Ingersoll-Rand Liftstar LS2-600H Setup guide

Product Maintenance
Information
Liftstar Hydraulic Winch
Model LS2–600H and PS2–1000H
(Dwg. MHP2827)
Save These Instructions
R
Form MHD56361
Edition 4
January 2014
43801737
©2014 Ingersoll Rand

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 Information Manual (Non-Man Rider) MHD56250 Product Information Manual MHD56359
Product Parts Information Manual MHD56360
INSPECTION
Frequent inspections should be performed on equipment in regular service. Refer
to Product Information Manual.
nPeriodic Inspection
Refer to Table 2 ‘Inspection Classifications’ on page 2 for suggested winch
inspection classifications for Periodic Inspection intervals. Select inspection periods
most appropriate to application conditions.
Table 2: Inspection Classifications
Conditions Normal Heavy Severe
Typical Use (operating time) Infrequent Regular Continual/Constant
Load Range Usually light loads, occasional max. loads Usually medium loads, frequent max. loads Usually max. loads or almost max. loads
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
for continuing evaluation. Inspect all items listed in ‘Frequent Inspection‘. Also
inspect the following at the suggested intervals recommended in Table 3
‘Maintenance Interval Chart’ on page 3:
1. Siderails, Spacers, 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. Lubricate after cleaning.
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, A. Wire;
B. Crown to Crown; C. Strand; D. One Lay.
A
B
C
D
(Dwg. MHP0056)
5. All Components. Inspect for wear, damage, distortion, deformation 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 drum band brake
to compensate for normal brake lining wear. Refer to ‘Adjustments‘ in the
“MAINTENANCE” section. If brake band cannot be adjusted to hold rated load,
replacethebrakebandassembly.Adjustmentscannotbemadeto thediscbrake.
The disc brake must be repaired as described in the “MAINTENANCE” section.
7. FoundationorSupportingStructure.Checkfordistortion,wearandcontinued
abilitytosupportwinch and rated load. Ensurewinchisfirmly mounted and that
fasteners are in good condition and tight.
8. Control Valve. Check control valve operation. Ensure control valve handle
moves freely in both directions without sticking and automatically returns to
neutral when released.
9. Drum Guard. Verify fasteners are tight and in good condition. Ensure guard is
in good condition.
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 ‘Periodic Inspection’ and Table 2 ‘Inspection Classifications’ on page 2, for
maintenance interval guidance.
NOTICE
• Perform an annual winch load test for all applications.
2 Form MHD56361 Edition 4

Table 3: Maintenance Interval Chart
Normal Application
The following work can be completed by owner maintenance personnel
System Hydraulic Filter Inspect system hydraulic filter every 45 days or 125 hours.
Grease Fittings Lubricate grease fittings every 180 days or 500 hours.
It is recommended that the following work be completed by an 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 8 years or 8,000 hrs
Inspect Motor X X X
Inspect Disc Brake X X
Inspect Gearbox X X
Replace Winch Anchor Bolts X X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Heavy Application
The following work can be completed by owner maintenance personnel
System Hydraulic Filter Inspect system hydraulic filter every 30 days or 100 hours.
Grease Fittings Lubricate grease fittings every 90 days or 250 hours.
It is recommended that the following work be completed by an 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 7 years or 7,000 hrs
Inspect Motor X X X
Inspect Disc Brake X X
Inspect Gearbox X X
Replace Winch Anchor Bolts X X X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Severe Application
The following work can be completed by owner maintenance personnel
System Hydraulic Filter Inspect system hydraulic filter every 30 days or 100 hours.
Grease Fittings Lubricate grease fittings every 90 days or 250 hours.
It is recommended that the following work be completed by an 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 7 years or 7,000 hrs
Inspect Motor XXXXXX
Inspect Disc Brake X X X X
Inspect Gearbox X X X
Replace Winch Anchor Bolts X X X X
Inspect Control Valve X X X X X X
Inspect Drum, Housings and Main Frames XXXXXX
Note: Hours are for actual winch drum rotation. Perform an annual winch load test for all applications.
Recommend complete general overhaul.
Form MHD56361 Edition 4 3

INSPECTION REPORT
Ingersoll Rand Model LS2–600H and PS2–1000H 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 and Parts Information Manual and “INSPECTION” section for the 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, Siderails and Spacers
Disc Brake (125% Load Test)
Disc Brake (Visual Inspection)
Motor
Controls
Hydraulic System
Fasteners
Reduction Gears
Labels and Tags ---
Shafts
Guards
Wire Rope Wedge ---
Wire Rope ---
Other Components (list in NOTES section)
Testing: Pass Fail NOTES
Operational (No Load)
Operational (10% Load)
Operational (Maximum Test Load*)
*Maximum test load is 125% of rated line pull. Testing to more than 125% of rated load may be required to set pressure relief valve and to comply with standards and
regulations set forth in areas outside the USA.
This page may be photo copied and used as an inspection record.
4 Form MHD56361 Edition 4

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 does 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 ports.
Motor may be damaged. Disassemble and clean the motor and replace any broken or damaged parts.
System relief valves set too low. Adjust system relief valves to meet the requirements listed in the “SPECIFICATIONS”
section in Product Information Manual.
Load continues to move when winch is
stopped. Brake is slipping. Check brake friction disc wear.
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. 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.
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 upline flow controls are set as
required to run the winch.
Relief valve dumps full pressure. Confirm no downline 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.
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.
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.
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.
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. Remove and disassemble motor as recommended by the motor manufacturer.
Examine all parts and replace any that are worn or damaged.
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.
Form MHD56361 Edition 4 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 technicians to perform maintenance on
this product.
•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.
•UseofotherthangenuineIngersollRand partsmayresultinsafetyhazards,
decreasedperformance,andincreasedmaintenanceandmay invalidateall
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.
Itisextremely importantthatmechanics and operatorsbefamiliar withtheservicing
procedures of these winches or similar products, and are physically capable of
conducting the procedures. These personnel shall have a general working
knowledge that includes:
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.
nMaintenance Intervals
Refer to Table 3 ‘Maintenance Interval Chart’ on page 3 for recommended
maintenance schedule.
nAdjustments
nDisc Brake
Disc brake adjustment is not required. If disc brake does not hold rated load,
disassemble and repair.
If brake slippage occurs during tests prior to placing winch in service or during
normal use of the winch, follow the winch disassembly procedure and check friction
disc (58) thickness as shown in Dwg. MHP2858 on page 6, A: 0.047 inch minimum
(1.2 mm minimum). If this dimension is less than shown, the friction discs (58) must
be replaced.
66
60
59
57
58
0.047 inch minimum
(1.2 mm minimum)
A
(Dwg. MHP2858)
NOTICE
• Original friction disc thickness is 0.047 in (1.2 mm).
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.
6 Form MHD56361 Edition 4

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 clean-out 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
manufacturers of the system or components.
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
NOTICE
• Refer to the Product Parts Information Manual for drawings unless
specified elsewhere.
nGeneral Disassembly Instructions
The following instructions provide the necessary information to disassemble,
inspect,repair, andassemblewinch.PartsdrawingsareprovidedintheProductParts
Information Manual.
If product is being completely disassembled for any reason, follow the order of the
topics as they are presented. It is recommended that all maintenance work on the
winch be performed in a clean dust free work area.
In the process of disassembling the product, observe the following:
1. Never disassemble product 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 the
winch.
6. When grasping a part in a vise, always use leather-covered or copper-covered
vise jaws to protect the surface of the 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 the
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 Guard Disassembly
Refer to Dwg. MHP2826.
1. Remove screws (37) from uprights (5).
2. Remove drum guard (36) and store with screws until reassembly.
nWinch Disassembly
Refer to Dwgs. MHP2824, MHP2826 and MHP2846.
1. Shut off and bleed down hydraulic oil supply to winch.
2. Disconnect and tag all hydraulic lines.
3. Remove winch from its mounting and set in a clean area on a sturdy work bench.
4. Remove tubing assemblies (80) and (81).
5. Remove capscrews (96) and washers (95) securing control valve (94) to guard
(35). Remove control valve.
6. Remove capscrews (34), lockwashers (8) and guard (35).
7. Tag and remove hydraulic lines to valve (98).
8. Remove capscrews (84) and valve (98) assembly.
9. Remove and store ‘O’ rings (99).
10. Position several blocks of wood on the work bench and stand the winch in a
vertical position with the motor end up.
11. Remove two capscrews (71) and lockwashers (70) that secure motor (72) to
motor adapter (68) and extract motor (72).
12. Removeoildrain plugs(14)and returnthewinch toahorizontal positiontodrain
the oil from the reducer housing into a suitable container.
13. Remove capscrews (56) and washers (55) from flange on brake housing cover
(53). Pull disc brake assembly from upright (5).
14. Remove end cover (3).
a. Pull bearing (6) from the end cover (3).
15. Remove capscrews (7) and lockwashers (8) from uprights (5).
16. Remove spacers (45) and (46).
17. Remove the drum (10) from the winch.
18. Remove drum wear rings (40) from the drum if they require replacement.
19. Remove retainer ring (11) and exhaust washers (41).
nFree Spool Disassembly
Refer to Dwg. MHP2620.
1. Removecapscrews (7)andwashers(8)that secureone upright(5)with freespool
assembly from winch assembly.
2. Unscrew and remove knob (238) from shaft (245).
3. Turn lever (237) to disengage free spool and remove free spool assembly from
end cover (3).
4. Tap pin (236) from lever (237) and remove lever.
5. Pry bushings (141) from end cover.
6. Remove capscrew (22) and separate shaft (244), spring (243) and cam (242).
7. Remove spring stopper (246), spring (247) and retainer ring (248).
8. Remove retainer ring (249), press shaft and bearing assembly from gear (253).
9. Remove retainer ring (252) and press bearing (251) from shaft (245).
nDisc Brake Disassembly
Refer to Dwg. MHP2824.
1. Remove motor and piping as described in ‘Winch Disassembly’.
2. Carefully remove capscrews (69) one half turn at a time each, until spring
compression is relaxed. Separate the motor adapter (68) from brake housing
cover (53) and brake housing (61).
3. Remove springs (67).
4. Remove brake housing (61) with piston (66).
5. Extract the brake piston (66) by using low pressure air in the brake port.
6. Remove and discard 'O' rings (62), (64) and backup rings (63), (65) from piston
(66).
7. Removesplinedhub (60) andbrakereaction plate (59)frombrakehousing cover
(53).
8. Remove friction plates (58) and drive plates (57). Note stacking order.
nReduction Gear Disassembly
Refer to Dwgs. MHP2824 and MHP2825.
1. Remove motor, piping and brake assembly as described in ‘Winch Disassembly’.
2. Remove gasket (26).
3. Remove capscrews (22) and washers (23) that secure end cover (15).
4. Carefully pry reduction gear end cover (15) with planetary gears assembly and
ring gear (19) from reducer housing (27).
5. Remove retainer ring (12) on sliding gear (20).
NOTICE
• It may be necessary to use small amount of air pressure in fill hole of
reduction gear end cover (15) to separate from housing (27).
6. Remove and discard ‘O’ ring (16) on reduction gear end cover (15).
7. It is not necessary to remove bearing (39) from end cover (15) unless damaged.
Replace as necessary.
8. Support end cover (15) and tap out sliding gear (20).
9. Remove bearing (13) and oil seal (17) replace seal and bearing if necessary.
10. Remove bearing (21) and ring gear (19).
11. Tap out planet pins (33) and remove planet gears (31), spacers (30), needle
bearings (28), bearing rings (29).
nHydraulic Motor
Refer to Dwg. MHP2824.
Do not disassemble hydraulic motor. Contact factory or Ingersoll Rand trained
Technician for maintenance information.
nControl Valve
Refer to Dwg. MHP2846.
Do not disassemble control valve. Contact factory or Ingersoll Rand trained
Technician for maintenance information.
nRemote Control Valve (optional)
Refer to Dwg. MHP3401 and MHP2823.
Do not disassemble remote control valve. Contact factory or Ingersoll Rand trained
Technician for maintenance information.
nCleaning, Inspection and Repair
nCleaning
Clean all winch component parts in solvent (except for the brake friction discs). The
use of a stiff bristle brush will facilitate the removal of accumulated dirt and
sediments in the drum and reduction assembly. If drum wear rings have been
removed it may be necessary to carefully scrape old Loctite® from the drum wear
ring grooves. Dry each part using low pressure, filtered compressed air. Clean the
brake friction discs using a wire brush or emery cloth.
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 the shaft. Inspect all surfaces on which oil seal lips seat. These
surfaces must be very smooth to prevent damage to the seal lip.
Form MHD56361 Edition 4 7

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. Inspectthebrakestationaryplatesandfrictiondiscsforoil.If thestationaryplates
have become glazed, sand them lightly using fine emery cloth and a flat surface
as backing. Inspect the remaining brake parts for warpage or other damage, and
replace damaged parts as necessary.
7. Measure the thickness of the brake friction discs. The brake friction discs must
show an even wear pattern. If the brake friction discs are 0.047 in (1.2 mm) or
less, replace the discs.
8. Inspect drum wear rings for wear. If thickness is less than 0.040 in (1 mm) replace
drum wear rings.
NOTICE
• Original thickness of drum wear rings is 0.060 in (1.5 mm).
nRepair
Actual repairs are limited to the 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. Wornor damagedpartsmust bereplaced. RefertotheProductParts Information
Manual for specific replacement parts information.
2. Inspect all remaining parts for evidence of damage. Replace or repair any part
which is in questionable condition. The cost of the part is often minor in
comparison with the cost of redoing the 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. Polish the edges of all shaft shoulders to remove small nicks which may have
been caused during handling.
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.
nReduction Gear Assembly
NOTICE
• Refer to the Product Parts Information Manual for drawings unless
specified elsewhere.
Refer to Dwg. MHP2825.
1. Insert bearing (21) in planet gear support (32).
2. Install bearings (28), bearing rings (29) and spacer (30) in each planetary gear
(31).
3. Install planetary gears with bearings into planetary support (32). Locate with
planet pins (33). Stepped end of planet pins must fit over bearing (21).
4. Lubricate oil seal (17) and install in reduction gear end cover (15) so lip is toward
bearing (13). Install bearing (13) in reduction gear end cover (15).
5. Tap sliding gear (20) into bearing (21).
6. Install ring gear (19) so planet gear teeth mesh with ring gear. Time planet gears
as shown in Dwg. MHP1406 on page 8, A: Planetary Support; B: Timing Marks;
C: Planet Gear.
7. Install reduction gear end cover (15) with bearing (13) on sliding gear (20).
8. Tapbearing(39) intoreductiongear endcoverand securewith retainer ring(12).
9. Secure reduction gear end cover (15) with capscrews (22) and washers (23).
Apply Loctite 243 on capscrew threads. Refer to
“TORQUE CHART” on page 10 for torque requirements.
B
A
C
(Dwg. MHP1406)
nDisc Brake Assembly
Refer to Dwgs. MHP2824 and MHP2825.
1. Place the reduction gear assembly in a vertical position with reduction gear end
cover on a bench.
2. Lubricate and install ‘O’ ring (16) on brake housing cover (53).
3. Install brake housing cover on reducer housing (27).
4. Install splined hub (60) on sliding gear (20).
5. Install friction plate (58) then drive plate (57) into brake housing (53), alternating
between each.
6. Lubricate and install ‘O’ rings (62) and (64) and backup rings (63) and (65) onto
piston (66).
7. Install reaction plate (59) on last friction plate.
8. Remove plug (14) and install piston (66) into brake housing (61) being careful
not to damage ‘O’ rings.
9. Install springs (67) in brake piston spring holes using a small amount of grease
on each spring.
10. Install motor adapter (68) on brake housing cover (53) with capscrews (69).
Tightencapscrews(69), onehalfturnatatimeeach,untilmotoradapterissecure.
Use Loctite 243 on the threads. Refer to “TORQUE CHART”on page 10 for torque
requirements.
nControl Valve Assembly
Refer to Dwg. MHP2846.
Ensure control valve is assembled in accordance with control valve manufacturer’s
literature.
nHydraulic Motor Assembly
Refer to Dwg. MHP2824.
Ensure motor is assembled in accordance with motor manufacturer’s literature.
nWinch Assembly
Refer to Dwgs. MHP2824, MHP2826 and MHP2846.
Apply a light coat of Loctite® 243 to all threaded components prior to assembly.
1. Install wear rings (40) in the grooves provided in the drum (10) after applying a
generous amount of grease. Press wear rings into position to eliminate any gaps
between drum and wear rings. Gap between the ends of each wear ring should
be approximately 1/8 in (3 mm). Position wear ring gaps to ensure they are
staggered (offset) from each other by 4 in (100 mm).
2. Install exhaust washers (41) in drum (10) and secure with retainer ring (11).
3. Install gear (43) in drum (10) and secure with retainer ring (44).
4. Install bearing (6) in drum (10).
5. Install end cover (3) onto upright (5) and secure with capscrews (1) and
lockwashers (2).
6. Install plugs (4) and (18) in end cover (3).
7. Install upright (5) and end cover in bearing (6) and drum (10).
8. Place the assembly in a vertical position, with the upright on the bench.
9. Install spacers (45) and (46) on upright and install capscrews (7) and lockwashers
(8) without totally tightening.
10. Install upright (5) on spacers and secure with capscrews (34) and lockwashers
(8) without totally tightening.
11. Install second retainer ring (11).
12. Lubricatewearringswith grease andinstallreducerand brake assemblyindrum
bore. Check that reducer housing rotates freely in the drum wear rings. Partially
liftout motorgear brakeassemblytocheckpositioningofwearringsthen secure
with capscrews (56) and lockwashers (55). Refer to
“TORQUE CHART” on page 10 for torque requirements.
13. Place the winch in a horizontal position and tighten capscrews (7). Refer to
“TORQUE CHART” on page 10 for torque requirements.
14. Ensure key (83) is in place on motor. Align key with keyway in splined hub (60).
Install motor.
15. Secure motor (72) to motor adapter (68) with two capscrews (71) and
lockwashers (70). Refer to “TORQUE CHART” on page 10 for torque
requirements.
16. Lubricate and install ‘O’ rings (99) on valve (98) then install valve (98) assembly
on motor with capscrews (84).
17. Attach hydraulic lines to valve (98).
18. Install control valve (94) on guard (35) and secure with capscrews (96) and
washers (95).
19. Install tubing assemblies (80) and (81).
20. Install guard (35) with capscrews (34) and lockwashers (8).
21. Tighten all spacer capscrews (34) and (7).
8 Form MHD56361 Edition 4

nFree Spool Assembly
Refer to Dwg. MHP2620.
1. Install bearing (251) onto shaft (245) secure with retainer ring (252).
2. Press fit shaft assembly into gear (253).
3. Secure shaft assembly with retainer ring (49).
4. Install spring (247) onto shaft, retainer ring (248) will stop spring.
5. Install spring stopper (246) with flat side toward gear (253).
6. Install spring (243) onto spindle (244). Ensure bent end of spring is facing away
from spindle head.
7. Install cam (242) onto spindle (244). Cam needs to be placed on spindle so bent
end of spring will engage slot in cam. Refer to Dwg.
Dwg. MHP2639 on page 9.
8. Install spindle cam assembly into plate (3) hole with bushings (141).
9. Position spring end and cam (242) so capscrew (241) is between.
10. Install handle (237), ensure bushing is in place. Align pin holes and secure with
pin (236).
11. Rotate cam (242) using the lever to clear the hole and slide shaft assembly with
spring stopper into center hole of plate (3). Push in until you hear a click.
12. Install knob (238).
(Dwg. MHP2639)
nWinch Guard Installation
Refer to Dwg. MHP2826.
To install a wire rope guard or reverse the position of the guard use the following
procedures:
1. Position guard (36) between uprights (5) and align screw holes.
2. Install screws (37) to secure guard.
TESTING
nOperational Tests
Prior to initial use, all new, altered or repaired winches shall be tested to ensure
proper operation.
1. Operate winch in both directions with no load.
2. Check operation of free wheel clutch and brake.
3. Check operation of limit switches and other safety devices when provided.
4. Check all winch mounting fasteners are secure.
nLoad Test
Prior to initial use, all extensively repaired, or altered winches shall be load tested by
or under the direction of an Ingersoll Rand trained Technician, and a written report
furnished confirming the rating of the winch. Test loads shall not be less than
100% of rated line pull and should not exceed 125% of the rated line pull. Testing
to more than 125% of rated capacity may be required to comply with standards
outside of the USA.
The minimum load test for European countries are according to the information
below. If not found below you should use the tests recommended by FEM.
The dynamic test shall be carried out with an overload coefficient 1 = 1,2 i.e. with a
load equal to 120% of the safe working load. All motions shall be carefully operated
in turn, without checking speeds of temperature rises in the motors.
The static test shall be carried out with an overload coefficient 2 = 1,4 i.e. with a load
equal to 140% of the safe working load. The test must be carried out under still
conditions and consists of hoisting the safe working load a small distance above the
ground and then adding the required surplus without shock.
Form MHD56361 Edition 4 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 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 reference.
10 Form MHD56361 Edition 4

SERVICE NOTES
Form MHD56361 Edition 4 11

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