Ingersoll-Rand LIFTSTAR FG 1500/CN Series Installation guide

Form SAM0030
“LIFTSTAR” AIR WINCHES
FG 1500/CN SERIES
PARTS, OPERATION AND MAINTENANCE
MANUAL
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance
information. Make this manual available to all persons responsible for the
operation, installation and maintenance of these products.
Do not use this winch for lifting, supporting, or transporting people or lifting or supporting
loads over people.
Always operate, inspect and maintain this winch in accordance with American National
Standards Institute Safety Code (ASME B30.7) and any other applicable safety codes and
regulations.
Refer all communications to the nearest Ingersoll-Rand Material Handling Products Office
or Distributor.
Form SAM0030
Edition 5
MARCH 1994
38540944
© 1994 IR/SAMIIA
MATERIAL HANDLING

DESCRIPTION PAGE NO.
SafetyInformation
Danger,Warning, Caution andNotice .................................................................................................................. 3
Safety,Summary.._.......
......................................................................................................................................... 3
SafeOperatingInstructions ................................................................................................................................... 4
Warning Label ....... .............................................................................................................................................. 4
Specifications
PerformanceGraph............................................................................................................................................... 5
How to order ......................................................................................................................................................... 5
Description
Description of Operation.......
................................................................................................................................ 6
Installation
Mounting ...............................................................................................................................................................
6
Wire Rope
..............................................................................................................................................................
6
Air Supply
...............................................................................................................................................................
7
Motor......................................................................................................................................................................
7
Initial OperatingChecks..
...........
............................................................................................................................
7
Operation
Winch Control.... . .
. .............................................................................................................................................. 8
Lubrication
Wire Rope..
............................................................................................................................................................
9
ReductionGearAssembly..
....................................................................................................................................
9
Drum Bushings
.......................................................................................................................................................
9
SealsandBearings
.................................................................................................................................................
9
Inspection
RecordsandReports
...............................................................................................................................................
9
FrequentInspection
................................................................................................................................................
9
Periodic Inspection
.................................................................................................................................................
10
Winchesnot in RegularUse
...................................................................................................................................
10
Troubleshooting
Troubleshooting Chart.... ....................................................................................................................................... 11
Maintenance
GeneralDisassemblyProcedures..
.........................................................................................................................
12
Winch Disassembly- Inspection -Winch assembly
..............................................................................................
12
Control Valve Disassembly- Inspection - Control Valve Assembly ....................................................................14
Air GearMotor Disassembly- Inspection - Air GearMotor Assembly
................................................................ 14
Optional Valve Disassembly-Optional Valve Assembly.....................................................................................
15
Optional PendantControl disassembly- Optional PendantControl Assembly.................................................... 15
Testing . .................................................................................................................................................................
16
Parts
Winch AssemblyDrawing.................
....................................................................................................................
Winch AssemblyPartsList ....................................................................................................................................
Air GearMotor Assembly Drawing.......................................................................................................................
Air GearMotor AssemblyPartsList......................................................................................................................
Control Valve Assembly Drawing andParts
List .................................................................................................
Optional Control Assembly Drawing andPartsList .............................................................................................
Optional Valve Assembly Drawing andPartsList ...............................................................................................
Pendant
Control Assembly Drawing andPartsList .............................................................................................
Return GoodsPolicy
warranty..... ..............................................................................................................................................
............................................................................................................................................................
2
17
18
20
21
22
23
24
25
26
27

This manualprovides important information for all
personnelinvolved with the safeinstallation, operationand
propermaintenanceof this product. Even if you feel you
arefamiliar with this or similar equipment,you shouldread
andunderstandthis manualbeforeoperatingtheproduct.
Danger, Warning, Caution and Notice
Throughout this manualtherearestepsandprocedures
which, if not followed, mayresult in injury. The following
signal words areusedto identify thelevel of potential
hazard.
Dangeris usedto indicatethe
presenceof ahazardwhich will
causesevereinjury, death,or
substantialproperty damageif the
warning is ignored.
Warning is usedto indicate the
presenceof a hazardwhich can
causesevereinjury, death,or
substantialproperty damageif the
warning is ignored.
Caution is usedto indicate the
presenceof a hazardwhich will or
can cause minor injury or property
damageif thewarning is ignored.
Notice is usedto notify peopleof
installation, operation,or
maintenanceinformation which is
important but not hazard-related.
Safety Summary
- Do not use this winch for lifting, supporting, or
transporting people or supporting loads over people.
l The supporting structures and load-attaching devices
usedin conjunction with this winch must provide and
adequate safety factor to handle the rated load, plus the
weight of the winch and attached equipment. This is the
customer’s responsibility. If in doubt, consult a qualified
registered engineer.
TheNational SafetyCouncil, Accident PreventionManual
for Industrial Operations,Eighth Edition andother
recognizedsafetysourcesmakeacommonpoint.
Employeeswho work nearcranesor assistin hooking onor
arrangingaload shouldbeinstructed to keepout from
underthe load.From a safetystandpoint,onefactoris
paramount:conductall lifting operationsin suchamanner
that if therewereanequipmentfailure, nopersonnelwould
beinjured. This meanskeepout from underaraisedload
andkeepout of the line of force of any load.
INGERSOLL-RAND Material Handling winchesare
manufacturedin accordancewith the latestASME B30.7
standards.
The OccupationalSafetyandHealth Act of 1970,generally
placestheburdenof compliancewith theowner/employer,
not themanufacturer.Many OSHA requirementsarenot
concernedor connectedwith themanufacturedproductbut
are,rather,connectedwith thefinal installation. It is the
owner’sresponsibility anduser’sresponsibility to determine
thesuitability of aproduct for any particular use.It is
recommendedthatall applicable industry, tradeassociation,
federal,stateandlocal regulations bechecked.Readall
operatinginstructions andwarnings beforeoperation.
Rigging: It is theresponsibility of theoperatorto exercise
caution, usecommonsenseandbefamiliar with proper
rigging techniques.SeeASME B30.9 for rigging
information, AmericanNational StandardsInstitute, 1430
Broadway,New York, NY 10018.
l Using other than genuine INGERSOLL-RAND
Material Handling parts will void the warranty.
3

Thefollowing warnings andoperatinginstructionshave
beenadaptedin part from American National (Safety)
StandardANSI B30.7 andareintendedto avoid unsafe
operatingpracticeswhich might leadto injury or property
damage.
INGERSOLL-RAND recognizesthat mostcompanieswho
usewincheshaveasafetyprogramin forcein their plants.
In theeventthat someconflict existsbetweenarule set
forth in this publication andasimilar rule alreadysetby an
individual company,themorestringent of thetwo should
takeprecedence.
SafeOperatingInstructions areprovided to makean
operatorawareof dangerouspracticesto avoid andarenot
necessarilylimited to the following list. Referto specific
sectionsin themanualfor additional safetyinformation.
1. Only allow personneltrained in safetyandoperationto
operateandmaintain awinch.
2. Only operateawinch if you arephysically fit to do
SO.
3. Whena “DO NOT OPERATE” sign is placedon the
winch, do not operatethe winch until thesignhasbeen
removedby designatedpersonnel.
4. Beforeeachshift, check thewinch for wearor
damage.
5. Never lift a load greaterthan theratedcapacityof the
winch. Seewarning labelsattachedto winch.
6. Keephands,clothing, etc.,clearof moving parts.
7. Neverplaceyour hand inthe throat areaofa hook or
in thevicinity of the wire ropeasit spoolsonto the
drum.
8. Always rig loadsproperly andcarefully.
9. Becertain the load is properly seatedin thesaddleof
thehook. Do not tipload thehook asthis leadsto
spreadingandeventual failure of thehook.
10. Do not “side pull” or “yard”.
11. Make sureeveryoneis clear of the loadpath.Do not
lift aload over people.
12. Never usethe winch for lifting or lowering peopleand
venerallow anyone to standon a suspendedload.
13. Easetheslackout of the wire ropewhen startingalift.
Do notjerk the load.
14. Do not swing a suspendedload.
15. Never suspenda load for anextendedperiodof time.
16. Never leaveasuspendedload unattended.
17. Payattention to theload at all times whenoperating
thewinch.
18. After use,properly securewinch andall loads.
19. Theoperatormust maintain an unobstructed view of
theload at all times.
20. Never usethe winch wire ropeasasling.
Eachwinch is supplied from the factory with thewarning
tagshown.If the tagis not attachedto your unit, ordera
new tagandinstall it. Seethepartslist for thepartnumber.
Readandobeyall warnings andother safetyinformation at-
tachedto this winch. Tag may not beshownactualsize.
I
Read the latest edition of
ASME B50.7. Comply with other
federal. state and local rules.

REMOTE
COlJTROl
Ini -
LEVER
GUARD
Short
Drum model
(Dwg. D6310029)
Air Pressure : 90 psig (6.3 bar)
Air Flow : 124scfm(3.5 cu.m/min)
Drum Size:
Barrel dia. 7-3/32 in. (180 mm)
Flange dia. 11-13/32in. (290mm)
Length BetweenFlanges: 14-3/16in. (360 mm) :
Long drum model
Length BetweenFlanges: 7 - 1/16in. (180 mm) :
Shortdrum model Performance at 90 psi - 3/8 in. (10 mm) wire rope
Drum Wire Rope Storage Capacity :
3/8 in. (10 mm) wirerope: 398ft. (121 m) :
Long drum model
3/8 in. (10 mm) wire rope : 191ft. (58m) :
Shortdrum model
Line Pull Hoisting :
35
3
Maximum full drum line pull 3,300lbs (1500kg)
(5:1safetyfactor)
Line Pull Pulling :
Maximum pulling capacity at 1stlayer 5,250lbs (2400kg)
(3.5:1safetyfactor)
Line Speed:
Speed
In M/min 2 4 6 a 10 12 14
Maximum speedwith no load49 fpm (15 m/min). fpm I I 1 I I I I I 1 1 1
-----GO 10 20 30 40 50
with 3,303 lbs (1500kg) - 23 fpm (7 m/mn) at3rd layer.
with 5,250 lbs (2400 kg) - 13fpm (4 m/mn) at 1stlayer.
Winch Weight :
Without wire rope 155lbs (70.5kg) : Long drum model
Without wire rope 132lbs (60 kg) : Shortdrum model (Dwg. D6310014)
Example: FG1500L-PH4M-CN
3300lbs capacity, with 4 m of control pendent,anddrum guard.
Series Ratings Drum - Control
FG 1500 L - PH PendentHoseLength - Clutch - Options
4M CN - GP
FG L = Long Drum No
Letter = Lever throttle 2M = 2 meters (std.) CN= Clutch G = Drum Guard
No letter = Short Drum on winch XXM = Specify length fitted P = Marine paint
P H = Remote control pendent in meters as standard Z = Sand blast,
1500 =1500kg
handle (aluminum) and primer
PHR = Brass pendent handle
5

TheFG 15OO/CNis anair poweredplanetarywinch desi- thewire ropedrum through theoutput shaft.Thebrakeis
gnedfor lifting andpulling applications.The winch utilizes spring appliedandreleasedby pilot air pressurewhenthe
amulti-disc brakewhich is automatically appliedif thereis winch is operated.In theeventof alossof air pressurethe
alack of air pressure.The output from theexternally moun- brakeautomatically applies.
tedair gearmotor is transmittedthrough afist stage TheFG 1500/CNis equippedwith a manually operatedfree
reduction gearandshaftto theplanetaryreduction.Thepla- wheelclutch. The freewheel clutch permits unloadedwire
netaryreduction drives aring gearwhich is connectedto ropetobepulled from thedrum by hand.
Prior to installing thewinch, carefully inspectit for possible
shipping damage.
l Owners and usersare advised to examine specific,
local or other regulations, including American National
Standards Institute and/or OSHA Regulations which
may apply to a particular type of useof this product
before installing or putting winch to use.
Mounting
1. If winch is to bemountedin oneposition besurethe
mounting surfaceis evenandof sufficient strengthto
handlethe ratedload andpreventpossiblebinding of
thewinch.
2. Make surethemounting surfaceis flat to within 1/32
inch (0.8 mm). Shim if necessary.
3. Mounting bolts mustbe 1/2in. (12 mm)diameter,
Grade8 or better.Useself-locking nutsor nutswith
lockwashers.
4. Tighten mounting bolts evenly andtorqueto 30 lb.ft.
(40N-m) dry. If thefastenersareplated,lubricatedor a
threadlocking compoundis usedtorqueto 23 lb. ft.
(3lN-m).
A
(Dwg. D6310019)
5. Maintain afleet anglebetweenthe sheaveandwinch
of no morethan 1-1/2degrees.For every inch of drum
length, thelead sheavemustbeatleast1.6feet(0.5m)
from the drum.
6. Do not weld to any part of thewinch
Bolt Hole Dimensions
with std long drum With short drum
“A” 14-3/16in. (360 mm) 7-1/16in. (180mm)
“B” 6-17/32 in. (166 mm) 6-17/32 in. (166mm)
“C" 17/32in. (13.5 mm) 17/32in. (13.5mm)
“D” 16.85in. (428 mm) 9.76in. (248mm)
Wire rope
.
.
Maintain at least 3 wraps of wire rope on the drum at
all times.
. Install the wire rope to comeoff the drum in an
underwind position asindicated on the direction of
rotation tag.
Wire Rope Selection
Consult areputablewire ropemanufactureror distributor
for assistancein selectingthe appropriatetypeandsizeof
wire ropeand,wherenecessary,aprotective coating.Usea
wire ropewhich provides anadequatesafelyfactorto
handletheactual working load and meetsall applicable
industry, tradeassociation,stateandlocal regulations.
Whenconsidering wire roperequirementstheactual
working load must include not only thestaticor deadload
but alsoloadsresulting from acceleration,retardationand
shockload.Consideration mustalsobegiven to thesizeof
thewinch wire ropedrum, sheavesandmethodof reeving.
Wire ropediameterfor lifting is 3/8 in. (10 mm).Maximum
wire ropediameteris limited by the wire ropeanchor.
Installing Wire Rope
1. Cut wire rope to length in accordancewith thewire
ropemanufacturer’sinstructions.
2. Feedthe endof the wire rope into thesmalleranchor
hole in thewire ropedrum andpull through
approximately onefoot (0.3 m) of wire rope.
3. Tuck theendof thewire ropeback into thewire rope
anchorpocket forming aloop in thewire rope.
4. Insert the wire rope anchorandpull thewire rope
through the slot tightening the wire ropearoundthe
wire rope anchor.
6

Air Supply
The air supply mustbecleanandfreefrom moisture.
(Dwg. D6310020)
l Make sure the first wrap of wire rope is flush against
the drum flange.
5. Pull the wire rope anchorinto position in thedrum
anchorpocket.
Wire Rope Spooling
To compensatefor unevenspooling anddecreasein line
pull capacityasthedrum fills up, useasshortawire rope
aspractical. To rewind wire ropeapply tensionto eliminate
slack.This helpsachievelevel winding andtight spooling.
SafeWire Rope Handling Procedures
1. Always usegloves when handling wire rope.
2. Never usewire ropewhich is frayedor kinked.
3. Never usewire ropeasasling.
4. Always ensurewire rope is correctly spooledandfirst
layer is tight.
Rigging
Make sureall wire ropeblocks, tackle andfasteningshave
sufficient safetymargin to handlethe requiredload. Do not
allow wire rope to contactsharpedgesor makesharpbends
which will causedamageto wire rope, useasheave.Refer
to wire rope manufacturer’shandbookfor propersizing, use
andcareof wire rope.
SafeInstallation Procedures
1. Do not usewire ropeasaground for welding.
2. Do not attachawelding electrodeto winch or wire
rope.
3. Never run the wire ropeover asharpedge.Usea
correctly sizedsheave.
4. When a lead sheaveis used,it mustbealigned with the
centerof the drum. The diameterof theleadsheave
mustbeat least 18timesthe diameterof thewire rope.
5. Always maintain atleastthreefull wrapsof wire rope
on thedrum.
Air Lines
The inside diameterof the winch air supply lines should not
besmallerthan 3/4 in. (19 mm) for flexible lines and5/8in.
(17 mm) for connectors.Before making final connections,
all air supply lines should bepurgedbeforeconnectingto
systeminlet. Supply lines shouldbeasshortandstraight as
installation conditions will permit. Long transmissionlines
andexcessiveuseof fittings, elbows, tees,globevalves,
etc.causeareduction in pressuredueto restrictionsand
surfacefriction in the lines.
Air Line lubricator
Always usean line lubricator with thesemotors.Usea
lubricator having aninlet andoutlet at leastaslargeasthe
inlet on themotor. Install thelubricator in
aheadof themotor. theair line just
l Lubricator should be located no more than 10ft. (3m)
from the motor.
The air line lubricator should bereplenisheddaily andsetto
provide 2 to 3 dropsper minute of SAE 30Woil (minimum
viscosity 135Cstat 104°F (40°C)).
Winchesaredelivered with the gearbox filled with oil.
Motor
For optimum performanceandmaximum durability of
parts.operateair motor at 90psi at 70scfm(6.3bar/630
kpa at3.5cu.m/min) air pressureandvolume.The winch
shouldbeinstal1edasnearaspossibleto thecompressoror
air receiver.
Initial Operating Checks
Winchesaretestedfor properoperationprior to leaving the
factory. Beforethewinch is placedinto servicethe
following initial operatingchecksshouldbeperformed.
1. Whenfirst running the motor somelight oil shouldbe
injectedinto the inlet connection to allow good
lubrication.
2. Whenfirst operating the winch it is recommendedthat
themotor bedriven slowly in both directions for afew
minutes.
For winchesthat havebeenin storagefor aperiod of more
thanonemonth thefollowing start-upprocedureis
recommended.
1. Pourasmall amountof gasoline fluid in themotor
inlet port.
2. Operatethe motor for 10seconds
lo flush out any
impurities.
3. Poursmall amountof oil in themotor air inlet port.
4. Operatethe motor for anadditional 2 lo 3 seconds.
The winch is now readyto work.
7

Thefour mostimportant aspectsof winch operationare:
1. Follow all safetyinstructions whenoperatingthe
winch.
2. Allow only peopletrained in safetyandtheoperation
of this winch to operatethe winch.
3. Subjecteachwinch to aregular inspectionand
maintenanceprocedure.
4. Be awareof thewinch capacityandweight of loadat
all times.
l The FG 1500/CNWinch is not designedor suitable for
lifting, lowering or moving persons.Never lift loadsover
people.
Winch Control
The winch spring loadedmanualcontrol throttle is mounted
to theair motor.
Whenviewed from theair motor endmovethecontrol
throttle handletothe right (clockwise) to payout wire rope.
Whenviewed from theair motor endmovethecontrol
throttle handleto theleft (counterclockwise) to haul in wire
rope.
To ensuresmoothoperation of thewinch sudden
movementsof control valve shouldbeavoided.
RemotePilot Pendant Throttle (optional)
Thependentcontrol throttle is equippedwith two separate
leversfor winch operation.Pilot pressurefrom thependant
throttle activatesthewinch control valve. Direction of drum
rotation is controlled by whichever lever is depressed.
l To avoid damageto the rigging, the structure
supporting the rigging and the winch, do not “two-
block” the end of the wire rope.
Free Wheel Clutch
To disengagethe freewheel clutch pull out the spring
loadedplunger until it clearsthegroove in thehandleshaft.
Maintain ahold on theplunger knob andpull out thefree
wheelclutch handle.Releasethespring loadedplunger soit
locksbackinto the shaftgroove.Gently pull andpushon
thefreewheel chutch handleto checkplunger is engaged.
l Never disengageclutch with a load on the wire rope.
l Winch controls must be in the neutral position before
operating the free wheel clutch.
To engagethefree wheel clutch pull out thespring loaded
plunger until it clearsthegroove in thehandle shaft.
Maintain ahold on theplunger knob andpushin thefree
wheelclutch handle.Releasethe spring loadedplunger soit
locksbackinto the shaftgroove. Gently pull andpushon
thefreewheel clutch handleto checkplunger is engaged.It
maybenecessaryto rotatethe durm slowly by handto
allow theclutch drive shaftto engage.

Wire Rope
Referthewire ropemanufacturer’srecommendations.At a
minimum observethe following :
1. Clean with abrush or steamif thereis dirt, rock dust
or other foreign material on the surfaceof thewire
rope
l Do not usean acid-based solvent or other cleaning
fluid.
2. Apply awire ropelubricant or SAE 30Woil.
3. Brush, drip or spraylubricant weekly, or more
frequently, dependingon severity of service.
Reduction Gear Assembly
Winchesaredelivered with thegearbox filled with oil.
Replacetheoil in thereduction housing atleastonceevery
year.If thewinch is usedat anormal frequency,theoil in
thereduction housing is suitablefor oneyearsoperation
without changing. However, when the winch is usedata
high frequeney,theoil may needto bechangedonamore
frequentbasis.
To ensurecorrectperformance,highest efficiency andlong
life, it is essentialthat thelubricating oil bemaintainedat
thecorrectlevel. The recommendedgradeof oil must be
usedatall timessincethe useof unsuitableoil mayresult in
excessivetemperaturerise, lossof efficiency andpossible
damageof thegears.
The reduction gearassemblyis filled andshippedwith SAE
8OW90oil having akinematic viscosity of 145mm2/sat
40°C (104°F) from the factory. Useonly high quality
lubricants in thereduction gearassemblysuchashigh grade
EPtype oil or theequivalent.
Fill thereduction gearassemblyuntil theoil is level with
theworking rim.
Oil capacity : 0.13gall (0.5Ltrs)
Below 32°F (0°C) SAE 5ow EP4
32” to 80°F (0°’to 27°C) SAE 90 EP4
Above 80°F (27°C) SAE 140 EP4
Drum Bushings
Lubricate greasefittings monthly with 2or 3pumpsof a
greasegun. Rotatethedrum slowly asgreaseis being
applied.For temperatures-20° to 50°F (-29” to 10°C)usea
multipurpose lithium-based EPl grease.For temperatures
30” to 120°F(-1° to49°C) usea multipurposelithium-
basedEP2grease.
Sealsand Bearings
If winch is disassembled,cleanall partsthoroughly and
coatbearingsandsealswith cleangrease.Usesufficient
greaseto provide agoodprotective coat.
Free Wheel Clutch
If winch is disassembled,apply alight coating of greaseto
theplunger andclutch handleshaft.
Storage
For exchangewinchesor winchesthat will not beoperated
for extendedperiodspour asmall amountoil into the motor
inlet port or supply line. Operatethe motor for 2 to 4
secondsto lubricate themotorpartsthenplug theair inlet
port.
Therearetwo typesof inspection, the frequentinspection
performedby theoperatorwhile using thewinch and
periodic inspectionsperformedby personneltrainedin the
operationandmaintenanceof this winch. Careful
inspection on aregular basiswill revealpotentially
dangerousconditions while still in the early stages,
allowing corrective action to betakenbeforethecondition
becomesdangerous.
Any deficiency revealedthrough inspection mustbe
reportedlo an appointedperson.A determinationmustbe
madeasto whetheradeficiency constitutesasafetyhazard
beforeresuming operationof the winch.
Records and Reports
Someform of inspection recordmustbemaintainedfor
eachwinch, listing all points requiring periodic inspection.
A written report shouldbemademonthly on thecondition
of thecritical partsof eachwinch. Thesereportsshouldbe
dated, signedby thepersonwho performedthe inspection,
andkept on file wherethey arereadily available for review.
Frequent Inspection
On awinch in continuous service,frequentinspection
shouldbemadeatthebeginning of eachshift. In addition,
visual inspectionsshouldbeconductedduring regular
servicefor any damageor evidenceof malfunction.
1. OPERATION. Checkfor visual or abnormalnoises
which could indicate adefect.Do not operateawinch
unlessthewire ropefeedsonto thewinch drum
smoothly. If wire ropebinds orjumps, cleanand
lubricate the wire rope.If problem persists,replacethe
9

wire rope.Do not operatethe winch until all defects
havebeencorrected.
2. AIR SYSTEM. Checkair lines, valvesandother
componentsfor leakage.Repairif necessary.
3. WIRE ROPE.Wire ropeis aconsumableitemwhich
mustbereplacedwhen worn. The following list is a
guide to theacceptedstandardsby which wire rope
mustbejudged andis not presentedasasubstitutefor
anexperiencedinspector:
a. Damage,suchasbird cages,kinking, core
protrusion, crushing, heatdamage,andmain
stranddisplacement.
b. Corrosionandnicking.
C.
Wearof crown wires.Replaceat l/3 wearof any
crown wire.
d. Brokenwires or strands,particularly at
connections.Replacementis necessaryif one
wire is broken ataconnection; six wiresbroken
within onelay; threewires broken in onestrand
within-one lay.
e. Lubrication.
Replacewire ropeif any doubtexistsasto wire rope
serviceability.
4. WIRE ROPEREEVING. Cheekreeving andensure
wire ropeis properly securedto thedrum.
5. CONTROLS. Seethat controls function properly and
control handlereturns to neutral centerwhenreleased.
Periodic Inspection
According to ASME B30.7, frequencyof periodic
inspection dependson theseverity of usage:NORMAL,
yearly; HEAVY, semi-annually; SEVERE,quarterly.
Disassemblymay,berequired for HEAVY or SEVERE
usage.Keepaccumulative recordsof periodic inspectionslo
provide abasisfor continuing evaluation. Inspectall the
itemsin afrequentinspectionplus the following:
1. FASTENERS.Check,capscrew,nuts,pins andother
fastenerson winch andair system.Replaceif missing
andtighten or secureif loose.
2. ALL COMPONENTS. Inspectfor wear,damage,
distortion, deformation andcleanliness.If external
evidenceindicates theneed,disassemble.Checkgears,
shafts,bearings,springs andcovers.Replaceworn or
damagedparts.Clean, lubricate andreassemble.
3. DRUM AND SHEAVES. Checkfor damageor
excessivewear.Replaceif necessary.
4. BRAKE. Perform functional load teston winch. Check
ability of thebraketo hold ratedload.
5. LABELS AND TAGS. Cheekfor presenceand
legibility. Replaceif necessary.
6. WIRE ROPE.Besidesthe itemsin afrequent
inspection,inspectfor the following :
a. Build-up of dirt andcorrosion.Cleanif
necessary.
b. Looseor damagedendconnection.Replaceif
looseor damaged.
C.
Cheekwire ropeanchoris secure.
d. Changesin thesizeof thewire ropediameter.
Periodically measurethediameterof thewire
ropefrom crown-to-crown throughoutthelife of
thewire rope.The actualdiametershouldbe
recordedwhen thewire ropeis underequivalent
loading and in thesameoperatingsection.If the
actualdiameterof the wire ropehasdecreased
morethan 1/64in. (0.4 mm)athorough
examination of thewire ropeshouldbe
conductedby anexperiencedinspectorto
determinethe suitability of thewire ropeto
remain in service.
(ref. Dwg. D6310012)
i
CROWN
TO
CROWN
1
(Dwg. D6310012)
7. FOUNDATION. Check for thecontinuedability
lo
handlethe imposedloads.
Winches Not in Regular Use
A winch which hasbeenidle for aperiod of onemonthor
more,but lessthan six months,shall begiven aninspection
conforming with the requirementsof “FrequentInspection”
beforebeing placedinto service.
A winch which hasbeenidle for aperiod of over six
monthsshall begiven acompleteinspectionconforming
with therequirementsof “Periodic Inspection”. Standby
winchesshall be inspectedal leastsemi-annuallyin
accordancewith the requirementsof “FrequentInspection”.
If abnormaloperating conditions apply, winchesmay
require amorefrequent inspection.
10

This sectionprovides theinformation necessaryfor troubleshootingthis winch. The troubleshooting guide provides ageneral
outline of problems whichcould beexperiencedwith normal useof this winch. It lists the symptom, thepossiblecause,andthe
possibleremedyfor the trouble being experienced.
SYMPTOM
Winch will not
operate.
Loadcontinues to
movewhen winch
isstopped.
CAUSE
No air supply to
winch.
Winch is overloaded.
Brake is slipping.
Winch is overloaded.
REMEDY
Checkconnectionsandhosesin air supply line.
Reduceloadto within ratedcapacity.
Checkbrakefriction discsandsprings
See“MAINTENANCE” section.
Reduceload towithin ratedcapacity.
Winchwill not lift
loador doesnot
liftratedcapacity.
Winch is overloaded.
Motor maybedamaged.
Brake is not releasing.
Insufficient air supply.
Reduceload to within ratedcapacity.
Inspectmotor.See“MAINTENANCE” section.
Checkbrakereleasepilot hole is not restricted.
Checksealson brakepiston arenot damaged.
Checkair supply pressureand volume.
oilleaksfrom
drumbushing area.
Lowpower.
Motordoesnot
operatesmoothly.
Reduction assembly
is leaking.
Low air pressureat
the inlet.
Worn or damaged
motor gears.
Improper lubrication
or dirt building up
in the motor.
Winch binds during
operation.
Worn or brokenrotor
bearings.
Disassemblewinch andinspect reduction
assemblyseals.
Checkair pressureat theinlet while winch is running.
Inspectmotor.See“MAINTENANCE” section.
Lubricate asinstructedin “LUBRICATION” section.
If this doesnot help, flush the motor asinstructed
in the“INSTALLATION” section.
Checkwinch mounting surfaceis flat anddoesnot
distort during winch operation.
Examineeachbearing.Install new bearingsas
necessary.
11

l Never perform maintenance on the winch while it is
supporting a load.
l Before performing maintenance, tag controls :
DANGER - DO NOT OPERATE - EQUIPMENT
BEING REPAIRED.
l Only allow service personnel trained in the operation
and service of this winch to perform maintenance.
l After performing any maintenance on the winch, test
winch to 125% of its rated capacity before returning to
service.
l Do not useTrichloroethylene to clean parts.
Disc Brake (ref. Dwg. D6310008)
AdJustment
No brakeadjustmentis required.
Inspection
If brakeslippageoccursduring testsprior to placing winch
in serviceor during normal useof thewinch, thefollowing
procedureis required.
1. Turn off air system,depressurizeair lines and
disconnecttheair hose.
2. move thewinch to asuitablerepair areaandstandin a
vertical position sorearendcover (65) is down.
3. Removethe four screwswhich securethemotor
assembly(31)to themounting flange (32) andpull off
themotor straight away from thewinch.
4. Removethe four screws(33) which securethe
mounting flange (32) to the front endcover(40).
Removethe mounting flange using two jacking screws
HM6-25 metric threadlength oneinch (25mm) to
extract themounting flange.
5. Removethegearwheel (39).
6. Checkdimension “C” from thebrakepiston (27) to the
front endcover (40) asshown in Dwg. D6310003.If
this dimension is greaterthan0.16in. (4 mm), the
brakediscs(21 and22) mustbereplacedby following
thewinch disassemblyprocedure.
General Disassembly Procedures
Thefollowing instructions provide the necessary
information to disassemble,inspect,repair, andassemble
thewinch. Referto thewinch assemblydrawing provided
in thePartsSection.
If a winch is being completely disassembledfor anyreason,
follow theorderof thetopics asthey arepresented.
It is recommendedthatall maintenancework on thewinch
beperformedon abenchin acleandust freearea.
In theprocessof disassemblingthe winch, observethe
following:
Neverdisassemblethewinch any further thanis
necessaryto accomplishthe neededrepair.A good
partcanbedamagedduring thecourseof disassembly.
Neveruseexcessiveforce when removing parts.
Tappinggently aroundtheperimeterof acoveror
housingwith asoft hammer,for example,is sufficient
tobreaktheseal.
Do not heatapart with a flame to freeit for removal,
unlessthepartbeing heatedis already worn or
damagedbeyondrepair andno additional damagewill
occurto other parts.
In general,thewinch is designedto permit easy
disassemblyandassembly.The useof heator excessive
forceshouldnot berequired.
4.
5.
6.
7.
Keepthework areaascleanaspractical, to prevent
dirt andother foreign matterfrom getting into bearings
or othermoving parts.
All sealsand ‘0’ rings shouldbediscardedoncethey
havebeenremoved.New sealsand‘0’ rings shouldbe
usedwhenassemblingthe winch.
Whengraspingapart in avise always useleather-
coveredor copper-coveredvisejaws to protectthe
surfaceof thepart andhelp prevent distortion. This is
particularly true of threadedmembersandhousings.
Do not removeany part which is pressfit in or ona
subassemblyunlesstheremoval of thatpartis
necessaryfor repairsor replacement.
Disassembly Instructions
Winch Disassembly (ref. Dwg. D6310008)
1. Disconnectandtagtheair lines.
2. Removewinch from its mounting andsetin aclean
work areaon asturdy work bench.
3. Position thewinch vertically with themotor enddown.
4. Removethe nuts (2) andlock washers(3).
(Dwg. D6310032)
12

5. Removethe rearend-cover(65):
5.1 Unscrew the handle(75) andpull theplunger
(80) to removeaxle (74), clutch (69) andthe
spring (73).
5.2 If necessaryremoveretainer rings (77and78) to
removeclutch (69) andbearing(79) from axle
(74).
5.3 Removescrews(71), plunger body (70)andthe
plunger (80).
5.4 Extract theexhaustwashers(66) andtherings
(67).
5.5 Pull bearing (68) from rearendcover(65).
6. Pull thedrum (64) from thewinch.
6.1 Removethe spacer(76).
6.2 Removethe drum bushings(47) if theyrequire
replacement.
7. Removethereduction gearandbrakeassemblyfrom
thedrum.
8. Removetheoil drain plug (6) anddrain theoil from
thegearcasing.
9. Removethe four screwswhich securethemotor(31)
to the mounting flange (32) andpull off themotor
straight away from thewinch. For disassemblyof the
motor and thevalve, follow thecorresponding
procedure.
10. Removethegasket(37) and the‘0’ ring (29) anddrain
theoil from thebrakethrough the mounting flange
bore.
11. Removethe threenuts(2) and lock washers(3) and
removethe threetie rod spacers(4).
12. Removethegearboxandbrakeassemblyfrom the
output shaft(5).
13. Disassemblyof the front end-cover(40):
13.1 Removescrews(33).
13.2 Removethe mounting flange (32). Extract theoil
seal(36), bearing (35) andthepins (28).
The oil seal has been installed with Loctite® 460on the
backside of the seal.
13.3 Removethe gasket(38) andthe‘0’ ring (29).
13.4 Removethegearwheel (39) andthespacer(44).
13.5 Removethe screws(42).
13.6 Removethe front endcover (40).
14. Disassemblyof thebrake:
14.1 Removethe ‘0’ ring (26).
14.2 Removethe springs(49).
14.3 Extract thebrakepiston (27) by usinglow
pressurecompressedair in brakereleaseport.
14.4 Removethe ‘0’ rings (24 and25).
14.5 Removescrews(43). -
14.6 Extract the stopring (23) by usingjacking
screwsin thethreeM6 threatedholes.
Stop ring (23) hasbeeninstalled with Loctite®
Instajoin t 574.
14.7 Removefriction discs(21), steeldiscs(22) and
stopring (46).
15. Disassemblyof thegearbox:
15.1 Removescrews(55) andlock washers(56).
15.2 Extract thegearbox coverby usingjacking
screwsin thetwo M4 threatedholes.
15.3 Pressout theoutput shaft(5) andtheoutput
annulargear(58).
15.4 Removethebearings(59 and61), oil seal(60)
andthe‘0’ ring (9).
15.5 Removethebearing(10), spring washer(57) and
theoutput annular gear(58).
15.6 Removethe satellite supportassembly.
15.7 Pushout thesatellite axles (11).
15.8 Removethesatellites(15), bearingstuds(12)
andstoprings (13).
15.9 Removetheneedlebearings(14) andthespacers
(16).
15.10Disassemblyof thefixed annular gear(19):
- compressthe‘0’ ring (20) by using thespecial
tool M6313400.
- removetheretainer ring (17).
- pushout thefixed annular gear(19).
- removethe‘0’ ring (9).
- removethepins (28).
- removethe‘0’ ring (20).
15.11Disassemblyof theshaftspindle(18):
- removetheretainerring (45).
- pushout theshaftspindle (18) andremovethe
coupling sleeve(51).
15.12Removetheretainerring (48).
15.13Removethebearing(52).
Inspection
1.
2.
3.
Inspectall gearsfor worn, cracked,or brokenteeth.
Inspectall bushingsfor wear,scoring, or galling.
Inspectall bearingsfor play, distordedraces,pitting
androller or ball wearor damage.Inspectbearingsfor
freedomof rotation.
4.
5.
6.
7.
8.
13
Inspectshaftsfor ridgescausedby wear.If ridges
causedby wearareapparenton shafts,replacethe
shaft.Inspectall surfaceson which oil seallips seat.
Thesesurfacesmustbevery smoothtoprevent
damageto theseallip.
Inspectall threadeditemsandreplacethosehaving
damagedthreads.
Inspectall remaining partsfor evidenceof damage.
Replaceor repairany part which is in questionable
condition. Thecostof thepart is often minor in
comparisonwith the costof redoing thejob.
Smoothout all nicks, burrs, or galled spotson shafts,
bores,pins, or bushings.
Examine all gearteethcarefully, andremovenicks or
burrs.

9.
10.
11.
12.
13.
Polish theedgesof all Shaftshouldersto removesmall
nicks which may havebeencausedduring handling.
Removeall nicks andburrscausedby lockwashers.
Replaceall gaskets,oil seals,and‘0’ rings anytime
thewinch is disassembledfor repair.
Inspectdrumbushings (47) for wear,if thicknessis
lessthan0.039in. (1 mm),replacedrumbushings.
Inspectbrakediscs(21 and22) for wear,if thickness
lessthan0.354in. (9 mm),replacethem.
winch Assembly
Assemblyof thegearbox is thesameasdisassemblyin
oppositeorder.
.
Periodic lubrication of drum bushings can bedoneby
applying greasethrough nipple (28) at the bottom of
motor casing.
Carefully clean exhaustwashers(66) withpetroleumand
compressedair.
Fill up the gearbox with oil SAE 8OW90
kinematic viscosity 145mm’/sat40°C (104°F)
capacityof gearbox : 0.13 gall (0.5Ltrs)
Control Valve Disassembly (ref. Dwg. D6310006)
.
For correct assemblyof planet gears,eachplanet gear
must bepositioned with the timing mark asshown on
drawing D6310013.
(Dwg. D6310013)
1. After assemblyof satellite support(54) with thefixed
annular gear(19) and theshaftspindle(18) ,checkfor
goodindexing of planetgearsandrepeattheabove
operationif necessary.
2. Stopring (23) assembly:
2.1 On thefaceof thestopring (23) which makes
contactwith the gearbox (53) apply abeadof
Loctite® instajoint No. 574 aroundthefixing
holesandtheexternal diameter.
3. Oil seal(36) assembly:
3.1 Cleanthemounting flange (32) boreandapply a
beadof Loctite® No. 460 on thebacksideof
theoil seal.Install oil seal.
4. Drum bushing (47) assembly:
4.1 Scrapeold Loctite® from thedrumbushingbore
andapply abeadof Loctite® 406 on thesmooth
faceof drum bushings(47).
4.2 Install drum bushing in drum bushingboreby
taking careto adjustthegapsof thedrum
bushingsto 3.9 ins. (100mm) do not allow any
clearancebetweendrum bushingsanddrum.
4.3 Lubricate drum bushingswith grease.
4.4 Install thedrum on the gearbox assembly.
4.5 Lift out thedrum to checkfor goodpositioning
of drum bushings.
1. Removescrews(10) andlock washers(11).
2. Removethe valve assemblyfrom the motor.
3. Tapout thepin (8).
4. Extract thecontrol lever (1).
5. Removescrews(7).
6. Removestop(9).
7. Removethereturn spring (4).
8. Pull out therotary valve (6).
.
Localize the mounting position of the rotary valve in
the valve housing.
9. Remove‘0’ ring (5).
Inspection
Worn or damagedpartsmustbereplaced,polish theedges
of rotary valve to removesmall nicks if necessary.
Control Valve Assembly
Assemblyof control valve is the sameasdisassemblyin
oppositeorder.
Mounting of rotary valve must be done carefully to
avoid damage.Lubricate rotary valve before assembly.
Lubricate spring (4).
Screws(7) mustbe installed with Loctite® NO.243.
Air Gear Motor Removal (ref. Dwg. D6310005)
1. Standwinch in avertical position on therearend
cover.
2. Removethe4 screwswhich securethemotorto the
mounting flange.
3. Removemotor andcontrol valve assembly.
4. Removethe4 screwswhich securethecontrol valve to
themotor andremovethecontrol valve.
Air Gear Motor Disassembly
1. Removethe screws(1) andlock washers(2).
2. Removethe motor housing (27).
3. Removethe ‘0’ ring (16).
4. Removethe gasket(15).
14

5.
6.
7.
8.
9.
10.
11.
12.
Remove screws(26).
Removethe motor cover (14).
- removethe‘0’ rings (9).
- removetheexhaustwasher(7) andtheplug (8).
- removetheneedlebearings(5 and 11)if they have
to bechanged.
- removepins (3).
Immobilize the motor rotors with anpin betweenthe
teethandremovenuts (18 and23).
Removethe motor rotors (13 and4) .
- removetheshaftsegment(6) andtheinternal ring.
Removethe screw(21) andthewasher(20).
Removeball bearings(17 and24).
Removethe spacer(12).
Removethe stopper(25), thespring (19) andtherear
stop(22).
Inspection
- inspectgearsandremovenicks or burrs
- inspectandreplacebearingsif necessary
- inspectmotor body and smoothout all nicks or burrs
- inspectthevalve andsmoothout all nicks or burrs
Air Gear Motor Assembly
Assemblyof motor is the sameasdisassemblyin opposite
order.
l To correctly assemblethe exhaust washer, spacer,
valve and the spring, carefully follow instructions:
- Take the motor body andput it in the sameposition as
mounting on thewinch andview from thebacksideof
themotor body, stopper,spring, valve andthe spacer
mustbe mountedin the left bore.Checkfor good
functioning of thevalve.
- The exhaustwashermustbemountedon thesameside
asthe valve in the left bore.
- Beforeassemblylubricate bearing with grade2 grease.
- Install ball bearingssomarkingson bearingremain
visable.
- After assemblyof theair motor, it mustturn smothly in
both direction.
- The screws(21 and26) the nuts (18 and23) mustbe
securedwith LOCTITE® 243, securethenutswith a
centerpunch.
Valve Disassembly Optional Remote Control
(ref. Dwg. D6310026)
1. Removescrews(3).
2. Removethe valve assemblyfrom the motor.
3. Removethe cover (4) from the valve body (10).
l The cover (4) has been installed with Loctite®
instajoint No. 574.
4. Remove screws(1) andlock washers(2)
5. Removetheendcaps(7) andandtherearstops(8).
6. Removethe slide valves (9) andreturn spring (5).
6.1 Removethequadrings (12).
7. Removethequadrings (6) from the valve body.
Valve Assembly Optional Remote Control
Assembyof optional valve assemblyis thesameas
disassemblyin oppositeorder.
l Screws(3) must besecured with Loctite® No. 243.
Pendant Control Disassembly (Ref. Dwg. D6310027)
1. Removethe malefittings (1) andthering (9).
2. Removetheretainerring (2).
3. Putout therearcovers(4) with the‘0’ ring (5).
4. Removethe springs(3).
5. Removethe “slide valve assemblies”(6) with thequad
ring (8).
6. Removethe springs(7).
7. Removethe valve coneassemblies(10).
8. Removethe screws(12).
9. Takeout thepin (11) in orderto removethelevers
(13).
Pendant Control Assembly (ref. Dwg. D6310027)
1. Assemblyof thependantcontrol is thesameas
disassemblyin oppositeorder.
2. Adjustment
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Connectthe inlet of the pendantto 100psi
(7 bar) pressureair supply.
Connectamanometerat theoutlet of the leverto
beadjusted.
Put someLoctite® No. 243on theadjustment
screw.
Tighten theadjustmentscrewto obtain a
pressureof 15psi (1 bar) without actioning the
lever.
Releasetheadjustmentscrewby ahalf turn
(pressuremustfall down to zero).
Pushthe lever.
Checkthatpressurereaches93*‘psi (6.5’ o.5bar).
Checkthat thereis no leak atexhaust.
Releasethelever, exhaustmustoccurby rapid
pressurereduction.
Repeatoperations“2.6 and2.7” from 2 to 3
times.
Disconnectthemanometer.Checkthat thereis
no leak when thelever is not actuated.
2.10 Repeattheoperationsfrom 2.1 to 2.9 with each
lever.
15

Testing
Operational Tests
Prior to initial use,all new,alteredor repairedwinches
shall betestedto ensureproperoperation.
1. Operatewinch in both directions with no load.
2. Checkoperationof freewheelandbrake.
3. Checkoperationof limit switchesandothersafety
deviceswhenprovided.
Load Test
Prior to initial use,all new,extensively repaired,or altered
winchesshall beload testedby or underthedirection of a
persontrained in theoperationandserviceof this winch,
andawritten report furnished confirming therating of the
winch. Testloadsshall not bemorethan 125%of therated
line pull.
4. Checkall winch mounting bolts aresecure.
Tooling installation M6313400
(Dwg. D6310031)
M6313100
16

(Dwg. D6310008A)
17

7
ITEM DESCRIPTION
QTY
PART NO.
NO. OF PART TOTAL
2
3
4
Nut 6 4300-0211
Lock washer 6 4520-0010
Tie rod spacer
(14-3/16 in. Ig drum) 3 9631-0052
Tie rod spacer(7-1/16 in. lg drum) 963I-0008
n
Item cancelled from Serial number:93-07-09
18

ITEM DESCRIPTION
QTY
PART NO.
NO. OF PART TOTAL
l 50
'o'ring 1 5820-7129
51 Coupling sleeve 1 9631-0070
52 Bearing 1 5ooO-0002
53 Gearbox 1 963l-0004
54 Satellite support 1 9620-0010
55 Screw 6 4131-1106
56 Lock washer 6 4520-0004
57 Spring washer 1 6917-2132
58 Output annular gear 1 9620-0031
59 Bearing 1 5080-0009
5801-2130
83”
84*
85*
86*
87*
88*
89*
90*
91
92
93
Steelair filter 3/4” BSP
Filter - Lubricator (F.L.) 3/4” BSP
Filter - Regulator - Lubricator
(F.R.L.) 3/4” BSP
Galvanized wire rope
l 9 mm 0 - Break load 7330kg -Per m.
l 10mm0 - Break load9070kg - Perm.
l 10mm0 - Breakload9800kg - Perm.
Thimble mount on rope
Hook mountedon thimble
Warning tag
Nameplate
IR Logo
1 7428-2079
1 7999-0067
1 7999-0066
1 6972-0009
1 6972-0010
1 6975-0010
1 6972-9999
1 6972-9998
1 7106-0529
1 7106-7003
1 71lo-6322
I
* Recommended spare
Optional partsandaccessoriesnot shownon drawing
19

(Dwg D6310005B)
20