Ingersoll-Rand LIFTSTAR, Parts And Maintenance Manual

Page: 5 / 36

5
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 :
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.
8. 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.
2. Remove winch from 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 nuts (2) and lock washers (3).
5. 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)
6. 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)
7. Remove the drum (56) from the winch.
7.1.
Remove the spacer (64).Only for PS series.
7.2. Remove the drum bushings (38) from the
drum (56) if they require replacement.
8. Remove the oil drain plug (6) and return the winch
to drain the oil from the gear casing.
9. 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.
10. Remove the gasket (31) and the 'O'ring (27) and
drain the oil from the brake through the front end
cover bore.
11. Remove the three nuts (2) and lock washers (3) and
remove the three tie rod spacers (4).
12. Remove the output shaft (5) from the gearbox and
brake assembly.
13. 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).
NOTICE
•
The oil seal 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 (41).
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).
15.9. Remove the needle bearings (14) and the
spacers (16).