Product

Maintenance
Information

Air Powered Man RiderTM Winch

LS2-150RLP Series
Models
LS2-150RLP-L-( )-E LS2-150RLP-PHXXM-( )-E
(Lever Control) (Remote Control)

Save These Instructions

Form MHD56305
Edition 2
March 2008
71455570
© 2008 Ingersoll Rand Company
Only allow Ingersoll Rand trained Technicians to perform maintenance on this Product. For additional information contact Ingersoll Rand factory or nearest Distributor.
For additional supporting documentation refer to Table 1 ‘Product Information Manuals’ on page 2.
Manuals can be downloaded from www.irtools.com.
The use of other than genuine Ingersoll Rand replacement parts may result safety hazards, decreased performance and increased maintenance and may invalidate all warranties.
The original language of this manual is English.
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 (Man Rider) MHD56251 Product Parts Information MHD56306
Product Information MHD56293

INSPECTION

Frequent inspections should be performed on equipment in regular service. Refer to

Product Information Manual.

„ Periodic 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. Side Rails, 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. Buildup 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-crown throughout the life of the wire rope. Recording of the
actual 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.
6. Brakes: Individually test brakes installed to ensure proper operation. Brakes
must hold a 125% rated load 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 on page 7. If brake band cannot be adjusted to hold rated load, replace
the brake band assembly. Adjustments cannot be made to the disc brake. The
disc brake must be repaired as described in the “MAINTENANCE” section on page
7.
7. Foundation or Supporting Structure: Check for distortion, wear and continued
ability to support winch and rated load. Ensure winch is firmly 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. Ensure locking button moves freely and locks control handle in
neutral when not depressed.
9. Limit Switches: Operate winch in both directions to activate limit switches.
Limit switches should engage (stop winch operation) at established settings (+/
- 2 feet [+/- 0.6 metres]). Reset limit switch by operating winch in opposite
direction. Refer to ‘Limit Switches’ in “MAINTENANCE” section on page 7.
10. Emergency Stop Valve: During winch operation verify the emergency stop valve
operation. Valve must stop winch operation quickly. Valve must reset properly.
Refer to ‘Emergency Stop Valve’ in the “OPERATION” section in Product
Information Manual for procedures.
11. Overload Device: Ensure overload device is properly set to stop the winch when
loads exceed 150% (+/- 25%) of winch rated capacity. If winch does not shut
down, contact your distributor or the factory for repair information.
12. Slack Line Detector: Inspect rollers for wear and grooves or ridges. Replace
worn or grooved rollers. Check arms move freely and activate sensor valve.
Ensure rollers rotate freely. Check sensor valve plunger operation. If damaged or
stiff, replace sensor valve.
13. Press Roller: Inspect rollers for wear and grooves or ridges. Ensure rollers rotate
freely. Lubricate roller bores if rotation is rough or stiff. Check that springs keep
press rollers tight against wire rope drum diameter.
14. Emergency Lowering Device: Provide auxilary supply air to emergency lowering
power entry port and activate valve. Verify winch operation.
15. Drum Guard: Verify fasteners are tight and in good condition. Ensure guard is in
good condition.
16. Labels and Tags: Check for presence and legibility of labels. Replace if damaged
or missing.

„ Records and Reports

D Inspection records, listing all points requiring periodic inspection, should be
maintained for all load-bearing equipment. Written reports, based on severity of
(Dwg. MHP0056) 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
5. All Components: Inspect for wear, damage, distortion, deformation and person who performed the inspection, and kept on file where they are readily
cleanliness. If external evidence indicates damage, disassemble as required to available for review.
conduct a detailed inspection. Inspect gears, shafts, bearings, sheaves, springs
and covers. Replace worn or damaged parts. Clean, lubricate and reassemble.

2 Form MHD56305 Edition 2

„ Maintenance 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.

Table 3: Maintenance Interval Chart

Normal Application
The following work can be completed by owner maintenance personnel:
System Air Filter Inspect system air 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.
1 year or 2 years or 3 years or 4 years or 5 years or 6 years or 8 years or
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs 8,000 hrs
Inspect Motor X X X X
Inspect Automatic Band Brake * X X X X X X X
Inspect Disc Brake X X
Inspect Gearbox X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Press Roller X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X

Form MHD56305 Edition 2 3

Table 3: Maintenance Interval Chart (continued)
Heavy Application
The following work can be completed by owner maintenance personnel:
System Air Filter Inspect system air filter every 30 days or 80 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.
1 year or 2 years or 3 years or 4 years or 5 years or 6 years or 7 years or
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs 7,000 hrs
Inspect Motor X X X
Inspect Automatic Band Brake * X X X X X X X
Inspect Disc Brake X X
Inspect Gearbox X X
Replace Winch Anchor Bolts X X
Inspect Control Valve X X X X
Inspect Drum, Housings and Main Frames X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X
Limit Switches X X X X X X X
Press Roller X X X X
Slack Line Device X X X X X X X
Emergency Lowering Device X X X X X X X

Severe Application
The following work can be completed by owner maintenance personnel:
System Air Filter Inspect system air filter every 30 days or 80 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.
1 year or 2 years or 3 years or 4 years or 5 years or 6 years or 7 years or
Standard Components
1,000 hrs 2,000 hrs 3,000 hrs 4,000 hrs 5,000 hrs 6,000 hrs 7,000 hrs
Inspect Motor X X X X X X
Inspect Automatic Band Brake * X X X X X X X
Inspect Disc Brake X X X X
Inspect Gearbox X X X
Replace Winch Anchor Bolts X X X
Inspect Control Valve X X X X X X
Inspect Drum, Housings and Main Frames X X X X X X
Emergency Shut-Off Valve X X X X X X X
Overload Device X X X X X X
Limit Switches X X X X X X X
Press Roller X X X X X X
Slack Line Device X X X X X X
Emergency Lowering Device X X X X X X X

Note 1: Hours are for actual winch drum rotation. Perform an annual winch load test for all applications.
* Do not disassemble air cylinder unless brake operation or visual inspection indicates a requirement.
Recommend complete general overhaul.

4 Form MHD56305 Edition 2

 INSPECTION REPORT
Ingersoll Rand Model LS2-150RLP Series Air Winch

Model Number: Date:

Serial Number: Inspected by:

Reason for Inspection: (Check Applicable Box)

1. Scheduled Periodic Inspection:
(_____ Quarterly _____ Semiannually _____ Yearly)
Operating Environment:
2. Discrepancy(s) noted during Frequent Inspection
3. Discrepancy(s) noted during maintenance Normal: ___ Heavy: ___ Severe: ___
4. Other: ___________________________
Refer to the Product Information and Parts Information Manual and “INSPECTION” section for 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.
CORRECTIVE
CONDITION
COMPONENT ACTION NOTES
Pass Fail Repair Replace
Uprights, Siderails and
Spacers
Drum Band Brake
(125% load test)
Disc Brake
(125% load test)
Drum Band Brake
(visual inspection)
Disc Brake
(visual inspection)
Motor
Controls
Air System
Fasteners
Reduction Gears
Labels and Tags ---
Shafts
Winch Guard
Wire Rope Wedge ---
Emergency Stop Valve
Overload Device ---
Wire Rope ---
Stowage Valve (if equipped)
Slack Wire Rope Device
Limit Switches
Press Roller
Emergency Air Supply
Tank or System
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 comply with standards and regulations set forth in areas
outside the USA.
This form may be photocopied and used as an inspection record.

Form MHD56305 Edition 2 5


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
Winch will not operate.
Load continues to move when winch is
stopped.
Winch hauls in but does not
payout.
Winch does not lift load.
Oil leak from motor end of winch.
Throttle or pendant lever moves but
winch does not operate.
Winch runs slow.
Automatic Band Drum Brake:
Brake cylinder will not release.
Automatic Disc Brake:
Brake will not release.
6 Form MHD56305 Edition 2
TROUBLESHOOTING
CAUSE
Insufficient or no air supply to winch.
Winch is overloaded.
Disc brake does not release.
Drum brake does not release.
Emergency stop valve engaged.
Motor may be damaged.
Air leak.
Overload device engaged.
Air lines frozen due to water in air supply.
Brake is slipping.
Winch is overloaded.
Winch controls sticking.
Lower limit switch activated.
Slack line detector activated.
Motor may be damaged.
Insufficient air supply.
Brake is not releasing.
Winch is overloaded.
Reduction gear assembly is leaking.
Motor may be damaged.
Insufficient air supply.
Improper hose or fitting sizes.
Motor may be damaged.
Brake(s) may not be releasing.
Ice in exhaust ports and/or air lines.
Motor may be damaged.
Band drum brake out of adjustment.
Leaking cylinder seals.
Dirty filter in air supply.
Low air supply pressure.
Leaking piston seals.
No release pressure at brake port.
Sticking brake piston.
REMEDY
Check air supply line connections and hoses.
Reduce load to within rated capacity.
Inspect brake piston seals and replace if seals appear to be leaking.
Refer to ‘Automatic Band Drum Brake’ Adjustment in the “MAINTENANCE” section
on page 7.
Reset emergency stop valve.
Disassemble, inspect and clean the motor. Replace any broken or damaged parts.
Check hose and fitting connections. Inspect hose(s) for leaks. Tighten fittings and
repair or replace hoses as necessary.
Reduce load to within rated capacity of winch. If overload device cannot be reset,
contact factory.
Install or drain air system moisture traps, moisture collecting air receivers and
compressor aftercoolers. After corrective action has been taken, disconnect lines
at winch inlet and purge with clean, dry air or nitrogen.
Check brake friction discs and automatic band drum brake wear.
Reduce load to within rated capacity.
Check pendant/throttle levers spring return to normal (neutral) position when
released.
Raise load and check limit switch settings.
Determine cause of slack line and rectify problem.
Remove and disassemble motor as described in the “MAINTENANCE” section on
page 7. Examine all parts and replace any that are worn or damaged.
Verify air supply pressure and volume at winch inlet meets the requirements listed
in the “SPECIFICATIONS” section in Product Information Manual. Clean air line
filter.
Check brake release pilot hole is not restricted. Check seals on brake piston are not
damaged. Brake will start to release at 50 psig (3.5 bar/350 kPa).
Reduce load to within rated capacity.
Disassemble winch and inspect reduction gear assembly seals.
Disassemble, inspect and clean motor. Replace any broken or damaged parts.
Ensure air pressure at winch inlet is at least 90 psig (6.3 bar/630 kPa) at rated
volume. Clean air line filter.
Check fittings, connections and hoses for correct size and length. Replace parts
that may cause restricted air flow. Inspect air line filter.
Remove and disassemble motor. Inspect all parts and replace all worn or damaged
parts.
Refer to brake sections below.
Check aftercoolers and traps. Add airline antifreeze to air supply.
Disassemble, inspect and clean motor. Replace any broken or damaged parts.
Adjust drum brake to maintain correct cylinder stroke.
If air is noticed escaping from cylinder breather when attempting to release brake,
replace or repair cylinder.
Clean or replace filter.
Ensure air pressure at inlet to disc brake is at least 60 psig (3.4 bar/340 kPa).
Remove brake housing plug and if air escapes from port when attempting to
release brake, replace brake seals.
Check for proper operation of winch controls.
Apply 60 psig (3.4 bar/340 kPa) to brake release port and check for brake disc
movement. If brake discs do not move, disassemble and inspect disc brake as
described in “MAINTENANCE” section on page 7.
 MAINTENANCE

WARNING
• Never perform maintenance on the winch while it is supporting a load.
• Before performing maintenance, tag controls:
WARNING - DO NOT OPERATE - E
EQUIPMENT BEING REPAIRED.
• Only allow Ingersoll Rand trained Service Technicians to perform 0.047 inch minimum
maintenance on this winch. (1.2 mm minimum)
• 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
than 125% of rated line pull may be required to comply with standards and
regulations set forth in areas outside the USA.)
• Shut off air system and depressurize air lines before performing any
maintenance.
• Do not use Trichloroethylene to clean parts.
• Use of other than genuine Ingersoll Rand replacement parts may result in A Piston Friction
safety hazards, decreased performance and increased maintenance, and may B Plate
invalidate all warranties. Drive
Plate
C D
„ General
Reaction
Correct disassembly (to prevent loss or damage of good parts), repair, assembly, Plate
testing and adjusting are critical to proper winch operation. Maintenance procedures (Dwg. MHP2849)
are technical in nature and require training and experience to accomplish correctly.
In addition, repair and testing require specialized equipment that is not typically NOTICE
found at the winch-mounting site.
• Original brake disc thickness is 0.059 in (1.5 mm)
Proper use, inspections and maintenance increase the life and usefulness of your
Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and all „ Overload Device
machined threads with applicable lubricants. Use of antiseize compound and/or
thread lubricant on capscrew and nut threaded areas prevents corrosion and allows • Overload is factory set and should not be adjusted without consulting an
for easy disassembly of components. Ingersoll Rand trained technician.
(Dwg. MHP2683)

It is extremely important that anyone involved with maintaining the winch be

familiar with the servicing procedures of these winches and be physically capable of
conducting the procedures. These personnel shall have skills that include:
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.

A
„ Maintenance Intervals
Refer to Table 3, “Maintenance Interval Chart,” on page 3 for recommended
B
maintenance schedule. (Dwg. MHP2683)

NOTICE 1. Connect winch to an air supply.

2. Release securing screw and adjusting screw in order to increase or decrease the
• Refer to the Product Parts Information Manual for drawings unless specified SWL (increase SWL by tightening the adjusting screw). Adjustment must be made
elsewhere. for an overload of 35% maximum of SWL.
3. Tighten securing screw.
4. Check winch operation at rated load. If necessary, repeat adjustment.
„ Adjustments
„ Automatic Band Drum Brake
„ Limit Switches
Refer to Dwg. MHP2880 on page 8.
Refer to ‘Limit Switches (optional feature)’ section in Product Information Manual. 1. Loosen locknut ‘B’.
2. Tighten nut ‘A’ until the adjustment dimension 0.43 to 0.51 inch (11 to 13 mm)
„ Disc Brake is achieved.
3. Tighten locknut ‘B’.
No brake adjustment is required. Refer to Dwg. MHP2849 on page 7, A. Piston; B. 4. Check brake operation.
Friction Plate; C. Drive Plate; D. Reaction Plate; E. 0.047 inch minimum (1.2 mm
minimum).
1. Remove motor as described in ‘Motor Removal’ section on page 8.
2. Remove the reaction plate (57), splined hub (53), friction plates (55) and (58),
and drive plates (56).
3. Inspect the friction plates (55) and (58) for wear. If friction plate thickness is
uneven or is less than 0.047 in (1.2 mm), replace all friction plates.
No further disassembly is required, if only the brake friction discs are being
inspected. Ensure friction and drive plates are assembled in the correct order. Refer
to ‘Disc Brake’ on page 11.
g. MHP2683)

Form MHD56305 Edition 2 7


0.43-0.51 inch
11-13 mm
Nut ‘A’ Locknut ‘B’
(Dwg. MHP2880)
„ General Disassembly Instructions
Refer to the winch assembly drawings provided in Product Parts Information Manual
unless otherwise noted.
The following instructions provide the necessary information to disassemble, inspect,
repair and assemble the winch. 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 the process of disassembling the winch, observe the following:
1. 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.
2. 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.
3. 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. Keep the work area as clean as practical, to prevent dirt and other foreign matter
from getting into bearings or other moving parts.
5. All seals and ‘O’ rings should be discarded once they have been removed. New
seals 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 and housings.
7. 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.
„ Disassembly
„ General
1. Disconnect and tag all external air lines.
2. Remove filter, regulator and lubricator (FRL) assembly from spacer (66).
3. Remove winch guards. Refer to winch guard disassembly.
4. Remove press roller assembly from spacer. Refer to press roller disassembly.
5. Remove slack wire rope device from spacer. Refer to press roller disassembly.
6. Remove limit switch assembly. Refer to limit switch disassembly.
„ Motor and Reduction Gear Removal
Refer to Dwg. MHP2812 and MHP2728.
Use the following procedure to remove the motor.
1. Shut off and bleed down main air supply to winch.
2. Disconnect and tag air lines.
3. To remove motor, stand winch in a vertical position, with the motor end up.
Ensure winch is properly supported.
8 Form MHD56305 Edition 2
4. Remove four capscrews (86) and washers (125) that secure motor and control
valve assembly to upright (62).
5. Carefully pull motor assembly from winch.
6. Clean capscrews (86) and threaded holes with Loctite® 7063 or equivalent so
they are free of Loctite® residue.
7. Store motor in a clean area until needed.
Refer to motor disassembly for additional instructions.
„ Winch Guard
Refer to Dwg. MHP2817.
1. Remove capscrews (171).
2. Remove drum guard (216), left panel (217) and right panel (218).
„ Automatic Band Drum Brake
Refer to Dwg. MHP2811.
1. Disconnect and tag the air lines.
2. Loosen nut (151) until brake band (111) is slack on drum.
3. Remove one cotter pin (113) from each pin (112) and tap out pins (112) from
brake band ends.
4. Remove brake band (111) and adjustment screw (149). Remove capscrews (156)
and lockwashers (64) that secure housing (147) to side rail (68). DO NOT
disassemble brake cylinder assembly. Contact an Ingersoll Rand trained service
technician for cylinder disassembly and repair.
„ Limit Switch
Refer to Dwg. MHP2730.
CAUTION
• It is not recommended to disassemble limit switch. Contact factory if repair
is required.
1. Remove and tag hose connections if not already done.
2. Remove nuts (504) from rods (502). Remove cover (505), gasket (490) and
housing (486) from limit switch adapter (450).
3. Remove capscrews (499) and pull spindle switch assembly (501) from limit
switch adapter (450).
4. Store limit switch assembly in a clean, dry area until winch reassembly.
„ Press Roller
Refer to Dwgs. MHP2728 and MHP2731.
1. Compress ends of springs (167) and (169) to disengage from spacer (66) and pin
on press roller arm (163).
CAUTION
• Use care when releasing springs (167) and (169) from press roller. Springs
are under tension.
2. Remove capscrews (183) and lockwashers (73). Remove press roller assembly
from spacer (66).
3. Remove capscrews (161) and washers (162) from both sides of roller arm (181).
Remove frames (176) and springs (169).
4. Remove capscrews (161) and washers (162) from both sides of roller arm (181).
Remove press rollers (184).
„ Slack Wire Rope Device
Refer to Dwgs. MHP2732.
1. Remove and tag hose connections if not already done.
2. Remove locknuts (301) and washers (307) from shoulder screws (310).
3. Remove spacers (308) and lift off slack wire arm assembly.
4. Tap shoulder screws (310) from uprights (62) and remove bearings (309).
5. Remove capscrews (302) and lockwashers (73) from axle (304).
6. Remove locknuts (301) and lockwashers (73) from roller axle (305). Separate
arms (303), rollers (306) and axles (304) and (305).
7. Remove capscrews (324) and lockwashers (2) from protector (323).
8. Remove protector (323) and sensor valve (327) from upright (62).
„ Winch Base and Drum
Refer to Dwgs. MHP2728, MHP2807 and MHP2812.
Refer to ‘Motor Removal’ section on page 8 to remove motor assembly from the
winch.
1. Remove external components. Refer to ‘General’ section.
2. Stand the winch in a vertical position with motor end up.
3. Remove reduction gear and brake assembly. Set assembly to one side for further
disassembly if needed.
4. Remove capscrews (65) and (67), nuts (63) and lockwashers (64) to remove
spacers (66) and lifting lugs (69).
5. Remove capscrews (67), nuts (63) and lockwashers (64) to remove siderails (68).
6. Remove upright (62) and tube (70).
7. Remove capscrews (50) and lockwashers (73). Separate drum end cover assembly
from upright (62).
8. Remove bearing (76) and oil seal (77) from drum (60) if not removed with drum
end cover (78).
9. Carefully turn drum over so limit switch end is up. 10. Remove valve seat (205).
10. Remove upright (62) from drum (60). 11. Remove spring (213).
11. Remove capscrews (50) and lockwashers (73) from drum end cover (78). 12. Remove capscrews (214).
12. Remove drum end cover (78) from upright (62). 13. Separate caps (202) and (211), washers (208) and (206), sleeve (209) and
13. Remove bearing (76) and oil seal (77) from drum (60) if not removed with drum diaphragm (212).
end cover (78). 14. Remove seals (203) and (210).
15. Pull stop nut (194) and separate plunger (198) with diaphragm (196) from base
„ Disc Brake plate (199).
16. Unscrew nut (194) and remove plunger (198) and washer (195).
Refer to Dwg. MHP2807. 17. Remove ‘O’ ring (197) and discard.
Refer to ‘Motor Removal’ section on page 8 to remove motor assembly from the 18. Install a screw (dia. M5) in threaded hole on base plate (199) and pull it from
winch. motor cover (97).
1. Remove capscrews (25) (black) allowing brake and reducer assembly to be
romoved together. „ Control Valve
2. Use the two threaded puller holes in the piston (51) to remove piston (51) and
brake reaction plate (57) from brake housing (41). Refer to Dwg. MHP2729.
3. Remove drive plates (56), friction plates (55) and (58), spacer (54) and splined 1. To separate control valve (100) from motor assembly, remove capscrews (137)
hub (53). Note position for later assembly. and (168) with lockwashers (2).
4. Remove ‘O’ ring (16) and ‘O’ ring (52) from piston (51) and discard. 2. Remove capscrews (118) and lockwashers (2) from stop plate (119). Remove
stop plate.
„ Reduction Gear 3. Partially remove capscrew (126) just far enough to allow emergency stop housing
assembly to be removed. Place emergency stop housing assembly to one side for
Refer to Dwg. MHP2807. later disassembly.
Refer to ‘Disc Brake’ section on page 7 to remove disc brake assembly from the 4. Remove spools (142) from valve housing (135).
reduction gear assembly. 5. Completely remove capscrew (126) and lockwasher (125).
1. Remove fill plug (14) and drain oil from reduction gear into a suitable container. 6. Remove lever assembly, coupling (124) and spring (116).
2. Remove capscrews (24) and (25) to separate reduction gear assembly from brake 7. Do not disassemble handle unless repairs are needed. To disassemble handle, tap
housing (41). out pin (120) and unscrew cap (121). Remove handle spool (123) and spring
3. Remove capscrews (22) and washers (23) that secure reduction gear end cover (130).
(15). 8. Remove retainer (140), spindle shaft (131) and gear (138).
4. Remove retainer ring (12) from gear shaft (20). 9. Remove retainer (140), spindle shaft (131) and gear cam (139).
10. Remove pins (132) from spindle shafts (115).
CAUTION 11. Remove bushings (133) and bushings (141).
• It may be necessary to use a small amount of air pressure in fill hole of Emergency Stop:
reduction gear end cover (15) to separate from housing (27). Refer to Dwg. MHP2729.
1. Remove emergency stop valve (164) from end cover (172).
5. Remove and discard ‘O’ ring (16) on reduction gear end cover (15). 2. Remove ‘O’ rings (175).
6. It is not necessary to remove bearing (39) from reduction gear end cover (15) 3. Unscrew and remove valve (165) with ‘O’ ring (171), ‘O’ ring (166) and protector
unless damaged. Replace as necessary. (170).
7. Remove bearing (13) and oil seal (17). Replace seal and bearing if necessary. 4. Remove retainer rings (178).
8. Remove bearing (21) and ring gear (19). 5. Remove springs (177) and balls (84).
9. Support end cover (15) and tap out shaft (20). 6. Unscrew check valve (83) and remove ball (84).
10. Remove retainer ring (36) from sun gear (34). 7. Remove ‘O’ rings (166).
11. Support reducer housing (27) and gently tap out sun gear (34).
12. Tap out gear shafts (33) and remove planet gears (31), spacers (30), needle „ 2-Function Emergency Stop Pendant (optional feature)
bearings (28) and bearing rings (29).
13. Remove retainer ring (49). Refer to Dwg. MHP2818.
14. Remove sun gear (34). 1. Disconnect hoses from pendant assembly (600).
15. Remove retainer ring (36) and bearing (35). 2. Remove fittings (152).
16. Remove and discard gasket (26) and ‘O’ ring (16) from brake housing (41). 3. Remove lifting eye (617), if necessary.
17. Remove and replace bearing (38) if necessary. 4. Tap out pin (618) to remove the levers (619).
5. Unscrew and remove check valve (83) and ball (84).
„ Motor 6. Remove setscrew (173) to remove the valve assemblies (165).
7. Remove protector (170), ‘O’ rings (166) and (171) from the valve (165).
Refer to Dwg. MHP2812. 8. Remove plugs (623) to remove the springs (177) and balls (84).
1. Remove motor assembly as described in ‘Motor Removal’ on page 8. 9. Remove emergency stop button (164).
2. Remove control valve assembly (100) from motor assembly. 10. Remove retainer ring (621) and exhaust washer (615) from handle (622).
3. Remove capscrews (103) and emergency stop end cover (185).
4. Remove and discard gasket (101).
5. Remove capscrews (107) and remove motor cover (97) from motor housing (87).
6. Remove and discard ’O’ rings (90).
„ Cleaning, Inspection and Repair
7. Remove valves (105) and springs (96) from motor cover (97). Refer to Product Parts Information Manual for item numbers referenced in the
8. Remove ‘O’ rings (94) only if necessary. ‘O’ rings will need to be cut for removal. “Cleaning, Inspection and Repair” section.
NOTICE „ Cleaning
• The two bearings (91) located in the motor housing (87) are bonded with
Clean all winch component parts in solvent (except drum brake bands and disc brake
Loctite® 603 or equivalent. Remove idle gear (104) and drive gear (92) only
friction plates). The use of a stiff bristle brush will facilitate removal of accumulated
if replacement is necessary; use a bearing punch (IR pn: 96441232) or
dirt and sediments on housings, frame and drum. If bushings have been removed it
standard drift punch and a hammer. Refer to Dwg. MHP2644 on page 11.
may be necessary to carefully remove old Loctite® from bushing bores. Dry each part
9. To remove both bonded bearings (91) from motor housing (87), it is necessary to using low pressure, filtered compressed air. Clean drum brake band using a wire brush
use a bearing punch and hammer. Two or three strikes are enough. or emery cloth. Do not wash drum brake band in solvent. If drum brake band lining is
10. If replacement is necessary, remove bearings (91) from drive gear (92) and idle oil soaked, it must be replaced.
gear (104) (use a suitable bearing extractor).
11. Remove check valve (83) and ball (84) from motor housing (87). „ Inspection
Motor Emergency Stop End Cover: All disassembled parts should be inspected to determine their fitness for continued
Refer to Dwg MHP2812. use. Pay particular attention to the following:
Refer to ‘Motor’ section on page 9 to remove emergency stop end cover assembly
Inspect gears for
from the motor assembly.
- worn, cracked or broken teeth. Replace if necessary.
1. Remove ‘O’ rings (90) and discard.
Inspect bushings for
2. Remove setscrew (180).
- wear, scoring or galling. Replace if necessary.
3. Remove ball (84).
Inspect shafts for
4. Remove valve seat (186).
- ridges caused by wear. Replace if necessary.
5. Remove seal (189) and axle (188).
- scoring or galling.
6. Remove ‘O’ rings (187).
Inspect all threaded items for
7. Remove spring (193).
- damaged threads. Replace if necessary.
8. Unscrew clamping screw (102).
9. Unscrew regulating screw (192). Remove ‘O’ ring (191) and discard.

Form MHD56305 Edition 2 9

Inspect drum band brake lining for For Winches with Vertical and Horizontal Wire Rope Take-off Angle:
- oil, grease and glazing. If drum band brake lining is oil-soaked, excessively 12. Install spools (142) in valve housing (135).
greasy or overly glazed, replace brake band. Remove small glazed areas of band 13. Install emergency stop housing assembly to valve housing (135). Install
brake lining by sanding lightly with a fine grit emery cloth. shoulder screw (127). Tighten capscrews (126) and (127) to secure emergency
- thickness of drum band brake lining. If drum brake band lining is less than stop housing.
0.062 in. (2 mm) thick anywhere along the edges, replace brake band 14. Install capscrews (118), lockwashers (2) and stop plate (119) on valve housing
assembly. (135).
Inspect motor housing gear bores for 15. Check operation of control valve to ensure smooth movement and ability to
- wear or scoring. For any large scratches or uneven/excessive wear patterns, spring return and lock in neutral.
replace motor housing.
Inspect motor gears (92) and (104) for
- ridges or excessive grooving on outside diamenter of gears.
- contact between gears and gear housing.
Inspect press roller and slack wire device for
- wear, grooves or scoring of rollers. Replace if any of these conditions exist.
- smooth rotation. Rollers must operate without binding and without excessive
side-to-side play.
Inspect bearings for
- loss of grease and evidence of grit, dirt or other contaminants. All motor
bearings are factory lubricated and sealed. If dry or contaminated, replace the
bearing.
- damage. Inspect roller bearings (needle). At any indication of damage or
contamination, replace bearings.
Inspect disc brake for
- wear. Replace brake discs if grooving pattern is no longer visible or if discs are
cracked or chipped.
- thickness of disc. If less than 0.047 in (1.2 mm), replace.

„ Repair
Actual repairs are limited to the removal of small burrs and other minor surface
imperfections from gears, shafts, housings and machined surfaces. Use a fine stone
or emery cloth for this work.
1. Worn or damaged parts must be replaced. Refer to applicable parts listing for
specific replacement parts information.
2. Inspect all remaining parts for evidence of damage. Replace or repair any part Horizontal
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 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.

„ Assembly
Refer to Product Parts Information Manual for item numbers referenced in the
“Assembly” section.

General instructions:
- use new gaskets and seals.
- replace worn parts.
- assemble parts using match marks applied during disassembly. Compare
replacement parts with originals to identify installation alignments.

„ Control Valve
Refer to Dwg. MHP2729.
1. Install bushings (133) and (141) in valve housing (135).
2. Install pins (132) in spindle shafts (115), so they extend an equal amount on
both sides.
3. Install retainer (140), spindle shaft (115), key (136) and gear cam (139) in
valve housing.
4. Install retainer (140), spindle shaft (131), key (136) and gear (138) in valve
housing. Ensure keys are vertically aligned and gear teeth are meshed.
5. If handle was disassembled, install spring (130) and handle spool (123) in lever
shaft (128). Align hole in handle spool (123) with slot in lever shaft (128) and
install pin (120) so it extends an equal amount on both sides. Install 'O' ring
(122) on cap (121) and screw cap (121) into lever shaft (128).
For Winches Requiring Vertical Wire Rope Take-off Angle:
6. Install pin (134) in the top pin hole in valve housing (134).
7. Install lever assembly in coupling (124). Install spring (116) and coupling/
handle assembly on lower spindle shaft (115). Align notch in coupling with pin
in spindle shaft. Spring (116) ends will point up. Refer to Dwg. MHP2998 on
page 10.
8. Install capscrew (126) and lockwasher (125) through coupling (124) and lower
hole in lever shaft (128).
For Winches Requiring Horizontal Wire Rope Take-off Angle:
9. Install pin (134) in the lower pin hole in valve housing (134).
10. Install lever assembly in coupling (124). Install spring (116) and coupling/
handle assembly on top spindle shaft (115). Align notch in coupling with pin in
spindle shaft. Spring (116) ends will point down. Refer to Dwg. MHP2998 on
page 10.
11. Install capscrew (126) and lockwasher (125) through coupling (124) and top
hole in lever shaft (128).
Standard Vertical
(Dwg. MHP2998)
„ Motor
Refer to Dwg. MHP2812.
1. Clean the grease from bearings (91).
2. Clean interior and exterior diameter of bearings with Loctite® 7063 or
equivalent.
3. Put a continuous thin film of Loctite® 603 or equivalent on interior diameter of
bearing (91). Refer to Dwg. MHP2644 on page 11, for correct application
locations. A. Use a continuous thin film of Loctite® 603 or equivalent to bond
one bearing on each gear. Apply where arrows indicate; B. Do not bond bearings
on this side of gears; C. Use of continuous thin film Loctite® 603 or equivalent;
D. Note: Wait 10 minutes with the housing in this position, to ensure proper
bond; E. Install splined hub (75) and rotate to ensure a proper bond.
4. Apply a continuous thin film of Loctite® 603 or equivalent on bearing diameter
on drive gear (92) and install bearing (91).
5. Install a second bearing (91), not bonded, on drive gear (92).
6. Apply a continuous thin film of Loctite® 603 or equivalent on interior diameter
of bearing (91).
7. Apply a continuous thin film of Loctite® 603 or equivalent on bearing diameter
on idle gear (104) and install bearing (91).
8. Install a second bearing (91), not bonded, on idle gear (104).

10 Form MHD56305 Edition 2

9. Apply a continuous thin film of Loctite® 603 or equivalent on bore for bearings 12. Insert axle (188) into valve seat (186) then install seals (189) on each end of
in the motor housing (87). axle (188).
10. Install drive gear (92) and idle gear (104) into motor housing, ensure the drive 13. Insert valve seat (186) into emergency stop end cover (185).
gear and idle gear are completely inside motor housing and leave the motor 14. Insert ball (84) into emergency stop end cover (185).
housing in a position as shown in Dwg. MHP2644 on page 10 for 10 minutes. 15. Install gasket (101) on motor cover (97).
11. Turn the gears with coupling and a tool. Check bearings do not rotate on bonded 16. Install emergency stop end cover (185) on motor cover (97) and secure with
diameters and gears rotate freely. capscrews (103).
12. Install pins (88) in motor cover (97). 17. Insert plug (182) if removed during disassembly.
13. Install exhaust washer (99) with a drop of Loctite® 601 or equivalent on motor 18. Install setscrew (180) in emergency stop end cover (185).
cover. 19. Install ‘O’ rings (90) on emergency stop end cover (185).
14. Install ‘O’ rings (90) on motor cover (97). 20. Install control valve assembly.
15. Install motor cover (97) on motor housing and secure with capscrews (107). 21. If pendant adapter plate (605) or (613) was removed from motor cover (83),
16. Lubricate ‘O’ rings (85) on valves (94) and (105). One ‘O’ ring is mounted in a refer to pendant assemblies for installation.
special groove. Ensure a good assembly.
17. Install springs (96) and valve assemblies (94) and (104) in motor cover (97). „ Reduction Gear
18. Lubricate and install ‘O’ rings (166) on check valve (83). Install ball (84) and
check valve assembly in motor housing (87). Refer to Dwg. MHP2807.
19. Check to ensure motor gears turn smoothly in both directions. 1. Install oil seal (17) in the bore of the reduction gear end cover (15) so seal lip is
toward the planet assembly side.
2. Lubricate and install ‘O’ ring (16) on outside diameter of reduction gear end
Use a continuous thin cover (15). Install plug (14).
A
film of Loctite® 603 or 3. Press bearings (13) and (39) into the reduction gear end cover (15). Install
equivilant to bond one retainer ring (12) on the gear shaft (20).
bearing on each gear. 4. Press gear shaft (20) into reduction gear end cover (15).
Apply where arrows 5. Install ring gear (19) and bearing (21) on gear shaft (20) and secure in position
indicate. with retainer ring (94). Install assembly in reducer housing (27).
6. Press bearing (35) onto the sun gear (34) and locate with retainer ring (36).
Install sun gear (34) with bearing (35) in the planet gear support (32) and
secure with retainer ring (49).
7. Install two bearings (28) with a spacer (30) between in the bore of each
planetary gear (31).
8. Install bearing rings (29) in each bearing (28).
9. Position each assembled planetary gear in the planet gear support (32) with the
Do not bond timing mark as shown on drawing Dwg. MHP1406 on page 11, A. Planet Gear
Support; B. Timing Marks; C. Planet Gear. Carefully install gear shafts (33).
bearings on
B
this side of CAUTION
gears.
• For assembly of planet gears, each planet gear must be positioned with the
timing mark as shown on Dwg. MHP1406.
Use of continuous
thin film of Loctite®
603 or equivilant. Planet Gear A
C Support

D
Note: Wait 10 minutes with
the housing in this position,
to ensure proper bond.

E
Install splined hub (75) and
rotate to ensure a proper
bond.
(Dwg. MHP2644)
Motor Emergency Stop End Cover:
Refer to Dwg. MHP2812.
1. Lubricate and install ‘O’ ring (201) and seal (189) on base plate (199).
2. Lubricate and install ‘O’ ring (197) to plunger (198).
3. Install diaphragm (196) and washer (195) with stop nut (194) on plunger (198)
and insert into base plate (199). Ensure plunger assembly moves freely in bore of
base plate.
4. Insert base plate (199) with plunger into motor cover (97).
5. Lubricate and install ‘O’ rings (204) on valve seat (205).
6. Place washer (206), diaphragm (212), cap (211), seal (203), sleeve (209) and
washers (206) and (208) onto capscrew (214) and insert into valve seat (205).
Apply a thin film of Loctite® 243 or equivalent to capscrew threads. Do not over
tighten capscrew.
7. Place seal (210) and cap (202) on capscrew (62). Place spring (213) on cap
(202).
8. Install valve seat assembly into emergency stop end cover (185).
9. Lubricate and install ‘O’ ring (191) on regulating screw (192); insert into
emergency stop end cover (185) avoiding damage to the ‘O’ ring. Secure with
screw (102). Install screw (102) with Loctite® 243 or equivalent.
10. Lubricate and install spring (193).
11. Install ‘O’ rings (187) to valve seat (186).
B
Timing
C
Marks Planet Gear
(Dwg. MHP1406)
10. Install planetary gear assembly in the reducer housing (27).
11. Install ball bearing (38) on the planet gear support (32). Check planet gears, sun
gear and ring gear teeth mesh smoothly.
12. Place the reduction gear assembly in a vertical position with the planetary gear
end up.
13. Fill the gear assembly to within 1 in. (25 mm) of the top with clean oil. Refer to
“LUBRICATION” section in Product Information Manual.
14. Install new gasket (20) on reducer housing (27).
15. Apply Loctite® 243 to capscrews. Refer to “TORQUE CHART” on page 15.
„ Disc Brake
Refer to Dwg. MHP2807.
1. Lubricate and install ‘O’ rings (16) and (52) on piston (51).
2. Install new gasket (26) on reducer housing (27) if not done during reduction
gear assembly.
3. Assemble brake housing (41) to reducer assembly and secure with capscrew (24).
4. Ensure plug (14) is removed, then press piston assembly into brake housing (41).
Puller screw holes must face out.
5. Install spacer (54) and splined hub (53). Start with friction plate (55) followed
by drive plate (56), friction plate with springs (58), drive plate (56), friction
plate (55), drive plate (56) and finishing with friction plate with springs (58).
6. Install plug (14).

Form MHD56305 Edition 2 11

„ Winch Base and Drum
Refer to Dwgs. MHP2728, MHP2807 and MHP2812.
1. Install oil seal (77) and rear bearing (76) on drum end cover (78). Oil seal lip
must be toward the bearing.
2. Install drum end cover assembly on upright (62) and secure with capscrews (50)
and lockwashers (73).
3. Position the upright on several block of wood with the rear bearing (76) up.
4. Check that plate (72) is securely installed in the drum with countersunk screws
(71).
5. Lubricate the outside diameter of oil seal (77) and install drum assembly on rear
bearing.
6. Install oil seal (77) and front bearing (76) on drum end cover (78). Oil seal lip
must be toward the bearing.
7. Install drum end cover assembly on front upright (62) and secure with capscrews
(50) and lockwashers (73).
8. Lubricate the outside diameter of oil seal (77) and install front upright assembly
on drum (60).
9. Rotate uprights so they are aligned and install spacers (66) and siderails (68)
with capscrews (65) and (67), nuts (63) and washers (64). Longer capscrews
(65) are required to attach lifting lugs (69). Mount lifting lugs diagonally
opposite.
10. Check pin (79) is installed in drum end cover (78).
11. Install motor reducer assembly. Ensure gear shaft (20) meshes with splined bore
in drum and secure with capscrews (86) and lockwashers (125).
12. Return winch to a horizontal position.
13. Install remaining external assemblies.
„ Automatic Band Drum Brake
Brake Cylinder:
Refer to Dwg. MHP2811.
It is recommended that any brake cylinder service work be conducted by an Ingersoll
Rand trained technician.
1. Install ‘O’ ring (145) on the piston (146).
2. Install oil seal (114), ring (143) and ‘O’ ring (145) in the cover (117).
3. Install piston (146) and spring (144) in the housing (147).
4. Install cover (117) and close brake cylinder assembly with capscrews (302) and
lockwashers (73). Before closing the brake cylinder, fill the spring housing with
about 1 oz. (25 ml) of SP 150 type oil.
Brake Band:
Refer to Dwg. MHP2811.
1. Thread nut (148) onto adjustment screw (149), then install adjustment screw
(149) in brake cylinder assembly.
2. Install the brake cylinder assembly with capscrews (156) and lockwashers (64)
on the siderail (68).
3. Install band brake (111) on drum (60). Anchor brake band ends to adjustment
screw (149) and piston (146) with pins (112) and cotter pins (113). Bend ends
of cotter pins apart.
4. Install locknut (151) and washer (150) on adjustment screw (149).
5. Adjust brake band assembly. Refer to ‘Adjustments’ section on page 7.
„ 2-Function Emergency Stop Pendant (optional feature)
Refer to Dwg. MHP2818.
1. Install ‘O’ rings (166) and protector (170) on valves (165). Install valve
assemblies in handle (514)
2. Install levers (503) in pendant handle (514) with pin (502). Stake pin in
pendant handle at both ends to secure.
3. Install screws (504) in levers.
4. Install screws (173) in handle.
5. Install balls (84) and springs (177) in handle (514). Secure in position with
plugs (518).
6. On pendants with emergency stop, install emergency stop button (164).
7. On pendants without emergency stop button, install plug (507).
8. Install exhaust washer (41) and secure in handle with retainer ring (512).
Adjustment:
a. Connect the inlet of the pendant to 100 psi (7 bar) air supply.
b. Connect a manometer at the outlet of the lever to be adjusted.
c. Apply a small amount of Loctite® No. 243 on the adjustment screw (521).
d. Tighten the adjustment setscrew to obtain a pressure of 15 psi (1 bar)
without actioning the lever.
e. Release the adjustment setscrew by a half turn (pressure must fall to zero).
f. Push the lever. Check that pressure reaches 93 +/-7 psi (6.5 +/- 0.5 bar).
Check that there is no leak at the exhaust.
g. Release the lever; exhaust must occur and result in rapid pressure
reduction.
h. Repeat operations ‘f’ and ‘g’ 2 to 3 times.
i. Disconnect the manometer. Check to ensure that there are no leaks when
the lever is not activated.
j. Repeat the operations from ‘b’ to ‘i’ with each lever.
„ Limit Switches
Refer to Dwg. MHP2730.
1. Install limit switch adapter (450) on drum end cover (78). Secure with capscrews
(98) and lockwashers (73).
2. Install spindle switch assembly (501) on limit switch adapter (450). Secure with
capscrews (499).
12
3. Install one gasket (490) on each end of housing (486).
4. Thread one nut (73) and washer (73) on each rod (502). Install four rods in limit
switch adapter (450) and tighten nut (73). Ensure full thread engagement of rod
in limit switch adapter.
5. Install housing (486) and housing cover (505). Position housing with cap
assembly (498) hole on top. Align housing cover holes with rods.
6. Install nuts (504) on rods (502) to secure housing and housing cover.
„ Slack Wire Rope Device
Refer to Dwg. MHP2732.
1. Assemble valve support (325) to sensor valve (327) with capscrews (318).
2. Assemble protector (322) to valve support (325) with capscrews (22) and
washers (23).
3. Assemble protector (323) and valve support (325) to upright (62) with
capscrews (324) and lockwashers (2).
4. Install bearings (309) on the shoulder screws (310).
5. Assemble arms (303), rollers (306) and axles (304) and (305). Install nuts (301)
and lockwashers (73) on roller axle (305) to secure.
6. Install capscrews (302) and lockwashers (73) on axle (304).
7. Install spacers (308) and slack wire arm assembly. Tap shoulder screws (310) into
uprights (62).
8. Install nuts (301) and washers (307) on shoulder screws (310).
9. Reconnect hoses.
„ Press Roller
Refer to Dwgs. MHP2728 and MHP2731.
1. Install press rollers (184) between roller arms (181) and secure with capscrews
(161) and washers (162).
2. Install frames (176) and springs (169) on roller arms (181). Secure with
capscrews (161) and washers (162).
3. Install press roller assembly in spacer (404). Secure with capscrews (183) and
lockwashers (73).
4. Compress ends of springs (167) and (169) to engage with spacer (66) and pin on
press roller arm (163).
Connect all air hoses as described in Product Information manual.
„ Testing
„ Operational Tests
Prior to initial use, winches shall be tested to ensure proper operation.
1. Check guards are installed and secure.
2. Check all winch mounting bolts are secure.
3. Operate winch in both directions with no load.
4. Check operation of brakes and emergency stop.
5. Check operation of limit switches, slack line device, press roller and other safety
devices when provided.
„ Load Test
Prior to initial use, all new, 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 rated line pull. To
test winch at 125% of rated load, apply following load with wire rope on the first
layer of the drum:
LS2-150RLP-* Winch 414 lb. (187 kg)
NOTICE
• Testing to more than 125% of rated line pull may be required to comply with
standards and regulations set forth in areas outside of the USA.
Form MHD56305 Edition 2
 SERVICE NOTES

Form MHD56305 Edition 2 13

 SERVICE NOTES

14 Form MHD56305 Edition 2

 TORQUE CHART
Standard Coarse Thread Torque
SAE Grade 5 SAE Grade 8
Size
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
SAE Grade 5 SAE Grade 8
Size
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
Class 8.8/9.8 Class 10.9
Size
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
Class 8.8/9.8 Class 10.9
Size
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-sieze coated fasteners.
PTFE: 2% minimum PTFE (teflon) 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 ref.

Form MHD56305 Edition 2 15

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