Ingersoll-Rand Liftstar LS2-600H User manual

Product Information
Liftstar Hydraulic Winch
Model LS2-600H and PS2–1000H
(Dwg. MHP2827)
Save These Instructions
R
Form MHD56359
Edition 2
February 2014
43801711
©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/Document Number Publication Part/Document Number
Product Safety Information Manual (Non-Man Rider) MHD56250 Product Maintenance Information Manual MHD56361
Product Parts Information Manual MHD56360
DESCRIPTION
These winches are hydraulic powered, planetary geared units designed for lifting
and pulling applications. Winches are supplied with an automatic disc brake.
The output from an externally mounted hydraulic motor is transmitted through a
coupling and shaft to the planetary reduction gear assembly.
The disc brake assembly consists of friction plates splined to a hub which in turn is
connected to the drive shaft from the motor. The brake friction plates are clamped
to the drum shaft through a spring applied piston.
Thewinchbraketypicallyconsistsofafail-safediscbrakeandacounterbalancevalve.
The brake is disengaged in the lowering (payout) direction only. In the raise (haul-
in) direction, the brake remains engaged, and an internal sprag clutch provides fail-
safe load lifting, preventing momentary downward load drifting at the instant the
winch control valve (refer to manufacturer’s provided information) is shifted to raise
the load. The brake release oil pressure is provided by fluid pressure ported from the
winch motor to the brake housing.
The counterbalance valve will prevent a runaway load condition. Should the load
try to drop faster than the winch is paying out, overrunning the winch motor, the
valve will sense a low pressure condition at the motor inlet, and restrict fluid flow
fromthe motoroutlet.Thiscreatesafluidback-pressure onthewinchmotor,causing
the motor to quickly slow down, stopping the runaway load.
The counterbalance valve should be preset to operate a minimum of 130% of the
maximum oil pressure induced by the rated winch load.
Pullstar is specific for pulling only.
Liftstar is specific for lifting.
SPECIFICATIONS
Models
Hydraulic System Rated Performance (at rated flow/volume) Hose Size (inside
diameter) Motor Displacement
Inlet Pressure
(max) *
Flow (at rated load) * Top Layer Line Pull Top Layer Line Speed Approx. Net
Weight**
gpm l/min lbs kgs fpm m/min lbs kgs inch mm cu. in/rev cu.m/rev
LS2–600H 210 5.5 25 1,320 600 66 20 115 52 1/2 12.7 2.44 40
PS2–1000H 1,543 700 154 70
* Contact factory prior to operating winch with pressures and flow rates above the
5:1 utility rating.
** Weight of standard winch without wire rope.
Table 2: Drum Wire Rope Storage Capacity * (feet/metres)
Drum
Option
Drum
Lengths Wire Rope Diameter
in mm 3/16
inch** 5 mm** 1/4 inch** 6.5 mm** 5/16 inch** 8 mm**
Standard 6.1 156 360 ft 110 m 360 ft 58 m 85 ft 26 m
GC 12.3 312 741 ft 226 m 741 ft 121 m 180 ft 55 m
* Recommended drum working storage capacity is 80% of values shown.
** Recommended wire rope size for both models. Refer to sales literature for winch
drum wire rope storage capacities and weight.
nTraceability
Loadbearingpartsaredocumentedtoprovidetraceability. Documentationincludes
chemical and physical properties of raw material, heat treating, hardening, tensile
and charpy tests as required for the part. Documentation provided upon request.
INSTALLATION
Prior to installing the winch, carefully inspect it for possible shipping damage.
Winches are supplied fully lubricated from the factory.
Check oil levels and adjust as necessary before operating winch. Refer to
“LUBRICATION” section for recommended oils and lubrication intervals.
CAUTION
• Owners and users are advised to examine specific, local or other
regulations, including Society of Mechanical Engineers (ASME) and/or
OSHA Regulations which may apply to a particular type of use of this
product before installing or putting winch to use.
NOTICE
• Prior to installation refer to Product Safety Information Manual for all
sections in “INSTALLATION”.
nMounting
1. Winch mounting surface must be flat and of sufficient strength to handle the
rated load plus the weight of winch and attached equipment. An inadequate
foundation can cause distortion or twisting of the winch uprights and spacers
resulting in winch damage.
2. Make sure the mounting surface is flat to within 0.005 in (0.127 mm) per inch (25
mm) of drum length. Shim if necessary.
3. Mounting bolts must be 3/8 in (10 mm) diameter, Grade 8 or better (class 8.8 or
10.9 for metric bolts). Use self-locking nuts or nuts with lockwashers.
4. Tighten mounting bolts evenly and torque to 50 ft lbs (68 Nm) for dry thread
fasteners. If the fasteners are plated, lubricated or a thread locking compound
is used, torque to 35 ft lbs (47 Nm).
5. 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.
6. Do not weld to any part of the winch.
Refer to Dwg. MHP0138 on page 7, A. Winch Drum; B. Short Drum; C. Long Drum.
nWire Rope
CAUTION
• Maintain at least 3 tight wraps of wire rope on the drum at all times.
•Do not use wire rope as a ground (earth) for welding.
• Do not attach a welding electrode to winch or wire rope.
• Install wire rope to come off drum for overwind operation (normal
application). Refer to Product Safety Information Manual.
2 Form MHD56359 Edition 2

nWire Rope Selection
Consult a reputable wire rope manufacturer or distributor for assistance in selecting
the appropriate type and 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, federal,
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. Maximum wire rope diameter is limited by
the wire rope anchor. It is recommended that wire rope construction be 6 X 19 or 6
X 37 IWRC right lay. Refer to Table 3 ‘Minimum and Maximum Wire Rope Size’
on page 3 for minimum and maximum recommended wire rope sizes.
Table 3: Minimum and Maximum Wire Rope Size
inch mm
0.26 6.5
Note 1: Maximum wire rope diameter is limited by size of wire rope anchor hole.
RefertoProduct Parts Information Manualforcorrect wire ropeanchorpart number.
nInstalling Wire Rope
Wire rope storage capacity based on wire rope top layer located a minimum of 1/2
inch (13 mm) below drum flange and meets ASME Standards B30.7.
Refer to Dwg. MHP2636 on page 7, A. Wire Rope Wedge; B. Wire Rope.
1. Cut wire rope to length and fuse end to prevent fraying of strands in accordance
with the wire rope manufacturer's instructions.
2. Feed the end of the wire rope into the wire rope anchor hole in the drum and
pull through approximately one foot (0.3 m) of wire rope.
3. Forming a large loop with the wire rope, insert the end back into the top of the
anchor hole.
4. Place the wire rope wedge into the wire rope anchor pocket in the drum. Install
thewedgesuch thatthewire rope willwraparound thewedgeas shown inDwg.
MHP2636 on page 7.
5. Pull the wire rope into position in the drum anchor pocket. Use of a copper drift
orsimilartoolmayberequiredtofullyinsertwireropeandwedgeintotheanchor
pocket. Ensure the loop in the wire rope is below the surface of the drum flange
diameter.
CAUTION
•Makesure thefirstwrapofwireropeistightand laysflush againstthedrum
flange.
•Ensure the correct wire rope anchor is used.
•Install wire rope to come off the drum in an overwind position as indicated
on the direction of rotation label.
nSafe Wire Rope Handling Procedure
- Always use gloves when handling wire rope.
- Never use wire rope that is frayed or kinked.
- Never use wire rope as a sling.
-Alwaysensurewireropeis correctlyspooledandthefirstlayeristight against
drum.
- Always follow wire rope manufacturer’s recommendation on use and
maintenance of wire rope.
nWire Rope Spooling
To compensate for uneven spooling and the decrease in line pull capacity as the
drum fills up, use as short a wire rope as practical. When rewinding apply tension to
the end of the wire rope to eliminate line slack. This helps achieve level winding and
tight spooling.
nRigging
Make sure all wire rope blocks, tackle and fasteners have a sufficient safety margin
tohandlerequired load underallconditions. Donotallow wire ropetocontact sharp
edges or make sharp bends which will cause damage to wire rope, use a sheave.
Refer to wire rope manufacturer’s instructions for proper sizing, use and care of wire
rope.
nSafe Installation Procedures
1. Do not use wire rope as a ground (earth) for welding.
2. Do not attach a welding electrode to winch or wire rope.
3. Never run wire rope over a sharp edge. Use a correctly sized sheave.
4. Whenalead sheaveisused, itmust be alignedwith centerofdrum. Thediameter
of lead sheave must be at least 18 times the diameter of wire rope. Refer to Dwg.
MHP2449 in Product Safety Information Manual.
5. Always maintain at least three full, tight wraps of wire rope on drum.
nWinch Guard (optional feature)
Use of a winch guard is recommended on all winches.
Refer to Product Parts Information Manual.
WARNING
•Do not allow wire rope to come in contact with winch guard panels during
winch operation. Wire rope could become worn and damaged. Adjust
winch guard panels to clear wire rope travel angle.
nHydraulic System
Refer to Dwg. MHP2853 on page 7.
nHydraulic Hoses
In order to maintain maximum efficiency of the winch, select the size of hydraulic
lines according to the maximum volume of oil to be used. Refer to Table 4 ‘Hydraulic
Hose Recommendations’ on page 3. If the hydraulic lines used are too small, they
may cause excessive back pressure, generating heat and causing inefficiency within
the hydraulic system.
The sizes in Table 7 are to be used as a guide only. If trouble is experienced due to
the use of long hoses, it may be necessary to use hoses which are one size larger.
Table 4: Hydraulic Hose Recommendations
Oil Flow *@ 3000 psig max Pressure Lines (inside diameter)
gpm 1/min inch mm
5.5 25 1/2 12.7
* Based on 17 fps (5.2 mps) oil viscosity
nHydraulic Fluid
The most frequent cause of malfunction or failure of hydraulic equipment is the
presenceofcontaminantsinthehydraulicfluid.Reducecontaminantsbyusingclean
hydraulic fluid, and changing the fluid before it deteriorates. When the hydraulic
fluid is changed, also clean out the hydraulic reservoir. At a minimum, the required
oil cleanliness level is ISO 18/13 or better. Periodic checks which may be performed
by the operator to test hydraulic fluid cleanliness include:
1. Check for a major change in color or noticeable thickening, which are signs of
severe deterioration and indicate the need to change the fluid.
2. Check oil for foaming and aeration which may indicate low oil level in the
hydraulic tank, leaks, faulty hydraulic line connections or moisture build-up in
the oil.
ISOVG 30,46and68oilswillgivegoodresults undernormal temperatureconditions.
The use of an oil having a high viscosity index will minimize cold-start trouble and
reduce the length of warm-up periods. A high viscosity index will minimize changes
in viscosity with corresponding changes in temperature.
CAUTION
•Donotsubstitutesyntheticfluidsunlessit hasbeendeterminedthatwinch,
motor and hydraulic system seals are compatible.
Use a premium anti-wear (AW) hydraulic fluid in the hydraulic system. The following
specifications are intended to serve as a general guide in selecting suitable oils.
Table 5: Recommended Hydraulic Oil
Temperature Recommended Hydraulic Oil
Fahrenheit Celsius
above 32° F 0° C ISO VG 46(SSU 230-240 @ 100° F)
0˚ to 32° F -17.7° to 0° C ISO VG 32(SSU 160-165 @ 100° F)
below 0° F below -17.7° C
Consult local oil company
representative for oil having a
maximumviscosityof7,400SSU’s
at the minimum temperature
encountered.
nFilters
Filtersshould beequippedwithdirtyfilterindicators,which shouldbe checkeddaily.
Replace filters if indicators show filter is dirty. It is also recommended that filters be
changed if hydraulic oil is changed or a major component (pump, valve, motor, etc.)
is repaired or replaced.
When the winch is installed with its own hydraulic system or when there is no filter
in the existing circuit, a partial flow microfilter should be installed between the
control valve and the reservoir. This filter should be rated at Beta 200=6µm. Filters
mustinclude anintegral50psi(345 kPa/3.45bar) bypasscheck valvewhichwillopen
when the filter element is filled to 80% capacity.
Refer to ‘Filter Maintenance’ in the “MAINTENANCE” section for servicing
information.
nHydraulic Connections
When repairing or servicing any hydraulic lines or fittings in the system, always flush
each line and connection of all foreign contaminants before making the final
connection. Always cap or plug open connections or lines. Verify port connections
match motor and installation information provided.
nPump
Ensure the pump used with the winch motor is capable of producing pressure and
volume as specified for the winch.
Form MHD56359 Edition 2 3

nControl Valve
Ensure control valve moves smoothly in the haul-in and payout directions before
operating winch with full load.
nMotor
For optimum performance and maximum durability of parts, ensure hydraulic
supply does not exceed recommended pressures and flows. When feasible the
motor should be installed as near as possible to the pump. Motor case drain lines
must be ported to the reservoir and must not exceed 30 psi (207 kPa/2 bar).
nDisc Brake
Disc brake is shipped with petroleum based cooling oil installed. Prior to operation,
confirm oil level is to manufacturer’s recommendations.
nInitial Winch Operating Checks
Winchesaretestedforproper operationpriortoleavingthe factory.Beforethewinch
is placed into service the following initial operating checks should be performed.
1. Makesurethehydraulicmotorandcasedrainlineisfilledwiththerecommended
hydraulic fluid. Internal motor leakage at low operating pressures may not be
sufficient to provide start-up lubrication.
2. Verify oil levels are in accordance with recommendations in “LUBRICATION”
section on page 3. Ensure all installation steps have been followed.
3. When first operating the winch it is recommended that the winch be driven
slowly in both directions for a few minutes.
4. Check operation of brakes. Adjust if necessary as described in the Product
Maintenance Information manual.
5. Check operation of limit switches, locking mechanisms and all safety devices
when equipped.
6. Check foundation mounting fasteners are secure.
7. Check winch enclosure is securely attached.
For winches that have been in storage, the following start-up procedures are
required.
1. Give the winch an inspection conforming to requirements of “Winches Not in
Regular Use” in the “INSPECTION” section on page 5.
2. Operate motor for 10 seconds in both directions to flush out any impurities.
3. The winch is now ready for normal use.
OPERATION
NOTICE
•RefertoProductSafetyInformationManualbeforeoperating any product.
nHydraulic System
Efficient operation of the winch requires attention to the hydraulic oil system. The
most important elements to ensure proper operation of the hydraulic system are:
Oil Temperature. The presence of hot fluid in a hydraulic system is a primary cause
of poor operation, component failure and system downtime. The fluid used in any
hydraulic system is formulated for operation within a temperature range of 32˚ to
140˚F(0˚ to60˚C). Ifthe temperature isfrequently exceededcomponentand system
operation will be degraded. Under continuous operating conditions the
temperature of the oil at any given point in the hydraulic system should not be
allowed to exceed 180˚ F (82˚ C).
Oil Cleanliness. Hydraulic system cleanliness is extremely important to ensure safe,
continued operation of components. Dirty or contaminated hydraulic fluid may
cause components to break down, operate erratically or damage valuable
equipment.
nWarm Up Procedure
CAUTION
• A warm up procedure is recommended at each start-up under normal
operating conditions, and is essential at ambient temperatures below 40˚
F (4˚ C).
To warm up the hydraulic oil and system, run the pump with the winch control valve
in neutral long enough to sufficiently warm up the system.
Once the system has warmed up, operate the winch, without a load, at slow speeds
in both directions several times to prime all lines with warm hydraulic fluid.
nWinch Controls
Thecontrolvalve ismountedandconnecteddirectlyonthewinch.Itisaproportional
valve with hydraulic remote control and mechanical actuation. Description: Pump
side module: Closed center version for system with variable displacement pumps.
One basic module open center in neutral position (A-B to tank) pressure limiting
valves individually adjustable for ports A & B Hydraulic and mechanical (by lever)
actuation.
nWinch Brakes
nAutomatic Disc Brake
Thewinchbraketypicallyconsistsofafail-safediscbrakeandacounterbalancevalve.
The brake is disengaged in the lowering (payout) direction only. In the raise (haul-
in) direction, the brake remains engaged, and an internal sprag clutch provides fail-
safe load lifting, preventing momentary downward load drifting at the instant the
winch control valve (refer to manufacturer’s information) is shifted to raise the load.
The brake release oil pressure is provided by fluid pressure ported from the winch
motor to the brake housing.
The counterbalance valve will prevent a runaway load condition. Should the load
try to drop faster than the winch is paying out, over-running the winch motor, the
valve will sense a low pressure condition at the motor inlet, and restrict fluid flow
fromthe motoroutlet.Thiscreatesafluidback-pressure onthewinchmotor,causing
the motor to quickly slow down, stopping the runaway load. The counterbalance
valve should be preset to operate a minimum of 130% of the maximum oil pressure
induced by the rated winch load.
nFree Spool
Refer to Dwg. MHP2626 on page 8, A. Pull Plunger out for Free Spooling; B. Rotate
Lever Clockwise to Release Plunger.
WARNING
•Donotengagefreespoolclutch when motor is running or drum isspinning
as this can damage internal parts.
nFree Spool Mode
Rotate lever clockwise and pull out the spring loaded plunger knob. Maintain a hold
on the plunger knob and rotate lever counterclockwise to lock plunger in freespool
position.
WARNING
• Never disengage clutch with a load on the wire rope.
•Winch controls must be in the neutral position before operating the free
spool clutch.
nWinch Operating Mode
Pull out the spring loaded plunger knob rotate the lever clockwise and release the
springloadedplungerallowingittolockbackintothedriveshaft.Itmaybenecessary
to rotate the drum slowly by hand to allow the clutch drive shaft to engage.
4 Form MHD56359 Edition 2

INSPECTION
Inspectioninformation isbased inpartonAmericanSocietyofMechanicalEngineers
Safety Codes (ASME B30.17).
WARNING
• All new or repaired equipment should be inspected and tested by
Ingersoll Rand trained Technicians to ensure safe operation at rated
specifications before placing equipment in service.
•Never use a winch that inspection indicates is damaged.
Frequent and periodic inspections should be performed on equipment in regular
service. Frequent inspections are visual examinations performed by operators or
Ingersoll Rand trained Inspectors and include observations made during routine
equipment operation. Periodic inspections are thorough inspections conducted by
Ingersoll Rand trained Technicians. ASME B30.7 states inspection intervals depend
upon the nature of the critical components of the equipment and the severity of
usage. Refer to ‘Inspection Classifications’ chart and ‘Maintenance Intervals’ chart in
ProductMaintenanceInformationManualforrecommendedmaintenanceintervals.
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.
Deficiencies revealed through inspection, or noted during operation, must be
reported to designated personnel to ensure corrective action is taken.
A determination as to whether a condition constitutes a safety hazard(s) must be
decided, and the correction of noted safety hazard(s) accomplished and
documented by written report before placing the equipment in service.
nWire Rope Reports
Records should be maintained as part of a long-term wire rope inspection program.
Records should include the condition of wire rope removed from service. Accurate
records will establish a relationship between visual observations noted during
frequentinspectionsandtheactual conditionofwireropeasdeterminedbyperiodic
inspections.
nFrequent Inspection
On equipment in regular service, frequent inspections should be made by operators
at the beginning of each shift. In addition, visual and audible inspections should be
conducted during regular operation for indications of damage or evidence of
malfunction (such as abnormal noises).
Disassembly may be required as a result of frequent inspection findings or in order
to properly inspect the individual components. Disassembly steps are described in
the Product Maintenance Information Manual.
1. Surrounding Area: Visually check for winch oil leaks. Do not operate winch if
leaking oil is found. Ensure surrounding area has no slippery surfaces and is
obstruction free.
2. HosesandFittings:Visuallyinspectfordamage, airleaksandlooseconnections.
Repair all leaks or damage and tighten lose connections prior to starting daily
tasks.
3. Manual Shut-off Valve: Test shut-off valve to ensure proper operation and free
movement.
4. Guards: Verify wire rope does not contact guard during winch operation and
that guards are secure and undamaged.
5. Winch: Visually inspect winch housings, control(s), external brake, siderails and
drum for damage. Check that all external bolts are in place and secure. Report
damage to supervisor and request additional inspection by a Ingersoll Rand
trained Technician.
6. Winch Operation: Power winch in both directions. Winch must operate
smoothly without sticking, binding or abnormal noises and have minimal
vibration.
7. HydraulicSystem:Check hydraulic lines, fittings, valves and other components
for deterioration, leakage or wear. Tighten, repair or replace as necessary. Check
reservoir sight gauge for proper hydraulic oil level. Check dirt alarms at both
pressure and return line filters for visual indication of dirty filter.
8. Pendant (optional feature): Ensure operation of pendant levers is smooth and
winch is responsive to pendant control. Pendant levers must spring return to
the neutral position when released.
9. Manual Throttle Lever: Ensure operation of manual throttle lever is smooth
and winch is responsive to lever movement. Lever must return to neutral and
lock in place when released. If winch responds slowly or controls stick, do not
operate winch until all problems have been corrected.
10. Wire Rope: Visually inspect all wire rope which can be expected to be in use
duringtheday’soperations.Inspectforwearanddamageindicatedbydistortion
of wire rope such as kinking, “birdcaging,” core protrusion, main strand
displacement, corrosion, broken or cut strands. If damage is evident, do not
operatewinch untilthe discrepancieshave beenreviewed andinspected further
by personnel knowledgeable on wire rope safety and maintenance procedures.
NOTICE
•Thefullextentofwireropewearcannotbedeterminedbyvisualinspection.
At any indication of wear inspect wire rope in accordance with instructions
in “Periodic Inspection.” Refer to Product Maintenance Information
Manual.
11. Wire Rope Spooling: Visually check reeving and ensure wire rope feeds on and
off the drum smoothly. Verify spooling direction (overwind or underwind) is
correct for winch and application.
12. Brake(s): Lift and lower the load a short distance to test brake(s). Brake(s) must
hold load without slipping. Automatic brake must release when winch control
throttle is operated. If brake(s) do not hold load or do not release properly, they
must be adjusted or repaired.
13. Lubrication: Refer to “LUBRICATION” sectionon page 5 for recommended
procedures and lubricants.
nWinches Not in Regular Use
1. Equipment which has been idle for a period of one month or more, but less than
six months, shall be given an inspection conforming to the requirements of
“Frequent Inspection” before being placed in service.
2. Equipment which has been idle for a period of over six months shall be given a
completeinspectionconformingwith the requirements of“PeriodicInspection”
before being placed in service. Refer to Product Maintenance Information
Manual.
3. Standby equipment shall be inspected at least semiannually in accordance with
the requirements of “Frequent Inspection”.
nStoring The Winch
1. Always store the winch in a no load condition.
2. Wipe off all dirt and water.
3. Oil the wire rope.
4. Place in a dry location.
5. Beforereturningwinch toservice, followinstructionsfor ‘WinchesNotIn Regular
Use’ in the “INSPECTION” section on page 5.
LUBRICATION
To ensure continued satisfactory operation of winch, all points requiring lubrication
must be serviced with correct lubricant at proper time interval as indicated for each
assembly.
Refer to ‘Maintenance Interval’ chart in Product Maintenance Information Manual
for recommended lubrication intervals. Use only those lubricants recommended.
Other lubricants may affect winch performance. Approval for use of other lubricants
must be obtained from your Ingersoll Rand distributor. Failure to observe this
precaution may result in damage to winch and/or its associated components.
Table 6: Lubrication Intervals
Intervals Lubrication Checks
Monthly
Lubricate components supplied by
grease fittings.
Inspect and clean or replace oil filter.
1 Year or 1,000 hrs of Winch Operation Check reduction gear oil level.
Change Gearbox Oil
nComponent Lubrication
Correct lubrication is one of the most important factors in maintaining efficient
winch operation.
1. The recommended grade of oil must be used at all times. Use of unsuitable oil
may result in excessive temperature rise, loss of efficiency and possible damage
to lubricated components. Refer to ‘Recommended Lubricants’
sectionon page 6.
2. It is recommend that the first oil change be done after approximately 50 hours
initial operation. Always inspect removed oil for evidence of internal damage
(metal shavings, dirt, water, etc.). Thereafter, drain and replace oil according to
Table 6 ‘Lubrication Intervals’ on page 5.
3. Always inspect removed oil for evidence of internal damage or contamination
(metal shavings, dirt, water, etc.). If indications of damage are noted, investigate
and correct before returning winch to service.
4. After winch operation, allow oil to settle before topping off.
5. Always collect lubricants in suitable containers and dispose of in an
environmentally safe manner.
WARNING
• Use recommended grade of oil to prevent extensive heat build up and
prevent wear that could cause sparks. Oil levels must be properly
maintained.
Form MHD56359 Edition 2 5

nRecommended Lubricants
Table 7: Reduction Gear Recommended Lubricants
Temperature Type Oil *
-4˚ to 125˚ F (-20˚ to 52˚ C) - Synthetic oil rinematic viscosity 68 Cst at 40˚ C- Indice of viscosity 148- Mobil
SHC 626
* Recommended type lubricants above or equivalent.
Table 8: Recommended Grease
Temperature Type Grease
-20˚ to 50˚ F (-30˚ to 10˚ C) EP 1 multipurpose lithium based grease
30˚ to 120˚ F (-1˚ to 49˚ C) EP 2 multipurpose lithium based grease
nReduction Gear Lubrication
The reduction gear is filled to the correct levels prior to shipment from the factory.
Check oil level before initial winch operation. This component is splash lubricated
by oil in the housing and has no other means of lubrication. It is therefore important
to use high quality Extreme Pressure (EP) rust and oxidation inhibited gear oil to
ensure maximum performance and minimum down time for repair.
CAUTION
• Do not over fill. Excess oil will reduce operating efficiency and increase oil
temperature.
To ensure correct performance, highest efficiency and long life, it is essential that
lubricating oil be maintained at correct level. Refer to Table 9 ‘Reduction Gear
Capacities’ on page 6 for reduction gear oil capacities.
Table 9: Reduction Gear Capacities
Capacity
quarts litres
0.13 0.120
nDisc Brake
Refer to the manufacturer’s literature for lubrication requirements.
nWire Rope
Follow the wire rope manufacturer's instructions. At a minimum, observe the
following guidelines.
1. Clean with a brush or steam to remove dirt, rock dust or other foreign material
on the surface of the wire rope.
CAUTION
•DoNOTuse an acid-basedsolvent.Only usecleaningfluidsspecified bythe
wire rope manufacturer.
2. Apply a wire rope lubricant.
3. Brush, drip or spray lubricant weekly, or more frequently, depending on severity
of service.
6 Form MHD56359 Edition 2

PRODUCT INFORMATION GRAPHICS
(Dwg. MHP0138)
Wire Rope
Wedge
Wire
Rope
A
B
(Dwg. MHP2636)
CB: Counter Balance Valve
LP1: Safety Main Relief Valve
LSA: Reducing Valve for Haul-in (winding)
LSB: Reducing valve for Payout (unwinding)
WINCH:
B1: Payout Port 1/2” BSPP
A1: Haul-in Port 1/2” BSPP
D: Drain Port 1/4” BSPP
REMOTE CONTROL:
P: Port 1/4“ BSPP
T: Port 1/4” BSPP
2 - 4: Ports 1/4” BSPP
CONTROL VALVE:
B: Payout Port 1/2” BSPP
A: Haul-in Port 1/2” BSPP
P: Inlet Port 1/2” BSPP
R: Tank Port 1/2 BSPP
Z & M: Ports 1/4” BSPP
1 - 2: Pilot Ports 1/4” BSPP
LS: Port 1/4” BSPP
* Not Supplied
LP1: 220b
a
b
LsA: 120b
LsB: 80b
20b
Remote Control Station
TP24
D
Z
LS
A
PR
B21
50b
Unload
A1
B1
CB
F
Hoses O 1/4
M
Hose O 1/2” (*) Hose O 1/2” (*) Hose O 1/2” (*)
Power Pack (*)
(Dwg. MHP2853)
Form MHD56359 Edition 2 7

PRODUCT INFORMATION GRAPHICS CONTINUED
Haul-In
Payout
Motor End
A
B
C
(Dwg. MHP2857)
Pull Plunger
Out for Free
Spooling
Rotate Lever
Clockwise
to Release
Plunger
B
A
(Dwg. MHP2626)
For reference only, motor/controls may be different for your model.
(Dwg. MHP3415)
8 Form MHD56359 Edition 2

SERVICE NOTES
Form MHD56359 Edition 2 9

SERVICE NOTES
10 Form MHD56359 Edition 2

SERVICE NOTES
Form MHD56359 Edition 2 11

R
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