Ingersoll-Rand LIFTSTAR 2000 H-1 User manual

Form MHD56298
• A copy of our “Safe Operating Practices” Manuals are always available free of charge either by downloading it from our
Technical Publications website @ www.airwinch.com or by contacting the Factory at [phone] for North America and
[phone] for International. The Safe Operating Practices manual must be read prior to anyone operating a
Ingersoll-Rand winch or hoist. The manual form numbers are as follows:
“Safe Operating Practices Non-Man Rider™ Winches” Manual, Form No. MHD56250
“Safe Operating Practices for Man Rider™ Winches” Manual, Form No. MHD56251
“Safe Operating Practices for Pneumatic, Hydraulic and Electric Hoists” Manual, Form No. MHD56295
• Available winch options may require additional supplements to the basic winch manual.
• For Man Rider™ winches ensure a copy of the Man Rider™ supplement is made available to the operator prior to winch
operation.
• We strongly recommend that ALL maintenance on Ingersoll-Rand equipment be carried out by personnel certified by
Ingersoll-Rand, or by Ingersoll-Rand Authorized Service Centers.
• Contact the Factory if in doubt about installation, operation, inspection and maintenance instructions.
• Use only Genuine Ingersoll-Rand parts when maintaining or repairing a winch, hoist or any component of a winch or hoist.
• ANSI / ASME recommends that a winch or hoist (or any components of a winch or hoist) that has been repaired be tested
prior to being placed into service:
Winch Man Rider™Supplements:
Model: Publication No. Model: Publication No.
FA2, FA2.5,
FH2, FH2.5 MHD56046 LS500RLP SAM0011
LS1000RLP SAM0012
FA5 MHD56042 and
MHD56220
LS150RLP SAM0082
LS150RLP/500/
1000 SAM0115
FA10 MHD56252
FA2.5A MHD56236 LS150RLP and
LS150PLP-PH SAM0120
FA2B and
HU40A MHD56207 LS500RLP-E SAM0122
FH10MR MHD56212 LS150RLP-
DP5M-F SAM0184
Fulcrum Electric MHD56277
LS500HLP/
LS1000HLP SAM0004 LS150HLP SAM0222
*Winches-ANSI / ASME B30.7 (BASE MOUNTED DRUM HOISTS) Refer to section 7.2.2 - Testing.
*Hoists - ANSI / ASME B30.16 (OVERHEAD HOISTS - UNDERHUNG) Refer to section 16.2.2 - Testing.
Form MHD56298
Edition 2
November 2004
71441844
© 2004 Ingersoll-Rand Company
IMPORTANT INFORMATION:

OPERATION AND MAINTENANCE MANUAL
FOR THE
HYDRAULIC WINCH
LIFTSTAR 2000 H - 1
AND
LIFTSTAR 2000 HGC - 1
READ THIS MANUAL BEFORE USING THESE PRODUCT. This manual contains
important safety, installation, operation and maintenance information. Make the
manual available to all persons responsible for the operation, installation and
maintenance of these product.
Do not use this winch for lifting, supporting, ortransporting people or lifting or supporting loads
over people.
Always operate, inspect and maintain this winch in accordance with National Standards
Safety Code of the country where the material is used and respect the other applicable
safety codes and particular regulations.
Refer all communications to the nearest IR/SAMIlA Material Handling Products Office or
Distributor.
Form SAM0052
Edition 4
November 1996 PRODUCTION EQUIPMENT

B.P 59
59450 SIN LE NOBLE - FRANCE
TEL. [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
DESCRIPTION
TREUIL DE LEVAGE HYDRAULIQUE NUMERO DENOMENCLATURE
HYDRAULIK HUBWINDE L 615
HYDRAULIC WINCH NUMERODUDOCUMENT
LIFTSTAR 2000 H -1
LECHEFDUBUREAUD'ETUDES
A - SAFETY INFORMATION AND TRAINING
Danger, Warning, Caution and Notice
Safety Summary
B - SAFE OPERATING INSTRUCTIONS
C - LABELLlNG - MARKING
D - SPECIFICATIONS
Technical sheet
E - INSTALLATION
Mounting
Wire Rope
Hydraulic Fluid Supply
Motor
Initial Operating Checks
F - OPERATION
Controls
G - LUBRICATION
Wire Rope
Reduction Gear Assembly
Seals and Bearings
H - INSPECTION
Records and Reports
Frequent Inspection
Periodic Inspection
Winches not in Regular Use
K - PARTS
Winch Assembly Drawing
Winch Assembly Part List
Hydraulic Bored Block Drawing and Part List
L - RECOMMENDED SPARE PARTS LIST
No DOCUMENT FOLIOS
94 05 12 2
9405 12 2
9405 12 1
96 11 12 1
94 05 13
9405 13
9405 13
94 05 12
94 05 05
94 05 05
94 05 08
94 10 01
4
3

TREUIL DE LEVAGE HYDRAULIQUE
B.P 59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
HYDRAULIK HUBWINDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
TELEFAX (33) 27.93.08.00
NUMERO DENOMENCLATURE
NUMERODUDOCUh4ENT
A - SAFETY INFORMATION AND TRAINING
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 must read
understand this manual before operating the product.
Training must be done by a qualified person to any personnel involved with
an hydraulic man-riding 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 personal injury, death, or substantial property
damage if the warning is ignored.
Warning is used to indicate the presence of a hazard which can
cause severe personal injury, death, or substantial property
damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which willor
can cause minorpersonnal 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
l Do not use this winch for lifting, supporting, or transporting people or supporting
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 customer’s responsibility. If in
doubt, consult a qualified structural engineer.
Employees who work near cranes 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 operations in such a manner that if
there were an equipment failure, no personnel would be injured.

B.P 59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
NUMERODENOMJ3CLATURE
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAUUK HUBWINDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
I NUMERODUDOCUMENT
This means keep out from under a raised load and keep out of the line of force of
any load.
To the best of our knowledge, IR/SAMIIA Material Handling winches are
manufactured in accordance with the latest standards in effect at time of
manufacture.
“It is the owner’s responsibility and user’s responsibility to determine the suitability
of a product for any particular use. Check all applicable industry, trade association,
federal, state an local regulations. 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.
Using other than genuine IR/SAMllA Material Handling parts will result in the void of
warranty.
B - SAFE OPERATING INSTRUCTIONS/
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 qualified personnel (trained in safety and operation) to operate
and maintain a winch.
2 - Only operate a winch if you are physically fit to do so.
3 - When a “DO NOT OPERATE” sign is placed on the winch, do not operate the
winch until the sign has been removed by designated personnel.
4 - Before each shift, check the winch for wear or damage.
5 - Never lift a load greater than the rated capacity of the winch. See warning
labels attached to winch.
6 - Keep hands, clothing, etc... , clear of moving parts.
7 - Never place your hand in the throat area of a hook or in the vicinity ofthe wire
rope as it spools onto the drum.
8 - Always rig loads properly and carefully.
9 - Be certain the load is properly seated in the saddle of the hook. Do not tipload
the hook as this leads to spreading an eventual failure of the hook.
10 - Do not “side pull” or “yard”.
11 - Make sure everyone is clear of the load path. Do not lift a load over people.
12 - Never allow anyone to stand on a suspended load.

NUMERODENOMENCLATURE
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAULlK HUBWINDE
B.P 59 HYDRAULIC WfNCH NUMERODUDOCUMENT
5960 SIN LE NOBLE - FRANCE
TEL. [phone] LIFTSTAR 2000 H -1 940 512 3/6
TELEX 820 221
TELEFAX (33) 27.93.08.00 he
LECHEFDUBURE D'ETUDES
13 - Ease the slack out of wire rope when starting a lift. Do not jerk the load.
14 - Do not swing a suspended load.
15 - Never suspend a load for an extented period of time.
16 - Never leave a suspended load unattended.
17 - Pay attention to the load at all times when operating the winch.
18 - After use, properly secure winch and all loads.
19 - The operator must maintain an unobstructed view of the load at all times.
20 - Never use the winch wire rope as a sling.
C - LABELLING - MARKING
The maximal lifting rated capacity of the
winch is noticed on one part of the winch.
Failure to follow these
warnings may result in
death, severe injury
or property damage :
. Do not operate this winch
before reading operation
and maintenance manual.
Each winch is supplied from the factory with the , Do not lift people or loads
warning label shown. If the label is not attached to over people.
your unit, order a new label and install it. See the . Do not lift more than rated
parts list for the part number. Read and obey all load
warnings and other safety information attached to . Do not allow less than three
this winch. Label may not be shown actual size : wraps of wire rope to remain
on drum at all times.
. Do not operate a damaged
or malfunctioning winch.
. Do not remove or obscure
warning labels

B.P 59
59450 SIN LE NOBLE - FRANCE
TEL. [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
NUMERO DE NOMENCLATURE
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAULIK HUBWlNDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
I NUMERO DU DOCUMENT
LECHEF DU BUREAU D’ETUDES
H - INSPECTION
There are two types of inspection, the frequent inspection performed by the operator
while using the winch and periodic inspections performed by qualified personnel.
Careful inspection on a regular basis will reveal potentially dangerous conditions while
still in the early stages, allowing corrective action to be taken before the condition
becomes dangerous
Any deficiency revealed through inspection must be reported to an appointed person. A
determination must be made as to whether a deficiency constitutes a safety hazard
before resuming operation of the winch.
Records and Reports
Some form of inspection record must be maintained for each winch, listing all points
requiring periodic inspection. A written report should be made monthly on the condition
of the critical parts of each winch. These reports should be dated, signed by the person
who performed the inspection, and kept on file where they are readily available to
authorized personnel.
FREQUENT INSPECTION
beginning
On a winch in continuous service, frequent inspection should be made at the
of each shift. In addition, visual inspections should be conducted during regular service
for any damage or evidence of malfunction.
1 - OPERATION. Check for visual or abnormal noises which could indicate a defect. Do
not operate a winch unless the wire rope feeds onto the winch drum smoothly. If wire
rope binds or jumps, clean and lubricate the wire rope. If problem persists, replace the
wire rope. Do not operate the winch until all defects have been corrected.
2 - HYDRAULIC CIRCUIT. Check hydraulic lines and components for leakage. Repair if
necessary - The hydraulic circuit and the tank must be very clean, without any metallic
particule. Do not introduce impurities in the circuit when mounting the fittings.
3 - WIRE ROPE. Wire rope is a consumable item which must be replaced when worn.
The following list is a guide to the accepted standards by which wire rope must be
judged and is not presented as a substitute for an experienced inspector :
a . Damage, such as bird cages, kinking, core protrusion, crushing, heat damage, and
main strand displacement,
b . Corrosion and nicking
c . Wear of crown wires. Replace at 1/3 wear of any crown wire.
d . Broken wires or strands, particularly at connections. Replacement is necessary if
one wire is broken at a connection ; six wires broken within one lay ; three wires broken
in one strand within one lay.
e . Lubrication.
Replace wire rope if any doubt exists as to wire rope serviceability.

B.P 59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAULIK HUBWINDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
NUMERO DE NOMEIKLATURE
NUMERODUDOCUMENT
4 - WIRE ROPE REEVING. Check reeving and ensure wire rope is properly secured to
the drum.
5 - CONTROLS. See that controls function properly and return to neutral when
released.
PERIODIC INSPECTION
The frequency of periodic inspection depends on the severity of usage : NORMAL,
yearly ; HEAVY, semiannually ; SEVERE, quarterly.
Disassembly may be required for HEAVY or SEVERE usage. Keep accumulative
records of periodic inspections to provide a basis for continuing evaluation. Inspect all
the items in a frequent inspection plus the following :
1 - FASTENERS. Check, capscrew, nuts, pins and other fasteners on winch and
hydraulic system. Replace if missing and tighten or secure if loose.
2 - ALL COMPONENTS. Inspect for wear, damage, distortion, deformation and
cleanliness. If external evidence indicates the need, disassemble. Check gears, shafts,
bearings, springs and covers. Replace worn or damaged parts. Clean, lubricate and
reassemble.
3 - DRUM AND SHEAVES. Check for damage or excessive wear. Replace if
necessary.
4 - BRAKE. Perform functional load test on winch.
rated load.
5 - LABELS AND TAGS. Check for presence and legibility. Replace if necessary.
6 -WIRE ROPE
Check ability of the brake to hold
a - Loose or damaged end connection. Replace if loose or damaged.
b - Changes in the size of the rope cross section. Measure crown-to-crown.

B.P59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAULIK HUBWINDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
NUMERODENOMENCLATURE
9405 12 6/6
v?-!+LECHEFD BUR AUD'ETUDES
7 - FOUNDATION. Check for the continued ability to sustain the imposed loads.
Winches Not in Regular Use
A winch which has been idle for a period of one month or more, but less than six
months, shall be given an inspection conforming with the requirements of “Frequent
Inspection” before being placed into service.
A winch which has been idle for a period of over six months shall be given a complete
inspection conforming with the requirements of “Periodic Inspection”. Standby winches
shall be inspected at least semiannually in accordance with the requirements of
“Frequent Inspection”. If adnormal operating conditions apply, winches may require a
more frequent inspection.

B.P 59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAUUK HUBWlNDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
NMERODENOMENCLATURE
NUMERODUDOCUMENT
D - SPECIFICATIONS

HYDRAULIC LIFTING NUMERO DE NOMENCLATURE
BP 39 L 615
59450 SIN LE NOBLE
TEL: [phone] WINCH NUMERO DU DOCUMENT
FAX: [phone]
TELEX: 820 221
Copyright © 1997
Ingersoll-Rand Company
AllRights Reserved Le chef du bureau d’etudes
Performance measured with mineral oil 37cSt at WC.
CUMULATIVE ROPE CAPACITY
Number of Iayers 1 2 3 4 5 6 7 8
Standard (m)rope o11,5mm 19 40 63 88 114 142 172 203
rope o 13 mm 17 36 57 79 103 129 156
Long drum (m) rope o11,5mm 35 73 114 153 205 254 307
rope ol3mm 142
ratinglimit
DESIGNATION and options
Hydraulic scheme
--- !
DESCRIPTION
l Conform with safety rules for liking winches FEM (IBM). Monobloc conception.
DESIGN
l GS cast iron and steel construction. especially compact design.
l Plain drum between ribbed flanges with distance pieces. Rope is anchored by a vertical wedge box on the flange.
- Planetary gear box is enclosed within drum for protestion and space saving.
l All rotating parts are supported on ball bearings.
l Fail safe automatic multi-disc brake springs applied, pressure released
l Dynamic braking is by a counter balance valve avoidind the permanent friction of the discs brake. -i
WINCH MOUNTING . I
l Winch designed for installation on a rigid support. Quick fastening by 4 bolts, grade 8/8.
l Use in any position, provided the drum is horizontal.
LUBRIFlCATION
l Oil bath gear box Oil grade SAE 80 W 90. Kinematic viscosity 145 cSt at 40°C.
OPTION
l “GS” version (great capacity) with long drum.
Theequipment described on this sheet is subject to the general sales and warranty conditions of INGERSOLL-RAND company. Because of the constant
evolutionof technology 1NGERSOLL-RAND company reserves the right to modify without notice the specifications contained in this document.

B.P 59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
Prior to installing the winch, carefully inspect it for possible shipping damage.
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAULIK HUBWINDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
MIMER0 DE NOMENCLATURE
NUMERO DUDOCUMENT
INSTALLATION
Owner and users are advised to examine specific, load or other regulations, which may
apply to a particular type of use of this product before installing or putting winch to use.
Mounting
1 - If product is to be mounted in one position be sure the mounting surface is even and of
sufficient strength to handle the rated load and prevent possible binding of the winch.
2 - Make sure the mounting surface is flat to within l/32 inch (0,8 mm). Shim if necessary
3 - Mounting bolts must be 5/8 in. (16 mm) diameter, Grade 8.8 (classe 8.8) or better. Use
self-locking nuts or nuts with lockwashers.
4 - Torque mounting bolts evenly.
5 - Maintain a fleet angle between the sheave and winch of no more than 1-1/2 degrees.
For every inch of drum lengh, the lead sheave must be at least 1.6 feet (0.5 m) from the
drum.
6 - Do not weld to any part of the winch
Bolt Hole Dimensions
Standard Drum
“A” 340 mm
“B” 449 mm
“C”o 18 mm
“D” 170 mm
Long Drum
“A” 340 mm
“B” 634 mm
“C”o 18 mm
“D” 170 mm

B.P 59
59450SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
Wire rope
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAULIK HUBWlNDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
NUMERODENOMENCLATURE
NUMERODUDOCUMENT
- Maintain at least 3 wraps of wire rope on the drum at all times.
- Install the wire rope to come off the drum in an overwind position as indicated on the
direction of rotation tag.
Wire rope selection
Consult a reputable wire rope manufacturer or distributor for assistance in selecting the
appropriate type size of wire rope and, where necessary, a protective coating. Use a
wire rope which provides an adequate safety factor to handle the actual working load
and meets all applicable industry, trade association, state and local regulations.
When considering wire rope requirements the actual working load must include not only
the static or dead load but also loads resulting from acceleration, retardation and shock
load. Consideration must also be given to the size of the winch wire rope drum, sheaves
and method of reeving. Wire rope diameter for lifting or lowering l/2 in. (13 mm)
imperative.
Installing Wire Rope
1 - Cut wire rope to length in accordance with the wire rope manufacturers instructions.
2 - Feed the end of the wire rope into the smaller anchor hole in the wire rope drum and
pull through approximately one foot (0,3 m) of wire rope.
3 - Truck the end of the wire rope back into the wire rope anchor pocket forming a loop
in the wire rope. he wire4 - Insert the wire rope wedge and pull the wire rope through the slot tightening t
rope around the wire rope wedge.
Make sure the first wrap of wire rope is flush against the drum flange.
5 - Pull the wire rope wedge into position in the drum anchor pocket.
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 first layer is tight.

TREUIL DE LEVAGE HYDRAULIQUE
B.P 59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
HYDRAUUK HUBWINDE
HYDRAULIC WINCH
TELEX 820 221 LIFTSTAR 2000 H -1
TELEFAX (33) 27.93.08.00
NUMERODENOMENCLATURE
NUMERODUDOCUMENT
9405l3 3/5
Wire Rope Spoofing
To compensate for uneven spooling and decrease in line pull capacity as the drum fills
up, use as short a cable as practical. To rewind wire rope apply tension to eliminate
slack. This helps achieve level winding and tight spooling.
Rigging
Make sure all wire rope blocks, tackle and fastenings have sufficient safety margin to
handle the required load. 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
manufacturers handbook for proper sizing, use and care of wire rope.
Safe Installation Procedures
1 - Do not use wire rope as a ground for welding
2 - Do not attach a welding electrode to winch or wire rope
3 - Never run the wire rope over a sharp edge. Use a correctly sized sheave.
4 - When a lead sheave is used, it must be aligned with the center of the drum. The
diameter of the lead sheave must be at least 18 times the diameter of the wire rope.
5 - Always maintain at least three full wraps of wire rope on the drum.
Hydraulic Fluid Supply
The hydraulic circuit and the tank must be very clean, without any metallic particule.
Do not introduce impurities in the circuit when mounting the fittings. For a continuous
use do not exceed a temperature of 80°C as well for the hydraulic circuit as for the
winch. The maxi filtration of the circuit must be10 microns . We recommend to use an
open centre control valve “H”.
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 the lines.
We recommend to use for the hydraulic fluid a mineral oil viscosity 37 to 68 cSt at 40°C.
Motor
For optimum performance and maximum durability of parts, operate hydraulic motor at
130 bar oil pressure - Oil supply : 60 1/mn. The hydraulic motor should be installed as
near as possible to the hydraulic power pack

B.P 59
59450 SIN LE NOBLE - FRANCE
TEL. [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
NUMERODENOMENCLATURE
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAULIK HUBWINDE
HYDRAULIC WINCH NUMERO DU DOCUMENT
LIFTSTAR 2000 H-1
Initial Operating Checks
Winches are tested for proper operation prior to leaving the factory. Before the winch is
placed into service the following initial operating checks should be performed.
When first operating the winch it is recommended that the motor be driven slowly in both
directions for a few minutes.
The winch is now ready to work.
The four most important aspects of winch operation are :
1 - Follow all safety instructions when operating the winch.
2 - Allow only qualified people to operate the winch
3 - Subject each winch to a regular inspection and maintenance procedure
4 - Be aware of the winch capacity and weight of load at all times.
The LIFTSTAR 2000H Winch is not designed or suitable for lifting, lowering or moving
persons. Never lift loads over people.
Winch control
We recommend to use an open centre control valve “H” type with minimum size of10 or
CETOP 5.
To avoid damage to the rigging, the structure supporting the rigging and the winch, do
not “two-block” the end of the wire rope.

B.P 59
59450 SIN LE N0BLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
TREUIL DE LEVAGE HYDRAULIQUE
HYDRAULIK HUBWINDE
HYDRAULIC WINCH
LIFTSTAR 2000 H -1
NUMERO DE NOMENCLATURE
NUMERODUDOCUMENT
LECHEFD BUREAUD'ETUDES
G - LUBRICATION
Wire rope
Refer the wire rope manufacturers recommendations. At a minimum observe the following :
1 - Clean with a brush or steam if there is dirt, rock dust or other foreign material on the
surface of the rope
Donot use an acid-based solvent orother cleaning fluid.
2 -Apply a wirerope lubricantor SAE 30W oil.
3 - Brush, dripor spray lubricantweekly, or more frequently,depending on severity of
service.
Reduction Gear Assembly
Replace the oil in the reduction housing at least once every year. If the winch is used at a
normal frequency, the oil in the reduction housing is suitable for one years operation without
changing. However, when the winch is used at a high frequency, the oil may need to be
changed on a more frequent basis.
To ensure correct performance, highest efficiency and long life, it is essential that the
lubricating oil be maintained at the correct level. The recommended grade of oil must be used
at all times since the use of unsuitable oil may result in excessive temperature rise, loss of
efficiency and possible damage of the gears.
The reduction gear assembly is filled and shipped with oil from the factory. Use only high
quality lubricants in the reduction gear assembly such as high grade EP type oil or their
equivalents. Fill the reduction gear assembly until the working rim is covered.
Oil capacity : 3 litres.
Recommended oil :
GRADE SAE 80 W 90 - Kinematic
Viscosity : 145 mm2/s at 40°C
Seals and Bearings
If winch is disassembled, clean all parts thoroughly and coat bearings and seals with clean
grease. Use sufficient grease to provide a good protective coat.
Grease features : semi-fluid extreme pressure for ambient temperature from -15°C to +40°C,
ASTM at 25°C penetration.
Motor
Since all the motor parts subject to friction are lubricated by the fluid carried, no maintenance
and no corrective action is to foreseen on this unit except the monitoring of the hydraulic
liquid used and the protection mechanisms.

TELEFAS (33) 27.93.08.00 LE CHEF DU ‘B&A” D’ETUDES
PLAN D’ENSEMBLE NUMERO DU DOCUMENT
@ LOCTITE INSTAJOINT 574
BP 59
59450 SIN LE NOBLE FRANCE
TEL. [phone] ASSEMBLY DRAWING 94/05/05 l/4
@ LOCTITE FREIN FILET 243
WINDEZEICHNUNG
0 LOCTITE TUBE ETANCHE 577
TELEX 820 221

NOMENCLATURE DU TREUIL DE LEVAGE HYDRAULIQUE
B.P 59
59450 SIN LE NOBLE - FRANCE DRUCKUJFT WADETEILLISTE
TEL [phone] WINCH ASSEMBLY PART LIST
TELEX 820 221
TELEFAX (33) 27.93.08.00
REPERE
ITEM
HINWEIS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
DESIGNATION DESCRIPTION BEZEICHNUNG
Moteur hydraulique hydraulic motor hydraulik motor
Satellite Satellite Trabant
Axe de satellite Satellite axle Trabantenachse
Entretoise Distance ring Distanzring
Couronne 60 dents 60 teeth-ring gear Zahnkranz 60 Zahne
Couronne 57 dents 57 teeth-ring gear Zahnkranz 57 Zahne
Flasque Flange Flansch
Pignon moteur Driving pinion Abtriebszahnrad
Manchon de liaison Coupling sleeve Kupplungsmuffe
Coin Wedge Keil
Corps de frein B rake housing Bremsgehause
Flasque bride Flange Flansch
Piston Piston Kolben
Entretoise Distance ring Distanzring
Bague de liaison Connecting ring Verbindungsring
Porte satellite Satellite support Satellitentrager
Palier avant Front bearing Votvvartslager
Porte couronne Ring gear support Zahnkranztrager
Palier de roulement Rolling bearing Walzlager
Palier arriere Rear bearing Lager hinten
Entretoise (standard) Distance ring (standard) Distanzring (standard)
Entretoise (GC) Distance ring (GC) Distanzring (GC)
Butee stop Anschlag
Tambour (standard) Drum (standard) Trommel (standard)
Tambour (GC) Drum (GC) Trommel (GC)
Sous ensemble clabot Claw of positive cluth Klaue einer Fuppelmuffe
Pour toute commande de pieces de rechange, il est recommande de rappeler le numero porte sur laplaque d'identification del'appareil
For each demand of spare parts, if is recommended to specify the number written on the identification p/ate of the device
Bei Bestellung von Ersatzleilen bitte Sereinnummer auf dem ldentifizierungsschild des Gertite angeben
Quantite
Quantity
Anrhal
1
4
4
4
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
NUMERO DE NOMENCLATURE
L615
NUMERO DU DOCUMENT
940505A 2/4
CODE CPN
6400-0903 38543013
9573-0018
9573-8019
9573-0021
9573-0055
9573-0056
9615-7002
9615-0006
9615-0016
9615-0009
961l-0005
9611-0007
9611-0003
9615-0017
9615-0018
9615-0023
9615-8042
9615-0043
9615-0044
9615-8049
9615-0005
9615-0050
9615-0051
9615-7001
9615-7052
3573-0001
38527941
38531208
38527966
38527974
38527990
38531232
38533055
38543039
38528014
38530572
38543039
38530580
38543047
38543062
38528022
38531240
38528048
38528055
38531257
38528196
38529822
38528071
38539458
38543732
38529764

B.P 59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
NOMENCLATURE DU TREUIL DE LEVAGE HYDRAULIQUE
DRUCKLUFT WINDETELLISTE
WINCH ASSEMBLY PART LIST
I I NUMERO DE NOMENCLATURE
L615
NUMERO DU DOCUMENT
940505 3/4
REPERE
ITEM
HINWEIS DESIGNATION DESCRIPTION BEZEICHNUNG Quantite
Quantity
Anzhal
CODE CPN
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Obturateur Blind washer Dichtung 1 9619-0013 38528816
Bouchon Plug Stopfen 1 6101-7128 38528329
Disque de friction Friction disc Reibcheibe 4 6305-9932 38528352
Disque acier Steel disc Stahlscheibe 3 6306-0032 38528360
Plaque d’identification Identification plate Typenschild 1 6676-7232 38529970
Bouchon Plug Stopfen 2 6516-0932 38528337
Graisseur hydraulique Hydraulic greaser Hydraulisher Schmiernippel 1 6730-l 727 38528345
Ressort Spring Feder 9 6915-9432 38530689
Roulement a billes Ball bearing Kugellager 1 5005-0015 38523346
Roulement abilles Ball bearing Kugellager 1 5080-0007 38526208
Roulement a billes Ball bearing Kugellager 1 5080-0024 38528477
Butee a aiguilles Needle stop Nadelanschlag 8 5605-4225 38528405
Cage a aiguilles Needle cage Nadelkafig 8 5650-3324 38528493
Contre plaque Thrust washer Druckscheibe 8 5731-2632 38528501
Bague d’etancheite Sealing ring Dichtring 1 5800-0830 38528519
Bague d’etancheite Sealing ring Dichtring 1 5801-9230 38528527
Joint torique O’ring O’ring 1 5821-2529 38522660
Joint torique O’ring O’ring 2 5821-6929 38528535
Bague Ring Ring 1 5821-7929 38528543
Joint torique O’ring O’ring 1 5822-4229 38528592
Joint V-ring Joint Dichtung 1 5840-4831 38528550
Joint V-ring Joint Dichtung 1 5840-5831 38528568
Joint cuivre Copper joint Kupferdichtung 2 5840-8031 38528576
Vis H Screw Schraube 3 4100-0201 38522751
Vis H Screw Schraube 24 4100-0401 38528667
Pour toute commande de pieces de rechange, il est recommande de rappeler le numbro porte sur la plaque d’identification de I’appareil
For each demand of spare parts, it is recommended to specify the number written on the identification plate of the device
Bei Bestellung von Ersatzleilen bitte Sereinnummer auf dem ldentifizierungsschild des Gerste angeben

NUMERO DE NOMENCIATURE
NOMENCLATURE DU TREUIL DE LEVAGE HYDRAULIQUE L615
B.P 59
59450 SIN LE NOBLE - FRANCE
TEL [phone]
TELEX 820 221
TELEFAX (33) 27.93.08.00
DRUCKLUFT WINDETElLLlSTE NUMERO DU DOCUMENT
WINCH ASSEMBLY PART LIST 9 40505 4/4
LE CHEF DU BUREAU D’ETUDES
REPERE
ITEM
HINWEIS DESIGNATION DESCRIPTION BEZEICHNUNG Quantite
Quantity
Anzhal CODE CPN
53 Vis H Screw Schraube 8 4100-6701 38533071
54 Vis FHc/90 Screw Schraube 6 411O-l 603 38528675
55 Vis CHc Screw Schraube 4 4130-l 006 38523593
56 Rivet Rivet Niete 4 4460-0821 38528683
57 Rondelle grower Split washer Scheibe 32 4520-0010 38522223
58 Goupille elastique Elastic pin Elastisches Stift 4 4650-4220 38528709
59 Circlips interieur Circlips Seegerring 1 4770-3062 38527149
60 Anneau expansif Expansive ring Expansives Ring 1 4783-6832 38528717
61 Anneau expansif Expansive ring Expansives Ring 1 4784-7832 38528758
62 Anneau expansif interieur Internal expansive ring lnneres Espansives Ring 1 4785-3932 38528725
63 Joint torique O’ring O-ring 1 5822-2429 38530705
64 Joint torique O’ring O-ring 1 5822-2529 38530713
65 Bague anti-extrusion Back-up ring Ring 1 5822-2629 38530812
67 Bague anti-extrusion Back-up ring Ring 1 5822-2729 38530820
68 Vis H Screw Schraube 2 4100-3401 38530028
69 Circlips exterieur Circlips Seegerring 1 4770-0022 38536405
70 Rondelle grower Split washer Scheibe 3 4520-0006 38522819
71 Rondelle plate washer Scheibe 2 4500-0112 38525523
72 VIS CHc Screw Schraube 12 4130-2206 38530036
73 bloc fore Bored block Gebohrter block 1 3598-0033
74 Joint papier Joint Dichtung 1 9584-0088 38543070
Pour toute commande de pieces de rechange, il est recommande de rappeler le numbro porte sur la plaque d’identification de I’appareil
for each demand of spare parts, it is recommended to specify the number written on the identification plate of the device
Bei Bestellung von Ersatzleilen bitte Sereinnummer auf dem ldentifizierungsschild des Gerste angeben