Ingersoll-Rand LS1500R User manual

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

PARTS AND MAINTENANCE MANUAL
FOR
“LIFTSTAR” AND “PULLSTAR”
AIR WINCHES MODELS
LS1500R & PS2400R SERIES
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important maintenance information. Make this manual
available to all persons responsible for the 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 European Security
Rules and any other applicable safety codes and regulations.
Refer all communications to the nearest IR/SAMllA Material Handling Products Office or
Distributor.
Form SAM0072
Edition 5
INGERSOLLRAND
January 1998
96310124 MATERIAL HANDLING
©1998 Ingersoll-Rand Company

Description Page No.
Maintenance Intervals.. ............................................................................................................................................................ 3
General Disassembly .............................................................................................................................................................. 4
Disassembly Instructions ......................................................................................................................................................... 4
Winch Disassembly ...................................................................................................................................................... 4
Lever Control Valve disassembly ................................................................................................................................. 5
Air Control Valve disassembly - Optional Europ Version ........................................................................................... 5
Air Gear Motor disassembly ......................................................................................................................................... 5
Pendant Control disassembly.. ...................................................................................................................................... 5
Pendant Control emergency stop disassembly.. ............................................................................................................ 5
Shut-off valve disassembly ........................................................................................................................................... 6
Emergency stop valve disassembly ............................................................................................................................... 6
Cleaning, Inspection and Repair.. ............................................................................................................................................ 6
Assembly Instructions .............................................................................................................................................................. 6
Winch Assembly ........................................................................................................................................................... 6
Lever Control Valve Assembly .................................................................................................................................... 7
Air Gear Motor Assembly ............................................................................................................................................ 8
Pendant Control Assembly.. ......................................................................................................................................... 8
Pendant Control with emergency stop Assembly.. ........................................................................................................ 8
Pendant Control Adjustment ......................................................................................................................................... 8
Accessories .............................................................................................................................................................................. 9
Testing .................................................................................................................................................................................... 9
Parts
Winch Assembly Drawing ..................................................................................................................................................... IO
Winch Assembly Parts List ...................................................................................................................................................... II
Air Gear Motor Assembly Drawing ......................................................................................................................................... 12
Air Gear Motor Assembly Part List.. ....................................................................................................................................... I3
Lever Control Valve Assembly Drawing and Part List. ........................................................................................................... 14
Control Valve Assembly Drawing and Parts List .................................................................................................................... I5
Control Valve Assembly Drawing and Parts List .................................................................................................................... 16
PHS2 Remote Control Assembly Drawing and Part List.. ....................................................................................................... 17
PHS2U Remote Control with Emergency Stop Assembly Drawing and Part List.. ................................................................. 18
Shu-off Valve Assembly Drawing and Parts List.. ................................................................................................................... I9
Emergency Stop Valve Assembly Drawing and Parts List ..................................................................................................... .20
Torque Limitor Assembly Drawing and Parts List ................................................................................................................. .2l
Drum Guard Assembly Drawing and Parts List.. .................................................................................................................... .22
Parts Ordering Information
Warranty .................................................................................................................................................................................. 23
Office Location ......_...................................................................................................._............................................................ 24
2

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 safety and
maintenance on 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. Testing to more than 125% of rated capacity
may be required to comply with standards outside the
USA.
l Shut off air system and depressurize air lines before
performing any maintenance.
l Do not use Trichloroethylene toclean parts.
Maintenance Intervals Adjustment
No brake adjustment is required.
The Maintenance Interval chart is based on intermittent
operation of the winch eight hours each day, five days per
week. If winch operation exceeds eight hours per day, or
use is under HEAVY or SEVERE conditions, more
frequent maintenance should be performed. Refer to
‘Periodic Inspection’ in the “INSPECTION” section for
interval guidance.
Inspection
If brake slippage occurs during tests prior to placing winch
in service or during normal use of the winch, following the
winch disassembly procedure until number 14.3 and check
dimension (( C )) from the brake piston (26) to the gear box
(45) as shown in Dwg. D6310032. If this dimension is
greater than 0,12 in. (3 mm), the brake discs (21 and 22)
must be replaced by following the winch disassembly
procedure.
INTERVAL
Start of each shift
(Operator or
Maintenance
Personnel)
Yearly
(Maintenance
Personnel
MAINTENANCE
Make a thorough visual inspection
of the winch for damage. Do not
operate the winch if damaged.
Operate the winch at low RPM in
both directions. Winch must
operate smoothly without
sticking, binding or abnormal
noises. Check the operation of the
brake.
Inspect the brake disc. Clean or
replace parts as required.
Inspect the winch gearing, shafts
and bearings for wear and
damage.
Repair or replace as necessary.
Check all the supporting
members, including the
foundation, fasteners, nuts,
sheaves and rigging, etc. for
indications of damage or wear.
Repair or replace as required.
Motor Removal
(Ref. Dwg. D6310041)
Use the following procedure to remove the motor.
1. Disconnect and tag the air lines.
2 Position several blocks of wood on the work bench
and stand the winch in a vertical position with the
motor end up. Make sure the weight of the winch
does not rest on the free wheel handle (65) or cause
damage to the free wheel parts
3. Remove the four capscrews (113) and lockwashers
(I 14) which connect the air motor to the front end
cover (30) and remove the motor assembly.
Brake
It is recommended that the brake assembly be removed
for maintenance and inspection once each year.
(Dwg.D6310032)
3

General Disassembly Procedures
The following instructions provide the necessary
information to disassemble, inspect, repair, and assemble
the winch. Refer to the winch assembly drawing provided
in the Parts Section.
If a winch 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 on a bench in a clean dust free area. In the
process of disassembling the winch. observe the following :
Never disassemble the winch any further than is
necessary to accomplish the needed repair. A good
part can be damaged during the course of
disassembly.
Never use excessive force when removing parts.
Tapping gently around the perimeter of a cover or
housing with a soft hammer, for example, is sufficient
to break the seal.
Do not heat a part with a flame to free it for removal,
unless the part being heated is already worn or
damaged beyond repair and no additional damage will
occur to other parts.
In general, the winch is designed to permit easy
disassembly and assembly. The use of heat or excessive
force should not be required.
4.
5
6.
7.
8.
Keep the work area as clean as practical, to prevent
dirt and other foreign matter from getting into
bearings or other moving parts.
All seals and ‘0’ rings should be discarded once they
have been removed. New seals and ‘0’ rings should
be used when assembling the winch.
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 and
housings.
Do not remove any part which is press fit in or on a
subassembly unless the removal of that part is
necessary for repairs or replacement.
When removing ball bearings from shafts, it is best
to use a bearing puller. When removing bearings
from housings, drive out the bearing with a sleeve
slightly smaller than the outside diameter of the
bearing. The end of the sleeve or pipe which
contacts the bearing must be square. Protect bearings
from dirt by keeping them wrapped in clean cloths
Disassembly Instructions
Winch Disassembly
(ref.Dwg.D6310041)
1. Disconnect and tag the air lines.
3
2. Remove winch from its mounting and set in a clean
work area ona sturdy work bench.
Position several blocks of wood on the work bench
and stand the winch in a vertical position with the
motor end down.
Remove the nuts (2) and lock washers (3).
5.
6.
7.
8.
9.
IO.
11.
12.
13.
Remove the rear end-cover (55).
5.1. Extract the exhaust washers (60) and the
rings (59).
5.2. Pull bearing (58) from rear end cover (55)
Clutch control disassembly (PS SERIES)
6.1. Unscrew the handle (65) and pull the plunger
(61) to remove clutch axle (66), clutch (72)
and the spring (69).
6.2. If necessary remove retainer rings (62 and
63) to remove clutch (72) and bearing (71)
from clutch axle (66)
6.3. Remove screws (67) washer (68), plunger
body (70) and the plunger (61)
Remove the drum (56) from the winch.
7.1. Remove the spacer (64). 0nly for PS series.
7.2. Remove the drum bushings (38) from the
drum (56) if they require replacement.
Remove the oil drain plug (6) and return the winch
to drain the oil from the gear casing.
Remove the four screws winch secure the motor
(29) to the front end cover (30) and pull off the
motor straightaway from the winch. For disassembly
of the motor and the valve, follow the corresponding
procedure.
Remove the gasket (3 I) and the ‘O’ring (27) and
drain the oil from the brake through the front end
cover bore.
Remove the three nuts (2) and lock washers (3) and
remove the three tie rod spacers (4).
Remove the output shaft (5) from the gearbox and
brake assembly.
Disassembly of the front end-cover (30).
13.1. Remove the screws (34).
13.2. Remove the front end cover (30).
13.3. Remove the retainer ring (32).
13.4. Remove the oil seal (35).
l The oil has been installed with loctite ® 460 on the
backside of the seal.
14. Disassembly of the brake piston.
14.1. Remove the O’ring (25) and the gasket (33).
14.2. Remove the springs (4 I).
14.3. Remove the bearing (36).
14.4. Extract the brake piston (26) by using low
pressure compressed air in brake release port.
15. Disassembly of the gear box
15.1 Remove screws (47) and lock washers (48).
15.2. Extract the gear box cover by using jacking
screws in the two M4 threaded holes.
15.3. Press out the output shaft (5) and the output
annular gear (50).
15.4. Remove the bearings (51 and 53), oil seal
(52) and the O’ring (9).
15.5. Remove the bearing (10), spring washer (49)
and the output annular gear (50).
15.6. Remove the satellite support assembly.
15.7. Push out the satellite axles (11).
15.8. Remove the planet gear (15), bearing studs
(12) and stop rings (13).
4

15.9. Remove the needle bearings (14) and the
spacers (16).
15.10. Disassembly of the fixed annular gear (19),
friction discs (21 and steel steel discs (22) :
l compress the ‘O’ring (20) by using the
special tool M6313400.
l remove the retainer ring (17).
l push out the fixed annular gear (19).
l remove the ‘O’ring (9).
l remove the pins (39).
l remove the ‘O’ring (20).
l remove the friction discs (21) and steel
discs (22).
15.11. Disassembly of the shaft spindle (I 8).
l remove the retainer ring (37).
l remove the gear wheel (43).
l push out the shaft spindle (I 8).
15.12 Remove the retainer ring (40).
15.13. Remove the bearing (44).
Lever Control Valve Disassembly
(ref. Dwg. D6310006 or D6310035)
I. Remove screws (130) and lock washers (131).
2 Remove the lever control valve assembly from the
motor.
3.
4.
5
_.
6.
7.
Tap out the pin (128).
Extract the control lever (121).
Remove screws (127) to remove stop (129).
Remove the return spring (124).
Pull out the rotary valve (126).
l Localise the mounting position of the rotary valve in
the valve housing.
8. Remove the ‘O’ring (125) from the rotary valve (126) if
necessay.
Valve Disassembly Optional Remote Control
(ref. Dwg. D6310026)
I. Remove screws ( 143).
2. Remove the valve assembly from the motor.
3. Remove the cover (144) from the valve body (150).
4. Remove screws (141) and lock washers (142).
5
_. Remove the end caps (147) and the rear stops (148).
6. Remove the slide valves (149) and return spring
(145).
6.1. Remove the quad rings (151).
7. Remove the quad rings (146) from the valve body.
Air Gear Motor Disassembly
(Ref. Dwg.D6310005)
Refer to control valve disassembly sections to remove lever
or pendant control valve from motor
1.
2.
?
3.
4.
5
. .
6.
7.
8.
9.
IO.
I I.
12.
Remove the screws (81) and lock washers (82).
Remove the motor housing (112).
Remove the 'O'ring (11O).
Remove the gasket (95).
Remove screws ( 109).
Remove the motor cover (84).
- remove the ‘O’rings (89) and pin (83).
- remove the exhaust washer (87) and the plug
(88).
- remove the needle bearings (85 and 91) if they
have to be changed.
lmmobilise the motor rotors with a pin between the
teeth and remove nuts (101 and 106).
Remove the motor rotors (93 and 94).
- remove the shaft segment (86) and the internal
ring.
Remove the screw (104) and the washer (103).
Remove ball bearings (100 and 107).
Remove the spacer (92).
Remove the stopper (108) the spring (I 02) and the
rear stop (105).
“PHS2” Pendant Control Disassembly
(Ref. Dwg.D5790002)
1. Disconnect all hoses from winch motor.
2. Remove the fittings (161) and the lifting eye (170).
3. Remove the retainer ring (162).
4. Pull out rear covers (164) with the ‘0’ rings (163).
5
- . Remove the springs (165).
6. Remove the “slide valve assemblies” (166) with the
quad rings ( 167).
7. Remove the springs (I 68).
8. Remove the valve cone assemblies (169)
9. Remove the setscrews (174).
IO. Tap out pin (171) to remove the levers (173) .
“PHS2U” Pendant Control with Emergency Stop
Disassembly
(Ref. Dwg.D5790003)
Refer to PHS2 control disassembly to begin PHS2U
disassembly
I I. Remove emergency stop button (179).
12. Remove the setscrews (175).
13. Remove the spools (178).
14. Pull on the shuttle valve stop (180) with ball (176).
IS. Remove the ‘0’ rings (181) from shuttle valve stop
and spool (178).
l The cover (4) has been installed with Loctite ®
instajoint No 574.
5

Shut-off Valve Disassembly
(Ref. Dwg.D6170004)
I. Remove the screw (202).
2. Remove the cover (201) with the spring (203).
3. Remove the ‘0’ ring (204) from the cover (201).
4. Remove the cover (213) and the ‘0’ ring (215).
5. Remove the diaphragm (211).
6. lmmobilise the valve cone (214) by its hole with a rod
in one of two orifices of the body (209) and remove
the screw (208).
7. Remove the valve cone (205,214) with joints (206)
and distance ring (210) with the washer (207).
Emergency Stop Valve Disassembly
(Ref. Dwg.D6170003)
Refer to air control valve disassembly to begin disassembly
8. Remove emergency stop button (179).
9. Remove the setscrews (175).
IO. Remove the spools (178).
I I. Pull on the shuttle valve stop (180) with ball ( 176).
12. Remove the ‘0’ ring (181) from shuttle valve stop
(180) and spool (176).
Cleaning, Inspection and Repair
Use the following procedures to clean, inspect, and repair
the components of the winch.
l A bearing that appears loose or does not rotate
smoothly must be replaced. Failure to observe this
precaution will result in bearing and/or winch
component damage.
Clean all winch component parts in solvent (except for the
brake friction disc). The use of a stiff bristle brush will
facilitate the removal of accumulated dirt and sediments in
the drum and reduction assembly. If drum bushings have
been removed it may be necessary to carefully scrape old
Loctite® from the drum bushing bore. Dry each part using
low pressure, filtered compressed air. Clean the brake
friction disc using a wire brush or emery cloth. Do not
wash the brake friction disc in liquid. If the brake friction
discs are oil soaked, they must be replaced.
Inspection
All disassembled parts should be inspected to determine
their fitness for continued use. Pay particular attention to
the following:
I. Inspect all gears for worn, cracked, or broken teeth.
2. Inspect all bushings for wear, scoring or galling.
3. Inspect all bearings for play, distorted races, pitting
and roller or ball wear or damage. Inspect bearings
for freedom of freedom
4.
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.
5
- .
6.
7.
8.
9.
IO.
I I.
12.
Inspect all threaded items and replace those having
damaged threads.
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.
Smooth out all nicks, burrs, or galled spots on
shafts, bores, pins or bushings. Examine all gear
teeth carefully, and remove nicks or burrs.
Polish the edges of all shaft shoulders to remove
small nicks which may have been caused during
handling.
Remove all nicks and burrs caused by lockwashers.
Replace all gaskets, oil seals, and O’rings any time
the winch is disassembled for repair.
Inspect drum bushings (47) for wear, if thickness is
less than 0.039 in. (1 mm), replace drum bushings.
Inspect brake discs (21 and 22) for wear, if thickness
less than 0.354 in. (9 mm), replace them.
Repair
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.
I. Worn or damaged parts must be replaced. Refer to the
applicable Parts Listing for specific replacement parts
information.
3
-. 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.
Assembly Instructions
Winch Assembly
(Ref. Dwg. D6310041)
I. Gear box assembly.
1.1. Assembly of the shaft spindle (18)
- Install bearing (44) with the retainer ring
(40)
- Put the shaft spindle (I 8) in the bearing
(4).lnstall the gear wheel (43) with the
retainer ring (37)
I .2. Assembly of the fixed annular gear (19).
- Install the friction disc (21) and steel disc
(22) in the gear box (45).
- Install the ‘0’ ring (20) and the pin (39).
- Install the ‘0’ ring (9) in the fixed annular
gear (19) , install this ass’y in the gear box
(45) and secure with the retainer ring
(17).

1.3.
1.4.
I .5.
I .6.
1.7.
Install the needle bearings (14) and the spacer
(16) in the planet (15).
Install the three planet ass’y, bearing studs
(12) and stop rings (13) in the planet support
(46).
Install the planet axle (11) and the bearing
(10).
Install the planet support assembly.
After assembly of planet support (46) with
the fixed annular gear (19) and the shaft
spindle (18) , check for good indexing of
planet gears and repeat the above operation if
necessary.
(Dwg. D6310013
2.
?
3.
4.
l For correct assembly of planet gears, each planet
gear must be positioned with the timing mark as shown
on drawing D6310013.
I .8. Install the spring washer (49) and the output
annular. gear (50).
I .9. Assembly of the box cover
- Install the oil seal (52) and the bearing
(51 and 53).
- Install the output shaft (5) with the
retainer ring (54) in the gear box cover.
- Install the ‘0’ ring (9).
- Install the gear box cover ass’y and secure
with screws (47) and washers (48).
Assembly of the brake piston
2.1. Install the brake piston with the ‘0’ rings (23
and 25).
2.2. Install bearing (36)) spring (4 I) and gasket
(33).
Assembly of the front end cover.
3.1. Clean the mounting front end cover (30) bore
and apply a bead of Loctite No.460 on the
backside of the oil seal (35). lnstall the oil
seal.
3.2. Install the retainer ring (32).
3.3. Install the front end cover (30) and secure
with screws (34).
Install the three tie rod spacer (4) with the nuts (2)
and the washer (3).
5.
6.
7.
8.
9.
10.
I I.
12.
13.
Fill up the brake with oil.
Install the gasket (31) and the ‘0’ ring (27).
install the motor ass’y and secure with the four
screws.
Position the winch vertically with the motor end
down.
Fill up the gear box with oil SAE 80W90
- kinematics viscosity 145 mm% at 40°C( 104°F)
- capacity of gear box : 0.13 gall (0.5 Litres)
Drum assembly
IO. I. Scrape old Loctite from the drum bushing
bore and apply a bead of Loctite No406 on
the smooth face of drum bushings (38).
10.2. install drum bushing in drum bushing bore
by taking care to adjust the gaps of the drum
bushing to 3.9 ins (100mm) do not allow any
clearance between drum bushings and drum.
10.3. Lubricate drum bushings with grease.
10.4. Install the drum on the gear box assembly.
10.5. Lift out the drum to check for good
positioning of drum bushing
Clutch control assembly (PS SERIES)
I I. I. Install plunger body (70) and plunger (61) on
the rear end cover (55) and secure with screw
(67) and washer (68).
I I .2. Install bearing (7 I) on clutch axle (66) with
retainer ring (65) and install the clutch (72)
with the retainer ring (62).
11.3. Pull the plunger (61) to introduce the clutch
axle with the spring (69) into the plunger
body (70) and install the handle (65).
Assembly of the rear end cover (55).
12. I. Install bearing (58) on the rear cover.
12.2. Install exhaust washers (69) with ring (59).
Install spacer (64) on the output shaft (PS SERIES).
Install the rear end cover Ass’y on the three tie rod
(4) and secure with lock washers (3) and nuts (2).
Lever Control Valve Assembly
(Ref. Dwg.D6310006 or D6310035)
1. Lubricate and install ‘0’ ring (125) on rotary valve
(126).
7
-. Lubricate and carefully install rotary valve in valve
housing (I 22).
3. Lubricate and install spring (124) on rotary valve.
Ensure pin (123) is installed in valve housing (I 22).
4. Install stop (129). Apply a small amount of Loctite%
243 to threads of screws (127) and install.
5
_. Install control handle (121) on rotary valve and align
pin hole. Install pin (128) to secure control handle.

Air Gear Motor Assembly
(Ref. Dwg. D6310005)
I. Install the stop (105) ,spring (102) and stopper (108).
2. Install the spacer (92).
3. Install the bearing (100 and 107) and secure with the
screw ( 104) and washer (103).
4. Install the internal ring of the bearing (85) on the rotor
5
- . motor (84) and secure with the retainer ring (86).
6. Install the motors rotors with a pin between the teeth
and secure with the nuts (101 and 106).
7. Install the pin (83), the needle bearing (85 and 91) ,
the ‘0’ ring (89), the exhaust washer (87) and the plug
(88) in the motor cover.
8. install the motor ass’y on the motor cover with the
screws (109)
9. Install the ‘0’ ring (110) and the gasket (95) in the
motor housing (112).
IO. Install the motor ass’y in the motor housing (112) and
secure with the screws (81 and 82).
l To correctly assemble the exhaust washer, spacers,
valve and spring, carefully follow instructions:
- Take the motor body and put it in the same
position as mounting on the winch and view
from the backside of the motor body, stopper,
spring, valve and the spacer must be mounted
in the left bore. Check for good functioning of
the valve.
- The exhaust washer must be mounted on the
same side as the valve in the right bore.
- Before assembly lubricate bearing with grade 2
grease.
- Install ball bearings so markings on bearing
remain visible.
- After assembly of the air motor, it must turn
smoothly in both direction.
- The screws (104 and 109) the nuts (101 and
106 must be secured with Loctite ® 243,
secure the nuts with a centre punch.
‘PHS2” Pendant Control Assembly
(Ref. Dwg.D5790002)
I. Install lever (173) in pendant handle (172) with pin
(17 I). Stake pin in pendant handle at both ends to
secure.
2. Install setcrews (174).
3. Check that ‘0’ ring is undamaged and securely crimped
in valve. lnstall valve assemblies (169).
4. Install springs (168).
5. Check that ‘0’ ring is undamaged and securely crimped
in spool. lnstall quad ring (I 67) and spools (166).
6. Install springs ( 165).
7. Lubricate and install ‘0’ ring (163) on rear cover
(164). Install rear cover in pendant handle.
8. Install retainer rings (162).
‘PHS2U” Pendant Control with Emergency Stop
Assembly
(Ref. Dwg.D5790003)
Refer to PHS2 control assembly to begin PHS2U assembly.
9. Install ‘0’ ring (181) on shuttle valve stop (180) and
spool (178).
IO. Install that shuttle valve stop (180) with ball (176), those
spools (178) in pendant handle (172) and secure with
setscrew (175).
I I. Install the emergency stop bottom (179).
12. Install the eyebolt (170) and fitting (161).
Pendant Control Adjustment.
I.
9
A.
3.
4.
5
_.
6.
7.
8.
9.
IO.
Connect the inlet of the pendant to 100 psi (7 bar)
air supply.
Connect a manometer at the outlet of the lever to be
adjusted.
Apply a small amount of Loctite® No. 243 on the
adjustment setscrew (174).
Tighten the adjustment setscrew to obtain a pressure
of IS psi (1 bar) without action the lever.
Release the adjustment setscrew by a half turn
(pressure must fall to zero).
Push the lever. Check that pressure reaches 93 +/- 7
psi (6.5 +/- 0.5 bar). Check that there is no leak at
the exhaust.
Release the lever, exhaust must occur and result in
rapid pressure reduction.
Repeat operations “6 and 7” from 2 to 3 times.
Disconnect the manometer. Check to ensure that
there are no leaks when the lever is not activated.
Repeat the operations from 2 to 9 with each lever.

Tooling installation M63 13400
(Dwg. D6310031)
Testing
Operational Tests
Prior to initial use,all new,altered or repaired winches shall
be tested to ensure proper operation.
I. Operate winch in both directions with no load.
3
-. Check operation of free wheel and brake.
3. Check operation of limit switches and other safety
devices when provided.
4. Check all winch mounting bolts are secure.
Load test
Prior to initial use, all new, extensively repaired, or altered
winches shall be load tested by or under the direction of a
person trained in the operation and service of this winch
and a written report furnished confirming the rating of the
winch.
- For air winches LS series.
The minimum load test for European countries are
according to the chart below. lf not found below you should
use the tests recommended by the FEM.
The dynamic test shall be carried out with an overload
coefficient pl = I,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 p2 = 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 in hoisting the safe working load to
a small distance above the ground and then adding the
required surplus without shock.
- For air winches PS series.
The dynamic test shall be carried out with the nominal
line pull.
The static test shall be carried out vvith an overload
coefficient p2 = 1,4 i.e. with a load equal to 140% of the
safe working load.
9

(Dug D6310041)

112
96-97-98
109 L108
82
-81
83
85
86
87
88
89
90
91
93
84
83
(D\vg. D6310005)
12

DESCRIPTION TOTAL PART
SO. OF PART
QTY
NO.
31 Gasket I 9631-0118
80 Motor Ass’y 7631-0077
(incl’s itsm 31 & item 81 through 114)
81 Screw 5 1101-3001
82 Lock washer 7 4520-0006
83 Pin 4 4600-0416
84l Motor cover I 9631-0042 I
85 Bearing I 5646-2813
87 Exhaust washer
I 9620-0045
90
91
92
93
94
Rear
stop
Bearing
Spacer
Motor rotor
Repulsion rotor
2 9620-0069
I 5649-2213
I 9631-0018
I 9620-0033
I 9620-0026
99 Motor housing (incl’s item 96, 97 and 98) I 9620-0008
I
104 Screw t 4110-3403
IO5 t 9412-0030
• 106
107 Bearing I 5060-0004
1O8 Stopper I 9631-0017
109 Screw 4130-2206
III Greasing nipple I 6710-2227
112 Motor housing I 9631-0078
113 Screw 1 4100-0201
114 Lock Washer 1 4520-0006
Recommended Spare
13

128
(Dwg. D6310006)
ITEM DESCRIPTION TOTAL
NO. OF PART
QTY
PART NO.
120 Control Valve Ass’y (incl’s item 121 through 131) I 7631-0081
121 Control lever I 9618-0031
I 122 Valve housing I I I 9631-0021 I
I 2 I 4600-1216
127 I Screw I 2 4110-3403 I
I 128 IPin I 1 I 4650-7220 I
129 stop
130 Screw HM
I 9618-0034
4 41Ol-6601
Recommended Spare
14

(Dwg. D6310035)
ITEM DESCRIPTION
NO. OF PART
119 Control Valve Ass’y (incl’s item 121 through 133)
TOTAL
QTY
1
PART
NO.
I 121 I---
Control lever 1 9631-0056
122
123
Valve housing
Pin
I 9631-0058
2 4600-1216
I 127 Screw I 2 I 411O-3403
I 128 Pin 2 4650-7220
129
130
stop
Screw HM
Lock washer
Handle
Setscrew
Axle
I 9618-0034
4 4101-6601
131
132
133
134
4 4520-0006
1 6956-6232
I 4200-1507
I 9631-0057
Recommended Spare

(Dwg. D6310026)
ITEM
NO.
140
DESCRIPTION
OF PART
Pendant Control Valve Assy
(incl’s item 141 through 153)
TOTAL PART
QTY
NO.
I 7617-0010
I 141 Screw I 8 I-- 4130-0206
I 142 Lock washer 8 4520-0006 I
I 143 Screw I 4 I 4130-5906
I 144 I
Cover I I I 9617-0050 I
Return spring
I 147 End cap
2 I 9617-0049 I
148
149
Read stop 2 9412-0031
Slide valve 2 9617-0047
Valve body
I
152 Fitting I 3 I 6165-2632 I
153 Lifting Eye I 6422-2332
Recommended Spare
16

(Dwg.D5790002)
ITEM
NO.
160
DESCRIPTION
OF PART
Pendant Control Valve Ass’y
(incl’s item 161 through 174)
TOTAL PART
QTY
NO.
7579-0038
161 Fitting 3 6165-2632
162 Retainer Ring 2 4770-3028
164 Rear Cover 2 9579-0037
165 Spring 2 6915-8732
166 Spool (with ‘O’Ring crimped) 2 9579-0035
168 Spring 2 6915-8632
169 Valve Ass’y (with ‘O’Ring crimped) 2 9579-0036
170 Lifting Eye I 6422-2332
Pendant Handle 1 9579-0034
173 Lever 2 9579-0038
174 Setscrew 2 4200-7807
Recommended Spare
17

(Dwg.D5790003)
ITEM DESCRIPTlON TOTAL PART
NO. OF PART
QTY
NO.
161 Fitting 3 6165-2632
165 I Spring I 2
I
6915-8732 I
I
172 Pendant Handle I 9579-0095
173 Lever 2 9579-0038
174 Setscrew 2 4200-7807
175 Setscrew 3 4200-8307
176 Ball I 6940-1625
177 Spring 3 6911-3941
178 Spool 3 9579-0085
179 Emergency stop button 1 6859-8632
180 Shuttle Valve Stop I I I 9579-0098
182
183
Label kit
Pendant control with emergency stop ass’y
(incl’s item 161 through 182)
I 9579-0099
I 7579-0071
Recommended Spare
18

(Dwg. D6170004)
ITEM DESIGNATION
QTY
PART
NO OF PART TOTAL NUMBER
200
Shut-off Valve Assembly (incl’s item 201 through 215) I 7617-0016
201 Cover I 9617-0059
202 Screw 7 4130-6706
203 Spring 1 6915-8732
205 Valve Cone 1 9617-0053
207 Washer 2 4570-0005
205 Screw I 4130-8206
209 Body I 9617-0061
210 Distance Ring I 9617-0055
212 Filling 2 6165-2632
213 Cover
1
9617-0052
211 Valve Cone
I
9617-0054
Recommended Spare.
19