• If winch continues to move (payout load) after emergency
stop activates, brake(s) are not holding load and may require
adjustment or repair.

When control valve senses a preset pressure difference between
ports, a pilot signal is sent to stop flow of air, all winch movement
will stop.

• If winch overload occurs, overload device, if equipped, also
stops winch. T o operate winch after an overload, reduce load
and reset overload.

• Cannot be added to old style control valve. Refer to
MHP2036 on page 50.

Dwg.

Emergency Stop Reset

Refer to Dwg. MHP2048 on page 15.

1. Rotate red stop button, in counterclockwise direction until

red stop button ‘pops’ up.

2. Winch is ready to resume operation.

Emergency Stop Reset

Refer to Dwg. MHP2047on page 15.
Emergency stop device is located on the control valve. When
activated, winch drum rotation will immediately cease. T o activate
emergency stop, conduct the following:

1. Depress (push down) red palm valve, located on top of

MHD56037 - Edition 5 15

Emergency Stop (o ptional feature)

(Dwg. MHP2048)

control valve.

Overload Device

An overload device is available on winches with the emergency
shutoff option. Overload device operation is based on differential
pressure between air motor inlet and exhaust. The overload
device is factory preset to actuate at 150% (± 25%) of winch rated
capacity. When an overload condition is sensed, the valve poppet
closes, to cut off supply air to winch, stopping winch operation. If
an overload shutoff occurs, winch load must be reduced. Reset the
overload valve and operate winch in payout direction to lower
load. Refer to ‘Emergency Stop Reset’ section.

Checking Overload Valve Setting

1. Attach load line to a load that is calibrated to maximum load
for which winch is rated.

2. Move control lever to haul-in position. If winch does not lift
load, adjust the adjustment screw. Refer to ‘Overload Valve
Adjustment’ section
feature)” on page 26.

Setting the Overload

Refer to MHP2049 on page 16 and MHP2216 on page 27.
Attach load line to a load that is calibrated to 150% of winch rated
capacity. Shift control lever to haul-in position.

1. If overload valve activates, reset overload valve. Winch is
ready for normal operation.

2. If winch lifts load, lower load. Turn adjustment screw
counterclockwise in 1/4 turn increments until overload valve
activates when control lever is shifted to haul-in position.
After each 1/4 turn, retest winch.

Overload Valve Reset

“Overload Valve Adjustment (optional

2. To operate winch, depress appropriate ‘Haul-in’ or ‘Payout’
lever.

3. In event of an emergency all winch operation can be stopped
by pushing the emergency stop button. This will prevent air
from reaching winch motor, engage winch automatic
brake(s) and stop winch haul-in or payout movement.

4. If depressed, the ‘OFF’ button will also stop winch
operation.

5. To reset Emergency Stop Valve:
a. Locate serrated ring directly below emergency stop

button. Rotating serrated ring clockwise, will cause
emergency stop button to ‘pop up’.

b. Depress emergency stop valve ‘ON’ button.

Emergency Stop Operation (old style)

(Dwg. MHP1485)

Local Control Emergency Stop Valve Operation

(Dwg. MHP0754)

(Dwg. MHP2049)

Emergency Stop (optional feature)

Refer to Dwgs. MHP1485, MHP0754 on page 16 and MHP1892
on page 17.
The emergency stop device is located at air inlet of winc h on local
control models, and on pendant on remote control models. When
activated, winch drum rotation will immediately cease.

1. To star t winch operation depress the ‘ON’ button.

16 MHD56037 - Edition 5

Remote Pendant Emergency Stop Valve Operation

WARNING

(Dwg. MHP1892)

Winch Overload Device (optional feature)

The overload device is integrated into winch air motor control air
system and prevents winch from lifting a load greater than
overload value. Refer to “INSPECTION” section
an overload is detected, inlet supply air is stopped and winch will
not operate.
If overload device is activated load must be lowered and reduced.
To lower load and reset emergency stop valve:

1. Locate serrated ring directly below emergency stop button.
Rotating serrated ring clockwise, causes emergency stop
button to ‘pop up’.

2. Depress emergency stop valve ‘ON’ button.

3. Operate winch control in payout direction.

on page 21. If

• Ensure slack load line is taken up by operating winch control
valve with selector in NORMAL position. If selector lever is
placed in TENSION position the winch will immediately
attempt to establish line tension causing line to ‘snap’
resulting in injury or damage to property.

4. Operate winch normally to remove slack from load line.

5. Actuate valve to TENSION position to set winch to
automatically haul-in load line and maintain line tension.

Winch Brakes

Manual Drum Brake

Refer to Dwg. MHP0153 on page 48.
The manual drum brake may be applied by pushing down on
handle (104) and released by pulling up. If handle is pushed down
fully, it should lock in that position and prevent drum rotation,
until released by operator. The brake must be kept properly
adjusted to hold required load. Refer to ‘Adjustments’
in “MAINTENANCE” section for adjustment instructions.

Automatic Drum Brake (optional feature)

Refer to Dwg. MHP0153 on page 48.
The automatic drum brake is a spring applied, air released brake
which utilizes an air actuated, spring loaded cylinder (110), that
automatically disengages brake when motor is operated. Air
pressure in cylinder overcomes spring pressure to release brake.
When control valve is placed in neutral position, air in cylinder
(110) is vented and spring automatically engages brake to prevent
drum rotation.

The cylinder clevis (107) must be kept properly adjusted to hold
required load.

on page 26

Constant Tension (optional feature)

Refer to Dwg. MHP1865 on page 12.
With auxiliary valve in the NORMAL position, winch provides
normal operation. Placing valve selector in TENSIONING
position allows winch to automatically operate to haul-in slack
wire rope to maintain tension.

Auxiliary valve provides preset air pressure to air motor and disc
brake. This allows brake to be released and winch to overhaul
during TENSIONING operations. In this position, winch will
maintain constant tension on wire rope.

Auxiliary valve is pre-set at zero from the factory. Specific
adjustments must be made in the field. Adjustments can be
modified at anytime to accommodate the load conditions . Refer to
‘Regulator Adjustment’ in the “MAINTENANCE” section for
specific procedure.

Constant Tension (operation)

1. Place auxiliary valve in NORMAL position.

2. Operate winch normally to position end of load line.

3. Connect load line to load.

Automatic Disc Brake (optional feature)

Refer to Dwg. MHP0152 on page 46.
The automatic disc brake is a spring applied, air released brake.
Using an air actuated, spring loaded piston (10), the brake
automatically disengages when motor is operated and engages
when throttle is returned to neutral position.

Air pressure ported through brake housing (21) overcomes spring
(9) pressure and moves piston (10) which releases brake. When
control valve is placed in neutral position, air is vented, spring
pressure overcomes air pressure and spring (9) pressure moves
piston, engages brake and prevents drum rotation.

Drum Locking Pin (optional feature)

Refer to Dwg. MHP0155 on page 61.
The drum locking pin is mounted to winch on outboard upright,
opposite motor. It should be engaged if a load is left suspended.
The drum lock is operated by rotating a pin between a shallow
groove (disengaged) and a deep groove (engaged).

To Engage:

1. Rotate drum (80) to align one of the holes in flange with
locking pin (136). Pull out, straight away from outboard
upright, pull rod (140) and rotate counterclockwise 90°,
aligning pin (135) with deep groove in gland (138). Release

MHD56037 - Edition 5 17

pull rod and ensure locking pin engages and is seated in drum

WARNING

WARNING

hole and gland deep groove.

• Ensure that all braking mechanisms are engaged and all
personnel are clear of winch load and rigging before
disengaging locking pin.

• Extremely difficult locking pin release is an indication tha t
load is held by locking pin and braking mechanisms are not
functioning properly. Do not release locking pin until load
control is established.

To Disengage:

1. Pull out, straight away from outboard upright, pull rod (140)
and rotate clockwise 90°. Align pin (135) with the shallow
groove in gland (138) and release pull rod. Ensure locking
pin (136) is clear of the drum (80) flange and pin is seated in
gland shallow groove.

Limit Switch (optional feature)

Pre-set limit switch settings prevent winch wire rope payout and
haul-in by stopping air flow to the winch motor when a defined
set point has been reached. It is the owner’s and operator’s
responsibility to adjust winch operating limits prior to using
winch.
To adjust set points refer to ‘Adjustments’ in “MAINTENANCE”
section.

• Ensure limit switch set points are established and operating

properly before using winch.

18 MHD56037 - Edition 5

LUBRICATION

NOTICE

To ensure continued satisfactory operation of winch, all points
requiring lubrication must be serviced with correct lubricant at
proper time interval as indicated for each assembly.

The lubrication intervals recommended in this manual are based
on intermittent operation of winch eight hours each day, five days
per week. If winch is operated almost continuously or more than
the eight hours each day, more frequent lubrication will be
required. Also, lubricant types and change intervals are based on
operation in an environment relatively free of dust, moisture, and
corrosive fumes. Use only those lubricants recommended. Other
lubricants may affect winch performance. Approval for use of
other lubricants must be obtained from your Ingersoll
distributor. Failure to observe this precaution may result in
damage to winch and/or its associated components.

INTERVAL LUBRICATION CHECKS

Start of each shift Check flow and level of air line lubricator

(approximately 6 to 9 drops per minute
required at maximum motor speed).

Check winch motor oil level.

Monthly Lubricate components supplied by grease

fittings.
Inspect and clean or replace air line filter.
Check reduction gear oil level.

Yearly Drain and refill winch reduction gear oil.

Drain and refill winch motor oil.

Note: Intervals are based on winch operation in a normal
environment as described in the “INSPECTION” section. In
‘Heavy’ or ‘Severe’ operating conditions adjust lubrication
intervals accordingly.

Rand

Recommended Lubricants

Reduction Gear Recommended Lubricant

Recommended Grease

Temperature Type Oil

-20° to 50° F

(-30° to 10° C)

30° to 120° F

(-1° to 49° C)

• Do NOT use synthetic lubricants in air motor. Synthetic
lubricants will result in oil blowing by piston rings.

EP 1 multipurpose

lithium based grease

EP 2 multipurpose

lithium based grease

Component Lubrication

General Lubrication

Correct lubrication is one of the most important factors in
maintaining efficient winch operation.

1. The recommended grade of oil must be used at all times. Use
of unsuitable oil may result in excessive temperature rise,
loss of efficiency and possible damage to lubricated
components. Refer to ‘Recommended Lubricants’ section.

2. Drain and replace oil in motor, disc brake and reduction gear
after the first 50 hours of initial winch operation. Thereafter,
drain and replace oil according to operating environment
(yearly in NORMAL and HEAVY; quarterly in SEVERE), or
more frequently if desired.

3. Always inspect removed oil for evidence of internal damage
or contamination (metal shavings, dirt, water, etc.). If
indications of damage are noted, investigate and correct
before returning winch to service.

4. After winch operation, allow oil to settle before topping off.

5. Always collect lubricants in suitable containers and dispose
of in an environmentally safe manner.

Temperature Type Oil

Below 32° F (0° C) ISO VG 68 (2 EP)

32° to 80° F (0° to 27° C) ISO VG 100 (3 EP) *

Above 80° F (27° C) ISO VG 150 (4 EP)

* Units are shipped from factory with ISO VG 100 (3 EP) lubri­cant. Reduction gear capacity is approximately 2 quarts (1.9
litres).

Air Motor and Disc Brake Recommended Lubricant

Temperature Type Oil

Below 32° F (0° C) ISO VG 32 (SAE 10W)

32° to 80° F (0° to 27° C) ISO VG 68 (SAE 20W) *

Above 80° F (27° C) ISO VG 100 (SAE 30W)

* Units are shipped from factory with ISO VG 68 (SAE 20W)
lubricant. Motor oil capacity is approximately 3 quarts (2.8
litres).

MHD56037 - Edition 5 19

Motor

Refer to Dwg. MHP2126 on page 20.
The motor is splash lubricated by oil in motor housing and has no
other means of lubrication. It is therefore important to use only
good quality, non-deter gent motor oil to ensure maximum
performance and minimum downtime for repairs. Refer to
‘Recommended Lubricants’ section.

Oil capacity for the K5B-546 motor is 3 quarts (2.8 litres). Add
oil through filler opening until oil flows from level plug hole.
Add oil slowly to prevent spilling.

The motor should be level-checked daily or at the start of each
shift after any accumulated water has been drained off. When
motors are operated in temperatures below freezing, wait long
enough at end of shift for water to separate from oil but not long
enough for it to freeze. Drain water then refill to level plug (225),
located on side of motor housing (217). If desired, all oil may be
drained at end of shift and motor refilled with new oil.

K5B Motor Lubrication Locations

CAUTION

CAUTION

NOTICE

(Dwg. MHP2126)

To ensure correct performance, highest efficiency and long life, it
is essential that lubricating oil be maintained at correct level.
Rotate drum until fill plug is located at top dead center then add
oil up to level plug hole. Oil capacity for reduction gear assembly
is 4 quarts (3.8 litres).

Reduction Gear Lubrication Plug Locations

Air Throttle

Refer to Dwg. MHP0165 on page 54. Periodically, depending on
winch usage and severity of environment, lubricate lever air
throttle (local and remote) with recommended grease at grease
fitting (246).

Wire Rope

Follow wire rope manufacturer’s instructions. At a minimum,
observe the following guidelines.

1. Clean with a brush or steam to remove dirt, rock dust or other
foreign material on surface of wire rope.

• Do not use an acid-based solvent. Only use cleaning fluids

specified by wire rope manufacturer.

2. Apply Ingersoll Rand LUBRI-LINK-GREEN or ISO VG
100 (SAE 30W) oil as a wire rope lubricant.

3. Brush, drip or spray lubricant weekly, or more frequently,
depending on severity of service.

Reduction Gear Assembly

(Dwg. MHP0140)

Disc Brake (optional feature)

Refer to Dwg. MHP1348 on page 20.
The friction plates and drive plates are in a self contained oil bath
and have no other means lubrication. After an oil change or winch
overhaul remove the breather plug (22) and pour a small amount
of oil [4 to 6 ounces (0.2 litres)] through breather hole in brake
housing. Allow oil to fully settle between fillings.

• If too much oil is added excess oil will be discharged through
breather plug when control valve is actuated.

Refer to Dwg. MHP0140 on page 20.
It is recommend that the first oil change be done after
approximately 50 hours initial operation. Always inspect removed
oil for evidence of internal damage (metal shavings, dirt, water,
etc.).
The reduction gear is filled to the correct levels prior to shipment
from the factory. Check oil level before initial winch operation.
This component is splash lubricated by oil in the housing and has
no other means of lubrication. It is therefore important to use high
quality Extreme Pressure (EP) rust and oxidation inhibited gear oil
to ensure maximum performance and minimum down time for
repair.

• Do not over fill. Excess oil will reduce operating efficiency

and increase oil temperature.

20 MHD56037 - Edition 5

(Dwg. MHP1348)

Seals and Bearings

If winch is disassembled, clean all parts thoroughly and coat
bearings and seals with clean grease. Refer to ‘Recommended
Lubricants’ section. Use sufficient grease to provide a good
protective coat. Lubricate grease fittings monthly with 2 or 3
pumps of a grease gun.

Drum Locking Pin (optional feature)

WARNING

NOTICE

Refer to Dwg. MHP0155 on page 61.
Lubricate at least once every month, depending on environment
and duty cycle, through grease fitting (139) located in gland (138)
with 2 or 3 pumps of a grease gun.

INSPECTION

If drum locking pin is disassembled, clean all parts thoroughly
and coat with clean grease. Refer to ‘Recommended Lubricants’
section. Use sufficient grease to provide a good protective coat.

Lubrication will help to prevent rust and allow easier locking pin
operation.

Inspection information is based in part on American Society of
Mechanical Engineers Standards Safety Codes (ASME B30.7).

• All new or repaired equipment should be inspected and
tested by personnel instructed in safety, operation and
maintenance of this equipment to ensure safe operation at
rated specifications before placing equipment in service.

• Never use a winch that inspection indicates is damaged.

Frequent and periodic inspections should be performed on
equipment in regular service. Frequent inspections are visual
examinations performed by operators or personnel trained in
safety and operation of this equipment and include observations
made during routine equipment operation. Periodic inspections
are thorough inspections conducted by personnel trained in safety ,
operation and maintenance of this equipment. ASME B30.7 states
inspection intervals depend upon the nature of critical
components of the equipment and severity of usage. The
inspection intervals recommended in this manual are based on
intermittent operation of winch eight hours each day, five days
per week, in an environment relatively free of dust, moisture, and
corrosive fumes. If winch is operated almost continuously, or
more than eight hours each day, more frequent inspections will be
required.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages, allowing
corrective action to be taken before condition becomes dangerous.
Deficiencies revealed through inspection, or noted during
operation, must be reported to designated personnel instructed in
safety, operation and maintenance of this equipment.
A determination as to whether a condition constitutes a safety
hazard(s) must be decided, and correction of noted safety
hazard(s) accomplished and documented by written report before
placing equipment in service.

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 condition
of critical parts as a method of documenting periodic inspec tions.
These reports should be dated, signed by the person who
performed inspection, and kept on file where they are readily
available for authorized review.

Wire Rope Reports

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).

1. WINCH. Prior to operation, visually inspect winch housings,
controls, brakes, side rails and drum for indications of
damage. Do not operate winch unless the wire rope feeds
onto drum smoothly. Any discrepancies noted must be
reviewed and inspected further by authorized personnel
instructed in operation, safety and maintenance of this winch.

2. WIRE ROPE. Visua lly inspect all wire rope which can be
expected to be in use during the day’s operations. Inspect for
wear and damage indicated by distortion of wire rope such
as kinking, “birdcaging,” core protrusion, main strand
displacement, corrosion, broken or cut strands. If damage is
evident, do not operate winch until the discrepancies have
been reviewed and inspected further by personnel
knowledgeable on wire rope safety and maintenance
procedures.

• The full extent of wire rope wear cannot be determined by

visual inspection. At any indication of wear inspect wire rope
in accordance with instructions in “Periodi c I ns p ection.”

3. AIR SYSTEM. Visually inspect all connections, fittings,
hoses and components for indication of air leaks. Repair any
leaks or damage.

4. PENDANT (optional feature). Ensure operation of pendant
levers is smooth and winch is responsive to pendant control.
Pendant levers must spring return to the neutral position
when released.

5. MANUAL THROTTLE LEVER. Ensure operation of
manual throttle lever is smooth and winch is responsive to
lever movement. Lever must return to neutral and lock in
place when released. If winch responds slowly or controls
stick, do not operate winch until all problems have been
corrected.

6. BRAKES. During winch operation test brakes. Brakes must
hold load without slipping. Automatic brakes must release
when winch motor throttle is operated. If brakes do not hold
load, or do not release properly, brakes must be adjusted or
repaired.

7. 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.

8. LUBRICATION. Refer to “LUBRICATION” section for
recommended procedures and lubricants.

9. LIMIT SWITCHES (optional feature). If equipped, ensure
limit switches engage and prevent operation at the required
set point and with drum rotating in correct direction. Ensure
limit switch properly resets.

MHD56037 - Edition 5 21

10. MOTOR. During operation check motor housing for excess
heat build up. Housing should not be hot to touch. Listen for
grinding or knocking noises. Ensure lubricated air supply
provides 6 to 9 drops per minute of ISO VG 32 (SAE 10W)
oil when winch is operated at rated capacity. Operate winch
slowly in both directions to verify operation.

Periodic Inspection

Periodic inspection intervals for winch use under various
conditions is listed below:

NORMAL HEAVY SEVERE

yearly semiannually quarterly

Disassembly may be required as a result of frequent inspection
findings or in order to properly inspect individual components.
Refer to “MAINTENANCE” section
written records of periodic inspections to provide an accumulative
basis for continuing evaluation. Inspect all items listed in
“Frequent Inspection.” Also inspect the following:

1. SIDE RAILS AND UPRIGHTS. Check for deformed,
cracked or corroded main components. Replace damaged
parts.

2. FASTENERS. Check retainer rings, split pins, 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 diameter of wire

rope from crown-to-crown throughout life of wire rope.

Recording of actual diameter should only be done with

wire rope under equivalent loading and in same

operating section as accomplished during previous

inspections. If actual diameter of wire rope has

decreased more than 1/64 inch (0.4 mm) a thorough

examination of wire rope should be conducted by an

experienced inspector to determine suitability of wire

rope to remain in service. Refer to Dwg. MHP0056

page 22.

on page 26. Maintain

on

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. If brake
lining thickness is less than minimum as described in
“MAINTENANCE” section replace brakes. Clean and
replace components as necessary. Adjustments cannot be
made to disc brake. The disc brake must be repaired as
described in “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 (optional feature). Operate winch in
both directions to activate limit switches. Limit switches
should engage (stop winch operation) at established settings
(+/- 2 feet [+/- 0.6 metres]). Reset limit switch by operating
winch in opposite direction. Refer to ‘Limit Switch
Adjustment’ in “MAINTENANCE” section.

10. DRUM GUARD (optional feature). Verify fasteners are tight
and in good condition. Ensure guard is in good condition.

11. EMERGENCY STOP VALVE (optional feature). During
winch operation verify emergency shut-off valve operation.
Valve must stop winch operation quickly. Valve must reset
properly. Refer to ‘Emergency Stop Valve’ in the
“OPERATION” section for procedures.

12. OVERLOAD DEVICE (optional feature). Ensure overload
device is properly set to stop winch when load exceeds
150% (+/- 25%) of winch rated capacity. If winch does not
shut down, contact your distributor or factory for repair
information.

Winches Not in Regular Use

1. Equipment which has been idle for a period of one month or
more, but less than six months, shall be given an inspection
conforming to requirements of “Frequent Inspection” 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” before being
place in service.

3. Standby equipment shall be inspected at least semi-annually
in accordance with requirements of “Frequent Inspection”.

(Dwg. MHP0056)

22 MHD56037 - Edition 5

INSPECTION AND MAINTENANCE REPORT

Ingersoll-Rand Force 5 Series FA5 and FA5T Air Winches

Model Number: Date:

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection
(_____ Quarterly _____ Semiannually _____ Yearly) Operating Environment:

2. Discrepancy(s) noted during Frequent Inspection

3. Discrepancy(s) noted during maintenance

4. Other: ___________________________

Refer to the 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.

COMPONENT

Uprights and
Side Rails

Drum Band Brake
(125% Load Test)

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
Wire Rope Wedge --­Emergency Stop Valve --­Overload Device --­Wire Rope --­Other Components

(list in NOTES section)

CONDITION

Pass Fail Repair Replace

CORRECTIVE

ACTION

Normal ___ Heavy ___ Severe ___

NOTES

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 comply with standards and

regulations set forth in areas outside the USA.

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

MHD56037 - Edition 5 23

TROUBLESHOOTING

This section provides basic troubleshooting information. Determination of spec ific 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. 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 50 psig (3.4 bar/340 kPa).

Shipping plugs may still be in
place.

Drum brake does not release. Disengage manual drum brake, or refer to ‘Automatic Drum Brake

Load continues to move when
winch is stopped.

Winch does not lift load or
does not lift rated capacity.

Throttle or pendant lever
moves but winch does not
operate.

Motor runs hot or makes
excessive noise during
operation.

Winch runs slow. Improper hose or fitting sizes. Check fittings, connections and hoses for correct size and length. Replace

Air lines freeze. Water in air supply. Install or drain air system moisture traps, moisture collec ting air receivers

Throttle lever hard to actuate,
or lever does not spring return
to neutral.

Automatic Drum Brake:

Brake cylinder will not
release.

Drum brake is slipping. Check drum brake adjustment on page 26 and brake band lining wear.
Winch is overloaded. Reduce load to within rated capacity.
Winch motor controls sticking. Check pendant/throttle levers spring return to normal (neutral) positions

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

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

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

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

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 on

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

Damaged or broken piston or
connecting rod.

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

Brake(s) not releasing. Refer to brakes in “MAINTENANCE” section on page 26.

Valve body sticking in
bushing.

Drum brake out of adjustment. Adjust drum brake to maintain correct cylinder stroke.
Leaking cylinder seals. If air is noticed escaping from cylinder breather when attempting to

Dirty filter in air supply. Clean or replace filter .
Faulty dump valve. Check dump valve exhaust port. Air should exhaust when control valve

Remove shipping plugs in valve and motor exhaust ports.

Adjustment’

when released.

section
damaged.

listed in the “SPECIFICATIONS” section

rated volume. Clean air line filter.

fittings and repair or replace hoses as necessary.

page 19. Set lubricator to provide 6 to 9 drops of oil per minute at
maximum winch operating capacity.

slowly, in both directions. If noise still exists or motor overheats
disassemble and repair motor.

Disassemble and repair motor.

parts that may cause restricted air flow. Inspect air line filter.

section
parts.

and compressor aftercoolers. After corrective action has been taken,
disconnect lines at winch inlet and purge with clean, dry air or nitrogen.

Lubricate valve through grease fitting with recommended lubricant. Refer
to ‘Air Throttle’

release brake, replace or repair cylinder.

handle is in neutral. If no air escapes, replace dump valve.

on page 26.

on page 30. Examine all parts and replace any that are worn or

on page 5. Clean air line filter.

on page 30. Inspect all parts and replace all worn or damaged

on page 19 in “LUBRICATION” section.

24 MHD56037 - Edition 5

SYMPTOM CAUSE REMEDY
Automatic Disc Brake:

Brake fails to release. Low air supply pressure. Ensure air pressure at inlet to disc brake is at least 50 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.

Sticking brake piston. Apply 50 psig (3.4 bar/340 kPa) to brake release port and check for brake

Check for proper operation of winch controls.

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.

MHD56037 - Edition 5 25

MAINTENANCE

WARNING

CAUTION

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 service personnel trained in safety and service on

this winch to perform maintenance.

• After performing any maintenance on winch, test winch to

125% of its rated capacity before returning to service. Testing
to more than 125% of rated capacity may be required to
comply with standards outside the USA.

• Shut off air system and depressurize air lines before

performing any maintenance.

Maintenance Intervals

The Maintenance Interval chart is based on intermittent operation
of winch eight hours each day, five days per week. If winch
operation exceeds eight hours per day, or use is under HEAVY or
SEVERE conditions, more frequent maintenance should be
performed. Refer to ‘Periodic Inspection’
“INSPECTION” section for interval guidance.

INTERVAL MAINTENANCE CHECK

Start of each shift

(Operator or
Maintenance
Personnel)

3 Months
(Maintenance
Personnel)

Yearly

(Maintenance
Personnel)

Make a thorough visual inspection of winch
for damage. Do not operate winch if
damaged.

Operate winch at low RPM in both
directions. Winch must operate smoothly
without sticking, binding or abnormal
noises. Check operation of brake(s)

Inspect drum brake friction linings. Clean or
replace parts as required. Adjust drum brake
as necessary.

Inspect winch gearing, shafts and bearings
for wear and damage. Repair or replace as
necessary.

Check all supporting members, including
foundation, fasteners, nuts, sheaves and
rigging, etc. for indications of damage or
wear. Repair or replace as required.

on page 22 in

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.

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

or less, brake bands (128) or linings must be replaced.

Automatic Drum Brake Adjustment (optional feature)

Refer to Dwg. MHP0153 on page 48.

1. Remove cotter pin (102) and washer (129) at adjustment
clevis (107).

2. Apply air to brake cylinder (110) and remove pin (106) and
second washer (129) 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 washer
(129) and 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). Readjust if necessary.

6. Install cotter pin (102) and second washer (129) to secure
clevis to brake lever when adjustment is complete.

7. With brake “On”, adjust screw (127) to just touch arm (124).

Pilot Air Control Valve Adjustment (optional feature)

Refer to Dwg. MHP0141 on page 60.
If winch operating speeds differ from performance specifications
pilot air control valve may require adjustment. 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. 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.

Overload Valve Adjustment (optional feature)

Adjustments

Disc Brake Adjustment (optional feature)

Refer to Dwg. MHP0152 on page 46.
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 (23)
is installed and located at top of brake housing during reassembly.

Manual Drum Brake Adjustment

Refer to Dwg. MHP0153 on page 48.

1. Release wire rope tension on drum.

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

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

26 MHD56037 - Edition 5

new style

Refer to Dwg. MP2216 on page 27
5/16 in. or 8 mm open ended wrench required.

1. Adjust overload valve by turning adjustment screw located at
bottom of control valve.

2. Rotating adjustment screw clockwise will increase pressure
required to activate overload valve.

• This adjustment can cause overload device to NOT activate

before winch’s safety limit is exceeded. This procedure should
only be done by personnel trained in testing and servicing this
winch.

3. Rotating adjustment screw counterclockwise will decrease

WARNING

pressure required to activate overload valve.

Overload Valve Adjustment (new style)

Overload Valve Adjustment (old style)

(Dwg. MHP1678)

(Dwg. MHP2216)

Overload Valve Adjustment (optional feature)

old style

Refer to Dwg. MHP1678 on page 27.
Adjust overload valve by turning adjustment screw located at
bottom of valve.
Rotating screw clockwise will increase pressure required to
activate shutoff valve.

• This adjustment can cause overload device to NOT activate
before winch’s safety limit is exceeded. This procedure should
only be done by personnel trained in testing and servicing this
winch.

Rotating adjustment screw counterclockwise will decrease
pressure required to activate shut off valve.

Checking Overload Valve Setting:

1. Attach load line to a load that is calibrated to 150% of the
maximum load for which winch is rated. Move control lever
to haul-in position. If winch lifts load, adjust screw as
described below.

Setting the Overload:

1. Attach load line to a load that is calibrated to 150% of winch
rated capacity.

2. When control lever is moved to haul-in position, overload
valve should activate shut off valve. Reset emergency stop
valve, valve is adjusted.

3. If winch lifts load, lower load. Turn adjustment screw
counterclockwise in ¼ turn increments until shut off valve is
activated. After each ¼ turn, retest winch.

Limit Switch Adjustment (optional feature)

(Dwg. MHP0607)

To set winch maximum wire rope payout limit switch:

1. Remove access plate from top of limit switch.

2. Loosen blue setscrew in center of limit switch, below access
cover.

3. Position winch wire rope at desired payout position.

4. Rotate left cam adjustment screw counterclockwise until it
fully activates cutoff valve, causing system air to vent. 2¾
turns of the cam adjustment screw are required for each full
cam revolution.

5. Hold cam adjustment screw in position (venting air) and
tighten blue setscrew to lock cam in place.

6. If required, adjust haul-in limit switch. Test winch set points
by operating winch through three complete cycles to ensure
consistent limit switch operation within +/- 2 feet (2/3 metre)
of set points.

7. Install access cover when final adjustments are complete.

To set winch maximum wire rope haul-in limit switch:

1. Remove access plate from top of limit switch.

2. Loosen red setscrew in center of limit switch, below access
cover.

3. Position winch wire rope at desired switch activation
position.

4. Rotate right cam adjustment screw clockwise until it fully
activates cutoff valve, causing system air to vent. 2¾ turns of
cam adjustment screw are required for each full cam
revolution.

MHD56037 - Edition 5 27

5. Hold cam adjustment screw in position (venting air) and

WARNING

WARNING

WARNING

tighten red setscrew.

6. If required, adjust payout limit switch. Test winch set points
by operating winch through three complete cycles to ensure
consistent limit switch operation within +/- 2 f eet (2/3 metre)
of set points.

7. Install access cover when final adjustments are complete.

Constant Tension Adjustment (optional feature)

Refer to Dwg. MHP1865 on page 12.
The regulator is preset at 0 psig (0 bar/0 kPa), therefore requires
adjustment when winch is installed. To adjust for specific load
applications, regulator pressure may be adjusted to increase or
decrease tension setting.
Regulator gauge and regulator are accessible through cover.

• When adjusting regulator, ensure winch control lever is

locked in neutral position and tension selector lever is in the
NORMAL position.

• Winch supply air is NOT shut off during regulator

adjustments. To prevent accidental winch operation, allow
only a single person, trained in safety, operation and
maintenance of this product, to conduct regulator
adjustments.

Regulator Adjustment Procedure:

Refer to Dwg. MHP1865 on page 12.

1. Attach test load of desired weight to load line, or connect
load line to scale.

• Ensure load line is connected to load and excessive slack is

taken up before activating auxiliary valve. When activated,
auxiliary valve will automatically engage and winch will
operate at full speed to set tension on load line.

2. With winch control valve remove all slack from load line.

Setting with test load:

1. Actuate auxiliary valve to TENSIONING position. W inch
should operate, causing load line to become taut. To increase
tension, turn regulator knob clockwise until load begins to
rise. Turn regulator knob counterclockwise a minimum of ¼
turn, or until load is balanced (does not raise or lower). Note
pressure indicated on gauge for future setting reference.

Setting with scale:

1. Actuate auxiliary valve to TENSIONING position. W inch
should operate, causing load line to become taut. To increase
tension, turn regulator knob clockwise until scale indicates
desired tension. Note pressure indicated on gauge for future
setting reference.

Disassembly

General Disassembly Instructions

The following instructions provide necessary information to
disassemble, inspect, repair, and assemble winch. Parts drawings
are provided in parts section. If a winch is being completely
disassembled for any reason, follow the order of topics as t hey 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 suf f ic ient 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 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 Dwg. MHP0157 on page 40, MHP2093 on page 44 and
MHP0152 on page 46.

1. Remove wire rope from drum.

2. Operate winch to position reduction gear drain plug at it’s
lowest position.

3. Relieve pressure in air lines by operating winch control
several times after air supply has been turned off.

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

performing any disassembly procedures.

4. Disconnect and tag air lines.

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

6. Remove lower case drain plug (225) on K5B motor housing
(217) and allow oil to drain into a suitable container . Loosen
fill cap (210) to vent motor housing.

28 MHD56037 - Edition 5

7. Drain oil from reduction gear assembly by removing one

WARNING

NOTICE

plug (48) when positioned at it’s lowest point, and one plug
(48) from it’s highest point to vent. Refer to Dwg. MHP0140
on page 20 in “LUBRICATION” section. 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.

8. For winches with a disc brake remove pipe plug (24) in
brake housing (21) to drain brake oil.

9. Remove drum band brake, drum guard and any other
externally mounted winch attachments.

• The K5B air motor weighs approximately 260 lb. (118 kg).

Adequately support air motor before removing motor
mounting capscrews.

10. Remove capscrews (4) and lockwashers (3) securing motor
assembly to motor adapter (6). Using a hoist to support
motor, pull motor straight away from winch. Reference the
applicable Motor Disassembly section if motor disassembly
is required.

Instructions 11 through 17 apply only to winches with a disc
brake.

11. Alternately and evenly loosen eight capscrews (1) until brake
spring tension has been released. Remove capscrews and
motor adapter (6).

12. Remove brake housing (21). If brake housing sticks, tap it
with a soft faced hammer until parts separate.

To disassemble reduction gear refer to Reduction Gear

Disassembly section.

Manual or Automatic Drum Brake Disassembly

Refer to Dwg. MHP0153 on page 48.

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), washers (129) and pin (106).

Separate clevis (107) 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. 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 ‘Brake Lining Instruction Sheet’ (Form
MHD56142) for brake lining replacement procedures.

Reduction Gear Disassembly

Refer to Dwg. MHP0157 on page 40.

Note position of all brake parts for reassembly.

13. Remove three friction plates (16) and two drive plates (17).

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

15. Remove brake piston (10) from brake housing (21). Tap
lightly with a plastic mallet to separate parts if necessary.

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

17. Loosen capscrew in collar (18) and slide collar from shaft
(35) with splined hub (19) and spacer (34) from shaft (35).

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

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

20. Support drum (80) and remove capscrews (39) from drum
shaft (41). Pry drum shaft (41) from inboard upright (42).

21. Remove capscrews (85) and lockwashers (86) which secure
side rails (82) and (83) to inboard upright (42). Drive out
dowel pins (87).

22. Remove inboard upright (42).

23. Remove end cover (95), capscrews (97) and lockwashers
(96) from outboard upright (84).

24. Remove capscrews (93) and shaft retainer (92) from drum
(80).

25. Remove drum and reduction gear assembly.

26. Remove remaining capscrews (85) and lockwashers (86)
which attach side rails (82) and (83) to outboard upright
(84). Drive out dowel pins (87).

27. Remove bearing (49) and seal (99) from outboard upright
(84).

28. Remove capscrews (45) and lockwashers (46) securing gear
carrier (47) to drum (80).

29. Install two 3/4 inch - 10 NC x 3 inch long capscrews into
threaded holes in outer bolt pattern ring of gear carrier (47).
Use these capscrews to break seal. Remove reduction gear/
gear carrier assembly from drum (80).

• It is important to maintain a clean work area when reduction
gear assembly is disassembled.

1. Place reduction gear assembly on a clean work bench such
that end containing bearing (49) is down.

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

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

4. Remove and discard ‘O’ rings (62) from ring gear (72).

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

6. Remove spacer (71), ring gear (63) and sun gear (66).

7. If required, remove thrust plate (55) from sun gear (66).
Remove and discard ‘O’ rings (62) from ring gear (63).

8. Remove capscrews (60) from input housing (59). Separate
input housing from gear carrier (47).

9. Remove planet assembly (58).

10. Remove ring gear (53). Remove three dowel pins (52) from
between input housing (59) and gear carrier (47) and store in
a safe place.

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

12. Remove retainer ring (57) and sun gear (56). If required,
remove thrust plate (55) from sun gear.

13. Remove planet assembly (54).

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

MHD56037 - Edition 5 29

NOTICE

CAUTION

NOTICE

Control Valve Removal and Replacement

NOTICE

NOTICE

• Do not disassemble planetary gear assemblies (54), (58) and
(67).

K5B Motor Disassembly

Refer to Dwg. MHP2093 on page 44.

1. Remove five capscrews (1) from exhaust flange (253) or

(254). Do not remove the two capscrews (255) from throttle
valve assembly (260).

2. Remove rotary valve housing (247) by pulling it out of
motor housing (217) as an assembly with exhaust flange
(253) or (254).

• Do not remove the exhaust flange (254) until rotary valve

(250) has been removed from rotary valve housing (247).

3. Remove rotary valve (250) by pulling it out from assembly
through the motor housing end of rotary valve housing (247).

4. Remove exhaust flange (254) and throttle valve assembly
(260) by removing capscrews (255) and (257), respectively.

5. Remove each cylinder head (201) by removing four
capscrews (200). Remove head gasket (209).

6. Pull cylinder liner (208) straight out.

7. Position piston (204) at top of its stroke. In this position,
with cylinder liner pulled out in step 7, wrist pin (203) can
be removed. Remove one retainer ring (205) from either side
of piston (204). Push wrist pin (203) out by hand from one
side. If wrist pin is too tight it is acceptable to carefully heat
piston to 200° F (93° C) or less and then push wrist pin out.

Refer to Dwg. MHP2036 on page 50 or MHP0165 on page 54.

Replacement of K5B control valve with K5C2 control valve.

1. Turn off air supply to valve and disconnect main air supply
line at motor .

2. Disconnect auxiliary air line(s) from fitting(s) located on
control valve.

3. Remove muffler and/or exhaust piping.

4. Remove capscrews (1) and (255), and washers (96) from
exhaust flange cap (254). Discard gasket (317).

5. Remove capscrews (257) and washers (96) from control
valve.

6. Remove control valve from rotary housing and discard
gasket (248).

7. Install gaskets (946) and control valve assembly (900)
securing with capscrews (951) and washers (949).

8. Install gasket (970) and exhaust cap (971) to rotary housing
on motor.

9. Install fittings (957), (958) and muffler (959) on control
valve. These are optional parts.

K5C2 Control Valve Disassembly

Refer to Dwg. MHP2036 on page 50.

Handle Removal

It is not recommended to disassemble handle.

1. Carefully pry off plug (935).

2. Remove capscrew (901) and tablock washer (909).

• Observe spring (937) connection during disassembly. This

spring is under tension and is required to return handle to
neutral position.

• If piston, wrist pin, connecting rod or cylinder liner are to be
re-assembled, number each set. Also add radial alignment
marks for each piston and cylinder liner to motor housing.

8. Remove remaining cylinder liners and pistons as described in
steps 7 and 8. To remove crank assembly, all pistons and
cylinder liners must be removed.

9. Crank assembly (231) can now be removed with oil slinger
(230) by pulling straight out from motor housing (217). Use
care while guiding connecting rods (206) through inside of
motor housing.

Crankshaft Disassembly

1. Remove cotter pin (236) and pin nut (237).

2. Remove lock pin (235) by carefully driving it out of its
location. Use care not to damage pin threads.

3. Pull crankshaft valve end (231) off crankshaft.

4. Remove connecting rod rings (234), connecting rod bushing
(233), sleeve (232) and connecting rods (206). Record five
connecting rod (206) numbers and foot directions so they
can be re-installed in same order.

5. Oil slinger (230) does not have to be removed unless
damaged. If removal is required, heating of five screws (229)
may be necessary to loosen Loctite

® connection.

3. Carefully pull handle assembly (930) from reverse valve
(943). Remove spring (937).

Reverse Valve Removal

1. Remove capscrews (938), (925) and washers (924) from seal
bracket (939). Remove seal bracket from housing. Remove
and discard ‘O’ rings (941) and (942).

2. Remove capscrews (901) and washers (902) from exhaust
flange (955). Remove flange from housing. Remove and
discard ‘O’ ring (942).

3. Move reverse valve (943) out exhaust flange side of housing
until ball (916) is visible on reverse valve. Allow ball (916)
to drop out of bushing (944) and remove ball (916).

4. Remove bushing (944) out exhaust flange side of housing.

• Dowel pin (945) allows the bushing to be removed only from

the exhaust flange side of housing. Ball (916) retains reverse
valve (943) in bushing (944).

• Do not remove reverse valve (943), bushing (944) and ball

(916) at the same time, damage may occur to bushing.

• Take care to not allow ball (916) to drop in motor. If this

occurs it may be necessary to disassemble motor to retrieve
ball (916).

30 MHD56037 - Edition 5

Piston Removal

NOTICE

NOTICE

NOTICE

NOTICE

1. Remove capscrews (901) and washers (902) from piston
cover (919). Remove cover and discard gasket (918).

2. Remove capscrews (901) and washers (902) from poppet
cover (903). Remove cover and discard gasket (904).

3. Remove the following items from housing poppet bore:
spring (905), poppet cap (906) and poppet seal (907).

4. From poppet side, push piston (922) out of housing. Remove
‘O’ rings (921) and (923) and discard.

Pilot Valve Removal

• For easier removal it is recommended to use IR pilot valve

tool (920). This must be purchased separately .

3. Move reverse valve (943) out exhaust flange side of housing
until ball (916) is visible on reverse valve. Allow ball (916)
to drop out of bushing (944) and remove ball (916).

4. Remove bushing (944) out exhaust flange side of housing.

• Dowel pin (945) allows the bushing to be removed only from

the exhaust flange side of housing. Ball (916) retains reverse
valve (943) in bushing (944).

• Do not remove reverse valve (943), bushing (944) and ball

(916) at the same time, damage may occur to bushing.

Piston Removal

Follow disassembly instructions for K5C2 Control Valve.

Pilot Valve Removal

If pilot valve is not damaged it is not necessary to disassemble
completely.

1. Remove plug (912).

2. Remove pilot valve assembly (910) as an assembly.

3. Discard and replace pilot valve assembly (910) if necessary.

K5B Control Valve Disassembly (old style)

Refer to Dwg. MHP0165on page 54.

• Match mark throttle valve parts to ensure proper re­assembly.

1. Remove two capscrews (302) and lockwashers (96) that hold
the valve body retainer (305).

2. Mark square end on valve body (316) and handle (300) to
ensure correct orientation during reassembly.

3. Drive out pin (301) and remove handle (300).

4. Make note on how spring (303) is positioned before
removing it. Pull valve body (316) out of valve bushing
(314) while disconnecting spring (303).

5. Remove seal rings (315) from valve body (316).

6. Check parts for score marks or wear.

7. Measure clearance between valve bushing (314) and valve
body (316). Clearance between valve bushing and valve
body should not exceed 0.002 inch (0.05 mm) or excessive
air leakage will occur.

K5C2-E Control Valve Disassembly

Refer to Dwg. MHP 2180 on page 52.

Follow disassembly instructions for K5C2 Control Valve.

Emergency Stop Removal

1. Remove adapter (706) and E-Stop button (705).

2. Remove plunger (707). Remove and discard ‘O’ rings (703).

3. Pull spring (711) out of valve housing and discard.

Overload Valve Removal

1. Remove cap (700). Remove and discard grommet (701).

2. Pull out plunger (702), remove and discard ‘O’ rings (703).

3. Remove capscrews (901) and washers (902) from cover
(719) underneath valve housing.

• Cover (719) retains spring (718). To remove capscrews (901)

and washer (902) unscrew in a crisscross pattern.

4. Remove adjusting screw (720).

Cleaning, Inspection and Repair

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 accumulate d dirt and sediments on
housings, frame and drum. If bushings have been removed it may
be necessary to scrape old Loctite
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.

® from bushing bores. Dry each

Handle Removal

Follow disassembly instructions for K5C2 Control Valve.

Reverse Valve Removal

1. Remove capscrews (938), (925) and washers (924) from seal
bracket (939). Remove seal bracket from housing. Remove
and discard ‘O’ rings (941) and (942).

2. Remove capscrews (721) and washers (902) from exhaust
flange (955) and exhaust adapter (723). Remove and discard
‘O’ rings (942) and (722).

MHD56037 - Edition 5 31

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.

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

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

NOTICE

NOTICE

NOTICE

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.

6. Measure thickness of drum band brake lining. If drum brake
band linings are less than 0.062 inch (2 mm) thick anywhere
along edges replace brake bands (128) as a set.

7. 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).

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.

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
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.

Assembly

General instructions

4. Holding ball (916) in position on reverse valve platform,
rotate reverse valve from neutral position to approximately
45 degrees in either direction. Ball will ‘walk’ up side of
reverse valve platform and move in ball hole in bushing.

• Do not rotate reverse valve past a 90 degree position, it may

result in the ball (916) falling in motor.

5. Slowly push reverse valve, while still in the 45 degree
position, the rest of the way in housing until flush with
surface. From other side of valve rotate reverse valve back to
neutral position, ball should be seated in ball slot at that time.

6. Lubricate ‘O’ ring (942) and place it in groove in exhaust
flange (955).

7. Secure exhaust flange (955) to valve housing with capscrews
(901) and washers (902).

8. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’
ring (942) and place into groove in seal bracket.

9. Place seal bracket over end of reverse valve. Using finger
pressure, press until seal is seated on reverse valve and seal
bracket is seated on valve housing. Secure with washers
(924) and capscrews (925) and (938).

Pilot Valve Assembly

• For easier installation it is recommended to use IR pilot valve

tool (920). This must be purchased separately.

1. Install pilot valve assembly (910).

2. Apply thread sealant Loctite 567® to pilot valve assembly
(910), place pilot valve assembly into valve housing. Use a
large flat tipped screw driver t o engage slots in pilot seat and
tighten until pilot assembly is 1/8 in. (3.175 mm) from
housing bore.

3. Insert plug (912) and tighten.

• 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 VG 100 (SAE 30W).

K5C2 Control Valve Assembly

Refer to Dwg. MHP2036 on page 50.

Reverse Valve Assembly

1. Insert reverse valve (943) into bushing (944) with ball slot
oriented UP, approximately 2-1/2 in. (64 mm).

2. Insert bushing (944) and reverse valve (943) into valve
housing (917) from exhaust flange side, ensuring that groove
in bushing is aligned with pin (945).

3. Insert ball (916) onto reverse valve platform. With finger ,
push ball (916) in housing until ball hits end of reverse
valve.

32 MHD56037 - Edition 5

Piston Assembly

1. Lubricate and install ‘O’ rings (921) and (923) on piston
(922).

2. Insert assembled piston into valve housing (917) from
handle side.

3. Secure with gasket (918), piston cover (919), washers (902)
and capscrews (901).

4. Place poppet seal (907) into poppet cap (906). Place this
assembly into valve housing and seat on piston (922).

5. Place spring (905) over this assembly.

6. Secure with gasket (904), poppet cover (903), washers (902)
and capscrews (901).

Handle Assembly

1. Place spring (937) over reverse valve handle end in seal
bracket.

• Spring (937) will have to be ‘Cocked’ over stud in seal

bracket. This will ensure handle returns to neutral.

2. Place handle assembly over reverse valve end. Slide handle

NOTICE

NOTICE

NOTICE

will have to be lifted slightly to allow pin to fit into slot in
seal bracket.

3. Secure handle assembly (930) to reverse valve with tab lock
washer (909) and capscrew (901), torque to 15 ft lbs. (21
Nm). W a sher (909) has small tab on side, engage with small
hole in handle.

4. Bend tabs of washer (909) over flats of capscrew.

5. Press plug (935) into handle assembly to cover capscrew.
Check control handle movement. Correct any discrepancies.

Pilot Valve Assembly

Follow assembly instructions for K5C2 Control Valve.

Piston Assembly

Follow assembly instructions for K5C2 Control Valve.

Handle Assembly

K5B Control Valve Assembly (old style)

Refer to Dwg. MHP0165 on page 54.

• During assembly align parts using match marks made

during disassembly.

• This valve is no longer available and should be replaced with

K5C2, if necessary.

1. Install seal rings (315) on each end of valve body (316).

2. Install valve body (316) into valve bushing (314).

• Valve bushing (314) is shown exploded for refere n ce ON LY.

3. Install valve body retainer (305) with two capscrews (302)
and lockwashers (96). Torque capscrews to 25 ft lbs (34 Nm).

4. If removed, reinstall spring retaining stud (306) and torque
to 25 ft lbs (34 Nm).

5. Install spring (303) and handle (300) on square shaft of valve
body. Spring (303) ends must straddle spring retaining stud
on throttle handle. Install roll pin (301).

6. Check throttle handle moves fully left and right without
sticking or binding. Throttle handle should center, by spring
force, automatically when released.

K5C2-EX Control Valve Assembly

Refer to Dwg. MHP2180 on page 52.

Reverse Valve Assembly

1. Insert reverse valve (943) into bushing (944) with ball slot
oriented UP. Apply grease to ball (916) and insert into ball
slot of reverse valve (943) through bushing (944).

2. Insert bushing (944), reverse valve (943) and ball (916) into
valve housing (917) from exhaust flange side, ensuring that
groove in bushing is aligned with pin (945).

3. Lubricate ‘O’ rings (942) and (722), and place in grooves in
exhaust adapter (723).

4. Lubricate ‘O’ rings (942) and place in grooves in exhaust
flange (955).

5. Secure exhaust adapter with exhaust flange to valve housing
with capscrews (721) and washers (902).

6. Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’
ring (942) and place into groove in seal bracket.

7. Place seal bracket over end of reverse valve. Using finger
pressure, press until seal is seated on reverse valve and seal
bracket is seated on valve housing. Secure with washers
(924) and capscrews (925) and (938).

Follow assembly instructions for K5C2 Control Valve.

Emergency Stop Assembly

1. Insert spring (711) into valve housing (917).

2. Place ‘O’ rings (703) on plunger (707).

3. Insert plunger into valve housing.

4. Screw adapter (706) and E-Stop button (705) into valve
housing.

5. Tighten adapter until snug, do not over tighten.

Overload Valve Assembly

1. Replace ‘O’ rings (703) on plunger (702).

2. Insert plunger (702) with ‘O’ rings in valve housing (917).

3. Replace grommet (701) in cap (700).

4. Install and tighten cap (700) flush to valve housing.

5. Replace piston (712) if appears damaged or worn.

6. Insert ‘O’ ring (713) on piston (712).

7. Replace gasket (714).

• Cover (719) retains springs (718), adjustment nut (717) and

plate (715). Insert capscrews (902) and washers (901) in a
crisscross pattern until tightened evenly.

8. Insert adjusting screw (720), refer to ‘OPERATION’ section
for overload valve adjustment.

9. Secure Control Valve Assembly to intake manifold using
capscrews (951) and washers (949). Use new gaskets (946)
between control valve and manifold.

10. Test control valve for proper operation. Lift slide handle and
move handle all the way in one direction and release hand.
Control handle should return and lock in the neutral position.
Repeat for other direction.

11. Connect brake line.

12. Connect air supply line.

K5B Motor Assembly

Refer to Dwg. MHP2093 on page 44.

1. Assemble throttle valve assembly (260), gasket (248) and
exhaust flange (254) to rotary valve housing (247) using four
capscrews (257) and lockwashers (223). Install two
capscrews (255) and lockwashers (223) that attach exhaust
flange (254) to throttle valve housing.

2. Tighten capscrews (255) and (257) to 25 ft lbs (34 Nm).
Throttle handle should move fully left and right without
sticking or binding, and should center (by spring force)
automatically when released.

MHD56037 - Edition 5 33

3. Install two seal rings (251) on each end of rotary valve

NOTICE

NOTICE

NOTICE

(250). Place bearing (252) onto the rear of rotary valve (250)
and press into position. Press only on bearing inner race.
With rotary valve housing (247) exhaust flange down, install
rotary valve into housing.

4. Install ‘O’ ring (244) into motor housing (217).

5. Install rotary valve housing gasket (243) onto rotary valve
housing. With exhaust flange down on bench, install motor
housing (217) onto rotary valve housing. Check for any
evidence of damage to ‘O’ ring when rotary valve housing is
fully engaged. Install and tighten capscrews (1) to 50 ft lbs
(68 Nm).

6. If removed, press crank bearing (228) on crank assembly
(231). Apply pressure only on inner race of bearing.

7. Place crank assembly on a work bench with oil slinger (230)
down and slide the sleeve (232) (with tang up) on crankpin.

8. Slide connecting rod bushing (233) over sleeve (232) and
first connecting rod ring (234) with chamfer up.

9. Install connecting rods (206) in same order as removed, with
all feet pointing in same direction, using first connecting rod
ring (234) to hold one side of connecting rod feet.

10. Slide second connecting rod ring over other side of
connecting rod feet with chamfer on ring facing down
(toward stem of connecting rod).

11. Slide crank shaft valve end over crank pin while
simultaneously aligning tang on sleeve (232) with slot in
crank shaft.

12. Rotate and position crank shaft valve end relative to crank
pin to allow installation of lock pin (235).

13. Tap lock pin (235) in place and install pin nut (237). Torque
nut to 60 ft lbs (81 Nm).

14. Install cotter pin (236) and bend ends over.

15. Install roll pin (240) and bearing (228) into valve end of
crank shaft.

16. Check that all connecting rods move freely around crank.
Position crank assembly into motor housing (217). Ensure
bearing (228) is seated and connecting rods (206) are
centered in cylinder holes.

• Make certain roll pin (240) and three lugs on rotary valve

(250) line up with corresponding hole and lugs on crank shaft.

• Do not allow rotary valve to slide back in ro tary valve

housing (247). If rotary valve slides in too far, seal ring (251)
will lock-up in internal grooves of rotary valve housing (247)
and restrict further assembly.

17. Rotate crank assembly until one connecting rod (206) is at
the top of its stroke. Install a piston (204) with its rings (202)
and (207) to connecting rod with wrist pin (203) and
retaining rings (205).

18. Install a new cylinder head gasket (209) before installing
cylinder liner (208).

19. Install cylinder liner over the piston by compressing both
piston rings and with a single band ring compressor.

20. Install cylinder head (201) over cylinder and secure cylinder
head to motor housing with four capscrews (200). T orque
capscrews to 60 ft lbs (81 Nm).

21. Repeat Steps 17 through 20 with remaining cylinders.

22. Rotate motor by hand. Motor should rotate without binding.

23. Install mounting flange (216) and gasket (226) on front of
motor housing. Make sure notches on both parts are aligned.

24. Lightly lubricate ‘O’ ring (5) and install in groove on motor
adapter (6).

• ‘O’ ring, item 5 listed in step 24 refers to part number 51459
as shown on winch assembly Dwg. MHP0157
part must be placed between mounting flange (216) and motor
adapter (6).

25. Temporarily install capscrews and nuts finger tight to retain
motor adapter (6).

26. Install eye bolts (213) and vent cap assembly (210) in motor
housing.

27. Ensure oil drain and level plugs (225) are installed.

Reduction Gear Assembly

Refer to Dwg. MHP0157 on page 40.

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

assemblies are reasse mbl ed . During reassembly clean each
part thoroughly and lightly coat with appropriate lubricant as
described in ‘Recommended Lubricants’
“LUBRICATION” section.

1. Install bearing (49) and retainer ring (50) in gear carrier (47).

2. Lubricate and install ‘O’ rings (51) on ring gear (53).

3. Align capscrew holes and dowel pins with gear carrier (47)
and install ring gear (53). Ensure ‘O’ rings are not damaged
during installation.

4. Install planet assembly (54).

5. Install thrust bearing (55) into sun gear (56). Install retainer
ring (57) on sun gear and locate in planet assembly (54).

6. Align capscrew and dowel holes and install input housing
(59). Apply a light coating of Loctite
threads and install by hand. Equally tighten capscrews in a
diametrically opposed pattern to allow for equal compression
of housing onto ring gear (53) and gear carrier (47). When
ring gear and input housing flanges are flush with gear
carrier torque capscrews to 95 ft lbs (128 Nm).

7. Install dowel pins (52) and tap into position until slightly
below input housing flange.

8. Install planet assembly (58) onto sun gear (56).

9. Lubricate and install ‘O’ rings (62) on ring gear (63).

10. Install dowel pins (70) in ring gear (63) so they extend an
equal distance on both sides of ring gear.

11. Align capscrew holes and dowel pins and install ring gear
(63) on input housing (59). Using a soft hammer or mallet,
carefully tap dowel pins and ring gear (63) onto input
housing until mating flanges are flush. Ensure ‘O’ rings are
not damaged during installation.

12. Place thrust bearing (55) in sun gear (66) and install sun gear
into planet assembly (58).

13. Install planet assembly (67) onto sun gear (66).

14. Align capscrew holes and dowel pins and install spacer (71)
onto ring gear (63). Using a soft hammer or mallet, carefully
tap spacer onto ring gear until mating flanges are flush.
Ensure ‘O’ rings are not damaged during installation.

15. Lubricate and install ‘O’ rings (62) on ring gear (72).

16. Using a soft hammer or mallet, carefully tap ring gear (72)
onto spacer (71). Ensure ‘O’ rings are not damaged during
installation.

17. Install sun gear (69) in planet assembly (67).

on page 40. This

on page 19 of the

® 262 to capscrew (60)

34 MHD56037 - Edition 5

18. Align capscrew and dowel holes and install cover (73). Use a

NOTICE

WARNING

soft hammer or mallet to carefully tap the cover until flush
with ring gear (72). Apply a light coating of Loctite

® 242 to

capscrew (75) threads and install by hand. Equally tighten
the capscrews in a diametrically opposed pattern to allo w for
equal compression of cover onto ring gear (72) and spacer
(71). When cover, ring gear and spacer flanges are flush
torque capscrews to 32 ft lbs (42 Nm).

19. Install dowel pins (74) and tap into position until slightly
below cover flange.

20. Place a bead of Loctite® 515 sealant on surface which mates
with gear carrier. Sealant location should be inside bolt
pattern.

21. Align capscrew and dowel holes and install reduction gear
assembly into drum. Apply a light coating of Loctite

® 242 to

capscrew (45) threads and install capscrews and lockwashers
(46). Torque capscrews to 255 ft lbs (346 Nm).

22. Install two dowel pins (87) and tap into position until
slightly below gear carrier flange.

23. Apply thin coat of Loctite® 609 to outside of seal (43) and,
with seal lip facing out, install in gear carrier (47).

Winch Assembly

Refer to Dwg. MHP0157 on page 40.

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 80 ft lbs (108 Nm).

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

® 609. Install retainer ring (38).

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).

Instructions 6 through 17 cover winches with a disc brake.
For winches without a disc brake skip to instruction 18.

6. Install spacer (34) on shaft (35). Install splined hub (19) so
splined side on outside diameter goes on first. Install
capscrew in locking ring (18) and place on shaft (35).
Maintain pressure on locking ring to keep it against splined
hub (19) and tighten capscrew in locking ring (18).

7. Lubricate and install ‘O’ ring (33) on hub of drum shaft.

8. Install brake housing (21) on drum shaft (41) being careful
not to damage ‘O’ ring (33).

9. Position brake housing so brake port is in the 2 o’clock
position (as viewed from the motor end). Install drain plug
(24) in brake housing at the 6 o’clock position.

10. Install fitting (22) and breather (23) in the top of the brake
housing.

11. Lubricate friction plates (16) with a light motor oil (refer to
‘Recommended Lubricants’

on page 19 in
“LUBRICATION” section). Install friction plates (16) and
drive plates (17) in brake housing. 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.

12. 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 35.

13. Install brake piston assembly in brake housing so stepped
side enters first. Gently tap into position using a soft mallet
until seated.

14. Install one brake spring (9) in each brake spring holes.

15. Lubricate and install ‘O’ ring (33) in groove on brake
housing (21).

• ‘O’ ring, item 33 listed in step 15 refers to part number 51460

as shown on disc brake Dwg. MHP0152

on page 46. This part
must be placed between brake housing (21) and motor adapter
(6).

Brake Seal Installation

(Dwg. MHP0139)

17. Install brake reaction plate (8) in motor adapter.

18. Install seal adapter (15) in mounting flange (216), if

required.

19. Tw o threaded holes in motor adapter (6) are centered

between mounting bolt holes. Install motor adapter with
these two holes in 6 o’clock position.

20. Secure motor adapter with eight capscrews (1) using

® 242. Torque to 125 ft lbs (170 Nm). On winches

Loctite
with a disc brake install capscrews evenly to compress brake
springs, and torque to 80 ft lbs (108 Nm). Do not allow plate
to become cocked. Evenly hand tighten all capscrews before
applying final torque.

21. On disc brake equipped winches install shaft extender (7) on

end of shaft (35). On winches without disc brake install seal
sleeve (14) on shaft (35).

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

23. Ensure seal adapter (15) and oil seal (2) are installed in bore

of motor assembly. Seal lip must face into motor assembly.

• The air motor weighs approximately 260 lb. (118 kg).
Adequately support air motor while installing motor
mounting capscrews.

24. If motor assembly is being mounted with winch in a vertical

position, install one short bolt and nut to keep motor
mounting flange from dropping off. Lower motor assembly
carefully onto the shaft. Position throttle assembly at the top.
Be careful not to damage oil seal (2). When correctly
positioned remove bolt and nut and lower motor assembly the
remaining distance.

MHD56037 - Edition 5 35

25. Install the motor assembly to motor mounting plate using

NOTICE

capscrews (4) and lockwashers (3). Lightly coat capscrew
threads with Loctite

® 242 and torque to 85 ft lbs (115 Nm).

26. On winches with a disc brake install fitting (31) in dump
valve (30) and screw into brake release port. Install vented
fitting (29) in dump valve (30). Install fitting (25) in valve
assembly (260) with elbow (26). Install steel tube (27)
between fitting on dump valve (30) and elbow (26).

Drum Assembly

1. Stand drum in an upright position. Align splines and
carefully lower inboard upright and drum shaft assembly
onto drum (80).

2. Using a ‘C’ clamp, secure inboard flange assembly to drum
flange and set complete assembly in a horizontal position.

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

4. Pack bearing (49) with grease and install in outboard upright
(84).

5. Install outboard upright (84) on drum end. Ensure assembly
is kept centered on seal and journal during this step.

6. Install shaft retainer (92). Secure by installing three
capscrews (93). Lightly coat capscrew threads with Loctite

®

242. T orque to 30 ft lbs (41 Nm).

7. Install spacer (91).

8. Apply a light coat of Loctite® 515 sealant to mating surface
of outboard upright (84) and install end cover (95). Secure
using six capscrews (97) and lockwashers (96). Lightly coat
capscrew threads with Loctite

® 242. Torque to 30 ft lbs (41

Nm).

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

10. Install side rails (82 and 83) to uprights (42 and 84) and
loosely secure using capscrews (85) and lockwashers (86).

11. Tap dowel pins (87) into position until flush with side rails.

12. Tighten eight capscrews (85) evenly. Torque to 140 ft lbs
(190 Nm).

13. Mount winch to foundation as described in ‘Mounting’.
Refer to “INSTALLATION” section

on page 8.

9. Install stop plate (126) on inside of side rail (82) with
capscrew (119) and washer (117). Install adjusting screw
(127) and locknut (120) through side rail (82) and stop plate
(126) until it contacts arm (124). Refer to Dwg. MHP0173
on page 36.

FA5 Band Brake Components

(Dwg. MHP0173)

• On FA5T winches install stop plate (126) at top edge of side

rail (82). Refer to Dwg. MHP0174

on page 36

10. Adjust brake as described under ‘Adjustments’ on page 26
in “MAINTENANCE” section.

FA5T Band Brake Components

Drum Brake Assembly

Ref. Dwg. MHP0153 on page 48.

1. Install pivot bracket (122) on end of arm (124) with pin (121)
and cotter pin (102). Recessed side of threaded hole must be
toward brake band side.

2. Install connecting link (125) on arm and secure in position
with pin (121), washer (123) and cotter pin (102). Bend ends
of cotter pin over to secure. Assemble connecting link so
curved surface matches contour of brake band.

3. Install halves of brake band (128) to connecting link and
secure with pins (101), (121) and cotter pins (102). Bend
ends of cotter pin over to secure.

4. Lift winch assembly, with a suitable hoist, approximately 6
inches (15 cm) off floor or work bench.

5. Position brake band subassembly around brake diameter on
drum (80) until arm lays at bottom. When positioned, lower
winch.

6. Mount pivot bracket on inside surface of side rail (83) and
secure in position with capscrews (116) and lockwashers
(117).

7. Screw link stud (103) into handle (104) and install handle
(104) in lug on end of brake band (128). Lubricate pivot
points being careful not to get grease on brake band lining.

8. Pull halves of brake band together and install pin (101)
through lug on band (128) and link stud (103) of handle
assembly.

(Dwg. MHP0174)

Automatic Drum Brake Actuator Assembly

1. Install bracket (118) on side rail (83) with capscrews (116)
and lockwashers (117).

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

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

4. Install cylinder (110) so it connects with bracket (118) and
brake lever (105). Use pins (106) and (134), washers (129)
and cotter pins (102) to secure in position.

5. Install dump valve (112), fittings and hose (113) and (115) to
the cylinder (110).

6. Adjust automatic brake as described under ‘Adjustments’ on
page 26 in the “MAINTENANCE” section.

36 MHD56037 - Edition 5

Testing

NOTICE

Operational Test

Prior to initial use, all new or repaired winches shall be tested to
ensure proper operation.

1. Check oil level in motor, reduction gear assembly and disc
brake are correct. Top off levels as required before operation
as described in the “LUBRICATION” section.

2. To initially ‘break in’ new or overhauled motors operate
without load, in both directions, for 15 minutes at 100 - 200
RPM.

3. New Drum Brake Band Lining Run-in Procedure: All new
drum brake band linings require a ‘run-in’ period. 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 drum
brake band lining fully engages. Do not allow brake to
overheat.

4. Check operation of brakes. Adjust if necessary as described
in the “MAINTENANCE” section.

5. Check operation of limit switches, locking mechanisms and
all safety devices when equipped.

6. Check foundation mounting fasteners are secure.

7. Install drum guard when provided.

Load Test

Prior to initial use, all new or extensively repaired winches shall
be load tested by or under the direction of a person trained in
safety and operation of this winch 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:

FA5 Winch 19,970 lb. (9,058 kg)
FA5T Winch 19,970 lb. (9,058 kg)

• T esting to mor e than 125% of rated line pull may be requir ed

to comply with standards and regulations set forth in areas
outside of the USA.

Limit Switches

Operate winch through three complete cycles to ensure consistent
limit switch operation within +/- 2 feet (0.6 metre) of set points.
Refer to ‘Limit Switch Adjustment’
“MAINTENANCE” section to establish set points.

on page 27 in

MHD56037 - Edition 5 37

FA5 WINCH ASSEMBLY DRAWINGS REFERENCE DIAGRAM

(Dwg. MHP1493)

38 MHD56037 - Edition 5

FA5 WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS

Description Page No.

Drum, Base and Reduction Gear Assembly Drawing (Dwg. MHP0157) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Drum, Base and Reduction Gear Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Drum, Base and Reduction Gear Assembly Parts List (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Muffler Assembly Drawing (Dwg. MHP2090) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

K5B Motor Assembly Drawing (Dwg. MHP2093). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

K5B Motor Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Disc Brake Assembly Drawing (Dwg. MHP0152) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Disc Brake Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Drum Brake Assembly Drawing (Dwg. MHP0153) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Drum Brake Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

K5C2 Control Valve Assembly Drawing (Dwg. MHP2036) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

K5C2 Control Valve Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Emergency Stop and Overload K5C2-EX Valve Assembly Drawing (Dwg. MHP2180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Emergency Stop and Overload K5C2-EX Valve Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

K5B Control Valve Assembly Drawing (Dwg. MHP0165) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Full Flow Remote Control Valve Assembly Drawing (Dwg. MHP2092) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Remote Pilot Air Control (optional) Assembly Drawing (Dwg. MHP0167) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Remote Pilot Air Control (optional) Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Remote Pendant Assembly Drawings (Dwg. MHP2346 and MHP1677) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Remote Pendant Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Pilot Air Control Valve (optional) Assembly Drawing (Dwg. MHP0141) and Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Drum Locking Pin (optional) Assembly Drawing (Dwg. MHP0155) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Drum Guard Assembly Drawing (Dwg. MHP0154) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Emergency Stop Valve and Overload Assembly Drawing (Dwg. MHP1341) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Pendant Control Assembly (optional) Drawing (Dwg. MHP0168) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Emergency Stop Overload Assembly Drawing (Dwg. MHP1488) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Emergency Stop Overload Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Limit Switch Assembly Drawing (Dwg. MHP2027) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Limit Switch Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Pilot Air Valve Plumbing Assembly Drawing (Dwg. MHP1679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Pilot Air Valve Plumbing Assembly Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Tensioning Manifold Assembly Drawing (Dwg. MHP2028) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Tensioning Manifold Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Air Preparation Assembly Drawing (Dwg. MHP0223) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Accessories Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Labels and Tags Replacement Drawing (Dwg. MHP1676) and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

MHD56037 - Edition 5 39

DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING

(Dwg. MHP0157)

40 MHD56037 - Edition 5

DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST

Item

No.

•2 Oil Seal 1 51873 61 Plug 4 71068571

•5 ‘O’ Ring 1 51459 66 Sun Gear 1

•33 ‘O’ Ring 1 51460 71 Spacer 1

•43 Seal 1 51464 84 Outboard Upright † 1 see Note 1

Description
of Part

3 Lockwasher 10 50181 62 ‘O’ Ring 4
4 Capscrew 10 52379 63 Ring Gear 1

6 Motor Adapter 1 14227 67 Planetary Assembly 1
14 Sleeve (w/o Disc Brake) 1 10598 69 Sun Gear 1
15 Seal Adapter 1 16354 70 Dowel Pin 4

Reduction Gear Assembly

34

(includes items 35, 51-75)**

35 Shaft, Drive † 1
36 Retainer Ring 1 52298 80 Drum 1 See Note 1

37 Bearing 1 51870
38 Retainer Ring 1 51872 5/8 inch (16 mm)
39 Capscrew 8 52380 3/4 inch (19 mm) 52000
40 Pin, Dowel 2 52334 7/8 inch (22 mm) 52308
41 Drum Shaft † 1 14020 82 Side Rail (Front - RH) † 1 see Note 1
42 Upright, Inboard † 1 see Note 1 83 Side Rail (Back - LH) † 1 see Note 1

44 Seal Sleeve* 2 51466 85 Capscrew 8 50872
45 Capscrew 12 52829 86 Washer 8 50203
46 Lockwasher 12 51012 87 Dowel Pin 10 71266670
47 Gear Carrier † 1 15418 88 Nameplate 1 71106967-R
48 Plug, Fill and Drain 2 51467 89 Screw, Drive 4 71028849
49 Bearing 2 51455 91 Spacer 1 15458
50 Retainer Ring 1 71018196 92 Shaft Retainer 1 15457
51 ‘O’ Ring 2
52 Dowel Pin 3 94 Capscrew 8 50910
53 Ring Gear 1 95 End Cover 1 15459
54 Planetary Assembly 1 96 Lockwasher 6 50200
55 Thrust Bearing 2 97 Capscrew 6 51780
56 Sun Gear 1 98 Plug 1 54292
57 Retainer Ring 1 •99 Seal 1 51463
58 Planetary Assembly 1 --- Reduction Gear (old style) 1 51721
59 Input Housing 1 •--- ‘O’ Ring Kit (includes 51 & 62) 1 27347
60 Capscrew 12 71068605

Total

Qty

1 28744

Number

28738** 75 Capscrew 8

Order Item 34

Part

10579 74 Dowel Pin 4

Item

No.

Description
of Part

72 Ring Gear 1
73 Cover 1

Wire Rope Anchors:

81

93 Capscrew 3 51086

Total

Qty

Part

Number

Order Item 34

52306

1

• Recommended spare for one winch, 2 years of normal operation.

*

Seal sleeve, item 44 is no longer used and is not available as a replacement part. For units purchased with seal sleeves requiring
replacement contact your Ingersoll-Rand distributor or factory.

**

Serial numbers A1480801 and above will have new reduction gear 28744, drive shaft 28738 and sun gear 28826. W inches with
Serial numbers below A1480801 needing reduction gear parts will have to purchase new reduction gear and drive shaft 28738.
Service kits are still available.

†

These parts also come in a cold weather version. For winches with a -C in the model code, adding CH to the end of these part
numbers is required to retain winch certification. Example: Order Drive Shaft (item 35) part number 10579 as part number
10579CH.

Note 1

Refer to UPRIGHT ASSEMBLY PARTS LIST, DRUM ASSEMBLY PARTS LIST and SIDE RAIL ASSEMBLY PARTS
LIST for parts information. RH = Right Hand Side, LH = Left Hand Side as viewed from the winch motor end. Inboard is end
closest to motor; outboard is end farthest away from motor.

MHD56037 - Edition 5 41

DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST (CONT’D)

UPRIGHT ASSEMBLY PARTS LIST

Inboard Upright

(Item 42)

Standard Drum Flange (27 inch) † 1 10789 Standard Drum Flange (27 inch) † 1 10790
Tall Drum Flange (35 inch) † 1 10787 Tall Drum Flange (35 inch) † 1 10788

DRUM ASSEMBLY PARTS LIST

Drum (Item 80) With

Band Brake

Drum - Standard Flange Height (27 inches):

Drum (12 inches long) †
Drum (16 inches long) † 10860-3 Drum (16 inches long) † 11378-3
Drum (24 inches long) † 10860-5 Drum (24 inches long) † 11378-5
Drum (30 inches long) † 10860-6 Drum (30 inches long) † 11378-6

Drum - Tall Flange Height (35 inches):

Drum (12 inches long)
Drum (16 inches long) 11043-3 Drum (16 inches long) 11380-3
Drum (24 inches long) 11043-5 Drum (24 inches long) 11380-5
Drum (30 inches long) 11043-6 Drum (30 inches long) 11380-6
Drum (36 inches long) 11043-9 Drum (36 inches long) 11380-9

Total

Qty

Total

Qty

1

1

Part

Number

Part

Number

10860-2 Drum (12 inches long) †

11043-2 Drum (12 inches long)

Outboard Upright

(Item 84)

Drum (Item 80) Without

Band Brake

Total

Qty

Total

Qty

1

1

Part

Number

Part

Number

11378-2

11380-2

SIDE RAIL PARTS LIST

Side Rail (Item 82)

Right Hand

Side Rail for drum with band brake:

with 12 inch Drum †
with 16 inch Drum † 11381-3 with 16 inch Drum † 11385-3
with 24 inch Drum † 11381-5 with 24 inch Drum † 11385-5
with 30 inch Drum † 11381-6 with 30 inch Drum † 11385-6

Side Rail for drum without band brake:

with 12 inch Drum †
with 16 inch Drum † 11386-3 with 16 inch Drum † 11386-3
with 24 inch Drum † 11386-5 with 24 inch Drum † 11386-5
with 30 inch Drum † 11386-6 with 30 inch Drum † 11386-6
with 36 inch Drum † 11386-9 with 36 inch Drum † 11386-9

† These parts also come in a cold weather version. For winches with a —C in the model code, adding CH to the end of these part

numbers is required to retain winch certification. Example: Order Drum (12 inches long) (item 80) part number 10860-2 as part
number 10860-2CH.

Total

Qty

1

1

Part

Number

11381-2 with 12 inch Drum †

11386-2 with 12 inch Drum †

Side Rail (Item 83)

Left Hand

Total

Qty

1

1

Part

Number

11385-2

11386-2

42 MHD56037 - Edition 5

MUFFLER ASSEMBLY DRAWING AND PARTS LIST

K5C2 Control Valve
Muffler Assembly

959

K5B Motor Muffler and K5B Control
Valve with Long Exhaust Manifold

165

169

957

958

K5B Motor Mufflers with Remote
Actuated Pilot Control Valve

355

172

165

169

171

K5B Motor Muffler

with Round Exhaust

Manifold K5B Control

161

163

173

170

Valve with Muffler

162

165

171

170

(Dwg. MHP2090)

Item

No.

161 Pipe Elbow 1 54513 172 Pipe Elbow 1 52103
162 Muffler 1 71264360 173 Muffler 1 52465
165 Reducer Bushing 1 71057459 355 Valve Assembly 1 20993
169 Pipe Elbow 1 71057434 957 Pipe Elbow 1 71273676
170 Muffler 1 50594 958 Pipe Nipple 2 71057483
171 Pipe Nipple 1 51704 959 Muffler 1 52472

Description
of Part

Total

Qty

Part

Number

169

Item

No.

171

Description
of Part

170

Total

Qty

Part

Number

MHD56037 - Edition 5 43

K5B MOTOR ASSEMBLY DRAWING

2

229

15

230

213

226

216

228

206

200

205

214

203

209

213

201

202

204

205

207

208

225

206

210

205

244

209

203

949

243

204

208

951

202

207

200

201

205

900

K5C2 Valve

946

231

K5B Valve

232

260

254

248

233

257

96

217

317

234

3

235

96

231

4

255

240

1

237

228

236

225

243

251

247

246

251

252

250

253

1

(Dwg. MHP2093)

44 MHD56037 - Edition 5

K5B MOTOR ASSEMBLY PARTS LIST

Item

Description

No.

of Part

Motor Assembly 230 Oil Slinger 1 K5B-540

199

with Control Valve *

without Control Valve * K5B-546LM-S 232 Sleeve 1 K5B-519
1 Capscrew 5 51471 233 Bushing 1 K5B-511
2 Oil Seal † 1 51873 234 Connecting Rod Ring 1 K5B-510
3 Lockwasher 10 50181 235 Lock Pin 1 HU-520
4 Capscrew 10 52379 236 Cotter Pin 1 53456

15 Seal Adapter † 1 16354 237 Pin Nut 1 D02-394

96 Lockwasher 6 50200 240 Roll Pin 1 54257
200 Capscrew 20 52317 243 Gasket 2 K5B-928
201 Cylinder Head 5 K5B-H505 244 ‘O’ Ring 1 20A11CM248
202 Compression Ring 1 Set K5B546-KRING 246 Grease Fitting 1 53095
203 Wrist Pin 5 HU-514A 247 Rotary Valve Housing 1 K5B-545
204 Piston 5 †† 248 Gasket 1 K5B-547
205 Retainer Ring 10 902A45-632 250 Rotary Valve Assembly 1 K5B-526EQ-RS
206 Connecting Rod 5 K5B-509 251 Seal Ring Assembly 1 set K5B-607A
207 Oil Ring Refer to Item 202 252 Bearing 1 50138
208 Cylinder Liner 5 K5B-L505-47 253 Exhaust Flange Round 1 KK5B-276M
209 Head Gasket 1 Set K5B-507-5 254 Exhaust Flange 1 K5B-276
210 Vent Cap Assembly 1 26604 255 Capscrew 2 54610
213 Eye Bolt 2 KU-888 257 Capscrew 4 51766
214 Pipe Plug 1 71263297 317 Gasket 1 K5B-275
216 Mounting Flange 1 K5B-502A
217 Motor Housing 1 K5B-501A
225 Pipe Plug (Drain) 3 54912 Valve Assembly K5C K5C2-X
226 Gasket 1 K5B-592 946 Gasket 1 set 27115
228 Bearing 2 51066 949 Washer 4 71376370
229 Button Head Screw 5 K5B-541 951 Capscrew 4 71369276

Total

Qty

1

Part

Number

K5B-546M-S 231 Crank Assembly 1 K5B-A516

Item

Description

No.

of Part

Valve Assembly K5B

900

Total

Qty

1

Part

Number

Not available

Order K5C2-X

• Recommended spare for one winch, 2 years of normal operation.

*

K5B-546 with K5B-REMOTE valve includes items 1, 3, 4, 96, 200 through 252, 254, 255, 257, 260 and 317.

*

K5B-546 with K5C valve includes items 1, 3, 4, 96, 200 through 253, 260 and 812.

*

K5B-546L includes items 1, 3, 4, 200 through 247, 251, 252 and 253.

†

When ordering Motor Assembly , also order Oil Seal (2) and Seal Adapter (15).

††

Parts not sold separately. Refer to “K5B Motor Assembly Kit List”

K5B Motor Assembly Kit List:

Item

•--- Air Motor Service Kit (includes items 3, 4, 200, 202, 207-209, 226, 243, 244, and 251 1 71390181

MHD56037 - Edition 5 45

Description

No.

of Part

231 Crank Assembly (Includes items 206 and 228 through 240) 1 K5B-A516
250 Rotary Valve Assembly (includes items 251 and 252) 1 K5B-526EQ-RS
261 Piston Assembly (Includes items 202 through 205 and item 207) 1 K5B-A513-47

--- Motor Gasket Kit (includes items 209, 226, 243, 244 and 248) 1 26823

Total

Qty

Part

Number

12

35

15

11

10

33

DISC BRAKE ASSEMBLY DRAWING

9

8

7

5

29

28

44

23

22

31

30

20

27

20

28

26

Note: Tee fitting for use
on units with Disc and
Auto Band Brake only.

1

6

2

(Dwg. MHP0152)

36

21

24

19

16

17

18

46 MHD56037 - Edition 5

DISC BRAKE ASSEMBLY PARTS LIST

Item

Description

No.

of Part

64 Brake Assembly (includes items 1, 7 through 32 and 44) 1 11366

1 Capscrew (with Disc Brake) 8 51471
2 Oil Seal 1 51873
6 Motor Adapter 1 14227
7 Shaft Extender 1 10594
8 Brake Reaction Plate 1 10597
9 Spring 15 50751

10 Brake Piston 1 15437

•11 Seal 1 51461

•12 Seal 1 51462
16 Friction Plate 3 50772
17 Drive Plate 2 50773
18 Collar 1 71039333
19 Splined Hub † 1 10600
20 Fitting, Sleeve 2 55014
21 Brake Housing 1 11322
22 Fitting, Reducer Bushing 1 51803
23 Breather 1 51857
24 Pipe Plug 1 51467
25 Fitting, Reducer Bushing 1 54688

Fitting, Elbow 1 71056972

26

Fitting, Tee (for units with auto drum band brake and disc brake only) 1 52181
27 Tubing 1 52520
28 Fitting, Nut 2 55013
29 Vented, Fitting 1 20770
30 Dump Valve 1 50276
31 Fitting, Nipple 1 50859

•32 ‘O’ Ring 1 51458

•33 ‘O’ Ring 1 51460
35 Drive Shaft † 1 10579
36 Retainer Ring 1 52298
44 Spacer 1 18683

Total

Qty

Part

Number

• Recommended spare for one winch, 2 years of normal operation.

† These parts also come in a cold weather version. For winches with a —C in the model code, adding CH to the end of these part

numbers is required to retain winch certification. Example: Order Drive Shaft (item 35) part number 10903 as part number
10903CH.

MHD56037 - Edition 5 47

DRUM BRAKE ASSEMBLY DRAWING

(Dwg. MHP0153)

48 MHD56037 - Edition 5

DRUM BRAKE ASSEMBLY PARTS LIST

Item

Description

No.

of Part

80 Drum with band brake 1 Refer to page 42
82 Side Rail, Right Hand
83 Side Rail, Left Hand

Common Parts:

101 Pin † 2 4308-S 4308-S
102 Cotter Pin See ( ) 51937 (5) 51937 (7)
103 Link Stud † 1 4115
104 Brake Lever - Manual Brake † 1 4127 - - ­105 Brake Lever - Automatic Brake 1 - - - 21158
106 Pin 1 - - - 8609
107 Clevis 1 - - - 8586
108 Nut 1 - - - 50152
109 Breather 1 - - - 52384
110 Cylinder 1 - - - 8575

111 Fitting, Bushing 1 - - - 52006
112 Dump Valve 1 - - - 51954
113 Hose End 2 - - - 51029
114 Fitting, Elbow 1 - - - 54272
115 Hose (bulk) As Req’d - - - 50923
116 Capscrew 3 - - - 52014
117 Washer See ( ) 51008 (4) 71293005 (5)
118 Bracket 1 - - - 11329
119 Capscrew See ( ) 71128193 (4) 71128193 (2)
120 Nut See ( ) 54661 (1) 54661 (2)
121 Pin † 3 4307-S
122 Pivot Bracket † 1 10881
123 Washer As Req’d 52915

Arm (27 inch Drum flange) † 1 10883

124

Arm (35 inch Tall Drum flange) 10884
125 Connecting Link † 1 10882
126 Stop Plate 1 10879
127 Screw, Adjusting 1 71033104

• 128 Brake Band † 1 Set 382-29302
129 Washer 2 52914
134 Pin 1 22442

Total

Qty

1 Refer to page 42

Manual Brake Automatic Brake

Part Number

• Recommended spare for one winch, 2 years of normal operation.

† These parts also come in a cold weather version. For winches with a —C in the model code, adding CH to the end of these parts

is required to retain winch certification. Example: Pivot Bracket (item 122) part number 10881 should be ordered as part number
10881CH.

MHD56037 - Edition 5 49

K5C2 CONTROL VALVE ASSEMBLY DRAWING

904

905

Note: Brake
Fitting

918

919

956

950

962

940

947

912

910

917

906

907

903

902

901

955

901

902

935

901

909

902

901

923

924

925

938

930

937

Old Version

K5C Control Valve

922

939

921

941

960

942

945

920

946

948

949

951

943

916

954

957

958

942

944

Optional

959

0.720

New Style

Piston (922)

Shown From

Cap (906) End

(Dwg. MHP2036)

* Item 920 is not sold with any valve parts, must be purchased separately.

50 MHD56037 - Edition 5

K5C2 CONTROL VALVE ASSEMBLY PARTS LIST

Item

Description

No.

of Part

900 Control Valve Assembly 1 K5C2-X 939 Seal Bracket (Note 3) 1 28733-S
901 Capscrew 9 71342034 940 Tag, No FA2B 1 71392757
902 Washer 8 71303408 941 ‘O’ Ring 1 71357198
903 Cover, Poppet 1 26997 942 ‘O’ Ring 2 51651
904 Gasket, Poppet 1 27064
905 Spring, Poppet 1 71351068 Reverse V alve (Reverse Bias)** 28002
906 Cap, Poppet 1 28734 Reverse Valve (Unbiased) ****
907 Seal, Poppet 1 26991
909 Washer, Tablock 1 71398091 Bushing (Reverse Bias)*** 27450
910 Pilot Valve Assembl y 1 28696 Bushing (Unbiased) ****
912 Plug 1 71267561 945 Pin 1 71146674
916 Ball 1 D10-280 946 Gasket 1 Set 27115
917 Valve Housing 1 * 947 Rivet 2 71028849
918 Gasket, Cover 1 26999 948 Label, Throttle Direction 1 71352777
919 Cover, Piston 1 26998 949 Washer 4 71413355
920 IR Pilot Valve Tool 1 28690 950 Plug 1 71366348
921 ‘O’ Ring 1 52537 951 Capscrew 4 71369276
922 Piston (Note 2) 1 28735-S 954 Plug 1 71263297
923 ‘O’ Ring 1 71355796 955 Exhaust Flange 1 26691
924 Washer 2 71271985 956 Fitting 1 71367932
925 Capscrew 2 71348338 957 Fitting, Elbow 1 71273676
930 Handle Assembly 1 27239-1 958 Fitting, Nipple 1 71057483
935 Plug 1 71348962 959 Muffler 1 52472
937 Spring 1 26966 960 Label, Warning 1 71373229
938 Buttonhead Screw 2 71394407 962 Breather 1 51559
939 Seal Bracket (Note 3) 1 28733-S

* Item 917 not sold separately, order item 900.

** Reverse Valve (Normal) for Standard Overwound operation. Reverse Valve (Reverse Bias) for Optional Underwound operation.

Ensure Bushing matches Reverse Valve (Reverse Valve (Normal) and Bushing (Normal)). Mixing these components can result in

***

erratic winch operation.

**** Reverse Valve (Unbiased) and Bushing (Unbiased) contact factory for application.

Total

Qty

Part

Number

Item

Description

No.

of Part

Reverse Valve Kit (Normal)**

943

Bushing (Normal)***

944

Total

Qty

1

1

Part

Number

27925-SX

26686

Note 1: For service kit descriptions and additional information on related publication(s) refer to Tables on page 76.
Note 2: Item 922 not sold separately, includes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
Note 3: Item 939 not sold separately, includes items (1) each of 901 and 909, items 924, 925, 935, 937, 938 and 941-942.

MHD56037 - Edition 5 51

EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE ASSEMBLY DRAWING

901

Note: Brake
Fitting

902

956

919

922

923

918

921

960

704

705

706

703

707

711

917

700

701

702

703

912

910

947

940

948

907

906

916

943

218

905

722

904

944

903

942

955

902

726

901

721

902

942

723

925

935

909

901

(Dwg. MHP2180)

930

924

937

938

941

939

942

920

945

713

714

717

902

901

720

712

715

716

718

719

946

951

949

0.720

New Style

Piston (922)

hown From

S

Cap (906) End

963

52 MHD56037 - Edition 5

EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE PARTS LIST

Item

Description

No.

of Part

908 Control Valve Assembly 1 K5C2-EX 920 IR Pilot Valve Tool (MHP2036) 1 26998
700 Cap 1 27491 921 ‘O’ Ring 1 52537
701 Grommet 1 71365779 922 Piston (Note 2) 1 28735-S
702 Plunger 1 27490 923 ‘O’ Ring 1 71355796
703 ‘O’ Ring 6 71127039 924 Washer 2 71271985
704 Label, Stop 1 95790099 925 Capscrew 2 71348338
705 Button, E-Stop 1 71372601 930 Handle Assembly 1 27239-1
706 Adapter 1 27488 935 Plug 1 71348965
707 Plunger 1 27489 937 Spring 1 26966
711 Spring 1 71365787 938 Buttonhead Screw 2 71394407
712 Piston 1 27964 939 Seal Bracket (Note 3) 1 28733-S
713 ‘O’ Ring 1 51768 940 Tag, No FA2B 1 71392757
714 Gasket 1 27493 941 ‘O’ Ring 1 71357198
715 Plate 1 27624 942 ‘O’ Ring 3 51651
716 ‘O’ Ring 1 71365795
717 Adjustment Nut 1 24374 Reverse Valve (Reverse Bias)** 28002
718 Spring 1 71053730 Reverse Valve (Unbiased) ****
719 Cover 1 27494
720 Screw, Adjusting 1 27571 Bushing (Reverse Bias)*** 27450
721 Capscrew 2 71365811 Bushing (Unbiased) ****
722 ‘O’ Ring 2 71138135 945 Pin 1 71146674
723 Adapter, Exhaust 1 27540 946 Gasket 1 Set 27115
726 Plug 1 27945 947 Rivet 2 71028849
901 Capscrew 11 71342034 948 Label, Throttle Direction 1 71352777
902 Washer 12 71303408 949 Washer 4 71413355
903 Cover, Poppet 1 26997 951 Capscrew 4 71369276
904 Gasket, Poppet 1 27064 954 Plug 1 71263297
905 Spring, Poppet 1 71351068 955 Exhaust Flange 1 26691
906 Cap, Poppet 1 28734 956 Fitting 1 71367932
907 Seal, Poppet 1 26991
909 Washer, Tab Lock 1 71398091
910 Pilot Valve Assembly 1 28696
911 ‘O’ Ring 2 71126825
912 Plug 1 71414817
916 Ball 1 D10-280
917 Valve Housing 1 * 960 Label, Warning 1 71373229
918 Gasket, Cover 1 26999 963 Plug 3 28628
919 Cover, Piston 1 26998

* Item 917 not sold separately, order item 908.

** Reverse Valve (Normal) for Standard Overwound operation. Reverse Valve (Reverse Bias) for Optional Underwound operation.

Ensure Bushing matches Reverse Valve (Reverse V alve (Norma l) and Bushing (Normal)). Mixing these components can result in

***

erratic winch operation.

**** Reverse Valve (Unbiased) and Bushing (Unbiased) contact factory for application.

Total

Qty

Part

Number

Item

Description

No.

of Part

Reverse Valve Kit (Normal)**

943

Bushing (Normal)***

944

Fitting, Elbow

957

(refer to Dwg. MHP2036)
Fitting, Nipple

958

(refer to Dwg. MHP2036)
Muffler

959

(refer to Dwg. MHP2036)

Total

Qty

1

1

1 71273676

1 71057483

1 52472

Part

Number

27925-SX

26686

Note 1: For service kit descriptions and additional information on related publication(s) refer to Tables 75.
Note 2: Item 922 not sold separately, includes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
Note 3: Item 939 not sold separately, includes items (1) each of 901 and 909, items 924, 925, 935, 937, 938 and 941-942.

MHD56037 - Edition 5 53

(old style)

K5B CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST

(Dwg. MHP0165)

Item

Description

No.

of Part

260 Valve Assembly (Includes item 96, 246 and 300 through 318) 1

96 Lockwasher 4 50200
246 Grease Fitting 1 53095
300 Handle 1 K5B-556
301 Roll Pin 1 K5B-1115
302 Capscrew 4 71326110
303 Spring 1 K5B-412
305 Valve Body Retainer 1 K5B-1110A
306 Spring Retaining Stud 1 K5B-553
307 Latch 1 K5B-869A
308 Roll Pin 1 HLK-20
309 Pipe Plug 2 E5UD-947
311 Valve Housing (matched set with item 314) 1 K5B-1101
312 Roll Pin 1 25A13C92
314 Valve Bushing (matched set with item 311) 1 K5B-1101
315 Seal Ring 2 K5B-606
316 Valve Body 1 K5B-944
317 Gasket 1 K5B-275
318 Flange 1 KK5B-276S

Total

Qty

Part

Number

Not available; order

K5C2-X Valve

on page 51

54 MHD56037 - Edition 5

FULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST

(Dwg. MHP2092)

Item

Description

No.

of Part

1 Capscrew 5 51471
113 Hose End 2 51029
115 Hose (bulk) As Req’d 50923
243 Gasket 1 K5B-928
253 Exhaust Cover 1 KK5B-276M
260 Control Valve Assembly 1 K5C2-SBK
321 Fitting, Elbow 4 54270
322 Hose End 4 54738
323 Hose (bulk) As Req’d 54737
819 Fitting, Elbow 1 71018022

Note: To convert live air control to remote live air control refer to “KITS” sectionon page 76.

Total

Qty

Part

Number

MHD56037 - Edition 5 55

REMOTE PILOT AIR CONTROL (OPTIONAL) ASSEMBLY DRAWING

113

113

115

324

To

Brake

324

113

115

343

324

97

96

335

115

340

552

355

324

552

324

115

348

334

333

357

358

Remote Pilot

Lever Throttle

348

Remote Pilot

Pendant Throttle

Old Style

Pendant Throttle

(Dwg. MHP0167)

56 MHD56037 - Edition 5

REMOTE PILOT AIR CONTROL (OPTIONAL) ASSEMBLY PARTS LIST

Item

Description

No.

of Part

96 Lockwasher 4 50200
97 Capscrew 4 51780

Fitting, Hose End – Disc Brake Only 8

113

Fitting, Hose End – Disc and Automatic Drum Brake 10
115 Hose, Bulk As Req’d 50923
248 Gasket (item not illustrated) 1 K5B-547
324 Fitting, Elbow 6 52182
333 Capscrew 4 54681
334 Lockwasher 4 50893
335 Manifold 1 13881
340 Fitting, Connector 1 51814
343 Shuttle Va lve 1
346 Fitting, Connector 2
347 Quick Exhaust Valve Assembly †
348 Fitting, Nipple 3 (6) 71048268
349 Hose Tie (3 for standard hose; 2 additional each 5 feet of hose) As Req’d Order item 352
352 Pendant Assembly* 1 Order item 353
353 Pendant Assembly 1 PHS2E
355 Valve Assembly 1 20993
357 Fitting, Elbow 2 51281
358 Pilot Lever Throttle Assembly 1 71069561
552 Fitting, Tee 2 54977

Total

Qty

Part

Number

51029

Order item

352

* Item 352 Pendant Assembly is no longer available.

† Hose length exceeding 50 feet (16 metres), contact factory.

MHD56037 - Edition 5 57

Pendant without Emergency Stop

445

446

REMOTE PENDANT ASSEMBLY DRAWINGS

440

444

453

447

449

451

455

454

443

452

457

458

448

456

470

(Dwg. MHP2346)

Pendant with Emergency Stop

445

446

444

455

442

443

454

458

457

446

443

440

447

453

443

451

452

448

456

441

449

443

451

452

(Dwg. MHP1677)

58 MHD56037 - Edition 5

REMOTE PENDANT ASSEMBLY PARTS LIST

Item

• 443 ‘O’ Ring 2(5) 58209229

• 449 ‘O’ Ring 2(3) 58235329

Description

No.

of Part

353 Pendant Assembly* 1 PHS2E PHS2E-U
440 Lifting Eye 1 64222332
441 Emergency Stop Valve 1 95790108
442 Plug 1 95790106

444 Plug 2(4) 54292
445 Spring 2(4) 69128541
446 Ball 2(5) 69401625
447 Pin 1 95790040
448 Setscrew 2 42008607

451 Protector 2(3) 95790107
452 Va lve 2(3) 95790104
453 Lever 2 95790122
454 Pendant Handle 1 order item 500
455 Setscrew 3(5) 71078158
456 Label Kit 1 95790111
457 Exhaust Washer 1 95790114
458 Retainer Ring 1 47713030
470 Plug 1 - - - 65129541

To ta l

Qty

With E-Stop Without E-Stop

Part

Number

- - -

* Pendant Assembly includes items 440 to 449 and 451 to 458.

• Recommended spare for one winch, 2 years of normal operation.

MHD56037 - Edition 5 59

PILOT AIR CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST

(Dwg. MHP0141)

Item

Description

No.

of Part

355 Valve Assembly (includes items 265 through 280) 1 20993
265 End Cap 1 71136725
266 Gasket 2 71136733
267 Valve Body 1 Not sold separately, order item 355
268 End Cap Assembly (includes items 270 and 271) 1 25591
269 Capscrew 8 71030118
270 Adjusting Screw 1 53545
271 Nut 2 50176
272 Shoulder Screw 1 54710
273 Guide 1 71136741
274 Spring 1 71136758
275 Washer 1 71136774
276 Spacer 1 71136766
277 ‘O’ Ring (only available in Pilot Air Control Valve Service Kit) 1 Order Kit
278 Valve Sleeve 1
279 Valve Spool 1
280 Washer 1 71332324

Service Kit Part Number

• Pilot Air Control Valve Service Kit (includes items 266 (qty 2) and 277 (qty 6)) 71356406

Total

Qty

Not sold separately, order item 355

Part Number

510 size

• Recommended spare for one winch, 2 years of normal operation.

60 MHD56037 - Edition 5

DRUM LOCKING PIN (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST

OLD STYLE

(Dwg. MHP0155)

Item

Description
No.

of Part

27 inch Standard Flange Drum (old style)

12 inch with band brake

12 inch without band brake 11378–2 16 inch with band brake 14596–3

16 inch with band brake 10860–3 24 inch with band brake 14596–5

80

16 inch without band brake 11378–3 30 inch with band brake 14596–6

24 inch with band brake 10860–5 36 inch with band brake 14596–36

24 inch without band brake 11378–5

30 inch with band brake 10860–6

30 inch without band brake 11378–6

80

135

84

136

137

138

Total

Qty

1

246

140

135

Part

Number

10860–2 12 inch with band brake

Item

No.

80

403

135

404

Description
of Part

35 inch Tall Flange Drum (old style)

For 12, 16, 24, 30 and 36 inch tall flange drums without
band brakes contact factory for information

304

140

138

401

137

136

Total

Qty

84

Part

Number

14596–2

1

Common Parts:

Outboard Upright 137 Spring 1 54453

84

(27 inch Drum flange)

(35 inch Drum flange) 14952 140 Pull Rod 1 16310
135 Pin (Zinc pt.) 2 71001135 246 Grease Fitting 1 53095
136 Lock Pin 1 16328

MHD56037 - Edition 5 61

1

14946 138 Gland 1 16329

DRUM GUARD ASSEMBLY DRAWING AND PARTS LIST

(Dwg. MHP0154)

Item

Description

No.

of Part
Drum Guard Assembly (includes items 3, 96 and 150 through 158)

12 inch long drum
16 inch long drum 10925-3 10927-3

149

24 inch long drum 10925-5 10927-5
30 inch long drum 10925-6 10927-6
36 inch long drum - - - 10927-9

3 Lockwasher 4 50181

96 Lockwasher 6 50200
150 Capscrew 6 71126742
151 Clamp 6 10399
152 Support 2 10934 10931

Drum Guard (12 inch long drum)
Drum Guard (16 inch long drum) 10935-3 10932-3

153

Drum Guard (24 inch long drum) 10935-5 10932-5
Drum Guard (30 inch long drum) 10935-6 10932-6

Drum Guard (36 inch long drum) - - - 10932-8
155 Nut 6 50198
156 Capscrew 4 50973
158 Nut 4 50171

Total

Qty

1

1

Standard Flange Tall Flange

Part Number

10925-2 10927-2

10935-2 10932-2

62 MHD56037 - Edition 5

EMERGENCY STOP VALVE, OVERLOAD ASSEMBLY DRAWING AND PARTS LIST

(old style)

(Dwg. MHP1341)

Item

Description

No.

of Part

96 Washer 2 50200 423 Valve, Shut-off 1 25541
113 Hose End 7 51029 424 Fitting, Nipple 1 52191
115 Hose (bulk) As Req’d 50923 425 Pilot Valve 1 71269039

163 Fitting, Nipple 2 71057483 426 Rotary Housing 1 24492
171 Fitting, Nipple 1 51704 481 Breather 1 50595
257 Capscrew 2 51766 482 Fitting, Elbow 1 71034714
324 Fitting, Elbow 1 52182 483 Fitting, Tee 1 54081
357 Fitting, Elbow 5 51281 484 Fitting, Elbow 9 52179
412 Washer 2 50177 485 Fitting, Pipe 1 71273676
413 Nut 2 50170 486 Muffler 1 52472
414 Brac ket , Overl o ad 1 24491 487 Fitting, Connector 7 71078158
417 Capscrew 2 51079 488 Fitting, Swivel-Tee 1 71067789
418 Emergency Stop Valve 1 35790066 489 Capscrew 2 50848
419 Bracket, E-Stop 1 24490 491 Valve, Delta P 1 36360002
421 Nut 2 53541 492 Fitting, Pipe 1 71149355
422 Washer 2 51676 535 Pipe Bushing 1 51706

MHD56037 - Edition 5 63

Total

Qty

Part

Number

Item

No.

Description
of Part

Total

Qty

Part

Number

(old style)

PENDANT CONTROL ASSEMBLY DRAWING AND PARTS LIST

(Dwg. MHP0168)

Item

Description

No.

of Part

348 Fitting, Adapter 3 71048268
352 Pendant Assembly (includes items 370–381 and 383) 1 No longer available

370 Pendant Handle (only available as part of assembly item 352) 1
371 Throttle Valve 2 MLK-K264B

372 Throttle Valve Face 2 R000BR1C-283
373 Spring 2 MKL-51A
374 Throttle Valve Cap 2 MLK-266A
375 Valve Cap Gasket 2 MLK-504
376 Lever 2 MLK-273
377 Throttle Lever Pin 1 DLC-120A
378 Pin Lock Washer 2 D02-138
379 Support 1 MLK-450
380 Lockwasher 2 H54U-352-10
381 Handle Screw 4 HRE20A-68
383 Pipe Plug 1 54247

64 MHD56037 - Edition 5

Total

Qty

Part

Number

Order item 353

on page 59

SERVICE NOTES

MHD56037 - Edition 5 65

EMERGENCY STOP OVERLOAD ASSEMBLY DRAWING

(Dwg. MHP1488)

66 MHD56037 - Edition 5

EMERGENCY STOP OVERLOAD ASSEMBLY PARTS LIST

Item

Description

No.

of Part

26 Fitting, Tee 1 52181 486 Muffler 1 52472
113 Hose End 26 51029 487 Fitting, Connector 1 71078158
115 Hose (bulk) As Req’d 50923 488 Fitting, Tee 2 71067789

163 Fitting, Nipple 1 71057483 491 Delta ‘P’ Valve 1 36360002
171 Fitting, Nipple 1 51704 515 Fitting, Elbow 3 71327316
325 Fitting, Elbow 2 52182 529 Bracket 1 26148
341 Hose Assembly 1 17073-6 531 Capscrew 2 71327324
346 Fitting, Connector 4 71048284 535 Pipe Bushing 1 51706
347 Valve, Exhaust * 4 20417 537 Fitting, Elbow 1 54237
348 Fitting, Connector 12 71048268 543 Capscrew 2 54240
357 Fitting, Elbow 2 51281 548 Fitting, Connector 1 54679
382 Fitting, Connector 2 52092 605 Plug 1 50860
423 Shut Off Valve 1 25541 616 Fitting, Tee 1 K6U-926
425 Pi lot Valve 1 71269039 618 Valve 1 54672
481 Breather 1 50595 620 Fitting, Elbow 1 71063473
482 Fitting, Elbow 1 71034714 621 Fitting, Connector 1 71110894
484 Fitting, Elbow 5 52179 625 Breather 1 51559
485 Fitting, Elbow 1 71273676 640 Pendant Assembly 1 PHS2E-U

Total

Qty

Part

Number

Item

No.

Description
of Part

Total

Qty

Part

Number

* Must be installed at 20 foot (6 metre) intervals. Part number 20417 (item 347) includes items 113 (quantity 2), 346 and 348.

MHD56037 - Edition 5 67

LIMIT SWITCH ASSEMBLY DRAWING

(Dwg. MHP2027)

68 MHD56037 - Edition 5

(

LIMIT SWITCH ASSEMBLY PARTS LIST

Item

Description

No.

of Part

93 Capscrew 3 51086

96 Lockwasher 6 50200

97 Capscrew 6 51780

115 Hose As Req’d 50923
357 Fitting, Elbow 4 51281
484 Fitting, Elbow 7 52179
501 Retainer (replaces Retainer, item 191, on standard winch) 1 11485
502 Washer 8 71372114
503 Buttonhead Screw 2 71393409
504 Bracket, Limit Switch 1 29102
505 Lockwasher 4 52909
506 Nut 4 54142
507 Coupling Assembly 1 52381

Limit Switch Assembly 357:1 (includes items 534, 536, 538 and 539)*

508

Limit Switch Assembly 120:1 (includes items 534, 536, 538 and 539)* 71402101

Limit Switch Assembly 20:1 (includes items 534, 536, 538 and 539)* 27306-3
509 Capscrew 4 71062475
511 Plate 2 2688
512 Capscrew 8 71365126
513 Block, Tall 1 27312
514 Block, Short 1 27311
516 Capscrew 2 53869
519 Valve 2 213-C
522 Access Plate 1 3394-B
523 Lockwasher 2 51801
524 Capscrew 2 71007009
527 Washer 2 50182
528 Plug 1 71027494
532 Breather 2 51559
533 Fitting, Tee 1 53940
534 Lever Assembly 2
536 Gasket 1
538 Capscrew 4
539 Cover Plate 1
546 Seal 1 52382

Total

Qty

1

Number

71402119

Order item 508

Part

* Dash numbers 1, 2 and 3 indicate ratio for limit switch.

MHD56037 - Edition 5 69

PILOT AIR VALVE PLUMBING ASSEMBLY DRAWING

Note:

This drawing is for Pilot Air Va lve Assembly with Limit Switch. For Remote Pilot Air installation refer to Dwg. MHP0167 on page 56.

(Dwg. MHP1679)

70 MHD56037 - Edition 5

PILOT AIR VALVE PLUMBING ASSEMBLY PARTS LIST

Item

Description
No.

of Part

96 Washer 4 50200

97 Capscrew 4 51780
113 Fitting, Hose End 5 51029
115 Hose (bulk) As Req’d 50923
269 Capscrew 2 71030118
324 Fitting, Elbow 2 52182
333 Capscrew 4 54681
334 Washer 4 50893
335 Adapter Manifold 1 13881
339 Fitting, Tee 2 54678
340 Fitting, Connector 2 51814
341 Tube Assembly 1 17073-6
343 Valve , Shuttle 1 50277
348 Fitting 1 71048268
355 Valve Assembly 1 20993
358 Throttle Valve Assembly 1 71069561
360 Nut 3 54567
382 Fitting, Connector 2 52092
482 Fitting, Elbow 2 71034714
484 Fitting, Elbow 1 52179
525 Valve 2 51756

Fitting, Elbow (Remote Control Va lve) 5 71098545

526

Fitting, Elbow (Pendant Control) 3 71062889
537 Fitting, Elbow 1 54273
548 Fitting, Nipple 2 54679
551 Fitting, Connector 2 54274
552 Fitting, Tee 1 54977
554 Capscrew 3 71002968
555 Bracket 1 20231
558 Washer 6 54785

Total

Qty

Part

Number

MHD56037 - Edition 5 71

TENSIONING MANIFOLD ASSEMBLY DRAWING

(Dwg. MHP2028)

72 MHD56037 - Edition 5

TENSIONING MANIFOLD ASSEMBLY PARTS LIST

Item

Description

No.

of Part

113 Fitting, Hose End 3 51029

115 Hose (bulk) As Req’d 50923
248 Gasket 2 K5B-547
260 Control Valve Assembly 1 K5B-REMOTE
343 Shuttle Valve 1 50277
701 Washer 4 71320964
702 Capscrew 4 71127054
703 Rivet 6 50915
704 Label, Tensioning Manifold 1 26217
705 Gasket 1 26216
706 Cover 1 26215
707 Fitting, Elbow 2 54869
708 Fitting, Elbow 5 52803
709 Fitting, Elbow 6 54243

711 Capscrew 3 71319073
712 Handle Ball 1 71138051
713 Valve 1 71316434
714 Plug 2 71069017
715 Fitting, Elbow 1 51001
716 Spacer 3 14998-8B
717 Handle 1 26149
718 Hose (bulk) As Req’d 51003
719 Fitting, Hose End 4 51002
721 Washer 4 51581
725 Fitting, Bushing 1 51705
726 Fitting, Nipple 2 71308258
727 Fitting, Elbow 1 50928
728 Fitting, Nipple 2 50933
729 Manifold, Control Valve 1 25874
732 Union 1 71328330
733 Fitting, Nipple 1 71328314
734 Check Valve 1 71320915
735 Fitting, Nipple 1 71328249
736 Washer 4 51607
737 Capscrew 4 71320949
738 Nut 3 71069132
739 Bracket 1 26095
741 Fitting, Nipple 1 71320907
742 Fitting, Elbow 1 26057
743 Regulator and Gauge * 1 71325047
744 Fitting, Connector 1 54943
745 Fitting, Tube Extension 1 71325591
746 Fitting, Elbow 1 71149975
753 Capscrew 4 71328199

Total

Qty

Part

Number

* Items not sold separately.

MHD56037 - Edition 5 73

AIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST

(Dwg. MHP0223)

Note: Drawing for reference only; components may not resemble those shown in drawing.

Item

Description

No.

of Part

575 Filter (1–1/2 FNPT) 1 F35-0B-C28
577 Regulator (1–1/2 FNPT) 1 R40-0B-G00
578 Pipe Nipple (1-1/2 FNPT*) As Req’d --­580 Lubricator (1–1/2 FNPT) 1 L40-0B-G00

** Liquidator (2 FNPT) 1 8834-W1-000

Air preparation components for 1-1/2 inch FNPT system.

*

Length as required for installation.

**

Item not illustrated.

Total

Qty

Part

Number

ACCESSORIES

Description of Accessory Accessory Part Number

Lubricant LUBRI-LINK-GREEN®

74 MHD56037 - Edition 5

LABELS AND TAGS

(Dwg. MHP1676)

Item

Description

No.

of Part

Label and Tag Kit *

650

Label and Tag Kit -E *

88 Nameplate 1

89 Drive Screw 4 71028849 658 Control Valve Operation -E 1 96180102

Winding Label

651

Winding Label -E 96180103 661 Warning Label (Only Non -E) 1 71107130
IR Logo Label 12-16 in. long

drum

652

IR Logo Label 24 in. and longer
drum

653 Label General -E 1 71153464

* Kits depend on drum length. Numbers ending in -4 are for drums 12-16 inches long. Numbers ending in -5 are for drums 24 in ches

or longer. -E kits contain all labels, EXCEPT item 661.

Total

Qty

1

2

1

Part

Number

22261-4-S
22261-5-S
24305-4-S

24305-5-S Warning Label -E 96180100

Contact Fac-

tory

71109516 659 Air Supply Label 1 71046395

71106272 662 Check Oil Level Label 1 71107148

71109102 663 Underwound Direction Label 1 71110068

Item

Description

No.

of Part

Product Label 12-16 in. long drum

654

Product Label 24 in. and longer
drum

Warning Label

655
656 Oil Level Label 1 71043616

657 Exhaust Label 1 71042196

Total

Qty

1

1

Part

Number

71111777
71109508
71060529

MHD56037 - Edition 5 75

KITS

Description
of Kit

Automatic Brake Kit (converts manual band brake to automatic band brake). Refer to Dwg. MHP0153on
page 48; includes items 102, 105 through 115, 117 through 120, 129 and 134.

Disc Brake Kit (adds disc brake to winch). Refer to Dwgs. MHP0152on page 46 and MHP0157on page 40;
includes items 1, 7–12, 16–32, 34–38)

Full Flow Remote Control Kit (converts winch live air control valve to remote control)
Refer to Dwgs. MHP2092on page 55 and MHP0165on page 54; includes items 113, 115, 253, 318, and 321–324.

with 10 feet (3.05 metres) hose 19999-1S
with 20 feet (6.1 metres) hose 19999-2S

Pendant Control Kit (converts winch live air control to pendant control). Refer to Dwg. MHP0167on page 56; includes all items, except
348, 357 and 358.

with 10 feet (3.05 metres) pendant hose FA-PRC
with 20 feet (6.1 metres) pendant hose FA-PRC-20
with 30 feet (9.15 metres) pendant hose FA-PRC-30
with 40 feet (12.1 metres) pendant hose FA-PRC-40

Limit Switch Kit (adds limit and controls to winch) Refer to Dwgs. MHP1679on page 70 and MHP2027on
page 68.

K5C2-X and K5C2-EX Control Valve Service Kits

Item

Kit Description

No.

• 780 K5C2 Control Valve Service Kit (includes items 904, 907, 918, 921, 923, 941, 942 and 946) 1 27240

930 Handle Assembly Kit (includes items 901, 902, 930 through 935) 1 27239

784 Reverse Valve Kit (includes items 943 and 956) 1 27925-SX

• 786 Overload Valve Service Kit † 1 27995-X

• 788 Emergency Stop Service Kit*† 1 27994-X

789 Emergency Stop Kit (Optional Feature)*† 1 28026

910 Pilot Valve Assembly Kit 28696

922 Piston Kit 1 28735-S

939 Seal Bracket Kit (includes items 901, 902, 924, 925, 935, 937-939, 941 and 942 1 28733-S

To ta l

Qty

Part

Number

FA5-ABK

FA5-DBRK

FA5-LSK

Part

Number

• Recommend spare for one winch, two years of normal service.

* Kits can be installed to new style control valve.

†

76 MHD56037 - Edition 5

Items not illustrated

PARTS ORDERING INFORMATION

NOTICE

Use of other than Ingersoll Rand replacement parts may
adversely affect the safe operation and performance of this
product.

For your convenience and future reference it is recommended that
the following information be recorded.

Model Number _______________________________________

Serial Number ________________________________________

Date Purchased _______________________________________

When ordering replacement parts, please specify the following:

1. Complete model number and serial number as it appears on
the nameplate.

2. Part number(s) and part description as shown in this manual.

3. Quantity required.

The nameplate is located on the winch outboard upright.

• Continuing improvement and advancement of design may

cause changes to this equipment which are not included in this
manual. Manuals are periodically revised to incorporate
changes. Always check the manual edition number on the
front cover for the latest issue.

• Sections of this manual may not apply to your winch.

• The use of other than genuine Ingersoll Rand r eplacement

parts may result in safety hazards, decreased performance
and increased maintenance and invalidate all warranties.

Return Goods Policy

Ingersoll Rand will not accept any returned goods for warranty

or service work unless prior arrangements have been made and
written authorization has been provided from the location where
the goods were purchased.

Winches which have been modified without Ingersoll Rand
approval, mishandled or overloaded will not be repaired or
replaced under warranty. A printed copy of the warranty which
applies to this winch is provided inside the back cover of this
manual.

Disposal

When the life of the unit has expired, it is recommended that it be
disassembled, degreased and parts separated as to materials so
that they may be recycled.

For additional information contact:

Ingersoll Rand

2724 Sixth Avenue South
Seattle, WA 98134 USA
Phone: [phone]
Fax: [phone]

or

Ingersoll Rand
Douai Operations

529, Avenue Roger Salengro
59450 Sin Le Noble, France
Phone: [phone]
Fax: [phone]

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SERVICE NOTES

78 MHD56037 - Edition 5

WARRANTY

LIMITED WARRANTY

Ingersoll Rand Company (I-R) warrants to the original user its
Hoists and Winches (Products) to be free of defects in material
and workmanship for a period of one year from the date of
purchase. I-R will repair, without cost, any Product found to be
defective, including parts and labor charges, or at its option, will
replace such Products or refund the purchase price less a
reasonable allowance for depreciation, in exchange for the
Product. Repairs or replacements are warranted for the remainder
of the original warranty period.

If any Product proves defective within its original one year
warranty period, it should be returned to any Authorized Hoist
and Winch Service Distributor, tr ansportation prepaid with proof
of purchase or warranty card.

This warranty does not apply to Products which I-R has
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.

This shipment has been thoroughly checked, packed and
inspected before leaving our plant and receipt for it in good
condition has been received from the carrier. Any loss or damage
which occurs to this shipment while enroute is not due to any
action or conduct of the manufacturer.

Visible Loss or Damage

If any of the goods called for on the bill of lading or express
receipt are damaged or the quantity is short, do not accept them
until the freight or express agent makes an appropriate notation on
your freight bill or express receipt.

I-R makes no other warranty, and all implied warranties
including any warranty of merchantability or fitness for a
particular purpose are limited to the duration of the
expressed warranty period as set forth above. I-R’s maximum
liability is limited to the purchase price of the Product and in
no event shall I-R be liable for any consequential, indirec t,
incidental, or special damages of any nature rising from the
sale or use of the Product, whether based on contract, tort, or
otherwise.

Note: Some states do not allow limitations on incidental or
consequential damages or how long an implied warranty lasts so
that the above limitations may not apply to you.

This warranty gives you specific legal rights and you may also
have other rights which may vary from state to state.

Damage Claims

You must file claims for damage with the carrier. It is the
transportation company’s responsibility to reimburse you for
repair or replacement of goods damaged in shipment. Claims for
loss or damage in shipment must not be deducted from the

Ingersoll

invoice be withheld awaiting adjustment of such claims as the
carrier guarantees safe delivery.

You may return products damaged in shipment to us for repair,
which services will be for your account and form your basis for
claim against the carrier.

Rand invoice, nor should payment of Ingersoll Rand

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.

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