4. Install cover (117) and close brake cylinder assembly with capscrews (302) and
lockwashers (73). Before closing the brake cylinder, fill the spring housing with
about 1 oz. (25 ml) of SP 150 type oil.
Brake Band:
1. Thread nut (148) onto adjustment screw (149), then install adjustment screw
(149) in brake cylinder assembly.
2. Install the brake cylinder assembly with capscrews (156) and lockwashers (64)
on the siderail (68).
3. Install band brake (111) on drum (60). Anchor brake band ends to adjustment
screw (149) and piston (146) with pins (112) and cotter pins (113). Bend ends of
cotter pins apart.
4. Install locknut (151) and washer (150) on adjustment screw (149).
5. Adjust brake band assembly. Refer to ‘Adjustments’ section on page 7.
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Limit Switches Assembly
Refer to Dwg. MHP2730.
1. Install limit switch adapter (450) on drum end cover (78). Secure with capscrews
(98) and lockwashers (73).
2. Install spindle switch assembly (501) on limit switch adapter (450). Secure with
capscrews (499).
3. Install one gasket (490) on each end of housing (486).
4. Thread one nut (73) and washer (73) on each rod (502). Install four rods in limit
switch adapter (450) and tighten nut (73). Ensure full thread engagement of rod
in limit switch adapter.
5. Install housing (486) and housing cover (505). Position housing with cap
assembly (498) hole on top. Align housing cover holes with rods.
6. Install nuts (504) on rods (502) to secure housing and housing cover.
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Slack Line Device Assembly
Refer to Dwg. MHP2732.
1. Assemble valve support (325) to sensor valve (327) with capscrews (318).
2. Assemble protector (322) to valve support (325) with capscrews (22) and washers
(23).
3. Assemble protector (323) and valve support (325) to upright (62) with capscrews
(324) and lockwashers (2).
4. Install bearings (309) on the shoulder screws (310).
5. Assemble arms (303), rollers (306) and axles (304) and (305). Install nuts (301)
and lockwashers (73) on roller axle (305) to secure.
6. Install capscrews (302) and lockwashers (73) on axle (304).
7. Install spacers (308) and slack wire arm assembly. Tap shoulder screws (310) into
uprights (62).
8. Install nuts (301) and washers (307) on shoulder screws (310).
9. Reconnect hoses.
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Press Roller Assembly
Refer to Dwgs. MHP2728 and MHP2731.
1. Install press rollers (184) between roller arms (181) and secure with capscrews
(161) and washers (162).
2. Install frames (176) and springs (169) on roller arms (181). Secure with capscrews
(161) and washers (162).
3. Install press roller assembly in spacer (404). Secure with capscrews (183) and
lockwashers (73).
4. Compress ends of springs (167) and (169) to engage with spacer (66) and pin on
press roller arm (163).
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Filter, Lubricator and Regulator Assembly
Refer to Dwg. MHP3100.
Horizontal Take-off Angle:
1.
Install FRL assembly (400) to bracket (401) with capscrews (402), washers (404)
and locknut (403).
2. Install bracket (401) to spacer (66) on press roller side of winch.
3. install hose connections and three way shut-off valve (407).
Vertical Take-off Angle:
1. Install FLR assembly (400) to spacer (66), opposite press roller side, with bracket
(418) and secure with capscrews (420) and washers (419).
2. Install hose connections and three way shut-off valve (407).
NOTICE
•
Run winch in both directions with no load to ensure proper connections
and no air leaks.
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Drum Guard Assembly
Refer to Dwg. MHP2817.
NOTICE
•
Install drum guard for proper take-off angle, refer to data (name) plate for
model.
1. Install drum guard (216) and both side panel guards and secure with capscrew
(161).
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2 Function Emergency Stop Pendant Assembly (optional)
Refer to Dwg. MHP2818.
1. Install ‘O’ rings (166) and protector (170) on valves (165). Install valve assemblies
in handle (514)
2. Install levers (503) in pendant handle (514) with pin (502). Stake pin in pendant
handle at both ends to secure.
3. Install screws (504) in levers.
4. Install screws (173) in handle.
5. Install balls (84) and springs (177) in handle (514). Secure in position with plugs
(518).
6. On pendants with emergency stop, install emergency stop button (164).
7. On pendants without emergency stop button, install plug (507).
8. Install exhaust washer (41) and secure in handle with retainer ring (512).
Adjustment:
1. a. Connect the inlet of the pendant to 100 psi (7 bar) air supply.
b. Connect a manometer at the outlet of the lever to be adjusted.
c. Apply a small amount of Loctite® No. 243 on the adjustment screw (521).
d. Tighten the adjustment setscrew to obtain a pressure of 15 psi (1 bar) without
actioning the lever.
e. Release the adjustment setscrew by a half turn (pressure must fall to zero).
f. Push the lever. Check that pressure reaches 93 +/-7 psi (6.5 +/- 0.5 bar). Check
that there is no leak at the exhaust.
g. Release the lever; exhaust must occur and result in rapid pressure reduction.
h. Repeat operations ‘f’ and ‘g’ 2 to 3 times.
i. Disconnect the manometer. Check to ensure that there are no leaks when
the lever is not activated.
j. Repeat the operations from ‘b’ to ‘i’ with each lever.
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Testing
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Operational Tests
Prior to initial use, winches shall be tested to ensure proper operation.
1. Check guards are installed and secure.
2. Check all winch mounting bolts are secure.
3. Operate winch in both directions with no load.
4. Check operation of brakes and emergency stop.
5. Check operation of limit switches, slack line device, press roller and other safety
devices when provided.
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Load Test
Prior to initial use, all new, extensively repaired, or altered winches shall be load
tested by or under the direction of an Ingersoll Rand trained technician and a
written report furnished confirming the rating of the 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:
NOTICE
•
Testing to more than 125% of rated line pull may be required to comply
with standards and regulations set forth in areas outside of the USA.
12
Form MHD56305 Edition 4
