Ingersoll-Rand Force 5i Series Guida all'installazione

Product Maintenance

Information

FORCE 5i Hydraulic Winch

Model

FH5i-DCOKER

Save These Instructions

Form MHD56375

Edition 2

May 2012

43808922

OnlyallowIngersoll Rand trainedtechnicianstoperformmaintenanceonthisproduct.ForadditionalinformationcontactIngersollRand factoryornearest

Distributor.

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

Manuals can be downloaded from http://www.ingersollrandproducts.com.

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

warranties.

Original instructions are in English. Other languages are a translation of the original instructions.

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

Table 1: Product Information Manuals

Publication Part/DocumentNumber Publication Part/Document

Number

Product Safety Manual (Non-Man Rider) MHD56250 Product Parts Information Manual MHD56374

Product Information Manual MHD56373

INSPECTION

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

to Product Information Manual.

Some options may not apply to your product, refer to data (name) plate for correct

model and any applicable manuals.

nPeriodic Inspection

Refer to Table 2 ‘Inspection Classifications’ on page 2 for suggested winch

inspection classifications for Periodic Inspection intervals. Select conditions most

appropriate to application.

Table 2: Inspection Classifications

Conditions Normal Heavy Severe

Typical Use (operating time) Infrequent Regular Continual/Constant

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

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

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

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

Maintain written records of periodic inspections to provide an accumulative basis

forcontinuingevaluation. Inspectallitems listedinthe ‘FrequentInspection’section

of the Product Information Manual. Also inspect the following at the suggested

intervals recommended in Table 3 ‘Decoking Winch Maintenance Interval Chart’

on page 3:

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

components. Replace damaged parts.

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

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

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

4. Wire Rope. In addition to ‘Frequent Inspection’ requirements, also inspect for

the following:

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

remove dirt and corrosion if necessary.

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

c. Check wire rope anchor is secure in drum.

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

crown-to-crownthroughoutthe lifeofthe wirerope.Recording of theactual

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

and in the same operating section as accomplished during previous

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

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

conducted by an experienced inspector to determine the suitability of the

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

(Dwg. MHP0056)

5. AllComponents. Inspect forwear,damage, distortion,deformation,cracks, 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%ratedload at mid drum without slipping. If indicated by poor

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

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

components as necessary. Adjustments can be made to the band brake to

compensate for normal brake lining wear. Refer to ‘’ on page 6. If band brake

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

Adjustments cannot be made to the disc brake. The disc brake must be repaired

as described in “MAINTENANCE” on page 6.

WARNING

• Replace band brakes that are worn or have metal to metal contact. Worn

or improperly functioning brakes may cause excessive heat build-up or

cause sparks.

7. FoundationorSupportingStructure.Checkfordistortion,wearandcontinued

abilitytosupportwinch and rated load. Ensurewinchisfirmly mounted and that

fasteners are in good condition and tight.

8. Guarding. Verify fasteners are tight and in good condition. Ensure guard is in

good condition and panels are correctly positioned.

9. Press Roller. Inspect rollers for wear and grooves. Ensure rollers freely rotate.

Replace rollers if worn or grooved. Replace bearings if rotation is rough or stiff.

10. Labelsand Tags.Checkfor presence andlegibilityof labels. Replaceifdamaged

or missing.

nRecords and Reports

Inspection records, listing all points requiring periodic inspection should be

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

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

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

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

available for review.

nMaintenance Intervals

Refer to Table 3 ‘Decoking Winch Maintenance Interval Chart’ on page 3 for

recommended maintenance schedule.

NOTICE

• Perform an annual winch load test for all applications.

•The decoking application is considered severe conditions. The interval

chart is intended for that specific application.

2 Form MHD56375 Edition 2

Table 3: Decoking Winch Maintenance Interval Chart

The following work can be completed by owner maintenance personnel

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

Grease Fittings Lubricate grease fittings every 90 days or 250 hours

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

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

Standard Components 1 year or

1,000 hrs 2 years or

2,000 hrs 3 years or

3,000 hrs 4 years or

4,000 hrs 5 years or

5,000 hrs 6 years or

6,000 hrs

Inspect Motor X X

Inspect Manual Band Brake X X X X X X

Inspect Disc Brake X X

Inspect Gearbox X X

Replace Winch Anchor Bolts X X

Rebuild Control Valve X X

Inspect Drum, Housings and Main Frames XXXXXX

Optional Components

Emergency Shut-Off Valve X X X X X X

Limit Switches X X X X X X

Automatic Band Brake * X X X X X X

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

NOTE: Hours are for actual winch drum rotation.

Recommend complete general overhaul.

Form MHD56375 Edition 2 3

INSPECTION REPORT

Ingersoll Rand Force 5 Infinity Series Model FH5i-DCOKR Hydraulic Winch

Model Number: Date:

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection:

(_____ Months _____ Years) Operating Environment:

Normal ____ Heavy____ Severe ____

2. Discrepancy(s) noted during Frequent Inspection

3. Discrepancy(s) noted during maintenance

4. Other: ___________________________

Refer to the Product Information Manual and Product Parts Information Manual and “INSPECTION” section for general inspection criteria. Also, refer to appropriate National

Standards and Codes of practice. If in doubt about an existing condition, contact the nearest Ingersoll Rand Distributor or the factory for technical assistance.

COMPONENT CONDITION CORRECTIVE ACTION NOTES

Pass Fail Repair Replace

Uprights and Siderails

Drum Band Brake (125% Load Test)

Disc Brake (125% Load Test)

DrumBandBrake(Visual Inspection)

Disc Brake (Visual Inspection)

Motor

Controls

Hydrualic System

Fasteners

Reduction Gears

Labels and Tags ---

Shafts

Winch Guard

Wire Rope Wedge ---

Press Roller

Wire Rope ---

Drum Locking Pin ---

Other Components (list in NOTES

section)

TESTING Pass Fail NOTES

Operational (No Load)

Operational (10% Load)

Operational (Maximum Test Load*)

*Maximumtestloadis 125% of rated linepull.Testingto more than 125%ofratedload may be required tosetoverloaddevice or comply withstandardsandregulations

set forth in areas outside the USA.

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

4 Form MHD56375 Edition 2

TROUBLESHOOTING

This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by personnel

instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common winch symptoms, probable causes and remedies.

SYMPTOM CAUSE REMEDY

Winch will not operate. Insufficient oil supply. Verify oil supply pressure and volume at winch inlet meets the requirements listed

in the “SPECIFICATIONS” section in Product Information Manual. Clean oil filter.

Winch is overloaded. Reduce load to within rated capacity.

Disc brake does not release. Pressurize disc brake release port and check for excessive leakage from the case

drain port. If excessive leakage is noted disassemble and repair motor as

recommended by the motor manufacturer.

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

Drum brake does not release. Disengage manual band brake, or refer to on page 6.

Motor may be damaged. Remove and disassemble motor as recommended by the motor manufacturer.

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

System relief valves set too low. Adjustsystemreliefvalvestomeetstherequirementslistedinthe“SPECIFICATIONS”

section in Product Information Manual.

Load continues to move when winch is

stopped. Brake is slipping. Checkbrake bandliningwear.Checkbrakefrictiondiscwear.Refer to“Adjustments”

on page 6

Winch is overloaded. Reduce load to within rated capacity.

Control valve may not be correct type. The

correct control valve should have all ports

open to reservoir when the spool is in the

neutral position.

If the motor ports in the valve are blocked by the spool (closed center) when the

control valve is in the neutral position, remove valve and replace with correct

tandem center (A & B to tank) or float center motor spool (P, A & B to tank) valve.

There is excessive back pressure acting on

the reverse port of the winch motor and disc

brake charge port.

Install pressure gauges in motor lines. Run the pump at its maximum RPM and, with

the control valve in the neutral position, read the pressure gauges. Pressure greater

than 140 psig (9.6 bar/9.8 kg/cm²) is too high. Check hose and control valve size.

Replace if necessary.

Winch does not lift load or does not lift

rated capacity. Winch does not lift/pull

load.

Motor may be damaged. Remove and disassemble motor as described in “MAINTENANCE” on page 6.

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

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

in the “SPECIFICATIONS” section in Product Information Manual. Clean oil filter.

No oil supply to winch. Check oil supply line connections, hoses and valves.

Winch is overloaded. Reduce load to within rated capacity.

System not delivering full pressure to winch. Confirm pump is running and on stroke. Check up-line flow controls are set as

required to run the winch.

Relief valve dumps full pressure. Confirm no down-line restrictions of valves are blocking free flow back to tank.

Relief valve set too low. Install pressure gauges in motor lines and apply a stall pull on the winch. If pressure

is low, increase relief valve setting until recommended pressure is obtained.

Oillevelinreservoirtoolow.Suctionline may

be restricted or have an air leak causing

cavitation at the inlet pump. ‘Whining’ noise

at pump is an indication of this problem.

Check oil level in reservoir. Check suction line externally and internally for damage.

Replace suction line if damaged. If cavitation has occurred, it is recommended that

the pump be disassembled and inspected for worn, pitted and damaged parts.

Repair and replace parts as necessary.

Relief valve is partially open. Remove relief valve and visually inspect and repair or replace worn or damaged

parts.Cleanall partsthoroughlyin a suitablesolvent. Reassemble, reinstallandreset

relief valve pressure setting.

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

Motor does not run smoothly, runs hot or

makes excessive noise during operation. Air entering hydraulic system. Check hoses and hose connections.

Incorrect oil type. Replace oil with type recommended in “LUBRICATION” section in Product

Information Manual.

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

may cause restricted line flow. Inspect filter.

Motor may be damaged. Remove and disassemble motor as recommended by the motor manufacturer.

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

Brake(s) not releasing. Refer to brakes in “MAINTENANCE” on page 6.

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

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

Hydraulic oil may be cold. Run hydraulic pump to warm and circulate oil through system.

Control valve lever hard to actuate, or lever

does not spring return to neutral. Valve spool sticking. Remove and disassemble control valve. Repair control valve as recommended by

the valve manufacturer.

Automatic Band Brake:

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

Damaged cylinder seals. Replace or repair cylinder.

Restricted return valve. Check return valve.

Automatic Disc Brake:

Brake fails to release. Low oil supply pressure. Ensure the oil pressure at the inlet to the disc brake is at least 300 psig (2069 kPa/

20.7 bar).

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

brake, replace brake seals.

No release pressure at brake port. Check line between manifold and brake.

Sticking brake piston. Apply 155 psig (1100 kPa/11 bar) to the brake release port and check for brake disc

movement. If brake discs do not move, disassemble and inspect the disc brake as

described in the manufacturer’s literature.

Form MHD56375 Edition 2 5

MAINTENANCE

WARNING

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

•Before performing maintenance, tag controls: WARNING - DO NOT

OPERATE-EQUIPMENT BEING REPAIRED

• Only allow Ingersoll Rand trained Service Technicians to perform

maintenance on this winch.

•After performing any maintenance on the winch, test winch to 125% of its

rated line pull at mid drum before returning to service. (Testing to more

than125%ofratedlinepullmay be required to comply with standards and

regulations set forth in areas outside the USA.)

• Shut off hydraulic system and depressurize lines before performing any

maintenance.

• Do not use Trichloroethylene to clean parts.

• Use of other than genuine Ingersoll Rand parts may result in a hazard,

decreased performance, and increased maintenance and may void all

warranties.

nGeneral

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

testing and adjusting are critical to proper winch operation. Maintenance

procedures are technical in nature and require training and experience to

accomplish correctly. In addition, repair and testing require specialized equipment

that is not typically found at the winch-mounting site.

Proper use, inspections and maintenance increase the life and usefulness of your

Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and

all machined threads with applicable lubricants. Use of antiseize compound and/or

thread lubricant on capscrew and nut threaded areas prevents corrosion and allows

for easy disassembly of components.

It is extremely important that anyone involved with maintaining the winch be

familiar with the servicing procedures of these winches and be physically capable

of conducting the procedures. These personnel shall have skills that include:

1. Proper and safe use and application of mechanics’ common hand tools as well

as special Ingersoll Rand or recommended tools.

2. Safety procedures, precautions and work habits established by accepted

industry standards.

Ingersoll Rand cannot know of, or provide all the procedures by which product

operations or repairs may be conducted and the hazards and/or results of each

method. If operation or maintenance procedures not specifically recommended by

the manufacturer are conducted, it must be ensured that product safety is not

endangered by the actions taken. If unsure of an operation or maintenance

procedure or step, personnel should place the product in a safe condition and

contact supervisors and/or the factory for technical assistance.

NOTICE

• Refer to the Product Parts Information Manual for drawings unless

specified elsewhere.

nMaintenance Intervals

Refer to Table 3 ‘Decoking Winch Maintenance Interval Chart’ on page 3 for

recommended maintenance schedule.

NOTICE

• Perform an annual winch load test for all applications.

•The decoking application is considered severe conditions. The interval

chart is intended for that specific application.

nAdjustments

nGuarding

Refer to Dwg. MHP2676.

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

procedures in Product Information Manual.

nDisc Brake

Refer to Dwg. MHP2674.

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

disassemble and repair.

If brake assembly is removed or disassembled, ensure breather (29) is installed and

located at top of brake housing during reassembly.

nManual Band Brake

Refer to Dwg. MHP2694.

1. Release wire rope tension on drum.

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

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

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

5. Install pin (101) and check adjustment.

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

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

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

over.

CAUTION

•Whenanypartofbrakeliningmeasures0.062in.(2mm)orless,brakebands

(128) or linings must be replaced.

nAutomatic Band Brake

Refer to Dwg. MHP2694.

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

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

brake lever (105).

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

clevis counterclockwise to decrease cylinder rod extension.

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

pressure to brake cylinder (110).

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

Re-adjust if necessary.

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

complete. Bend ends of cotter pin over.

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

nHydraulic System General Maintenance

Hydraulic systems operate efficiently when properly maintained. The following

information should be developed into a routine maintenance procedure to ensure

the hydraulic system and components operate efficiently.

nHydraulic Motor

Inspect as recommended per motor manufacturer’s literature. Establish a schedule

as part of an overall maintenance schedule.

nReservoir

Maintain fluid level at all times. The fluid should be checked after the first 10 hours

of initial operation. If satisfactory, routine checks should be made each 100 hours of

operation to verify that the fluid (class and type) meets the requirements of the

pump.Changefluid every 1000to2000hours of operationdependingupon severity

of application and operating environment. If manufacturer’s requirements

recommend fluid changes sooner, follow those recommendations.

nSpare Parts

Spare filter elements should be available to allow filter replacement as necessary to

maintain a clean hydraulic oil supply. Other spare parts (hoses, fittings, etc.) should

also be available to limit equipment downtime in the event that repairs are

necessary.

nCleanliness

Keep equipment clean. A thick layer of dirt acts as insulation, causing the hydraulic

system to retain heat resulting in higher operating temperatures. If the system is

opened for inspection or repair, a clean work area prevents foreign contaminants

from entering the system and damaging component internal parts.

nFilter Maintenance

Filters must be maintained. The key to good filtration is effective filter

maintenance. Check filter condition frequently.

Keep a record of how often filters need replacing and use this record to establish a

service schedule. Routinely replacing the filter before it affects operation of the

winch reduces unexpected downtime and potential wear. A system may be

equipped with the best filters available, and the filters positioned properly so they

candothe most good,but,if the filters arenotreplaced when dirty,themoney spent

for the filters and their installation will have been wasted. A filter that gets dirty after

1dayof serviceandthen isnot cleaneduntil29 dayslaterallows 29daysof unfiltered

fluid. A filter is only as good as the maintenance given to it.

Service Suggestions:

1. Set up a filter maintenance schedule and follow it carefully.

2. Replace the original filter cartridge after 50 hours of operation.

3. Change or clean filters as required or indicated by visual indicators on filters

supplied with such devices.

a. Average Operating Environment - replace filter cartridge after each 500

hours of operation.

b. Dirty Operating Environment - replace filter cartridge after each 250 hours

of operation.

4. Clean suction strainers after first 10 hours of operation and every 100 hours

thereafter.

5. Inspect filter elements that have been removed from the system for signs of

other system damage.

6. Do not return to the system any fluid that has leaked out.

7. Always keep supplies of fresh fluid covered tightly.

8. Use clean containers, hoses and funnels when filling reservoir. Use of a filter cart

when adding fluid is highly recommended.

9. Use common sense precautions to prevent entry of dirt into components that

have been temporarily removed from the system.

10. Make sure that all cleanout holes, filler caps and breather cap filters on the

reservoir are properly fastened.

11. Donotrun the system unlessallnormally provided filtration devicesarein place.

12. Make certain that the fluid used in the system is a type recommended by the

manufacturer’s of the system or components.

6 Form MHD56375 Edition 2

The above recommendations are based on an open system equipped with micro-

air breathers. Open systems without micro-air breathers are not recommended.

Visual inspection cannot be used to determine cartridge replacement. Particles

below 40 microns are not visible to the human eye.

Before changing from one type of fluid to another (for example, from a petroleum-

base to a fire-resistant fluid) consult component and filter manufacturers on the

selection of the fluid and the filters that should be used. Follow recommended

flushing procedures when changing fluids. Also consult ANSI B93.5M-1979 “Practice

for the Use of Fire Resistant Fluids for Industrial Hydraulic Fluid Power Systems.”

nDisassembly

nGeneral Disassembly Instructions

The following instructions provide necessary information to disassemble, inspect,

repairand assemblewinch. Partsdrawings areprovided inProductPartsInformation

Manual.

If winch is being completely disassembled for any reason, follow the order of topics

as they are presented. It is recommended that all maintenance work on winch be

performed in a clean dust free work area.

In the process of disassembling winch, observe the following:

1. Never disassemble winch any further than is necessary to accomplish needed

repair. A good part can be damaged during the course of disassembly.

2. Never use excessive force when removing parts. Tapping gently around

perimeter of a cover or housing with a soft hammer, for example, is sufficient to

break the seal.

3. Do not heat a part with a flame to free it for removal unless part being heated is

already worn or damaged beyond repair and no additional damage will occur

to other parts.

In general, winch is designed to permit easy disassembly and assembly. The use

of heat or excessive force should not be required.

4. Keep work area as clean as practical to prevent dirt and other foreign matter

from getting into bearings or other moving parts.

5. All seals, gaskets and ‘O’ rings should be discarded once they have been

removed. New seals, gaskets and ‘O’ rings should be used when assembling

winch.

6. When grasping a part in a vise, always use leather-covered or copper-covered

vise jaws to protect the surface of part and help prevent distortion. This is

particularly true of threaded members, machined surfaces and housings.

7. Do not remove any part that is a press fit in or on a subassembly unless removal

of that part is necessary for repairs or replacement.

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

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

smallerthanoutside diameter ofbearing.The end ofsleeveorpipe that contacts

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

in clean cloths.

nWinch Disassembly

Refer to Dwgs. MHP2850, MHP2859, and MHP2674.

1. Remove wire rope from drum.

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

3. Relievepressureinhydraulic lines by operating winchcontrolseveral times after

hydraulic supply has been shut off.

WARNING

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

performing any disassembly procedures.

4. Tag and disconnect hoses to motor and control valve.

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

beginning disassembly.

6. Drain oil from reduction gear assembly by removing one plug (48) when

positioned at its lowest point, and one plug (48) from its highest point to vent.

Refer to Dwg. MHP1756 in Product Information Manual. If winch is equipped

withadrum bandbrake,elevate winchoutboardend (opposite frommotorend)

to prevent draining oil from contaminating brake band lining.

7. Removedrumbandbrake,winchguardandanyother externallymountedwinch

attachments.

8. Winch guard disassembly, refer to Dwgs. MHP2676 and MHP2850:a.Remove

panels (805) and (807), one section at a time, by removing locknuts (804) and

crossbars (806).b.Remove capscrews (90) and washers (98) securing lifting lugs

(83) to uprights.c.Remove capscrews (809) and washers (96) securing frames

(802) and (801) to uprights (42) and (84).

9. Removenuts(8)and lockwashers (3) securing motorassemblytodisc brake (20).

Support motor and pull motor straight away from winch. Refer to motor

manufacturer’s literature if motor disassembly and service is required.

10. Remove brake assembly (20). If brake assembly sticks, tap it with a soft faced

hammer until assembly separates.

11. Drive out pin (9) and remove coupling (14) from drive shaft (35).

12. Remove seal adapter (10) from brake adapter (6).

13. Remove ‘O’ ring (5) and oil seal (2) from seal adapter (10) if they require

replacement.

14. Remove capscrews (4) and pull brake adapter from drum shaft (41).

15. Remove ‘O’ ring (33).

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

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

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

shaft (41) from inboard upright (42).

19. Removecapscrews(85)andlockwashers (98)thatsecuresiderails (82)toinboard

upright (42). Drive out dowel pins (86).

20. Remove inboard upright (42).

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

upright (84).

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

23. Remove drum and reduction gear assembly.

24. Removeremainingcapscrews (85) andlockwashers(98) that attachsiderails(82)

to outboard upright (84). Drive out dowel pins (86).

25. Remove bearing (87) from outboard upright (84).

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

(80).

27. Install two 3/4 in. - 10 NC x 3 in. long capscrews into threaded holes in outer bolt

pattern ring of gear carrier (47). Use these capscrews to break seal. Remove

reduction gear assembly from drum (80).

28. Remove dowel pins (86) from gear carrier (47).

nManual or Automatic Band Brake Disassembly

Refer to Dwg. MHP2852.

1. Automatic Brake:

a. Disconnect and remove hose and fittings from cylinder (110).b.c.d.

b. Remove cotter pin (102) and pin (101) from link stud (103) and brake band

(128).

c. Remove cotter pin (102) and pin (106). Separate cylinder clevis from brake

lever (105).

d. Remove cotter pin (102) and pin (134). Remove cylinder (110) from bracket

(118).

2. Manual Brake:

a. Removecotter pin(102) andpin (101)fromhandle(104)thenremovehandle

(104) from brake band (128).

3. Remove capscrews (119), lockwashers (117), and stop plate (126).

4. Remove cotter pin (102) and pin (121) from pivot bracket (122).

5. Use a hoist to raise winch approximately 6 inches (15 cm). Separate brake band

(128)halvesandrotate brake bandassemblyslowlyuntil it can beremovedfrom

drum (80).

6. Remove cotter pins (102) and pins (121) so brake band halves (128) can be

removed from arm (124). Lower winch when brake band assembly has been

removed.

7. Remove capscrews (116), washers (117), bracket (118), spacer (automatic brake

only) (107) and pivot bracket (122).

8. Remove cotter pin (102), pin (134) and hydraulic cylinder (110) from bracket

(118).

nReduction Gear Disassembly

NOTICE

•Itisimportanttomaintain acleanwork areawhenreduction gearassembly

is disassembled.

•Disassembly is not recommended, if it is unavoidable, use the following

steps.

Refer to Dwg. MHP2850.

1. Remove plug (48) from gear carrier (47). Rotate reduction gear to drain oil from

level plug hole.

2. Place reduction gear assembly on a clean work bench so that end containing

bearing (49) is down.

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

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

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

6. Remove four dowel pins (74) from between cover (73) and spacer (71) and store

in a safe place.

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

8. If required, remove thrust bearing (55) from sun gear (66). Remove and discard

‘O’ rings (62) from ring gear (63).

9. Remove capscrews (60) from input housing (59). Separate input housing from

gear carrier (47).

10. Remove planetary assembly (58).

11. Remove ring gear (53). Remove three dowel pins (52) from between input

housing (59) and gear carrier (47) and store in a safe place.

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

13. Remove retainer ring (57) and sun gear (56). If required, remove thrust bearing

(55) from sun gear.

14. Remove planetary assembly (54).

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

NOTICE

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

nMotor Disassembly

Refer to motor manufacturer’s literature for motor maintenance instructions. It is

not recommended that the motor be disassembled unless it is known that problems

exist.

nDisc Brake Disassembly

Refer to brake manufacturer’s literature for brake maintenance instructions . It is not

recommended that the brake be disassembled unless it is known that problems

exist.

nPress Roller Disassembly

Refer to Dwgs. MHP2695 and MHP2850.

1. Compress ends of springs (405) and (406) to disengage from side rail (82) and

pin on press roller arm (407).

CAUTION

•Springs are under tension. Use care when releasing springs (405) and (406)

from press roller.

2. Loosen collars (404).

Form MHD56375 Edition 2 7

NOTICE

• Ensure press roller assembly is adequately supported before removing

shaft (403).

3. Remove capscrews (408) and washers (409) from both ends of shaft (403), and

carefullyslideshaft (403)throughhole inupright(42). Pressrollerassembly (400)

and collar (404) will fall away from shaft (403).

4. It is not necessary to remove bushings (410) unless replacing

5. Remove springs (405) and (406) from press roller arm (407).

6. Removecapscrews (408),washers(409)androllers(402)from endsof pressroller

arm (407).

nDrum Locking Pin Disassembly

Refer to Dwg. MHP2675.

1. Remove capscrews (305) and washers (306) to separate drum locking pin

assembly from winch upright (84).

2. Unscrew shaft (304) from drum lock pin (312). Separate cover (307), spring (310),

drum lock pin (312) and housing (308) from assembly.

3. Remove nut (303) and capscrew (302) to separate handle (301) from shaft (304).

4. Do not remove bushing (311) from winch upright (84) unless replacement is

required.

nCleaning, Inspection and Repair

nCleaning

Clean all winch component parts in solvent (except drum brake bands). The use of

a stiff bristle brush will facilitate removal of accumulated dirt and sediments in the

reduction assembly, on housings, frame and drum. If bushings have been removed,

it may be necessary to scrape old Loctite® from bushing bores. Dry each part using

low pressure, filtered compressed air. Clean drum brake band using a wire brush or

emery cloth. Do not wash drum brake band in solvent. If drum brake band lining is

oil soaked, it must be replaced.

nInspection

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

use. Pay particular attention to the following:

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

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

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

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

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

damage. Inspect bearings for freedom of rotation.

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

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

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

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

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

than 0.062 in. (2 mm) thick anywhere along edges replace brake bands (128) as

a set.

nRepair

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

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

Do not use steel wool.

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

for specific replacement parts information.

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

that 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. Polishedgesofallshaft shoulderstoremovesmallnicks causedduringhandling.

6. Remove all nicks and burrs caused by lockwashers.

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

nAssembly

nGeneral Assembly Instructions

•Use all new gaskets and seals.

•Replace worn parts.

•Assemblepartsusingmatchmarks attached during disassembly. Compare

replacement parts with originals to identify installation alignments.

•Lubricateallinternalparts with rustandoxidationinhibiting lubricant, ISO

VG 100 (SAE 30W).

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

assembly.

nDisc Brake Assembly

Ensure disc brake is assembled in accordance with brake manufacturer’s literature.

nMotor Assembly

Ensure motor is assembled in accordance with motor manufacturer’s literature.

nReduction Gear Assembly

NOTICE

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

arereassembled.Duringreassemblycleaneachpartthoroughlyandlightly

coatwithappropriate lubricant asdescribedin ‘Recommended Lubricants’

in the “LUBRICATION” section of the Product Information Manual.

Refer to Dwg. MHP2850.

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 planetary assembly (54).

5. Install thrust bearing (55) into sun gear (56).

6. Install retainer ring (57) on sun gear and locate in planetary assembly (54).

7. Align capscrew and dowel holes and install input housing (59). Apply a light

coating of Loctite® 262 to capscrew (60) 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).

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

flange.

9. Install planetary assembly (58) onto sun gear (56).

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

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

sides of ring gear.

12. 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.

13. Place thrust bearing (55) in sun gear (66) and install sun gear into planetary

assembly (58).

14. Install planetary assembly (67) onto sun gear (66).

15. 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.

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

17. Using a soft hammer or mallet, carefully tap ring gear (72) onto spacer (71).

Ensure ‘O’ rings are not damaged during installation.

18. Install sun gear (69) in planetary assembly (67).

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

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

21. Place a bead of Loctite® 515 sealant on surface that mates with gear carrier.

Sealant location should be inside bolt pattern.

22. Align capscrew and dowel holes and install reduction gear assembly into drum

(80). 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).

23. Install two dowel pins (86) and tap into position until slightly below gear carrier

flange.

24. Apply thin coat of Loctite® 609 to outside of seal (43) and, with seal lip facing

out, install in gear carrier (47).

nDrum Assembly

Refer to Dwg. MHP2850.

Refer to “Winch Assembly” for assembly of inboard upright (42) and drum shaft (41).

1. Stand drum (80) 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 surface, pack bearing (87) with grease and install in outboard upright (84).

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

journal during this step.

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

capscrew threads with Loctite® 242. Torque to 30 ft lbs (41 Nm).

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

(84)andinstallend cover (95). Secureusingfourcapscrews (97) and lockwashers

(96). Lightly coat capscrew threads with Loctite® 242. Torque to 30 ft lbs (41 Nm).

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

(85) and lockwashers (98).

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

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

10. If lifting lugs (83) have been removed, attach with capscrews (90) and washers

(98) to upright(s) (42) and (84).

nManual or Automatic Brake Assembly

Refer to Dwg. MHP2852.

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

(102). Recessed side of threaded hole must be toward the band side.

2. Install connecting link (125) on arm (124) and secure in position with pin (121),

washer (98) and cotter pin (102). Assemble connecting link (125) so curved

surface matches contour of brake band.

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

(101), (121), washers (98) and cotter pins (102).

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

floor or work bench.

5. Position brake band sub-assembly around brake diameter on drum (80) so arm

(124) lays at the bottom. When band is positioned, lower winch.

6. Manual band brake: Mount pivot bracket (122) on inside surface of siderail (82)

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

8 Form MHD56375 Edition 2

7. Automatic band brake: Mount pivot bracket (122) on inside surface of siderail

(82).Positionspacer (107)andbracket (118) onoutside surface ofsiderail.Secure

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

8. Screw link stud (103) into handle (105) and install handle in lug on end of brake

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

lining.

9. Pull brake band halves together and install pin (101) through lug on band (128)

and adjusting screw (103) of handle assembly.

10. Install stop plate (126) on inside of siderail (82) with capscrews (119) and

lockwashers (117). Install adjusting screw (127) and locknut (120) through

siderail (82) and stop plate (126) until it contacts arm (124).

11. Automatic band brake: Install hydraulic cylinder (110) so it connects with

bracket (118) and brake lever (105). Use pins (106), (134) and cotter pins (102) to

secure in position.

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

nPress Roller Assembly

Refer to Dwgs. MHP2695.

Two people are recommended when installing press roller assembly.

1. If bushings (410) have been removed, replace and install in uprights (42) and

(84) and in both ends of arm (407). Grease bushings (410) for ease of installation.

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

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

threads of capscrews.

3. Install springs (405) and (406) so shorter end of springs are toward tabs on inner

portion of arm (407).

4. Position press roller so top of arm (407) is curved up toward the under side of

drum (80). One person must hold press roller in place while the other person

completes installation.

5. Adjustboth springs(405)and (406)so longendofspringsare oninside ofsiderail

(82).

NOTICE

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

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

adjusted to center of drum.

6. Install shaft (403) through hole in leg of upright (84) only.

7. Install one collar (404) on end of shaft (403) between upright and press roller

assembly.Donot tightencollar (404)untilsteps 10and11 havebeen completed.

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

9. Install second collar (404) and slide shaft through hole in leg of upright (42).

Ensure that long end of springs (405) and (406) are still between siderail (82) and

drum(80). Donot tightencollar (404)untilsteps10and11havebeencompleted.

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

small amount of Loctite® 242 to threads of capscrews.

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

collars (404).

12. Tighten collars (404).

13. Using extreme caution, pry short end of one spring (405) so it is positioned

behind the tab of arm (407).

14. Repeat step 13 for spring (406).

CAUTION

• Use caution when installing springs (405) and (406). Springs are under

tension.

nWinch Assembly

Refer to Dwg. MHP2850 and MHP2859.

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 drive 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).

6. Lubricate and install ‘O’ ring (33) on hub of drum shaft (41).

7. Install studs (7) in brake adapter (6), using Loctite® 242, if they were removed.

8. Install brake adapter (6) on drum shaft (41) being careful not to damage ‘O’ ring

(33). Secure in position with capscrews (4) using Loctite® 242.

9. Lubricate and install ‘O’ ring (5) on seal adapter (10). Install oil seal (2) in seal

adapter (10) ensuring seal lip will face into motor assembly.

10. Install seal adapter assembly in brake adapter (6) bore.

11. Align holes in brake assembly with studs (7) and install brake assembly (20) on

brake adapter.

12. Installmotorassembly (21) onstuds(7) andsecurewith lockwashers (3)andnuts

(8).

13. Install motor manifold (22) on motor ports using capscrews (23). Lightly coat

capscrew threads with Loctite® 242 and torque to 85 ft lbs (115 Nm).

14. Install elbow fittings (24) and hose assembly (25) between brake and manifold.

nGuard Assembly

Refer to Dwg. MHP2676 and MHP2850.

1. Secure frames (801) and (802) to uprights (42) and (84) with capscrews (809) and

washers (96).

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

(807) or lower (805) panel.

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

b. Attach panel to crossbar (806).

c. Holding second panel (805) in place, install second crossbar (806) by sliding

through hooked edges of the two panels.

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

e. Continue until all panels are in place.

3. Tighten all fasteners and check winch guard is secure. Ensure wire rope does not

interfere with winch guard during winch operation.

nDrum Locking Pin Assembly

Refer to Dwg. MHP2675.

1. Install new bushing (311) in winch upright (84) if replacement is required.

2. Install shaft (304) in handle (301) and secure with nut (303) and capscrew (302).

3. Install cover (307) on shaft (304) so capscrew holes are aligned with holes in

upright when handle (301) is in a horizontal position.

4. Install housing (308), spring (310) and drum lock pin (312) on shaft (304).

5. Install drum locking pin assembly in upright and secure with capscrews (305)

and washers (306).

nTesting

nOperational Test

Prior to initial use, winches shall be tested to ensure proper operation.

1. Check oil level in reduction gear assembly and disc brake are correct. Top off

levels as required before operation as described in the “LUBRICATION” section.

2. Run winch with no load. Confirm leak-free connections.

3. Install 0-3,000 psi (0-207 bar) pressure gauges with gauge snubbers teed into

the winch at or near the motor A and B ports. Run winch with no load. Record

pressure in both directions. Confirm winch hauls in when pulling throttle, and

pays out when pushing throttle. Ensure controls operate smoothly and winch

responds without sticking, binding or hesitation.

4. NewDrum BrakeBandLiningRun-inProcedure:Allnewdrumbrake bandlinings

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.

5. Check operation of brakes. Adjust band brake if necessary as described in the

“MAINTENANCE” section.

6. Check operation of limit switches, locking mechanisms and all safety devices

when equipped.

7. Check foundation mounting fasteners are secure.

8. Install winch guard when provided

nLoad Test

Prior to initial use, all extensively repaired 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 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:

FH5i DCOKR 5 metric ton (5,000 lbs)

NOTICE

•Testingtomorethan125%ofratedlinepullmayberequiredtosetoverload

device or comply with standards and regulations set forth in areas outside

of the USA.

Form MHD56375 Edition 2 9

TORQUE CHART

Standard Coarse Thread Torque

Size SAE Grade 5 SAE Grade 8

Dry Lubricated PTFE Dry Lubricated PTFE

1/4-20 8-10 6-7 4 12-14 9-10 5-6

5/16-18 17-20 13-15 8-9 25-28 18-21 11-13

3/8-16 31-35 23-26 14-16 44-49 33-37 20-22

7/16-14 49-56 37-42 22-25 70-79 52-59 31-36

1/2-13 75-85 57-64 34-38 106-121 80-90 48-54

9/16-12 109-123 82-92 49-55 154-174 115-130 69-78

5/8-11 150-170 113-128 68-77 212-240 159-180 95-108

3/4-10 267-302 200-227 120-136 376-426 282-320 169-192

7/8-9 429-487 322-365 193-219 606-687 455-515 273-309

1-8 644-729 483-547 290-328 909-1030 681-772 409-463

1 1/8-7 794-900 596-675 357-405 1288-1460 966-1095 580-657

1 1/4-7 1121-1270 840-952 504-571 1817-2059 1363-1545 818-927

Standard Fine Thread Torque

Size SAE Grade 5 SAE Grade 8

Dry Lubricated PTFE Dry Lubricated PTFE

1/4-20 10-11 7-8 4-5 14-15 10-12 6-7

5/16-24 19-22 14-16 9-10 27-31 20-23 12-14

3/8-24 35-40 26-30 16-18 49-56 37-42 22-25

7/16-20 55-63 41-47 25-28 78-88 58-66 35-40

1/2-20 85-96 64-72 38-43 120-136 90-102 54-61

9/16-18 121-137 91-103 55-62 171-194 128-146 77-87

5/8-18 170-193 127-144 76-87 240-272 180-204 108-122

3/4-16 297-337 223-253 134-152 420-476 315-357 189-214

7/8-14 474-537 355-403 213-242 669-758 502-568 301-341

1-12 704-798 528-599 317-359 995-1127 746-845 448-507

1 1/8-12 1023-1159 767-869 460-572 1444-1637 1083-1227 650-736

1 1/4-12 1425-1615 1069-1211 641-727 2012-2280 1509-1710 905-1026

Metric Coarse Thread Torque

Size Class 8.8 / 9.8 Class 10.9

Dry Lubricated PTFE Dry Lubricated PTFE

M6x1 9-10 6-7 4 11-12 8-9 5-6

M8x1.25 21-23 16-18 9-11 26-30 20-22 12-13

M10x1.5 41-47 31-35 19-21 53-60 39-45 24-27

M12x1.75 71-81 54-61 32-36 91-103 68-77 41-46

M14x2 115-130 86-98 52-59 147-166 110-125 66-75

M16x2 165-187 124-140 74-84 227-257 170-193 102-116

M20x2.5 321-364 241-273 144-164 443-502 332-376 199-226

M22x2.5 439-497 329-373 197-224 605-686 454-514 272-309

M24x3 556-630 417-473 250-284 767-869 575-652 345-391

M30x3.5 1103-1250 827-938 496-563 1521-1724 1141-1293 685-776

Metric Fine Thread Torque

Size Class 8.8 / 9.8 Class 10.9

Dry Lubricated PTFE Dry Lubricated PTFE

M8x1 22-25 17-19 10-11 28-32 21-24 13-14

M10x1.25 44-49 33-37 20-22 56-63 42-47 25-28

M12x1.25 78-89 59-67 35-40 100-113 75-85 45-51

M14x1.5 125-141 93-106 56-64 159-180 119-135 72-81

M16x1.5 176-200 132-150 79-90 243-276 183-207 110-124

M18x1.5 257-291 193-219 116-131 355-402 266-302 160-181

M20x1.5 358-406 268-304 161-183 494-559 370-420 222-252

M22x1.5 484-548 363-411 218-247 667-756 500-567 300-340

M24x2 609-690 456-517 274-310 839-951 630-713 378-428

M30x2 1227-1390 920-1043 552-626 1692-1918 1269-1438 761-863

Notes:

1. Definitions:

DRY: Cadmium plate, zinc plate, and oiled fasteners.

LUBRICATED: Molysulfide paste, carnaba wax, molysulfide grease and

copper-based anti-seize coated fasteners.

PTFE: 2% minimum PTFE (teflon) coated fasteners.

2. All torque values foot-pounds unless noted.

3. SAE grade 5 equivalent to ASTM A325 Type 2 and ASTM A449.

4. SAE grade 8 equivalent to ASTM A354 Grade BD, ASTM A490 Type 1.

5. If mixing fasteners use lowest torque value.

6. Torque values 75 to 85% of fastener proof load ref.

10 Form MHD56375 Edition 2

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