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Product Maintenance InformationAir Powered Man Rider™ WinchModelsLS2–150RLP-L-( )-E LS2–150RLP-PHXXM-( )-E(Lever Control)(Remote Control)Save These InstructionsForm MHD56305Edition 3April 201371455570Only 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 .The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate all warranties.Original instructions are in English. Other languages are a translation of the original instructions.Refer all communications to the nearest Ingersoll Rand Office or Distributor.Table 1: Product Information Manuals PublicationPart/Document Number PublicationPart/DocumentNumber Product Safety Manual (Man Rider)MHD56251Product Parts Information Manual MHD56306Product Instructions ManualMHD56293INSPECTIONFrequent inspections should be performed on equipment in regular service. Refer to Product Information Manual.n Periodic InspectionRefer to Table 2 ‘Inspection Classifications’ on page 2 for suggested winchinspection classifications for Periodic Inspection intervals. Select conditions most appropriate to application.Table 2: Inspection ClassificationsConditionsNormal Heavy Severe Typical Use (operating time)InfrequentRegularContinual/ConstantLoad Range 60% of Capacity 75% of Times Used80% of Capacity 75% of Times Used100% of Capacity 75% of Times UsedInstallation Protected/Enclosed/Dry Not Sheltered/ExteriorFull ExposureAtmosphere Clean/Non-Corrosive Dirty/Non-Corrosive/Freshwater Marine Dirty/Corrosive/Saltwater Marine ClimateDry/Stable TemperatureWet/Moderate Temperature FluctuationsWet/Severe Temperature FluctuationsMaintain written records of periodic inspections to provide an accumulative basis for continuing evaluation. Inspect all items listed in the ‘Frequent Inspection’ section of the Product Information Manual. Also inspect the following at the suggested intervals recommended in Table 4 ‘Maintenance Interval Chart’ on page 3:1.Siderails and Uprights. Check for deformed, cracked or corroded maincomponents. 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 forthe following:a.Build-up of dirt and corrosion. Clean with steam or a stiff wire brush toremove dirt and corrosion if necessary.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 fromcrown-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 previousinspections. 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 thewire rope to remain in service. Refer to Dwg. MHP0056 on page 2.B(Dwg. MHP0056)e.Inspect rope for broken strands/wires: When broken wires are evident closeto, or within, the termination, even if few in number, are indicative of high stresses at this position and can be caused by incorrect fitting of thetermination. The cause of this deterioration shall be investigated and, where possible, the termination shall be remade, shortening the rope if sufficient length remains for further use, otherwise the rope shall be discarded. One valley break may indicate internal rope deterioration, requiring closerinspection of this section of rope. When two or more valley breaks are found in one lay length, the rope should be considered for discard. If a complete strand fracture occurs, the rope shall be immediately discarded. Where broken wires are very close together, constituting a localized grouping of such breaks, the rope shall be discarded. If the grouping of such breaks occurs in a length less than 6d or is concentrated in any one strand, it may be necessary to discard the rope even if the number of wire breaks is smaller than the maximum number, refer to table on page 2Table 3: Wire RopeRope ConstructionTypeNumber Broken Wires in rope over a length 6x nominal diameter Number Broken Wires in rope over a length 30x nominal diameter6 x 19S-IWRC Single-layer rope366 x 37M-IWRC Single-layer rope10195.All Components. Inspect for wear, damage, distortion, deformation andcleanliness. If external evidence indicates damage, disassemble as required to conduct a detailed inspection. Inspect gears, shafts, bearings, sheaves, springs and covers. Replace worn or damaged parts. Clean, lubricate and reassemble.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 replacecomponents as necessary. Adjustments can be made to the band brake to compensate for normal brake lining wear. Refer toʽAdjustmentsʽon 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 “MAINTENANCE”sectionon 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 (+/- 2feet [+/- 0.6 metres]). Reset limit switch by operating winch in opposite direction.Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.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. Replaceworn 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. Ensure rollers freely rotate.Replace rollers if worn or grooved. Replace bearings if rotation is rough or stiff.14.Emergency Lowering Device. Provide auxiliary supply air to emergencylowering power entry port and activate valve. Verify winch operation.15.Drum Guard. Verify fasteners are tight and in good condition. Ensure guard isin good condition and panels are correctly positioned.bels and Tags. Check for presence and legibility of labels. Replace if damagedor missing.n Records and ReportsInspection records, listing all points requiring periodic inspection should be maintained for all load bearing equipment. Written reports, based on severity of service, should be made on the condition of critical parts as a method ofdocumenting periodic inspections. These reports should be dated, signed by the person who performed the inspection, and kept on file where they are readily available for review.n Maintenance IntervalsRefer to Table 4 ‘Maintenance Interval Chart’ on page 3 for recommended maintenance schedule.•Perform an annual winch load test for all applications.Table 4: Maintenance Interval ChartNote: Hours are for actual winch drum rotation.* Do not disassemble air cylinder unless brake operation or visual inspection indicates a requirement.Table 5: Maintenance Interval ChartNote: Hours are for actual winch drum rotation.* Do not disassemble air cylinder unless brake operation or visual inspection indicates a requirement.INSPECTION REPORTIngersoll Rand L2–150RLP Series Air WinchesModel Number:Date:Serial Number:Inspected by:Reason for Inspection: (Check Applicable Box)1. Scheduled Periodic Inspection:(_____ Months _____ Years)Operating Environment:Normal ____Heavy____Severe ____2. Discrepancy(s) noted during Frequent Inspection3. Discrepancy(s) noted during maintenance4. Other: ___________________________Refer to the Product Information Manual and Product 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.COMPONENTCONDITION CORRECTIVE ACTION NOTESPassFailRepairReplaceUprights and Siderails Drum Band Brake (125% Load Test) Disc Brake (125% Load Test) Drum Band Brake (Visual Inspection)Disc Brake (Visual Inspection) Motor ControlsLimit Switches Air System Fasteners--- Emergency Stop Valve Overload Device --- Reduction Gears Labels and Tags --- Output Shaft Shafts Drum Guard Wire Rope Wedge--- Emergency Air supply Tank or System--- Slack Line Devise --- Press Roller Wire Rope--- Other Components (list in NOTES section)TESTINGPassFailNOTES 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 set overload device or comply with standards and regulations set forth in areas outside the USA.This form may be photo copied and used as an inspection record.TROUBLESHOOTINGThis 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.MAINTENANCE•Never perform maintenance on the winch while it is supporting a load.•Before performing maintenance, tag controls:WARNING - DO NOT OPERATE, EQUIPMENT BEING REPAIRED.•Only allow Ingersoll Rand trained Technicians to perform maintenance on this winch.•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 parts may result in safety hazards, decreased performance and increased maintenance and may invalidate all warranties.•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.)•Refer to Product Information and Safety Manuals for specific information. n GeneralCorrect disassembly (to prevent loss or damage of good parts), repair, assembly, testing and adjusting are critical to proper winch operation. Maintenance procedures are technical in nature and require training and experience to accomplish correctly. In addition, repair and testing require specialized equipment that is not typically found at the products mounting site.Proper use, inspections and maintenance increase the life and usefulness of your Ingersoll Rand equipment. During assembly, lubricate gears, nuts, capscrews and all machined threads with applicable lubricants. Use of anti-seize compound and/ or thread lubricant on capscrew and nut threaded areas prevents corrosion and allows for easy disassembly of components.It is extremely important that anyone involved with maintaining the product be familiar with the servicing procedures of these products 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 wellas special Ingersoll Rand or recommended tools.2.Safety procedures, precautions and work habits established by acceptedindustry 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.•Refer to the Product Parts Information Manual for drawings unless specified elsewhere.Drawing No. from Parts ManualMHD56306Page No.MHP27284MHP272910MHP273016MHP273113MHP273214MHP28076MHP281112MHP28128MHP28174MHP281818MHP310020n Maintenance IntervalsRefer to Table 4 ‘Maintenance Interval Chart’ on page 3 for recommended maintenance schedule.n Adjustmentsn Limit SwitchesRefer to ʽLimit Switchesʽ section in Product Information Manual.n Disc BrakeNo brake adjustment is required. Refer to Dwg. MHP2849 on page 7, A. Piston; B. 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 isuneven 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 Assembly’ on page 9.(Dwg. MHP2849)NOTICE•Original brake disc thickness is 0.059 in (1.5 mm)n Overload DeviceWARNING•Overload is factory set and sealed with red paint and should not be adjusted without consulting an Ingersoll Rand trained technician.B(Dwg. MHP2683)1.Connect winch to an air supply.2.Release securing screw and adjusting screw in order to increase or decrease theSWL (increase SWL by tightening the adjusting screw). Adjustment must be made for an overload of 135% maximum of SWL.3.Tighten securing screw.4.Check winch operation at rated load. If necessary, repeat adjustment.n Automatic Band Drum BrakeRefer to Dwg. MHP2880 on page 8.1.Loosen locknut ‘B’.2.Tighten nut ‘A’ until the adjustment dimension 0.43 to 0.51 inch (11 to 13 mm)is achieved.3.Tighten locknut ‘B’.4.Check brake operation.(Dwg. MHP2880)n Disassemblyn General Disassembly InstructionsThe following instructions provide necessary information to disassemble, inspect, repair, and assemble product. Parts drawings are provided in Product Parts Information Manual.If a product is being completely disassembled for any reason, follow the order of topics as they are presented. It is recommended that all maintenance work on product be performed in a clean dust-free work area.In the process of disassembling product, observe the following:1.Never disassemble product any further than is necessary to accomplish neededrepair. A good part can be damaged during the course of disassembly.2.Never use excessive force when removing parts. Tapping gently aroundperimeter 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 part being heatedis already worn or damaged beyond repair and no additional damage will occur to other parts.In general, products are designed to permit easy disassembly and assembly. The use of heat or excessive force should not be required.4.Keep work area as clean as practical, to prevent dirt and other foreign matterfrom getting into bearings or other moving parts.5.All seals, gaskets and ‘O’ rings should be discarded once they have beenremoved. New seals and ‘O’ rings should be used when assembling product.6.When grasping a part in a vise, always use leather-covered or copper-coveredvise jaws to protect the surface of part and help prevent distortion. This isparticularly true of threaded members, machined surfaces and housings.7.Do not remove any part which is a press fit in or on a subassembly unless removalof that part is necessary for repairs or replacement.8.When removing ball bearings from shafts, it is best to use a bearing puller. Whenremoving bearings from housings, drive out bearing with a sleeve slightlysmaller than outside diameter of bearing. The end of sleeve or pipe whichcontacts bearing must be square. Protect bearings from dirt by keeping them wrapped in clean cloths.n External Components RemovalRefer to component disassembly sections for further repair.1.Disconnect and tag all external air lines.2.Remove filter, regulator and lubricator (FRL) assembly from spacer (66).3.Remove drum guards. Refer to drum 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.n Motor and Reduction Gear RemovalRefer to Dwg. MHP2812 and MHP2728.1.Shut off and bleed down main air supply to winch.2.Disconnect and tag air lines.3.Stand winch in a vertical position, with the motor end up. Ensure winch isproperly supported.4.Remove four capscrews (86) and washers (125) that secure motor and controlvalve assembly to upright (62).5.Carefully pull motor assembly from winch.6.Clean capscrews (86) and threaded holes with Loctite® 7063 or equivalent sothey are free of Loctite® residue.7.Store motor in a clean area until needed. If repair is required refer to specificdisassembly sections.n Drum Guard DisassemblyRefer to Dwg. MHP2817.1.Remove capscrews (171).2.Remove drum guard (216), left panel (217) and right panel (218).n Automatic Band Drum Brake DisassemblyRefer 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) frombrake 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 NOTdisassemble brake cylinder assembly. Contact an Ingersoll Rand trained service technician for cylinder disassembly and repair.n Limit Switch DisassemblyRefer 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) andhousing (486) from limit switch adapter (450).3.Remove capscrews (499) and pull spindle switch assembly (501) from limit switchadapter (450).4.Store limit switch assembly in a clean, dry area until winch reassembly.n Press Roller DisassemblyRefer to Dwgs. MHP2728 and MHP2731.press ends of springs (167) and (169) to disengage from spacer (66) and pinon 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 assemblyfrom 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).n Slack Line Device DisassemblyRefer 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).n Winch Base and Drum DisassemblyRefer to Dwgs. MHP2728, MHP2807 and MHP2812. Refer to ‘Motor and Reduction Gear Removal’ section on page 8 to remove motor assembly from the winch.1.Remove external components. Refer to ‘External Components Removal’ sectionon page 8.2.Stand winch in a vertical position with motor end up.3.Remove capscrews (86), and washers (125) that secure motor, reduction gearand brake assembly to drum end cover (76). Set assembly to one side for further disassembly if needed.4.Remove capscrews (65) and (67), nuts (63) and lockwashers (64) to removespacers (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 coverassembly from upright (62).8.Remove bearing (76) and oil seal (77) from drum (60) if not removed with drumend cover (78).9.Carefully turn drum over so limit switch end is up.10.Remove upright (62) from drum (60).11.Remove capscrews (50) and lockwashers (73) from drum end cover (78).12.Remove drum end cover (78) from upright (62).13.Remove bearing (76) and oil seal (77) from drum (60) if not removed with drumend cover (78).n Disc Brake DisassemblyRefer to Dwg. MHP2807.1.Remove capscrews (25) (black) allowing brake and reducer assembly to beremoved together.e the two threaded puller holes in the piston (51) to remove piston (51) andbrake reaction plate (57) from brake housing (41).3.Remove drive plates (56), friction plates (55) and (58), spacer (54) and splinedhub (53). Note position for later assembly.4.Remove ‘O’ ring (16) and ‘O’ ring (52) from piston (51) and discard.n Reduction Gear DisassemblyRefer to Dwg. MHP2807.1.Remove disc brake assembly refer to on page 92.Remove fill plug (14) and drain oil from reduction gear into a suitable container.3.Remove capscrews (24) and (25) to separate reduction gear assembly from brakehousing (41).4.Remove capscrews (22) and washers (23) that secure reduction gear end cover(15).5.Remove retainer ring (12) from gear shaft (20).•It may be necessary to use a small amount of air pressure in fill hole of reduction gear end cover (15) to separate from housing (27).6.Remove and discard ‘O’ ring (16) on reduction gear end cover (15).7.It is not necessary to remove bearing (39) from reduction gear end cover (15)unless damaged. Replace as necessary.8.Remove bearing (13) and oil seal (17). Replace seal and bearing if necessary.9.Remove bearing (21) and ring gear (19).10.Support end cover (15) and tap out shaft (20).11.Remove retainer ring (36) from sun gear (34).12.Support reducer housing (27) and gently tap out sun gear (34).13.Tap out gear shafts (33) and remove planet gears (31), spacers (30), needlebearings (28) and bearing rings (29).14.Remove retainer ring (49).15.Remove sun gear (34).16.Remove retainer ring (36) and bearing (35).17.Remove and discard gasket (26) and ‘O’ ring (16) from brake housing (41).18.Remove and replace bearing (38) if necessary.n Motor DisassemblyRefer to Dwg. MHP2812.1.Remove motor assembly as described in ‘Motor and Reduction Gear Removal’on page 8.2.Remove control valve assembly (100) from motor assembly.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).7.Remove valves (105) and springs (96) from motor cover (97).8.Remove ‘O’ rings (94) only if necessary. ‘O’ rings will need to be cut for removal.•The two bearings (91) located in the motor housing (87) are bonded with Loctite® 603 or equivalent. Remove idle gear (104) and drive gear (92) only if replacement is necessary; use a bearing punch (IR pn: 96441232) orstandard drift punch and a hammer. Refer to Dwg. MHP2644on page 11.9.To remove both bonded bearings (91) from motor housing (87), it is necessaryto use a bearing punch and hammer. Two or three strikes are enough.10.If replacement is necessary, remove bearings (91) from drive gear (92) and idlegear (104) (use a suitable bearing extractor).11.Remove check valve (83) and ball (84) from motor housing (87). Emergency Stop End Cover:1.Remove and discard ‘O’ rings (90).2.Remove setscrew (180).3.Remove ball (84).4.Remove valve seat (186).5.Remove seal (189) and axle (188).6.Remove and discard ‘O’ rings (187).7.Remove spring (193).8.Unscrew clamping screw (102).9.Unscrew regulating screw (192) and remove and discard ‘O’ ring (191).10.Remove valve seat (205).11.Remove spring (213).12.Remove capscrews (214).13.Separate caps (202) and (211), washers (208) and (206), sleeve (209) anddiaphragm (212).14.Remove seals (203) and (210).15.Pull stop nut (194) and separate plunger (198) with diaphragm (196) from baseplate (199).16.Unscrew nut (194) and remove plunger (198) and washer (195).17.Remove and discard ‘O’ ring (197) .18.Install a screw (dia. M5) in threaded hole on base plate (199) and pull it frommotor cover (97).n Control Valve DisassemblyRefer to Dwg. MHP2729.1.To separate control valve (100) from motor assembly, remove capscrews (137)and (168) with lockwashers (2).2.Remove capscrews (118) and lockwashers (2) from stop plate (119). Remove stopplate.3.Partially remove capscrew (126) just far enough to allow emergency stophousing assembly to be removed. Place emergency stop housing assembly to one side for later disassembly.4.Remove spools (142) from valve housing (135).pletely remove capscrew (126) and lockwasher (125).6.Remove lever assembly, coupling (124) and spring (116).7.Do not disassemble handle unless repairs are needed. To disassemble handle,tap out pin (120) and unscrew cap (121). Remove handle spool (123) and spring (130).8.Remove retainer (140), spindle shaft (131) and gear (138).9.Remove retainer (140), spindle shaft (131) and gear cam (139).10.Remove pins (132) from spindle shafts (115).11.Remove bushings (133) and bushings (141).Emergency Stop:Refer to Dwg. MHP2729.1.Remove emergency stop valve (164) from end cover (172).2.Remove and discard ‘O’ rings (175).3.Unscrew and remove valve (165) with ‘O’ ring (171), ‘O’ ring (166) and protector(170).4.Remove retainer rings (178).5.Remove springs (177) and balls (84).6.Unscrew check valve (83) and remove ball (84).7.Remove and discard ‘O’ rings (166).n 2 Function Emergency Stop Pendant Disassembly (optional) Refer to Dwg. MHP2818.1.Disconnect hoses from pendant assembly (600).2.Remove fittings (152).3.Remove lifting eye (617), if necessary.4.Tap out pin (618) to remove the levers (619).5.Unscrew and remove check valve (83) and ball (84).6.Remove setscrew (173) to remove the valve assemblies (165).7.Remove protector (170), ‘O’ rings (166) and (171) from the valve (165).8.Remove plugs (623) to remove the springs (177) and balls (84).9.Remove emergency stop button (164).10.Remove retainer ring (621) and exhaust washer (615) from handle (622).n Cleaning, Inspection and RepairRefer to Product Parts Information Manual for item numbers referenced in the “Cleaning, Inspection and Repair” section.n CleaningClean all winch component parts in solvent (except drum brake bands and disc brake friction plates). The use of a stiff bristle brush will facilitate removal of accumulated dirt and sediments on housings, frame and drum. If bushings have been removed it may be necessary to carefully remove old Loctite® from bushing bores. Dry each part using low pressure, filtered compressed air. Clean drum brake band using a wire brush or emery cloth. Do not wash drum brake band in solvent. If drum brake band lining is oil soaked, it must be replaced.n InspectionAll disassembled parts should be inspected to determine their fitness for continued use. Pay particular attention to the following:Inspect gears for-worn, cracked or broken teeth. Replace if necessary.Inspect bushings for•-wear, scoring or galling. Replace if necessary.Inspect shafts for•-ridges caused by wear. Replace if necessary.•-scoring or galling.Inspect all threaded items for•-damaged threads. Replace if necessary.Inspect drum band brake lining for•-oil, grease and glazing. If drum band brake lining is oil-soaked, excessively greasy or overly glazed, replace brake band. Remove small glazed areas ofband brake lining by sanding lightly with a fine grit emery cloth.•-thickness of drum band brake lining. If drum brake band lining is less than0.062 in. (2 mm) thick anywhere along the edges, replace brake bandassembly.Inspect motor housing gear bores for•-wear or scoring. For any large scratches or uneven/excessive wear patterns, replace motor housing.Inspect motor gears (92) and (104) for•-ridges or excessive grooving on outside diameter 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.。