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MHD56087 - Edition 4 35
REVIEW COPY 6
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21
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02
WARNING
• Incorrect assembly of the sprag clutch will adversely affect
winch operation. In haul-in operation, sprag clutch will be
engaged resulting in restricted winch operation. In neutral
and payout positions, the sprag clutch can rotate resulting in
brake not holding load. Ensure the sprag clutch is correctly
installed.
3. Install assembly on support plate (19).
4. Install twelve springs (17) in holes on inside of support plate
(19).
5. Install gasket (18) and pressure plate (15).
6. Determine correct alignment of cover (2), housing (6) and
support plate (19) by checking matchmarks placed during
disassembly, or by placing housing on support plate and
matching capscrew holes.
7. Correctly align with dowel slots on the housing (6) and
alternately install six separator plates (14) and five friction
plates (13), beginning with a separator plate. Align the outer
three indentations on plates to form a single groove.
8. Install the three dowel pins (9) in housing (6). Apply Loctite
®
515 sealant on mating surfaces of housing and end cover (2).
Install housing by aligning dowel pins with separator (13)
and friction plate (14) grooves and, also aligning capscrew
holes in housing with holes in end cover.
Sprag Clutch Assembly
(Dwg. MHP1197)
9. Install ring (4), and diaphragm support plate (5). Support
plate radius must be next to diaphragm (3).
10. Install diaphragm (3) and cover (2).
11. Locate as shown on Dwg. MHP1230 on page 42, and install
two capscrews (41). Evenly and alternately tighten capscrews
to compress springs. Torque capscrews to 18 ft lbs (24 Nm).
12. Install brake shaft (25) and place assembly on outboard
(opposite motor end) upright (26).
13. Align capscrew holes such that the breather (8) is slightly off
top dead center. Install six capscrews (1). Torque capscrews
to 18 ft lbs (24 Nm).
14. Install capscrews (1) securing brake to upright (26).
15. Install exhaust valve (79), elbow fitting (80) and connect air
hose (75) to elbow fitting.
16. Winch drum must rotate freely in the haul-in direction and
must not rotate in the payout direction, unless air is applied
to the brake, when assembled properly.
Drum Guard Assembly (optional feature)
Refer to Dwg. MHP0658 on page 62.
1. Place drum guard (590) on rear side rails (65) with longer
inside tab located under side rails edge and smaller outside
tabs located on top of side rails edge.
2. Place ‘O’ rings (109) on brackets (591) or bracket shaft
(596). Install ‘O’ rings in quantities required to remove any
‘play’ or gap between drum guard and brackets.
3. Align brackets (591) or (595) on mounting holes in uprights
(26) and (68). Secure in place with capscrews (592).
Testing
Operational Test
Prior to initial use, all new, altered 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
winch without load, in both directions, for 15 minutes at 100 -
200 RPM.
3. Check operation of brakes. Adjust if necessary as described
in the “MAINTENANCE” section.
4. Check operation of limit switches, locking mechanisms and
all safety devices when equipped.
5. Check foundation mounting fasteners are secure.
6. Install drum guard when provided.
Load Test
Prior to initial use, all new, extensively repaired, or altered
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 the winch. Test loads shall not
be less than 100% of rated line pull at mid drum and must not
exceed 125% of the rated line pull at mid drum. To test the winch
at 125% of the rated load at mid drum apply the following load:
FA5A Winch 125% Test Load 12,500 lb. (9,058 kg)
NOTICE
• Testing to more than 125% of rated line pull may be required
to comply with standards and regulations set forth in areas
outside the USA.