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//-->PARTS, OPERATION AND MAINTENANCEMANUAL for:PNEUMATIC WINCHESLS5000R / LS5000RGCPS10000R / PS10000RGCModelsREAD THIS MANUAL BEFORE USING THESE PRODUCTS. This manualcontains important safety, installation, operation and maintenanceinformation. Make this manual available to all persons responsible for theoperation, installation and maintenance of these products.WARNINGDo not use this winch for lifting, supporting, or transporting people or lifting or supportingloads over people.Always operate, inspect and maintain this winch in accordance with European or NationalStandards Safety Codes and any other applicable safety codes and regulations.Refer all communications to the nearest Ingersoll-Rand Material Handling Office orDistributor.Form SAM0218Edition 8November 2010©2010 Ingersoll-Rand Company1TABLE OF CONTENTSDESCRIPTIONPAGE NO.Safety InformationDanger, Warning, Caution and Notice ............................................................................................................3Safety, Summary ............................................................................................................................................3SpecificationsData Sheets .....................................................................................................................................................4Description ......................................................................................................................................................4Performances ..................................................................................................................................................5Schematics ......................................................................................................................................................5InstallationMounting.........................................................................................................................................................6Wire Rope .......................................................................................................................................................6Air Supply .......................................................................................................................................................6-7OperationInitial Operating Checks .................................................................................................................................8Winch control .................................................................................................................................................8Brake ...............................................................................................................................................................8Procedure to Start the Manual Emergency Brake Release xKit ......................................................................8Lubrication....................................................................................................................................................8InspectionRecords and Reports .......................................................................................................................................9Wire Rope Reports..........................................................................................................................................9Frequent Inspection .........................................................................................................................................9Periodic Inspection..........................................................................................................................................9Winches Not in Regular Use...........................................................................................................................10MaintenanceBrake Adjustment................................................................................. ...........................................................11Overload device................................................................................. ..............................................................11General Assembly / Disassembly Instructions ................................................................................................11Winch Assembly / Disassembly..................................................................... .................................................11Control Valve Assembly / Disassembly..................................................................... .....................................12Motor Assembly / Disassembly .....................................................................................................................12Reducer of Entry Assembly / Disassembly .....................................................................................................12Brake Assembly / Disassembly.......................................................................................................................12Reducer Assembly / Disassembly ...................................................................................................................13Rear Bearing Assembly / Disassembly ...........................................................................................................13Cleaning Inspection and Repair ......................................................................................................................13-14Assembly Drawing and Parts ListsIndex ....................................................................................... .......................................................................15Parts Section ....................................................................................... ...........................................................16-42Notes ....................................................................................... .......................................................................43-45Parts Ordering InformationReturn Goods Policy .............................................................................................................. .........................42Warranty information.......................................................................................................................................43Ingersoll-Rand Offices ........................................................................................................................... .........442SAFETY INFORMATIONThis manual provides important information for all personnelinvolved with the safe installation, operation and propermaintenance of this product. Even if you feel you are familiarwith this or similar equipment, you should read and understandthis manual before operating the product.Safety SummaryWARNING•Do not use this hoist or attached equipment for lifting,supporting, or transporting people or supporting loadsover people.•The supporting structures and load-attaching devicesused in conjunction with this hoist must provide andadequate safety factor to handle the rated load, plusthe weight of the hoist and attached equipment. This isthe customer's responsibility. If in doubt, consult aqualified structural engineer.The National Safety Council, Accident Prevention Manual forIndustrial Operations, Eighth Edition and other recognizedsafety sources make a common point.Employees who work near cranes or assist in hooking on orarranging a load should be instructed to keep out from underthe load. From a safety standpoint, one factor is paramount :conduct all lifting operations in such a manner that if therewere an equipment failure, no personnel would be injured.This means keep out from under a raised load and keep out ofthe line of force of any load.Ingersoll-RandMaterial Handling hoists are manufactured inaccordance with the latest FEM rules standards.Generally the burden of compliance to most standards is withthe user, not the manufacturer. Many requirements are notconcerned or connected with the manufactured product but are,rather, connected with the final installation. It is the owner'sand user's responsibility to determine the suitability of aproduct for any particular use. Check all applicable industry,trade association, federal, state and local regulations. Read alloperating instructions and warnings before operation.Rigging: It is the responsibility of the operator to exercisecaution, use common sense and be familiar with proper riggingtechniques.Danger, Warning, Caution and NoticeThroughout this manual there are steps and procedures which,if not followed, may result in injury. The following signalwords are used to identify the level of potential hazard.DANGERWARNINGCAUTIONDanger is used to indicate the presenceof a hazard whichwillcausesevereinjury, death, or substantialproperty damage if the warning isignored.Warning is used to indicate the presenceof a hazard whichcancausesevereinjury, death, or substantial propertydamage if the warning is ignored.Caution is used to indicate the presenceof a hazard whichwillorcancauseminorinjury or property damage if thewarning is ignored.Notice is used to notify people ofinstallation, operation or maintenanceinformation which is important but nothazard-related.NOTICENOTICE•Ingersoll-Rand Replacement Parts are specificallydesigned to ensure optimum performance of yourequipment. Use of other than genuine Ingersoll-RandMaterial Handling parts may adversely affect safeoperation and may invalidate the warranty.3SPECIFICATIONSLS5000R-L-EPS10000R-L-EDESCRIPTION•Compact design•Heavy duty steel construction -5/1 design factor for lifting. (LS5000R only)•Designed in conformity with the latest European standards (FEM class 1BM) (LS5000R only)•Automatic brake: an disc brake on the motor shaft.•Reliable gear type air motor in composite material.•Flameproof by nature.•High efficiency planetary gear box.•Low noise level,quiet operation•Variable speed and precise positioning through direct control lever.•Offshore paint.•Torque limiter with emergency stop valve for LS5000R « CE » model. Only•Emergency stop valve for PS10000R « CE » model. Only•Drum guard for CE model.4PERFORMANCESModelRated working loadMotor PowerWorking pressureAverage hoisting speedair consumptionWeight without ropeRope diameterBreaking load* 5thlayer for LS5000R** 1stlayer for PS10000R(metric ton)(hp)(bar)(m/min)(m3/min)(kg)(mm)(metric ton)LS5000RStandardGC5*5*10104 to 74 to 70 to 100 to 100 to 120 to 12≅640≅75019/2019/20≅25≅25PS10000RStandardGC10**10**10104 to 74 to 70 to 100 to 100 to 120 to 12≅640≅75019/2019/20≅25≅25SCHEMATIC5
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