Product Parts Information

Transcription

1 Product s Information Models FA2.5i FA5i FA5Ti (Dwg. MHP2669) Save These Instructions Form MHD56287 Edition 2 June Ingersoll Rand Company

2 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 on page 2 for Product Information Manuals. 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 may invalidate all warranties. Refer all communications to the nearest Ingersoll Rand Office or Distributor. Table 1: Product Manuals Publication /Document Publication /Document Product Safety Manual (Non-Man Rider) MHD56250 Product Information Manual (Man Rider) MHD56300 Product Safety Manual (Man Rider) MHD56251 Product Maintenance Information Manual MHD56288 Product Information Manual (Non-Man Rider) MHD56278 TABLE OF CONTENTS Page Dwg. Name Page s Ordering Information... 3 FA2.5i Drum, Base and Reduction Gear Assembly Drawing... 4 (Dwg. MHP2689)...4 FA2.5i Drum, Base and Reduction Gear Assembly s List... 5 FA5i/Ti Drum, Base and Reduction Gear Assembly Drawing... 6 (Dwg. MHP2670)...6 FA5i/Ti Drum, Base and Reduction Gear Assembly s List... 7 Motor Assembly Drawing (Dwg. MHP2693) Motor Assembly s List Disc Assembly Drawing (Dwg. MHP2674) Disc Assembly s List Drum Band Assembly Drawing (Dwg. MHP2694) Drum Band Assembly s List Control Valve Assembly Drawing (Dwg. MHP2696) Control Valve Assembly s List Emergency Stop and Overload Control Valve Assembly Drawing (Dwg. MHP2697) Emergency Stop and Overload Control Valve Assembly s List Full Flow Remote Control Valve Assembly Drawing and s List (Dwg. MHP2698) Pendant Operated Overload (Optional) Assembly Drawing and s List (Dwg. MHP0698) Pendant Operated Pilot Control Valve (Optional) Assembly Drawing (Dwg. MHP2778) Pendant Operated Pilot Control Valve (Optional) s List Remote Pendant (Optional) Assembly Drawings (Dwg. MHP2346) (Dwg. MHP1677) Remote Pendant (Optional) Assembly s List Drum Locking Pin (Optional) Assembly Drawing and s List (Dwg. MHP2675) Press Roller Assembly (Optional) Drawing and s List (Dwg. MHP2695) Limit Switch (Optional) Assembly Drawing (Dwg. MHP2677) Limit Switch (Optional) s List Winch Guard Assembly Drawing (Dwg. MHP2676) Winch Guard s List Air Preparation Assembly Drawing and s List (Dwg. MHP2679) Labels and Tags Assembly Drawing and s List (Dwg. MHP2718) Constant Tension (Optional) Assembly Drawing (Dwg. MHP2028) Constant Tension (Optional) Assembly s List Kits Accessories Form MHD56287 Edition 2

3 PARTS ORDERING INFORMATION These products are designed and constructed to provide long, trouble-free service. In time it may be necessary to order and install new parts to replace those that have been subjected to wear. For your convenience and future reference it is recommended that the following information be recorded. Model Serial Date Purchased When ordering replacement parts, please specify the following: 1. Complete model number and serial number as it appears on the data (name) plate. 2. number(s) and part description as shown in this manual. 3. Quantity required. The data (name) plate is located on the winch outboard upright. NOTICE Continuing improvement and advancement of design may cause changes to this equipment which are not included in this manual. Manuals are periodically revised to incorporate changes. Always check the manual edition number on the front cover for the latest issue. Sections of this manual may not apply to your winch. Using other than genuine Ingersoll Rand replacement parts may invalidate the warranty. Return Goods Policy Ingersoll Rand will not accept any returned goods for warranty or service work unless prior arrangements have been made and written authorization has been provided from the location where the goods were purchased. Products which have been modified without Ingersoll Rand approval, mishandled or overloaded will not be repaired or replaced under warranty. A printed copy of the warranty which applies to this product is provided inside the back cover of this manual. Disposal When the life of the product has expired, it is recommended that it be disassembled, degreased and parts separated as to materials so that they may be recycled. For additional information contact: Ingersoll Rand 2724 Sixth Avenue South Seattle, WA USA Phone:(206) or (866) Fax: (206) or Ingersoll Rand Douai Operations 529, Avenue Roger Salengro Sin Le Noble, France Phone:(33) Fax: (33) Form MHD56287 Edition 2 3

4 FA2.5I DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING (Dwg. MHP2689) 4 Form MHD56287 Edition 2

5 FA2.5I DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST of of 2 Oil Seal Sun Gear 1 3 Lockwasher Dowel Pin 4 4 Capscrew Spacer 1 5 O Ring Ring Gear 1 Order 34 6 Motor Adapter Cover 1 14 Sleeve (w/o Disc ) Dowel Pin 4 15 Seal Adapter Capscrew 8 33 O Ring Spacer *** Reduction Gear Assembly * Drum 1 Note 1 Wire Rope Anchor, 3/8 to 5/8 inch 35 Drive Shaft (10 to 16 mm) Retainer Ring Wire Rope Anchor l/2 in. (13 mm) (Note 3) Bearing Wire Rope Anchor 5/8 in. (16 mm) (Note 3) Retainer Ring Siderail 2 Note 1 39 Capscrew Lifting Lug Dowel Pin Upright, Outboard (without Drum Lock) Dowel Pin *** Upright, Outboard (with Drum Lock) Drum Shaft Capscrew Upright, Inboard Dowel Pin Seal Bearing Capscrew Data (name) Plate 1 Note 2 12 Capscrew *** Rivet Lockwasher Capscrew Gear Carrier Washer Pipe Plug Bearing Retainer Bearing Capscrew (no Disc ) Retainer Ring Capscrew Planetary Assembly 1 95 End Cover (without Limit Switch) Thrust Bearing 2 96 Washer O Ring 4 97 Capscrew Order Ring Gear 1 98 Washer Sun Gear O Ring Kit (includes item 62) 1 Contact Factory 67 Planetary Assembly 1 Recommended spare for one winch, 2 years of normal operation. Note 1: Refer to DRUM and SIDERAIL PARTS LIST on page 8. Note 2: Contact factory, model and serial number required. Note 3: Used on divided drums only. Not illustrated. * Reduction Gear Assembly includes items 54, 55, 62, 63, 66, 67, 69, **Man Rider winches are only available with a band brake drum. ***These parts are used only on an 8 inch long drum without a band brake. These parts also come in a cold weather version. Refer to model code, adding CH (DNV) or CHA (ABS) to the end of these part numbers is required to retain winch cold weather certification. Example: Order Drum item (80) (12 inches long) part number as part number CH. Certification Type Example To Order ABS CHA DNV CH --- Form MHD56287 Edition 2 5

6 FA5I/TI DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING (Dwg. MHP2670) 6 Form MHD56287 Edition 2

7 of FA5I/TI DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST of 2 Oil Seal Planetary Assembly 1 3 Lockwasher Sun Gear 1 4 Capscrew Dowel Pin 4 5 O Ring Spacer 1 Order 34 6 Motor Adapter Ring Gear 1 14 Sleeve (w/o Disc ) Cover 1 15 Seal Adapter Dowel Pin 4 33 O Ring Capscrew 8 34 Reduction Gear Assembly * Drum 1 Note 1 35 Drive Shaft Wire Rope Anchor, 1/2 to 5/8 inch (13 to 16 mm) Retainer Ring Bearing Wire Rope Anchor, 5/8 to 3/4 inch (16 to Retainer Ring mm) Capscrew Wire Rope Anchor, 7/8 inch (22 mm) Dowel Pin Wire Rope Anchor 5/8 inch (16 mm) (Note 3) Drum Shaft Wire Rope Anchor 3/4 inch (19 mm) (Note 3) Upright, Inboard - FA5i Wire Rope Anchor 7/8 inch (22 mm) (Note 3) Upright, Inboard - FA5Ti Siderail 2 Note 1 43 Seal Lifting Lug FA5i Capscrew Lifting Lug FA5Ti Lockwasher Upright, Outboard (w/o Drum Lock) FA5i Gear Carrier Upright, Outboard (with Drum Lock) FA5i Pipe Plug Upright, Outboard (w/o Drum Lock) FA5Ti Bearing Upright, Outboard (with Drum Lock) FA5Ti Retainer Ring Capscrew O Ring 2 86 Dowel Pin Dowel Pin 3 87 Bearing Ring Gear 1 88 Data (Name) Plate 1 Note 2 54 Planetary Assembly 1 89 Screw, Drive Thrust Bearing 2 Order Capscrew Sun Gear 1 91 Washer Retainer Ring 1 92 Bearing Retainer Planetary Assembly 1 93 Capscrew (no Disc ) Input Housing 1 94 Capscrew Capscrew End Cover (w/o Limit Switch) Plug Washer O Ring 4 97 Capscrew Ring Gear 1 Order Washer Sun Gear O Ring Kit (includes items 51 & 62) Recommended spare for one winch, 2 years of normal operation. Note 1: Refer to DRUM and SIDERAIL PARTS LIST on page 8. Note 2: Contact factory, model and serial number required. Note 3: Used on divided drums only. Not illustrated. * Reduction Gear Assembly includes items 51-53, 66, 67, 69, **Man Rider winches are only available with a band brake drum. These parts also come in a cold weather version. Refer to model code, adding CH (DNV) or CHA (ABS) to the end of these part numbers is required to retain winch cold weather certification. Example: Order Drum item (80) (12 inches long) part number as part number CH. Certification Type Example To Order ABS CHA DNV CH --- Form MHD56287 Edition 2 7

8 FA2.5I DRUM AND SIDERAIL PARTS LIST Drum ( 80) with Band Drum ( 80) w/out Band ** Drum ( 80) with Band and Drum Lock Drum ( 80) w/out Band with Drum Lock ** Drum (8 inches long) Drum (8 inches long) Drum (8 inches long) L Drum (8 inches long) L Drum (12 inches long) Drum (12 inches long) Drum (12 inches long) L Drum (12 inches long) L Drum (16 inches long) Drum (16 inches long) Drum (16 inches long) L Drum (16 inches long) L Drum (20 inches long) Drum (20 inches long) Drum (20 inches long) L Drum (20 inches long) L Drum (24 inches long) Drum (24 inches long) Drum (24 inches long) L Drum (24 inches long) L Drum (30 inches long) Drum (30 inches long) Drum (30 inches long) L Drum (30 inches long) L Drum (36 inches long) Drum (36 inches long) Drum (36 inches long) L Drum (36 inches long) L Siderail ( 82) with Band Siderail ( 82) w/out Band ** with 8 inch Drum with 8 inch Drum with 12 inch Drum with 12 inch Drum with 16 inch Drum with 16 inch Drum with 20 inch Drum with 20 inch Drum with 24 inch Drum with 24 inch Drum with 30 inch Drum with 30 inch Drum with 36 inch Drum with 36 inch Drum Note 1: Contact Factory for divided drum part numbers; not available for Man Rider application. **Man Rider winches are only available with a band brake drum and no drum lock. These parts also come in a cold weather version. Refer to model code, adding CH (DNV) or CHA (ABS) to the end of these part numbers is required to retain winch cold weather certification. Example: Order Drum item (80) (12 inches long) part number as part number CH. FA5I DRUM AND SIDERAIL PARTS LIST Drum ( 80) with Band Drum ( 80) w/out Band ** Drum ( 80) with Band with Drum Lock FA5TI DRUM AND SIDERAIL PARTS LIST Drum ( 80) w/out Band with Drum Lock** Drum (12 inches long) Drum (12 inches long) Drum (12 inches long) L Drum (12 inches long) L Drum (16 inches long) Drum (16 inches long) Drum (16 inches long) L Drum (16 inches long) L Drum (20 inches long) Drum (20 inches long) Drum (20 inches long) L Drum (20 inches long) L Drum (24 inches long) Drum (24 inches long) Drum (24 inches long) L Drum (24 inches long) L Drum (30 inches long) Drum (30 inches long) Drum (30 inches long) L Drum (30 inches long) L Drum (36 inches long) Drum (36 inches long) Drum (36 inches long) L Drum (36 inches long) L Siderail ( 82) with Band Siderail ( 82) w/out Band ** with 12 inch Drum with 12 inch Drum with 16 inch Drum with 16 inch Drum with 20 inch Drum with 20 inch Drum with 24 inch Drum with 24 inch Drum with 30 inch Drum with 30 inch Drum with 36 inch Drum with 36 inch Drum Drum ( 80) with Band Drum ( 80) w/out Band ** Drum ( 80) with Band with Drum Lock Drum ( 80) w/out Band with Drum Lock ** Drum (12 inches long) Drum (12 inches long) Drum (12 inches long) L Drum (12 inches long) L Drum (16 inches long) Drum (16 inches long) Drum (16 inches long) L Drum (16 inches long) L Drum (20 inches long) Drum (20 inches long) Drum (20 inches long) L Drum (20 inches long) L Drum (24 inches long) Drum (24 inches long) Drum (24 inches long) L Drum (24 inches long) L Drum (30 inches long) Drum (30 inches long) Drum (30 inches long) L Drum (30 inches long) L Drum (36 inches long) Drum (36 inches long) Drum (36 inches long) L Drum (36 inches long) L Siderail ( 82) with Band Siderail ( 82) w/out Band ** with 12 inch Drum with 12 inch Drum with 16 inch Drum with 16 inch Drum with 20 inch Drum with 20 inch Drum with 24 inch Drum with 24 inch Drum with 30 inch Drum with 30 inch Drum with 36 inch Drum with 36 inch Drum Note 1: Contact Factory for divided drum part numbers. Note 2: FA5Ti not available for Man Rider application. **Man Rider winches are only available with a band brake drum. These parts also come in a cold weather version. Refer to model code, adding CH (DNV) or CHA (ABS) to the end of these part numbers is required to retain winch cold weather certification. Example: Order Drum item (80) (12 inches long) part number as part number CH. 8 Form MHD56287 Edition 2

9 SERVICE NOTES Form MHD56287 Edition 2 9

10 MOTOR ASSEMBLY DRAWING K5C2 Control Valve (Dwg. MHP2693) 10 Form MHD56287 Edition 2

11 of MOTOR ASSEMBLY PARTS LIST of Motor Assembly 214 Pipe Plug with Control Valve * K5B-546M-S 216 Mounting Flange 1 K5B-502A 1 without Control Valve * K5B-546LM-S 217 Motor Housing (Note 1) S 2 Oil Seal ** Pipe Plug (Drain) Lockwasher Gasket 1 K5B Capscrew Bearing Seal Adapter ** Buttonhead Screw 5 K5B Reducer Bushing Oil Slinger 1 K5B Pipe, Elbow Crank Assembly 1 K5B-A Muffler Sleeve 1 K5B Pipe Nipple Connecting Rod Bushing 1 K5B Capscrew Connecting Rod Ring 2 K5B Cylinder Head 5 K5B-H Lock Pin 1 HU Compression Ring 1 Set K5B546-KRING 236 Cotter Pin Wrist Pin 5 HU-514A 237 Pin Nut 1 D Piston 5 *** 240 Roll Pin Retainer Ring A Gasket 2 K5B Connecting Rod 5 K5B O Ring 1 20A11CM Oil Ring Order Grease Fitting Cylinder Liner 5 K5B-L Rotary Valve Housing 1 K5B Head Gasket 1 Set K5B Rotary Valve Assembly 1 K5B-526EQ-RS 210 Vent Cap Assembly Seal Ring Assembly 1 set K5B-607A 211 Capscrew Bearing Eye Bolt Exhaust Flange 1 KK5B-276M Recommended spare for one winch, 2 years of normal operation. * K5B-546M-S includes items 2-4, 93, , 213, 214, 216, 217, 225, 226, , 240, 243, 244, 246, 247, , with K5C2 style control valve. * K5B-546LM-S includes items 2-4, 93, , 213, 214, 216, 217, 225, 226, , 240, 243, 244, 246, 247, ** When ordering Motor Assembly, also order Oil Seal (2) and Seal Adapter (15). *** s not sold separately. Refer to K5B Motor Assembly Kit List. Note 1: Motor housing (217) includes items 200, 211, 213, 949 and 951; Refer to control valve for 949 and 951, use caution before mounting control valve, these capscrews have been provided in both metric and standard threads for old and new style rotary housing. K5B Motor Assembly Kit List: of 231 Crank Assembly (includes items 206 and 228 through 240) 1 K5B-A Rotary Valve Assembly (includes items 251 and 252) 1 K5B-526EQ-RS 261 Piston Assembly (includes items 202 through 205 and 207) 1 K5B-A Motor Gasket Kit (includes items 209, 226, 243, 244 and 248) Air Motor Service Kit (includes items 3, 4, 200, 202, , 226, 243, 244, and 251) Form MHD56287 Edition 2 11

12 DISC BRAKE ASSEMBLY DRAWING (Dwg. MHP2674) 12 Form MHD56287 Edition 2

13 DISC BRAKE ASSEMBLY PARTS LIST of of 7 Shaft Fitting, Nipple Reaction Plate Dump Valve Spring Fitting, Vented Piston Fitting, Reducer Seal Breather Seal O Ring Collar Level/Drain Plug Housing Hose Assembly Drive Plate Tubing Assembly Contact Factory 19 Friction Plate Capscrew Reaction Disc * Label Plate, LP Gear Recommended spare for one winch, 2 years of normal operation. * Refer to Label Placement Dwg. MHP2718 on page 35. These parts also come in a cold weather version. Refer to model code, adding CH (DNV) or CHA (ABS) to the end of these part numbers is required to retain winch cold weather certification. Example: Order Shaft item (7) part number as part number 10594CH. Certification Type Example To Order ABS CHA DNV CH --- Form MHD56287 Edition 2 13

14 DRUM BAND BRAKE ASSEMBLY DRAWING (Dwg. MHP2694) 14 Form MHD56287 Edition 2

15 of DRUM BAND BRAKE ASSEMBLY PARTS LIST FA2.5i FA5i FA5Ti Manual Automatic Manual Automatic Manual Automatic 80 Drum with band brake 1 Refer to FA2.5i Drum and Siderail Refer to FA5i Drum and Siderail s Refer to FA5Ti Drum and Siderail 82 Siderail 2 s List on page 8. List on page 8. s List on page 8. Common s: 98 Washer Contact Factory 101 Pin Cotter Pin See ( ) (5) (7) (5) (7) (5) 103 Link Stud Lever - Manual Lever - Automatic Pin Clevis Nut Breather Cylinder Fitting, Bushing Contact Factory 112 Dump Valve Hose End Fitting, Elbow Hose (bulk) As Req d Capscrew Washer See ( ) (3) (4) (5) (4) 118 Bracket Capscrew See ( ) (3) (4) (4) 120 Nut Pin S Pivot Bracket Arm Connecting Link Stop Plate Screw, Adjusting 1 HU Band 1 Set Pin Contact Factory Recommended spare for one winch, 2 years of normal operation. These parts also come in a cold weather version. Refer to model code, adding CH (DNV) or CHA (ABS) to the end of these parts is required to retain winch cold weather certification. Example: Order Pivot Bracket item (122) part number should be ordered as part number 10881CH. Certification Type Example To Order ABS CHA DNV 10881CH --- Form MHD56287 Edition 2 15

16 CONTROL VALVE ASSEMBLY DRAWING (Dwg. MHP2696) 16 Form MHD56287 Edition 2

17 CONTROL VALVE ASSEMBLY PARTS LIST of of 900 Control Valve Assembly 1 K5C2-ELP 937 Spring Rivet Buttonhead Screw Plug Seal Bracket (Note 2) S 901 Capscrew Tag, No FA2B Washer O Ring Poppet Cover O Ring Poppet Gasket Reverse Valve Kit (Normal)** SX 905 Poppet Spring Reverse Valve (Reverse Bias)** Poppet Cap Reverse Valve (Unbiased) **** 907 Poppet Seal Bushing (Normal)*** Washer, Tablock Bushing (Reverse Bias)*** Pilot Valve Assembly Bushing (Unbiased) **** 912 Plug Dowel Pin Ball 1 D Gasket Set Valve Housing 1 * 948 Label, Throttle Direction Cover Gasket Washer Piston Cover Plug IR Pilot Valve Tool Capscrew O Ring Exhaust Flange Piston (Note 1) S 956 Fitting, Elbow O Ring Fitting, Elbow Washer Fitting, Nipple Capscrew Muffler Handle Assembly Label, Warning Plug Breather * 917 not sold separately, order item 900. ** Reverse Valve (Normal) for Standard Overwound operation. Reverse Valve (Reverse Bias) for Optional Underwound operation. *** Ensure Bushing matches Reverse Valve (Reverse Valve (Normal) and Bushing (Normal)). Mixing these components can result in erratic winch operation. **** Reverse Valve (Unbiased) and Bushing (Unbiased) contact factory for application. Note 1: 922 not sold separately, includes items (6) each of 901 and 902, items , 918, 921 and 923. Note 2: 939 not sold separately, includes items (1) each of 901 and 902, items 924, 925, 935, 937, 938 and 940. K5C2-X and K5C2-EX Control Valve Service Kits Kit 780 K5C2 Control Valve Service Kit, both standard and -E (includes items 96, 703, 713, 714, 722, 901, 902, 904, 907, 910, 916, 918, 921, 923, 941, 942 and 946) Handle Assembly Kit (includes items 901, 902 and 930; 1 each) Reverse Valve Kit (includes items 943 and 956) SX 786 Overload Valve Service Kit X 788 Emergency Stop Service Kit* X 789 Emergency Stop Kit (Optional Feature)* Pilot Valve Assembly Kit Piston Kit S 939 Seal Bracket Kit (includes items 901, 902, 924, 925, 935, , 941 and S Recommend spare for one winch, two years of normal service. * Kits can be installed to new style control valve. s not illustrated. Form MHD56287 Edition 2 17

18 EMERGENCY STOP AND OVERLOAD CONTROL VALVE ASSEMBLY DRAWING (Dwg. MHP2697) 18 Form MHD56287 Edition 2

19 EMERGENCY STOP AND OVERLOAD CONTROL VALVE ASSEMBLY PARTS LIST of of 908 Control Valve Assembly 1 K5C2-EXLP 918 Cover Gasket Rivet Piston Cover Plug IR Pilot Valve Tool Cap O Ring Grommet Piston (Note 1) S 702 Plunger O Ring O Ring Washer Label, Stop Capscrew Button, E-Stop Handle Assembly Adapter Plug Plunger Spring Spring Buttonhead Screw Piston Seal Bracket (Note 2) S 713 O Ring Tag, No FA2B Gasket O Ring Plate O Ring O Ring Reverse Valve Kit (Normal)** XLP 717 Adjustment Nut Reverse Valve (Reverse Bias)** 1 ** 718 Spring Reverse Valve (Unbiased) **** 719 Cover Bushing (Normal)*** Screw, Adjusting Bushing (Reverse Bias)*** 1 *** 721 Capscrew Bushing (Unbiased) **** 722 O Ring Dowel Pin Exhaust Adapter Gasket Set Label Plate, LP (Note 3) Label, Throttle Direction Plug Washer Capscrew Capscrew Washer Exhaust Flange Poppet Cover Fitting, Elbow Poppet Gasket Fitting, Elbow (refer to Dwg. MHP2696) Poppet Spring Fitting, Nipple (refer to Dwg. MHP2696) Poppet Cap Muffler (refer to Dwg. MHP2696) Poppet Seal Label, Warning Washer, Tablock Plug Pilot Valve Assembly Manifold Block Plug Gasket Ball 1 D Washer Valve Housing 1 * 967 Capscrew s 964 through 967 not illustrated. * 917 not sold separately, order item 908. ** Reverse Valve (Normal) for Standard Overwound operation. Reverse Valve (Reverse Bias) for Optional Underwound operation. *** Ensure Bushing matches Reverse Valve (Reverse Valve [Normal] and Bushing [Normal]). Mixing these components can result in erratic winch operation. **** Reverse Valve (Unbiased) and Bushing (Unbiased) contact factory for application. Refer to Control Valve Assembly s List on page 17 for Notes 1 and 2 and all other kit part numbers. Note 1: 922 not sold separately, includes items (6) each of 901 and 902, items , 918, 921 and 923. Note 2: 939 not sold separately, includes items (1) each of 901 and 902, items 924, 925, 935, 937, 938 and 940. Note 3: Refer to Label Placement Dwg. MHP2718 on page 35. Form MHD56287 Edition 2 19

20 FULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2698) of 900 Control Valve Assembly 1 K5C2-SBK 44 Hose Assembly As Req d Capscrew Gasket 1 K5B Exhaust Cover 1 KK5B-276M 321 Fitting, Elbow Hose End Hose (bulk) As Req d Fitting, Elbow Form MHD56287 Edition 2

21 PENDANT OPERATED OVERLOAD (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP0698) of 369 Adapter Setscrew Piston Plug, Orifice O Ring O Ring Adjustment Nut Spring Form MHD56287 Edition 2 21

22 PENDANT OPERATED PILOT CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING (Dwg. MHP2778) 22 Form MHD56287 Edition 2

23 of PENDANT OPERATED PILOT CONTROL VALVE (OPTIONAL) PARTS LIST of 96 Washer (2) Retainer Ring Valve Assembly: PTV 363 O Ring Single Air 364 Valve Piston Single Air -E Option Retainer Ring Contact Factory Dual Air s 366 Capscrew Dual Air s -E Option 367 Valve Cap (Note 4) Valve Shaft Capscrew Restrictor, Poppet Adapter, Standard Restrictor, Seat Adapter,-E Option O Ring Capscrew Pin Shims (3) Pin Cylinder (Note 4) Setscrew Spring (Note 4) Sleeve O Ring (Note 4) Valve Body 1 * 375 Piston (Note 4) Gasket O Ring (Note 4) Pin (Note 1) 1(2) 377 Seal Cup (Note 4) Valve Assembly (Note 1) 1(2) O Ring (Note 4) O Ring (Note 1) 2(4) 379 Setscrew (Note 4) Manifold Retainer, Spring (Note 4) Spring Clip Capscrew (Note 4) Washer Pin (Note 4) ** Capscrew Capscrew Gasket Pedant Bracket Pin 1(2) Valve Cap Assembly Exhaust Poppet Capscrew Plug Seal Washer Spring Shuttle Valve Body (Note 3) Inlet Poppet Elbow Fitting Gasket O Ring Fitting, Elbow (Note 3) Washer O Ring Capscrew Poppet Seat Recommended spare for one winch, 2 years of normal operation. * not sold separately. Order item 330. ** not shown, part of valve cap assembly. Refer to the following to determine Pin (347) and Valve Assembly (341) configuration requirements: Winches without disc or automatic drum band brake use quantity of 2 Pins (347). Note 1 Winches with a single automatic brake (disc or drum band) (Valve Assembly or 25440) use quantity of 1 Pin (347) and 1 Valve Assembly (341). Winches with disc and automatic drum band brakes (Valve Assemblies or 25468) use quantity of 2 Valve Assemblies (341). Quantity of 4 Washers (96) required to mount Adapter (369). Additional Washer (96) and Shim (371) quantities are As Required to establish clearance tolerances Note 2 described in MAINTENANCE section. Note 3 Refer to Dwg. MHP1403 to determine Shuttle Valve (388) configuration. Note 4 Order Valve Cap Assembly (385) part number Form MHD56287 Edition 2 23

24 REMOTE PENDANT (OPTIONAL) ASSEMBLY DRAWINGS Pendant without Emergency Stop (Dwg. MHP2346) Pendant with Emergency Stop (Dwg. MHP1677) 24 Form MHD56287 Edition 2

25 REMOTE PENDANT (OPTIONAL) ASSEMBLY PARTS LIST of With E-Stop Without E-Stop 353 Pendant Assembly* 1 PHS2E PHS2E-U 348 Fitting 3(5) Lifting Eye Emergency Stop Valve Valve O Ring 2(5) Plug 2(4) Spring 2(4) Ball 2(5) Pin Setscrew O Ring 2(3) Protector 2(3) Valve 2(3) Lever Pendant Handle 1 order item Setscrew 3(5) Label Kit Exhaust Washer Retainer Ring Plug Recommended spares for one winch, 2 years of normal operation. * PHS2E includes items and * PHS2E-U includes items 440, , and 470. Form MHD56287 Edition 2 25

26 DRUM LOCKING PIN (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2675) of FA2.5i FA5i/FA5Ti 300 Drum Locking Assembly Handle Grip Handle Capscrew Locknut Shaft Capscrew Washer Cover Housing Grease Fitting Spring Bushing Drum Lock Pin Note 1: Not available for Man Rider applications. 26 Form MHD56287 Edition 2

27 PRESS ROLLER ASSEMBLY (OPTIONAL) DRAWING AND PARTS LIST (Dwg. MHP2695) FA2.5i of 12 w/o Band 12 w/ Band 400 Press Roller Assembly * B 402 Roller Roller Shaft Arm of 24 w/o Band 24 w/ Band 400 Press Roller Assembly * B 402 Roller Roller Shaft B Arm w/o Band 30 w/o Band 16 w/ Band 30 w/ Band Contact Factory Contact Factory 20 w/o Band 36 w/o Band 20 w/ Band 36 w/ Band FA5i/Ti of 12 w/o Band 12 w/ Band 16 w/o Band 16 w/ Band 20 w/o Band 20 w/ Band 400 Press Roller Assembly B B B 402 Roller Roller Shaft B B Contact Factory 407 Arm of 24 w/o Band 24 w/ Band 400 Press Roller Assembly B 402 Roller Roller Shaft B 407 Arm w/o Band 30 w/ Band Contact Factory 36 w/o Band 36 w/ Band FA2.5i and FA5i/Ti Common s of 404 Shaft Collar Spring, Left Side Spring, Right Side Capscrew Washer Bushing Form MHD56287 Edition 2 27

28 LIMIT SWITCH (OPTIONAL) ASSEMBLY DRAWING (Dwg. MHP2677) 28 Form MHD56287 Edition 2

29 of LIMIT SWITCH (OPTIONAL) PARTS LIST 475 Limit Switch Assembly (Includes items 450, , and S 96 Washer Capscrew Adapter, Limit Switch Upper Support Block Capscrew Control Valve Fitting, Hose Tee Connection Block Fitting, Pipe Dump Valve Pin O Ring Housing Washer Capscrew Gasket Fitting, Cap Washer Capscrew Hose Assembly (37 in. [940 mm]) standard hose Hose Assembly (37 in. [940 mm]) stainless steel hose Hose Assembly (42 in. [1067 mm]) standard hose Hose Assembly (42 in. [1067 mm]) stainless steel hose Hose Assembly (42.5 in. [1080 mm]) standard hose Hose Assembly (42.5 in. [1080 mm]) stainless steel hose Fitting, Hose Cap Assembly Capscrew Lower Support Block Spindle Switch Assembly 1 * 502 Rod Washer Nut Cover, Housing Capscrew Fitting, Hose Tee Tube Fitting, Adapter Label, Limit Switch Configuration Label, Limit Switch Instructions, Underwind Winches Only Label, Limit Switch Instructions, Overwind Winches Only Recommended spare for one winch, 2 years of normal operation. * not sold separately. Order Limit Switch Assembly, 475. Form MHD56287 Edition 2 29

30 WINCH GUARD ASSEMBLY DRAWING (Dwg. MHP2676) 30 Form MHD56287 Edition 2

31 WINCH GUARD PARTS LIST FA2.5i Winch Guard of Winch Guard Assembly w/o Band w/o Drum Lock Winch Guard Assembly w/o Band w/ Drum Lock Winch Guard Assembly w/ Manual Band w/o Drum Lock * --- Winch Guard Assembly w/ Manual Band w/ Drum Lock Winch Guard Assembly w/auto Band w/o Drum Lock * Winch Guard Assembly w/ Auto Band w/ Drum Lock Frame w/o Band w/o Drum Lock Frame w/o Band w/ Drum Lock 801 Frame w/ Manual Band w/o Drum Lock * Frame w/ Manual Band w/ Drum Lock 801 Frame w/ Auto Band w/o Drum Lock * 1 8 in Drum 12 in Drum 16 in Drum 20 in Drum 24 in Drum 30 in Drum L L L L L L B B B B B B BL BL BL BL BL BL AB AB AB AB AB AB ABL ABL ABL ABL ABL ABL L L Frame L w/ Auto Band w/ Drum Lock Panel w/o Band w/o Drum Lock 5 Panel w/o Band w/ Drum Lock Panel B B B B B B 807 w/ Manual Band w/o Drum Lock * Panel B B B B B B 807 w/ Manual Band w/ Drum Lock Panel w/ Auto Band w/o Drum Lock * B B B B B B Panel w/ Auto Band w/ Drum Lock BL BL BL BL BL BL Crossbar w/o Band Crossbar w/ Manual Band 5 Crossbar w/ Auto Band B B B B B B Locknut w/o Band Locknut w/ Manual Band Locknut w/ Auto Band Washer Capscrew * Man Rider application requires a band brake and no drum lock. Form MHD56287 Edition 2 31

32 WINCH GUARD PARTS LIST (CONTINUED) FA5i Winch Guard of Winch Guard Assembly w/o Band w/o Drum Lock Winch Guard Assembly w/o Band w/ Drum Lock Winch Guard Assembly w/ Manual Band w/o Drum Lock * --- Winch Guard Assembly w/ Manual Band w/ Drum Lock Winch Guard Assembly w/auto Band w/o Drum Lock * Winch Guard Assembly w/ Auto Band w/ Drum Lock Frame w/o Band w/o Drum Lock Frame w/o Band w/ Drum Lock 801 Frame w/ Manual Band w/o Drum Lock * Frame w/ Manual Band w/ Drum Lock 801 Frame w/ Auto Band w/o Drum Lock * 1 12 in Drum 16 in Drum 20 in Drum 24 in Drum 30 in Drum 36 in Drum L L L L L L B B B B B B BL BL BL BL BL BL AB AB AB AB AB AB ABL ABL ABL ABL ABL ABL Frame w/ Auto Band w/ Drum lock Panel w/o Band w/o Drum Lock Panel w/o Band w/ Drum Lock Panel B B B B B B 807 w/ Manual Band w/o Drum Lock * Panel B B B B B B 807 w/ Manual Band w/ Drum Lock Panel w/ Auto Band w/o Drum Lock * B B B B B B Panel w/ Auto Band w/ Drum Lock B B B B B B Crossbar w/o Band Crossbar w/ Manual Band 7 Crossbar w/ Auto Band B B B B B B Locknut w/o Band Locknut w/ Manual Band Locknut w/ Auto Band Washer Capscrew * Man Rider application requires a band brake and no drum lock. 32 Form MHD56287 Edition 2

33 WINCH GUARD PARTS LIST (CONTINUED) FA5Ti Winch Guard of Winch Guard Assembly w/o Band w/o Drum Lock Winch Guard Assembly w/o Band w/ Drum Lock Winch Guard Assembly w/ Manual Band w/o Drum Lock * --- Winch Guard Assembly w/ Manual Band w/ Drum Lock Winch Guard Assembly w/auto Band w/o Drum Lock * Winch Guard Assembly w/ Auto Band w/ Drum Lock Frame w/o Band w/o Drum Lock Frame w/o Band w/ Drum Lock 801 Frame w/ Manual Band w/o Drum Lock * Frame w/ Manual Band w/ Drum Lock 801 Frame 802 w/ Auto Band w/o Drum Lock * 801 Frame 802 w/ Auto Band w/ Drum Lock Panel w/o Band w/o Drum Lock 805 Panel w/o Band w/ Drum Lock 805 Panel w/ Manual Band w/o Drum Lock * 805 Panel w/ Manual Band w/ Drum Lock 1 12 in Drum 16 in Drum 20 in Drum 24 in Drum 30 in Drum 36 in Drum L L L L L L B B B B B B BL BL BL BL BL BL AB AB AB AB AB AB ABL ABL ABL ABL ABL ABL B B B B B B B B B B B B B B B B B B 805 Panel w/ Auto Band w/o Drum Lock * Panel w/ Auto Band w/ Drum Lock Crossbar w/o Band Crossbar w/ Manual Band B B B B B B Crossbar w/ Auto Band Locknut w/o Band Locknut w/ Manual Band Locknut w/ Auto Band Washer Capscrew * Man Rider application requires a band brake and no drum lock. Form MHD56287 Edition 2 33

34 AIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST Lubricator Regulator Control Valve Lubricator Filter (Dwg. MHP2679) of --- Air Preparation Assembly Filter 1 F35-0B-C Regulator 1 R40-0B-G Pipe Nipple Pipe Nipple Lubricator 1 L40-0B-G U-Bolt Capscrew Washer Nut Bracket Hose, bulk (4 ft [1.22 mm]) * Fitting, Connector Hose Fitting ** Fitting ** Ball Valve FA2.5i FA5i/Ti Air preparation components for 1-1/2 inch FNPT system. * Length as required for installation. ** not illustrated. Refer to Product Safety Information Manual. 34 Form MHD56287 Edition 2

35 LABELS AND TAGS ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2718) of S of Product Label inch long drum Label and Tag Kit * S Product Label 24 inch and longer drum S Warning Label Label and Tag Kit -E * S Warning Label -E Data (Name) Plate R 656 Oil Level Label Drive Screw Exhaust Label Winding Label Control Valve Operation -E Winding Label -E Air Supply Label IR Logo Label inch long drum Warning Label (Only Non -E) IR Logo Label 24 inch long and longer drum Check Oil Level Label Underwound Direction Label Label General -E Label Kit * Kits depend on drum length. s ending in -4 are for drums inches long. s ending in -5 are for drums 24 inches or longer. -E kits contain all labels, EXCEPT 661. Form MHD56287 Edition 2 35

36 CONSTANT TENSION (OPTIONAL) ASSEMBLY DRAWING To Disc K5C2 Valve (Dwg. MHP2028) 36 Form MHD56287 Edition 2

37 CONSTANT TENSION (OPTIONAL) ASSEMBLY PARTS LIST of 900 Control Valve Assembly 1 K5B-REMOTE 113 Fitting, Hose End Hose (bulk) As Req d Gasket 1 K5B Shuttle Valve Washer Capscrew Rivet Label, Constant Tension Gasket Cover Fitting, Elbow Fitting, Elbow Fitting, Elbow Capscrew Handle Ball Valve Plug Fitting, Elbow Spacer B 717 Handle Hose (bulk) As Req d Fitting, Hose End Fitting, Bushing Fitting, Nipple Fitting, Elbow Fitting, Nipple Manifold, Control Valve Union Fitting, Nipple Check Valve Fitting, Nipple Washer Capscrew Nut Bracket Fitting, Nipple Fitting, Elbow Regulator and Gauge * Fitting, Connector Fitting, Tube Extension Fitting, Elbow Gasket Washer Capscrew * s not sold separately. Form MHD56287 Edition 2 37

38 KITS of Kit Automatic Kit (converts manual band brake to automatic band brake). Refer to Dwg. MHP2694; includes items 102, 105 through 115, 117 through 120, 129 and 134. Contact Factory Disc Kit (adds disc brake to winch). Refer to Dwgs. MHP2674; includes items 1, 7 12, 16 32, 34 38) Full Flow Remote Control Kit (converts winch live air control valve to remote control) Refer to Dwgs. MHP2698; includes items 113, 115, 253, 318, and with 10 feet (3.05 metres) hose S with 20 feet (6.1 metres) hose S Pendant Control Kit (converts winch live air control to pendant control). Refer to Dwg. MHP2720 and MHP2699; includes all items, except 348, 357 and 358. with 10 feet (3.05 metres) pendant hose with 20 feet (6.1 metres) pendant hose with 30 feet (9.15 metres) pendant hose Contact Factory with 40 feet (12.1 metres) pendant hose Limit Switch Kit (adds limit and controls to winch) Muffler Kit ACCESSORIES of Accessory Lubricant Accessory LUBRI-LINK-GREEN 38 Form MHD56287 Edition 2

39 WARRANTY Ingersoll Rand Company (I-R) warrants to the original user its Winch and Hoist Solutions (Products) to be free of defects in material and workmanship for a period of one year from the date of purchase. I-R will repair, without cost, any Product found to be defective, including parts and labor charges, or at its option, will replace such Products or refund the purchase price less a reasonable allowance for depreciation, in exchange for the Product. Repairs or replacements are warranted for the remainder of the original warranty period. If any Product proves defective within its original one year warranty period, it should be returned to any Authorized Winch and Hoist Solutions Service Distributor, transportation prepaid with proof of purchase or warranty card. This warranty does not apply to Products which I-R has determined to have been misused or abused, improperly maintained by the user, or where the malfunction or defect can be attributed to the use of non-genuine I-R parts. I-R makes no other warranty, and all implied warranties including any warranty of merchantability or fitness for a particular purpose are limited to the duration of the expressed warranty period as set forth above. I-R s maximum liability is limited to the purchase price of the Product and in no event shall I-R be liable for any consequential, indirect, incidental, or special damages of any nature rising from the sale or use of the Product, whether based on contract, tort, or otherwise. Note: Some states do not allow limitations on incidental or consequential damages or how long an implied warranty lasts so that the above limitations may not apply to you. This warranty gives you specific legal rights and you may also have other rights which may vary from state to state. IMPORTANT NOTICE It is our policy to promote safe delivery of all orders. This shipment has been thoroughly checked, packed and inspected before leaving our plant and receipt for it in good condition has been received from the carrier. Any loss or damage which occurs to this shipment while en route is not due to any action or conduct of the manufacturer. VISIBLE LOSS OR DAMAGE If any of the goods called for on the bill of lading or express receipt are damaged or the quantity is short, do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt. CONCEALED LOSS OR DAMAGE When a shipment has been delivered to you in apparent good condition, but upon opening the crate or container, loss or damage has taken place while in transit, notify the carrier s agent immediately. DAMAGE CLAIMS You must file claims for damage with the carrier. It is the transportation company s responsibility to reimburse you for repair or replacement of goods damaged in shipment. Claims for loss or damage in shipment must not be deducted from the Ingersoll Rand invoice, nor should payment of Ingersoll Rand invoice be withheld awaiting adjustment of such claims as the carrier guarantees safe delivery. You may return products damaged in shipment to us for repair, which services will be for your account and form your basis for claim against the carrier. Form MHD56287 Edition 2 39