Product Parts Information

Transcription

1 Product s Information Model FA5i (Dwg MHP2669) Save These Instructions Form MHD56287 Edition 4 December 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 Product Manuals on page 2 Manuals can be downloaded from wwwingersollrandproductscom 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 Manuals Publication /Document Publication /Document Product Safety Manual (Non-Man Rider) MHD56250 Product Information Manual (Man Rider) MHD56435 Product Safety Manual (Man Rider) MHD56251 Product Maintenance Information Manual MHD56288 Product Information Manual (Non-Man Rider) MHD56434 TABLE OF CONTENTS Page s Ordering Information 3 FA25i Drum, Base and Reduction Gear Assembly Drawing 4 FA25i Drum, Base and Reduction Gear Assembly s List 5 FA5i/Ti Drum, Base and Reduction Gear Assembly Drawing 6 FA5i/Ti Drum, Base and Reduction Gear Assembly s List 7 FA25i Drum and Siderail s List 8 FA5i Drum and Siderail s List 8 FA5Ti Drum and Siderail s List 9 Motor Assembly Drawing 10 Motor Assembly s List 11 Disc Assembly Drawing 12 Disc Assembly s List 13 Drum Band Assembly Drawing 14 Drum Band Assembly s List 15 Control Valve Assembly Drawing 16 Control Valve Assembly s List 17 Emergency Stop and Overload Control Valve Assembly Drawing (-E Model) 18 Emergency Stop and Overload Control Valve Assembly s List (-E Model) 19 Limit Switch (Optional) Assembly Drawing 20 Limit Switch (Optional) Assembly s List 21 CE Man Rider Control Valve Assembly Drawing 22 CE Man Rider Control Valve Assembly s List 23 Pendant Operated Pilot Control Valve (Optional) Assembly Drawing 24 Pendant Operated Pilot Control Valve (Optional) Assembly s List 25 Remote Pendant (Optional) Assembly Drawings 26 Remote Pendant (Optional) Assembly s List 27 Full Flow Remote Control Valve Assembly Drawing and s List 28 K5C2-MRCE Connection Assembly Drawing and s List 29 Pendant Operated Overload (Optional) Assembly Drawing and s List 30 Shut-off Valve Assembly Drawing and s List 30 Drum Locking Pin (Optional) Assembly Drawing and s List 31 Press Roller Assembly (Optional) Drawing and s List 32 Press Roller Assembly (Optional) Drawing and s List (Continued) 33 Winch Guard Assembly Drawing 34 Winch Guard Assembly s List 35 Winch Guard Assembly s List (Continued) 36 Winch Guard Assembly s List (Continued) 37 Air Preparation Assembly Drawing and s List 38 Labels and Tags Assembly Drawing and s List 39 Constant Tension (Optional) Assembly Drawing 40 Constant Tension (Optional) Assembly s List 41 Kits 42 Dwg Name Page (Dwg MHP2689) 4 (Dwg MHP2670) 6 (Dwg MHP2693) 10 (Dwg MHP2924) 12 (Dwg MHP2694) 14 (Dwgs MHP2696 and MHP3182) 16 (Dwg MHP2697) 18 (Dwg MHP2677) 20 (Dwg MHP3069) 22 (Dwg MHP3091) 24 (Dwgs MHP2346 and MHP1677) 26 (Dwg MHP2698) 28 (Dwg MHP3070) 29 (Dwgs MHP0698 and MHP2958) 30 (Dwg MHP2675) 31 (Dwg MHP2695) 32 (Dwg MHP2676) 34 (Dwg MHP2679) 38 (Dwg MHP2718) 39 (Dwg MHP2028) 40 2 Form MHD56287 Edition 4

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 Disposal For your convenience and future reference, it is recommended that the following information be recorded Model Serial Date Purchase When ordering replacement parts, please specify the following: 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 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 product 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 product 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 Return Goods Policy Ingersoll Rand will not accept any returned goods for warranty or service unless prior arrangements have been made and written authorization has been provided from the location the goods were purchased Products that have been modified without Ingersoll Rand approval, mishandled or overloaded will not be repaired or replaced under warranty A printed copy of the warranty that applies to this product is provided inside the back cover of the product information manual or in some cases the parts manual Form MHD56287 Edition 4 3

4 FA5I/TI DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING (Dwg MHP2670) 6 Form MHD56287 Edition 4

5 of FA5I/TI DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST of 2 Oil Seal Ring Gear 1 contact factory 3 Lockwasher Washer Capscrew Sun Gear 1 5 O Ring Planetary Assembly 1 Contact Factory 6 Motor Adapter Sun Gear Sleeve (without Disc ) Spring Pin Seal Adapter Spacer Nut Ring Gear O Ring Cover 1 34 Reduction Gear Assembly * Dowel Pin 4 Contact Factory 35 Drive Shaft Capscrew Retainer Ring Drum 1 Note 1 37 Bearing Wire Rope Wedge, 5/8 and 3/4 in (16 and 19 mm) Retainer Ring Wire Rope Wedge, 7/8 in (22 mm) Capscrew Wire Rope Anchor 5/8 in (16 mm) (Note 3) Dowel Pin Wire Rope Anchor 3/4 in (19 mm) (Note 3) Drum Shaft Wire Rope Anchor 7/8 in (22 mm) (Note 3) Upright, Inboard - FA5i S 82 Siderail 2 Note Upright, Inboard - FA5Ti S Lifting Lug FA5i Seal Lifting Lug FA5Ti Capscrew Upright, Outboard (without Drum Lock) FA5i S 1 46 Lockwasher Upright, Outboard (Note 4) FA5i S 84 Gear Carrier (Serial A and up) Upright, Outboard (without Drum Lock) FA5Ti Gear Carrier FA5Ti (Serial A and up) 1 Upright, Outboard (with Drum Lock) FA5Ti Gear Carrier (old style) Contact Factory 85 Capscrew Pipe Plug Dowel Pin Bearing Bearing Retainer Ring Data (Name) Plate (Note 2) RS 51 O Ring Screw, Drive Spring Pin 1 90 Capscrew Ring Gear 1 91 Washer Planetary Assembly 1 Contact Factory 92 Bearing Retainer Thrust Bearing 2 93 Capscrew (without Disc ) Sun Gear 1 94 Capscrew Retainer Ring End Cover (without Limit Switch) Planetary Assembly Washer Input Housing 1 Contact Factory 97 Capscrew Capscrew Washer Plug Bushing O Ring Note 1: Refer to DRUM and SIDERAIL PARTS LIST on page 8 Note 2: Model and serial number required Note 3: Used on divided drums only Not illustrated Note 4: 84 is predrilled for use with an IR Adjustable Level Wind and Drum Lock * Reduction Gear Assembly includes items 51-53, 66, 67, 69, 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 4 7

6 FA5I DRUM AND SIDERAIL PARTS LIST 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 in long) S Drum (12 in long) S Drum (12 in long) L-S Drum (12 in long) L-S Drum (16 in long) S Drum (16 in long) S Drum (16 in long) L-S Drum (16 in long) L-S Drum (20 in long) S Drum (20 in long) S Drum (20 in long) L-S Drum (20 in long) L-S Drum (24 in long) S Drum (24 in long) S Drum (24 in long) L-S Drum (24 in long) L-S Drum (30 in long) S Drum (30 in long) S Drum (30 in long) L-S Drum (30 in long) L-S Drum (36 in long) S Drum (36 in long) S Drum (36 in long) L-S Drum (36 in long) L-S Siderail ( 82) with Band Siderail ( 82) w/out Band ** with 12 in Drum S with 12 in Drum S with 16 in Drum S with 16 in Drum S with 20 in Drum S with 20 in Drum S with 24 in Drum S with 24 in Drum S with 30 in Drum S with 30 in Drum S with 36 in Drum S with 36 in Drum S Note 1: Contact Factory for divided drum part numbers; not available for Man Rider application ** Man Rider winches have a two brake system and 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 FA5TI DRUM AND SIDERAIL PARTS LIST Drum ( 80) with Band Drum (12 in long) Drum (16 in long) Drum (20 in long) Drum (24 in long) Drum (30 in long) Drum (36 in long) Siderail ( 80) with Band with 12 in Drum with 16 in Drum with 20 in Drum with 24 in Drum with 30 in Drum with 36 in Drum Drum ( 80) w/out Band S Drum (12 in long) S Drum (16 in long) S Drum (20 in long) S Drum (24 in long) S Drum (30 in long) S Drum (36 in long) Siderail ( 80) w/out Band S with 12 in Drum S with 16 in Drum S with 20 in Drum S with 24 in Drum S with 30 in Drum Drum ( 80) with Band with Drum Lock S Drum (12 in long) S Drum (16 in long) S Drum (20 in long) S Drum (24 in long) S Drum (30 in long) S Drum (36 in long) S S S S S S with 36 in Drum S Drum ( 80) w/out Band with Drum Lock L-S Drum (12 in long) L-S Drum (16 in long) L-S Drum (20 in long) L-S Drum (24 in long) L-S Drum (30 in long) L-S L-S L-S L-S L-S L-S Drum (36 in long) L-S Note 1: Contact Factory for divided drum part numbers Note 2: FA5Ti not available for Man Rider application 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 4

7 MOTOR ASSEMBLY DRAWING (Dwg MHP2693) 10 Form MHD56287 Edition 4

8 199 of MOTOR ASSEMBLY PARTS LIST of Motor Assembly 214 Pipe Plug for use with Control Valve * K5B-546M-S 216 Mounting Flange 1 K5B-502A 1 for use w/out 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 Screw Capscrew (Imperial thread) Oil Slinger 1 K5B-540 Capscrew (Metric thread) Crank Assembly 1 K5B-A516S 165 Reducer Bushing Sleeve 1 K5B Pipe, Elbow Connecting Rod Bushing 1 K5B Muffler Connecting Rod Ring 2 K5B Pipe Nipple Lock Pin 1 HU Capscrew (Metric thread) Cotter Pin Capscrew (Imperial thread) Pin Nut 1 D Cylinder Head 5 K5B-H Roll Pin Compression Ring 1 Set K5B546-KRING 243 Gasket 2 K5B Wrist Pin 5 HU-514A 244 O Ring 1 20A11CM Piston 5 ** 246 Grease Fitting Retainer Ring 1 902A Rotary Valve Housing 1 K5B-545M-S 206 Connecting Rod 5 K5B Rotary Valve Assembly 1 K5B-526EQ-RS 207 Oil Ring Order Seal Ring Assembly 1 set K5B-607A 208 Cylinder Liner 5 K5B-L Bearing 1 K5B Head Gasket 1 Set K5B Exhaust Flange 1 KK5B-276M 210 Vent Cap Assembly Screw Eye Bolt Label, Caution (Note 2) * K5B-546M-S includes items 2-4, 93, , 213, 214, 216, 217, 225, 226, , 240, 243, 244, 246, 247, , for use with control valve * K5B-546LM-S includes items 2-4, 93, , 213, 214, 216, 217, 225, 226, , 240, 243, 244, 246, 247, , for use without control valve ** 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 CAUTION Check serial number before mounting control valve, these capscrews have been provided in both metric and standard threads for old and new style rotary housing Refer to label item 411 Note 2: 411 is provided with kits and not shipped with complete unit 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 and 244) Motor Service Kit (includes items 2-4, 15, 200 (Note 1), 202, 205, 208, 209, 211, 226, 228, , 243, 244, 251, 411, 949 and 951) Recommended spare for one winch, 2 years of operation Form MHD56287 Edition 4 11

9 DISC BRAKE ASSEMBLY DRAWING To control valve (Dwg MHP2924) 12 Form MHD56287 Edition 4

10 DISC BRAKE ASSEMBLY PARTS LIST of of 1 Capscrew (with Disc ) Fitting, Reducer Bushing Shaft Extender Pipe Plug Reaction Plate Breather Spring O Ring Piston Level/Drain Plug Seal Label, Low Pressure Seal Rivet Collar Fitting, Nipple Friction Plate Gauge, Pressure Drive Plate Fitting, Tee Gear Dump Valve Reaction Ring Vented, Fitting Housing Kit List of 534 Disc Service Kit Recommended spare for one winch, 2 years of operation Note: Refer to KITS on page 42 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 Housing item (21) part number as part number CH Certification Type Example To Order ABS CHA DNV CH --- Form MHD56287 Edition 4 13

11 DRUM BAND BRAKE ASSEMBLY DRAWING 411 To control valve (Dwg MHP2694) 14 Form MHD56287 Edition 4

12 DRUM BAND BRAKE ASSEMBLY PARTS LIST of FA25i Manual Automatic FA5i Manual Automatic FA5Ti Manual Automatic 80 Drum with band brake 1 Refer to FA25i Drum and Siderail 82 Siderail 2 s List on page 9 Common s: Refer to FA5i Drum and Siderail s List on page 9 Refer to FA5Ti Drum and Siderail s List on page 9 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 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 411 Handle Grip Recommended spare for one winch, 2 years of operation Note: Refer to KITS on page 42 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 Pivot Bracket item (122) part number should be ordered as part number 10881CH Certification Type Example To Order ABS CHA DNV CH --- Form MHD56287 Edition 4 15

13 CONTROL VALVE ASSEMBLY DRAWING (Dwg MHP2696) Disc Control Valve (front side) * Requires tee at disc brake side for both auto disc and band brake, item not shown (Dwg MHP3182) 16 Form MHD56287 Edition 4

14 CONTROL VALVE ASSEMBLY PARTS LIST of of 900 Control Valve Assembly 1 K5C2-X 925 Capscrew Rivet Handle Assembly Plug Plug Fitting, Connector Spring Shuttle Valve Buttonhead Screw Fitting, Elbow Seal Bracket (Note 2) S 743 Fitting, Reducer Tag (No FA2B) Tubing, Assembly * O Ring Fitting, Elbow O Ring Capscrew Reverse Valve Kit (Normal) ** XLP 902 Washer Reverse Valve (Reverse Bias) ** Poppet Cover Reverse Valve (Unbiased) **** 904 Poppet Gasket Bushing (Normal) *** Poppet Spring Bushing (Reverse Bias) *** Poppet Cap Bushing (Unbiased) **** 907 Poppet Seal Dowel Pin Washer, Tablock Gasket Set Pilot Valve Assembly Label, Throttle Direction Plug Washer Ball 1 D Plug Valve Housing 1 * 951 Capscrew Cover Gasket Exhaust Flange Piston Cover Fitting, Elbow IR Pilot Valve Tool Fitting, Elbow O Ring Fitting, Nipple Piston (Note 1) S 959 Muffler O Ring Label, Warning Washer 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: Includes items (6) each of 901 and 902, items , 918, 921 and 923 Note 2: Includes items (1) each of 901 and 902, items 924, 925, 935, 937, 938, 941 and 942 K5C2-X and K5C2-EXLP Service Kits 780 Kit K5C2 Control Valve Service Kit, both standard and -E (includes items 96, 703, 713, 714, 722, 901, 902, 904, 907, 916, 918, 921, 923, 924, 925, 935, 937, 938, 941, 942 and 946) Overload Valve Service Kit Emergency Stop Service Kit * Recommended spare for one winch, 2 years of operation * Kits can be installed to new style control valve Form MHD56287 Edition 4 17

15 EMERGENCY STOP AND OVERLOAD CONTROL VALVE ASSEMBLY DRAWING (-E MODEL) Fitting Old Style (Dwg MHP2697) 18 Form MHD56287 Edition 4

16 EMERGENCY STOP AND OVERLOAD CONTROL VALVE ASSEMBLY PARTS LIST (-E MODEL) 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) ** 717 Adjustment Nut Reverse Valve (Reverse Bias) ** 1 ** 718 Spring Reverse Valve (Unbiased) **** 719 Cover Bushing (Normal) *** 720 Screw, Adjusting Bushing (Reverse Bias) *** 1 *** 721 Capscrew Bushing (Unbiased) **** XLP 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 refer to Dwg MHP3069 on page 22 * 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: Includes items (6) each of 901 and 902, items , 918, 921 and 923 Note 2: 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 39 Form MHD56287 Edition 4 19

17 LIMIT SWITCH (OPTIONAL) ASSEMBLY DRAWING A C B D D C B A #1 Main Air Hose #2 Cap Fitting #3 Haul-in Air Hose 496 #4 Payout Air Hose 495 (Dwg MHP2677) 20 Form MHD56287 Edition 4

18 LIMIT SWITCH (OPTIONAL) ASSEMBLY PARTS LIST of 475 Limit Switch Assembly (Note 1) S 96 Washer Capscrew Adapter (FA25i) of Hose Assembly (42 in [1067 mm]) standard hose Hose Assembly (42 in [1067 mm]) stainless steel hose Hose Assembly (425 in [1080 mm]) standard hose Hose Assembly (425 in [1080 mm]) stainless steel hose Adapter (FA5i/5Ti) Fitting, Hose Fitting, Hose Tee Cap Assembly Connection Block Capscrew Fitting, Pipe Spindle Switch Assembly (Note 2) S way Valve Rod Pin Washer O Ring Nut Housing Cover, Housing Washer Fitting, Hose Tee Capscrew Hose Gasket Fitting, Adapter Fitting, Cap Label, Limit Switch Configuration Washer Capscrew Hose Assembly (37 in [940 mm]) standard hose Hose Assembly (37 in [940 mm]) stainless steel hose Label, Limit Switch Instructions, Underwind Winches Only Label, Limit Switch Instructions, Overwind Winches Only * Chain As Req'd * Chain Grip Recommended spare for one winch, 2 years of operation Note 1: Includes items , and Note 2: not sold separately Order Limit Switch Assembly, item 475 Note 3: If converting a winch to have a Limit Switch Assembly order item 450 Form MHD56287 Edition 4 21

19 CE MAN RIDER CONTROL VALVE ASSEMBLY DRAWING (Dwg MHP3069) 22 Form MHD56287 Edition 4

20 CE MAN RIDER CONTROL VALVE ASSEMBLY PARTS LIST of of 908 Control Valve Assembly 1 K5C2-MRCE 919 Piston Cover Rivet IR Pilot Valve Tool Plug O Ring Cap Piston (Note 1) S 701 Grommet O Ring Plunger Washer O Ring Capscrew Label, Stop Handle Assembly Button, E-Stop Selector Valve Assembly Adapter Label, Mode Selector Plunger Plug Spring Spring Piston Buttonhead Screw O Ring Seal Bracket (Note 2) S 714 Gasket Tag, No FA2B Plate O Ring O Ring O Ring Adjustment Nut Reverse Valve Kit (Normal) ** 718 Spring Reverse Valve (Reverse Bias) ** 1 ** 719 Cover Reverse Valve (Unbiased) **** 720 Screw, Adjusting Bushing (Normal) *** 721 Capscrew Bushing (Reverse Bias) *** 1 *** 722 O Ring Bushing (Unbiased) **** XLP Exhaust Adapter Dowel Pin Label Plate, LP (Note 3) Gasket Set Plug Label, Throttle Direction Capscrew Washer Washer Capscrew Poppet Cover Exhaust Flange Poppet Gasket Fitting, Elbow Poppet Spring Fitting, Elbow (refer to Dwg MHP2696) Poppet Cap Fitting, Nipple (refer to Dwg MHP2696) Poppet Seal Muffler (refer to Dwg MHP2696) Washer, Tablock Label, Warning Pilot Valve Assembly Plug Plug Manifold Block Ball 1 D Gasket Valve Housing 1 * 966 Washer Cover Gasket Capscrew * 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: Includes items (6) each of 901 and 902, items , 918, 921 and 923 Note 2: 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 39 Form MHD56287 Edition 4 23

21 PENDANT OPERATED PILOT CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING Single Air : = 1 each of 341 and 347 Dual Air : = 2 of 341, 0 of 347 No Air : = 2 of 347, 0 of (Dwg MHP3091) 24 Form MHD56287 Edition 4

22 of PENDANT OPERATED PILOT CONTROL VALVE (OPTIONAL) ASSEMBLY PARTS LIST of 96 Washer (Note 2) Pin 1(2) Valve Assembly: 354 Exhaust Poppet Standard PTV1 355 Plug E Option 1 PTV1 E 356 Spring Reverse Bias PTV1 RB 357 Inlet Poppet Valve Shaft Gasket Restrictor, Poppet Fitting, Elbow Restrictor, Seat O Ring O Ring Poppet Seat Pin Retainer Ring Pin O Ring Setscrew Capscrew Sleeve Valve Cap Valve Body 1 * 368 Capscrew Gasket Pin (Note 1) 1(2) 369 Adapter, Standard Adapter, -E Option Valve Assembly (Note 1) 1(2) Capscrew O Ring (Note 1) 2(4) 381 Capscrew Manifold Elbow, Fitting Spring Clip O Ring Washer Washer Capscrew Capscrew Gasket * not sold separately Order item 330 Note 1: Refer to the following to determine Pin (347) and Valve Assembly (341) configuration requirements: Winches without disc or automatic band brake use quantity of 2 Pins (347) 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 band brakes (Valve Assemblies or 25468) use quantity of 2 Valve Assemblies (341) Note 2: Quantity of 4 Washers (96) required to mount Adapter (369) Additional Washer (96) quantities are As Required to establish clearance tolerances described in MAINTENANCE section Form MHD56287 Edition 4 25

23 REMOTE PENDANT (OPTIONAL) ASSEMBLY DRAWINGS Pendant without Emergency Stop (Dwg MHP2346) Pendant with Emergency Stop (Dwg MHP1677) 26 Form MHD56287 Edition 4

24 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 * PHS2E includes items and PHS2E-U includes items 440, , and 470 Kit Repair List: of s 730 Pendant Repair Kit Recommended spare for one winch, 2 years of operation Form MHD56287 Edition 4 27

25 FULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST (Dwg MHP2698) of 900 Control Valve Assembly 1 K5C2-X 44 Hose (bulk) As Req d Capscrew (Metric Thread) Capscrew (Emperial Thread) Gasket 1 K5B Exhaust Cover 1 KK5B-276M 321 Fitting, Elbow Hose End Hose (bulk) As Req d Fitting, Elbow Note 1: Requires special tool to install fittings into hose ends Note 2: Maximum hose length of 20 ft 28 Form MHD56287 Edition 4

26 K5C2-MRCE CONNECTION ASSEMBLY DRAWING AND PARTS LIST A To Limit Switch (Haul-in) # 4 D E 494 F To Limit Switch (Main Air) # B To Limit Switch (Payout) # C A Main Air B 607 C Disc NOTE: Refer to Limit Switch Assembly Drawing MHP2677 Haul-in Muffler Port D E Payout F Muffler Port (Dwg MHP3070) of of 44 Hose As Req d Dump Valve Fitting Fitting, Vented Shuttle Valve Disc Tubing Kit Hose Assembly Fitting Hose Assembly Valve Hose Assembly Fitting, Vented (angled) Fitting Fitting Capscrew * Fitting Fitting, Pipe Fitting, Hose Bushing, Pipe Fitting, Tee Regulator Fitting Fitting, Nipple PVC Pipe, 1/2 in * Pressure Gauge Loop Strap * Fitting, Tee * not illustrated, used for bundling hoses to siderail Form MHD56287 Edition 4 29

27 PENDANT OPERATED OVERLOAD (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg MHP0698) of of 369 Adapter O Ring Setscrew O Ring Piston Adjustment Nut Plug, Orifice Spring SHUT-OFF VALVE ASSEMBLY DRAWING AND PARTS LIST (Dwg MHP2958) of of 592 Valve, Shut-off Fitting, Nipple Note: Shut-off valve assembly is supplied unattached to product Refer to Product Information Manual for installation 30 Form MHD56287 Edition 4

28 DRUM LOING PIN (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg MHP2675) of FA25i FA5i/FA5Ti 300 Drum Locking Assembly S S 141 Handle Grip Handle Capscrew Locknut Shaft Capscrew Washer Cover Housing Grease Fitting Spring Bushing Drum Lock Pin Note: Not available for Man Rider applications Form MHD56287 Edition 4 31

29 PRESS ROLLER ASSEMBLY (OPTIONAL) DRAWING AND PARTS LIST (Dwg MHP2695) FA25i 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 32 Form MHD56287 Edition 4

30 PRESS ROLLER ASSEMBLY (OPTIONAL) DRAWING AND PARTS LIST (CONTINUED) 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 407 Arm of 24 w/o Band 24 w/ Band 400 Press Roller Assembly B- 402 Roller Roller Shaft B 407 Arm FA25i and FA5i/Ti Common s of 30 w/o Band 30 w/ Band Contact Factory 36 w/o Band Contact Factory 404 Shaft Collar Spring, Left Side Spring, Right Side Capscrew Washer Bushing w/ Band Form MHD56287 Edition 4 33

31 WINCH GUARD ASSEMBLY DRAWING (Dwg MHP2676) 34 Form MHD56287 Edition 4

32 WINCH GUARD ASSEMBLY PARTS LIST FA 25i 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 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 AB ABL BL AB ABL BL AB ABL- Frame w/o Band w/o Drum Lock Frame w/o Band w/ Drum Lock Frame w/ Manual Band w/o Drum Lock * Frame w/ Manual Band w/ Drum Lock L L 801 Frame w/ Auto Band w/o Drum Lock * Frame w/ Auto Band w/ Drum L Lock Panel w/o Band w/o Drum Lock 5 Panel w/o Band w/ Drum Lock BL AB ABL BL AB ABL BL AB ABL Panel w/ Manual Band w/o B B B B B B 807 Drum Lock * Panel w/ Manual Band w/ Drum B B B B B B 807 Lock Panel w/ Auto Band w/o Drum Lock * Panel w/ Auto Band w/ Drum Lock B B B B B B BL BL BL BL BL BL Crossbar w/o Band Crossbar w/ Manual Band 5 Crossbar w/ Auto Band 7 Locknut w/o Band 12 Locknut w/ Manual Band 10 Locknut w/ Auto Band B B B B B B Washer Capscrew * Man Rider application requires a band brake and no drum lock Form MHD56287 Edition 4 35

33 WINCH GUARD ASSEMBLY 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 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 AB ABL BL AB ABL BL AB ABL- Frame w/o Band w/o Drum Lock Frame w/o Band w/ Drum Lock Frame w/ Manual Band w/o Drum Lock * Frame w/ Manual Band w/ Drum Lock Frame w/ Auto Band w/o Drum Lock * Frame w/ Auto Band w/ Drum lock Panel w/o Band w/o Drum Lock Panel w/o Band w/ Drum Lock BL AB ABL BL AB ABL BL AB ABL Panel w/ Manual Band w/o B B B B B B 807 Drum Lock * Panel w/ Manual Band w/ Drum B B B B B B 807 Lock Panel w/ Auto Band w/o Drum Lock * Panel w/ Auto Band w/ Drum Lock B B B B B B B B B B B B Crossbar w/o Band Crossbar w/ Manual Band 7 Crossbar w/ Auto Band 9 Locknut w/o Band 14 Locknut w/ Manual Band 14 Locknut w/ Auto Band B B B B B B Washer Capscrew * Man Rider application requires a band brake and no drum lock 36 Form MHD56287 Edition 4

34 WINCH GUARD ASSEMBLY 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 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 AB ABL BL AB ABL BL AB ABL- Frame w/o Band w/o Drum Lock Frame w/o Band w/ Drum Lock Frame w/ Manual Band w/o Drum Lock * Frame w/ Manual Band w/ Drum Lock 801 Frame w/ Auto Band w/o Drum 802 Lock * 801 Frame w/ Auto Band w/ Drum 802 Lock 805 Panel w/o Band w/o Drum Lock Panel w/o Band w/ Drum Lock BL AB ABL BL AB ABL BL AB ABL Panel w/ Manual Band w/o B B B B B B 807 Drum Lock * Panel w/ Manual Band w/ Drum B B B B B B 807 Lock B B B B B B 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 16 Locknut w/ Manual Band Locknut w/ Auto Band Washer Capscrew * Man Rider application requires a band brake and no drum lock Form MHD56287 Edition 4 37

35 AIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST (Dwg MHP2679) of FA25i FA5i/Ti Air Preparation Assembly S 575 Filter 1-1/2 NPT 1 F Regulator Pipe Nipple Pipe Nipple Lubricator 1-1/2 NPT 1 L U-Bolt Capscrew Washer Nut Bracket Hose, bulk (4 ft [122 mm]) * Fitting, Connector (Note) Hose Fitting ** Fitting ** Ball Valve Air preparation components for 1-1/2 inch FNPT system * Length as required for installation ** not illustrated Refer to Product Safety Information Manual Note: Requires special tool to install fitting into hose ends 38 Form MHD56287 Edition 4

36 PN: LABELS AND TAGS ASSEMBLY DRAWING AND PARTS LIST (Dwg MHP2718) of of 89 Rivet Label, Oil Level Tag Kit, Warning Utility Label, Exhaust Tag Kit, Warning Man Rider Label, Air Supply Label, Overwind Tag Kit, Drum Guard S 2 Label, Underwind Tag, Check Oil Level Label, IR Logo 8-12 in drum Label, IR Logo in drum Label, Notice - Pressure Guage Data (Name) Plate - Utility CE & -E RS Label, IR Logo 24 + in drum Data (Name) Plate - Utility RS 653 Label, Oil Fill Data (Name) Plate - MR & MRCE RS 654 Label, Product - Utility 8-12 in drum Label, ATEX (CE, MRCE & -E) Label, Product - Utility in drum Label, Do Not Lift People - Utility Label, Product - Man Rider 8-12 in drum Label, Oil Drain Label, Product - Man Rider in drum Tag Kit, Aftermarket Label, CE and MRCE Tag, Encompass Inspected Note 1: Not all labels are illustrated Some labels are on component assembly drawings Note 2: Some labels may not be applicable to your product, refer to products date (name) plate and the Information Manual for specific model Note 3: For a replacement data (name) plate (664) a model and serial number are be required Form MHD56287 Edition 4 39

37 CONSTANT TENSION (OPTIONAL) ASSEMBLY DRAWING To Disc (Dwg MHP2028) 40 Form MHD56287 Edition 4

38 of CONSTANT TENSION (OPTIONAL) ASSEMBLY PARTS LIST 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 Control Valve Assembly 1 K5C2 X 946 Gasket Washer Capscrew * s not sold separately Form MHD56287 Edition 4 41

39 of Kit KITS FA25i 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 FA5i / FA5Ti 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 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 (305 metres) hose S with 20 feet (61 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 (305 metres) pendant hose with 20 feet (61 metres) pendant hose with 30 feet (915 metres) pendant hose with 40 feet (121 metres) pendant hose Limit Switch Kit (adds limit and controls to winch) Contact Factory Muffler Kit Form MHD56287 Edition 4