Ingersoll-Rand LIFTSTAR, Parts And Maintenance Manual

Page 1: ...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 accordanc...

Page 2: ...ting 10 Notes 11 Parts Winch Assembly Drawing 12 Winch Assembly Parts List 13 Air Gear Motor Assembly Drawing 14 Air Gear Motor Assembly Part List 15 OLD Lever Control Valve Assembly Drawing and Part...

Page 3: ...means of stopping winch operation WARNING It is the owner s and operator s responsibility to adjust winch operating limits prior to using the winch Limit Switch Adjustment Bottom limit switch cam Scre...

Page 4: ...r abnormal noises Check the operation of the brake Yearly Maintenance Personnel Inspect the brake disc Clean or replace parts as required Inspect the winch gearing shafts and bearings for wear and dam...

Page 5: ...its mounting and set in a clean work area on a sturdy work bench 3 Position several blocks of wood on the work bench and stand the winch in a vertical position with the motor end down 4 Remove the nut...

Page 6: ...46 from the valve body NOTICE The cover 4 has been installed with Loctite instajoint No 574 Air Gear Motor Disassembly Ref Dwg D6310005 Refer to control valve disassembly sections to remove lever or p...

Page 7: ...prevent damage to the seal lip 5 Inspect all threaded items and replace those having damaged threads 6 Inspect all remaining parts for evidence of damage Replace or repair any part which is in questio...

Page 8: ...AE 80W90 kinematics viscosity 145 mm s at 40 C 104 F capacity of gear box 0 13 gall 0 5 Litres 10 Drum assembly 10 1 Scrape old Loctite from the drum bushing bore and apply a bead of Loctite N 406 on...

Page 9: ...heck 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...

Page 10: ...d test for European countries are according to the chart below If not found below you should use the tests recommended by the FEM The dynamic test shall be carried out with an overload coefficient 1 1...

Page 11: ...11 NOTES...

Page 12: ...12 WINCH ASSEMBLY DRAWING Dwg D6310041...

Page 13: ...Bushing 3 96310014 39 Pin 5 46000416 40 Retainer ring 1 47703032 41 Spring 11 69165532 42 O ring 1 58207129 43 Gear wheel 1 96310095 44 Bearing 1 50000002 45 Gear box 1 96310092 46 Satellite support...

Page 14: ...14 AIR GEAR MOTOR ASSEMBLY DRAWING Dwg D6310005...

Page 15: ...aring 1 56492213 92 Spacer 1 96310018 93 Motor rotor 1 96200093 94 Repulsion rotor 1 96200026 95 Gasket 1 96310045 96 Selector stop 1 96090223 97 Ball 1 69401625 98 O ring 1 58212229 99 Motor housing...

Page 16: ...ve Ass y incl s item 121 through 131 1 76310011 121 Control lever 1 96180031 122 Valve housing 1 96310021 123 Pin 2 46001216 124 Return spring 1 96180035 125 O ring 1 58210229 126 Rotary valve 1 96310...

Page 17: ...134 1 121 Control lever 1 96310056 122 Valve housing 1 96310058 123 Pin 2 46001216 124 Return spring 1 96180035 125 O ring 1 58210229 126 Rotary valve 1 96310022 127 Screw 2 41103403 128 Pin 2 4650722...

Page 18: ...18 NEW LEVER CONTROL VALVE ASSEMBLY DRAWING From 1st December 2009 21 16 14 12 6 15 5 11 9 4 8 10 13 19 20 17 18 2 3 1 5 7 Dwg D6310863...

Page 19: ...6 4 Valve Housing 1 96310021 5 Screw 2 41322906 6 O ring 1 58210229 7 Lockwasher 2 45201005 9 Stop 1 96180034 10 Control Lever 1 96310338 11 Rotary Valve 1 96310122 12 Pin 1 46507220 13 Schoulder Scre...

Page 20: ...20 NOTES...

Page 21: ...rough 153 1 76170010 141 Screw 8 41300206 142 Lock washer 8 45200006 143 Screw 4 41305906 144 Cover 1 96170050 145 Return spring 1 94120289 146 Quad ring 2 58232429 147 End cap 2 96170049 148 Read sto...

Page 22: ...22 TWO LEVER PENDANT ASSEMBLY DRAWING Dwg D5790002...

Page 23: ...5 69401625 7 Spring 2 4 69128541 8 Plug 2 4 65107741 9 Screw 2 3 42008307 10 O Ring 2 5 58209229 11 Protector 2 3 95790107 12 Pendant Handle 1 95790129 95790131 95790132 95790116 95790130 13 Label Kit...

Page 24: ...76170016 201 Cover 1 96170059 202 Screw 7 41306706 203 Spring 1 69158732 204 O Ring 1 58214829 205 Valve Cone 1 96170053 206 Joint 2 96170056 207 Washer 2 45700005 208 Screw 1 41308206 209 Body 1 961...

Page 25: ...82 Label Kit 1 95790099 201 Cover 1 96170059 202 Screw 7 41306706 203 Spring 1 69158732 204 O Ring 1 58214829 205 Valve Cone 1 96170053 206 Joint 2 96170056 207 Washer 2 45700005 208 Screw 1 41308206...

Page 26: ...69400125 235 Spring Seat 1 96360023 236 Spring 1 69159432 237 Nut 1 43001111 238 Washer 1 96360019 239 Diaphragm 1 96360020 240 Cover 1 96360015 241 Usit Ring 2 58409731 242 Screw 2 96360022 243 Body...

Page 27: ...IMIT SWITCHES ASSEMBLY DRAWING 17 3 12 x 15 x 25 14 16 23 x 10 40 11 6 20 21 7 30 13 22 20 11 11 26 39 x 9 x 24 5 8 18 19 Dwg D6510862 NOTE X Screws securized with Loctite 243 or equivalent on the thr...

Page 28: ...28 LIMIT SWITCHES ASSEMBLY DRAWING 35 34 36 34 28 29 27 x Cam to adjust Top limit Switch Cam to adjust Bottom Limit Switch 39 x 30 38 37 33 31 32 32 31 32 41 37 37 43 44 42 Dwg D6510862...

Page 29: ...3 42007707 20 Retainer Ring 2 47803342 21 Spring Washer 2 69103442 22 Washer 1 45001110 23 Axle 1 96510003 24 Gasket 1 96510012 25 Cable Glands 1 60903542 26 O ring 1 58239129 27 Screw 2 41316506 28 P...

Page 30: ...GUARD ASSEMBLY DRAWING AND PART LIST 2 1 ITEM DESIGNATION QTY PART NUMBER NO OF PART TOTAL SHORT DRUM LONG DRUM Drum Guard Ass y Incl s item 1 and 2 1 76310026 76310027 1 Drum Guard 1 96310038 9631006...

Page 31: ...31 NOTES...

Page 32: ...32 NOTES...

Page 33: ...33 NOTES...

Page 34: ...iodically revised to incorporate changes Always check the manual edition number on the front cover for the latest issue Return Goods Policy INGERSOLL RAND will not accept returned goods for warranty o...

Page 35: ...e equipment and parts recognised as faulty by its technical or after sales services which are sent carriage paid and packing free without there being any claim for damage arising such as injury to per...

Page 36: ...country or write fax to Ingersoll Rand Material Handling P O Box 24046 2724 Sixth Avenue South Seattle WA 98124 0046 USA Phone 206 624 0466 Fax 206 624 6265 Canada National Sales Office Regional Ware...