Product s Information Models FA2.5i FA5i FA5Ti (Dwg. MHP2669) Save These Instructions Form MHD56287 Edition 2 June 2006 71444269 2006 Ingersoll Rand Company
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 www.winchandhoistsolutions.com 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... 10 (Dwg. MHP2693)... 10 Motor Assembly s List... 11 Disc Assembly Drawing... 12 (Dwg. MHP2674)... 12 Disc Assembly s List... 13 Drum Band Assembly Drawing... 14 (Dwg. MHP2694)... 14 Drum Band Assembly s List... 15 Control Valve Assembly Drawing... 16 (Dwg. MHP2696)... 16 Control Valve Assembly s List... 17 Emergency Stop and Overload Control Valve Assembly Drawing... 18 (Dwg. MHP2697)... 18 Emergency Stop and Overload Control Valve Assembly s List... 19 Full Flow Remote Control Valve Assembly Drawing and s List... 20 (Dwg. MHP2698)... 20 Pendant Operated Overload (Optional) Assembly Drawing and s List... 21 (Dwg. MHP0698)... 21 Pendant Operated Pilot Control Valve (Optional) Assembly Drawing... 22 (Dwg. MHP2778)... 22 Pendant Operated Pilot Control Valve (Optional) s List... 23 Remote Pendant (Optional) Assembly Drawings... 24 (Dwg. MHP2346)... 24 (Dwg. MHP1677)... 24 Remote Pendant (Optional) Assembly s List... 25 Drum Locking Pin (Optional) Assembly Drawing and s List... 26 (Dwg. MHP2675)... 26 Press Roller Assembly (Optional) Drawing and s List... 27 (Dwg. MHP2695)... 27 Limit Switch (Optional) Assembly Drawing... 28 (Dwg. MHP2677)... 28 Limit Switch (Optional) s List... 29 Winch Guard Assembly Drawing... 30 (Dwg. MHP2676)... 30 Winch Guard s List... 31-33 Air Preparation Assembly Drawing and s List... 34 (Dwg. MHP2679)... 34 Labels and Tags Assembly Drawing and s List... 35 (Dwg. MHP2718)... 35 Constant Tension (Optional) Assembly Drawing... 36 (Dwg. MHP2028)... 36 Constant Tension (Optional) Assembly s List... 37 Kits... 38 Accessories... 38 2 Form MHD56287 Edition 2
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 98134 USA Phone:(206) 624-0466 or (866) 273-3278 Fax: (206) 624-6265 or Ingersoll Rand Douai Operations 529, Avenue Roger Salengro 59450 Sin Le Noble, France Phone:(33) 3-27-93-08-08 Fax: (33) 3-27-93-08-00 Form MHD56287 Edition 2 3
FA2.5I DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING 48 50 49 47 46 45 40 83 91 90 42 41 40 43 39 37 38 36 33 35 15 14 6 93 5 80 2 81 3 4 76 75 73 62 72 62 71 74 69 67 66 55 54 62 63 70 62 83 97 96 90 91 84 34 87 95 94 92 85 98 89 88 82 82 86 (Dwg. MHP2689) 4 Form MHD56287 Edition 2
FA2.5I DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST of of 2 Oil Seal 1 51873 69 Sun Gear 1 3 Lockwasher 10 50181 70 Dowel Pin 4 4 Capscrew 10 52379 71 Spacer 1 5 O Ring 1 51459 72 Ring Gear 1 Order 34 6 Motor Adapter 1 14227 73 Cover 1 14 Sleeve (w/o Disc ) 1 10598 74 Dowel Pin 4 15 Seal Adapter 1 16354 75 Capscrew 8 33 O Ring 1 51460 76 Spacer *** 1 382-20327 34 Reduction Gear Assembly * 1 71394746 80 Drum 1 Note 1 Wire Rope Anchor, 3/8 to 5/8 inch 35 Drive Shaft 1 28737 1 382-31631 (10 to 16 mm) 81 36 Retainer Ring 1 52298 Wire Rope Anchor l/2 in. (13 mm) (Note 3) 1 52001 37 Bearing 1 51870 Wire Rope Anchor 5/8 in. (16 mm) (Note 3) 1 52306 38 Retainer Ring 1 51872 82 Siderail 2 Note 1 39 Capscrew 8 52380 83 Lifting Lug 2 382-30773 40 Dowel Pin 50984 Upright, Outboard (without Drum Lock) 382-30516-3 2 84 1 Dowel Pin *** 71460554 Upright, Outboard (with Drum Lock) 382-30516-1 41 Drum Shaft 1 14037 85 Capscrew 8 50872 42 Upright, Inboard 1 382-30514-1 86 Dowel Pin 8 71266670 43 Seal 1 51475 87 Bearing 1 71440002 45 Capscrew 50973 88 Data (name) Plate 1 Note 2 12 Capscrew *** 71413132 89 Rivet 4 71028849 46 Lockwasher 12 50181 90 Capscrew 8 71316491 47 Gear Carrier 1 15451 91 Washer 8 52915 48 Pipe Plug 2 51467 92 Bearing Retainer 1 382-30646 49 Bearing 1 51473 93 Capscrew (no Disc ) 8 52379 50 Retainer Ring 1 51479 94 Capscrew 2 50964 54 Planetary Assembly 1 95 End Cover (without Limit Switch) 1 382-30830 55 Thrust Bearing 2 96 Washer 4 71376370 62 O Ring 4 97 Capscrew 4 52160 Order 34 63 Ring Gear 1 98 Washer 8 50203 66 Sun Gear 1 --- 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, 70-75. **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 382-30698-2 as part number 382-30698-2CH. Certification Type Example To Order ABS --- 382-30698-2CHA DNV 382-30698-2CH --- Form MHD56287 Edition 2 5
FA5I/TI DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING 40 39 36 33 41 38 37 35 15 14 6 93 5 60 58 2 57 56 55 54 3 4 61 51 53 59 51 50 49 46 45 48 86 83 91 52 90 80 34 81 47 42 43 75 73 62 72 62 74 71 70 67 66 55 62 63 83 69 62 97 96 95 90 91 94 92 84 34 87 82 89 88 85 86 82 98 (Dwg. MHP2670) 6 Form MHD56287 Edition 2
of FA5I/TI DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST of 2 Oil Seal 1 51873 67 Planetary Assembly 1 3 Lockwasher 10 50181 69 Sun Gear 1 4 Capscrew 10 52379 70 Dowel Pin 4 5 O Ring 1 51459 71 Spacer 1 Order 34 6 Motor Adapter 1 14227 72 Ring Gear 1 14 Sleeve (w/o Disc ) 1 10598 73 Cover 1 15 Seal Adapter 1 16354 74 Dowel Pin 4 33 O Ring 1 51460 75 Capscrew 8 34 Reduction Gear Assembly * 1 71394753 80 Drum 1 Note 1 35 Drive Shaft 1 28738 Wire Rope Anchor, 1/2 to 5/8 inch (13 to 16 mm) 382-31631 36 Retainer Ring 1 52298 37 Bearing 1 71458418 Wire Rope Anchor, 5/8 to 3/4 inch (16 to 19 382-30555 38 Retainer Ring 1 51872 mm) 81 1 39 Capscrew 8 52380 Wire Rope Anchor, 7/8 inch (22 mm) 382-30987 40 Dowel Pin 2 52334 Wire Rope Anchor 5/8 inch (16 mm) (Note 3) 52306 41 Drum Shaft 1 14020 Wire Rope Anchor 3/4 inch (19 mm) (Note 3) 52000 42 Upright, Inboard - FA5i 382-30770-1 Wire Rope Anchor 7/8 inch (22 mm) (Note 3) 52308 1 Upright, Inboard - FA5Ti 382-31202-1 82 Siderail 2 Note 1 43 Seal 1 51464 Lifting Lug FA5i 382-30773 83 2 45 Capscrew 12 52829 Lifting Lug FA5Ti 382-31197 46 Lockwasher 12 51012 Upright, Outboard (w/o Drum Lock) FA5i 382-30771-3 1 47 Gear Carrier 1 15418 Upright, Outboard (with Drum Lock) FA5i 382-30771-1 84 48 Pipe Plug 2 51467 Upright, Outboard (w/o Drum Lock) FA5Ti 382-31201-3 1 49 Bearing 1 51455 Upright, Outboard (with Drum Lock) FA5Ti 382-31201-1 50 Retainer Ring 1 71018196 85 Capscrew 8 50872 51 O Ring 2 86 Dowel Pin 14 71266670 52 Dowel Pin 3 87 Bearing 1 71440002 53 Ring Gear 1 88 Data (Name) Plate 1 Note 2 54 Planetary Assembly 1 89 Screw, Drive 4 71028849 55 Thrust Bearing 2 Order 34 90 Capscrew 8 71316491 56 Sun Gear 1 91 Washer 8 52915 57 Retainer Ring 1 92 Bearing Retainer 1 382-30646 58 Planetary Assembly 1 93 Capscrew (no Disc ) 8 50910 59 Input Housing 1 94 Capscrew 2 50964 60 Capscrew 12 71068605 95 End Cover (w/o Limit Switch) 1 382-30830 61 Plug 4 71068571 96 Washer 4 71376370 62 O Ring 4 97 Capscrew 4 52160 63 Ring Gear 1 Order 34 98 Washer 8 50203 66 Sun Gear 1 --- O Ring Kit (includes items 51 & 62) 1 27347 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, 70-75. **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 382-30858-2 as part number 382-30858-2CH. Certification Type Example To Order ABS --- 382-30858-2CHA DNV 382-30858-2CH --- Form MHD56287 Edition 2 7
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) 382-30698-1 Drum (8 inches long) 382-30720-1 Drum (8 inches long) 382-30698-1L Drum (8 inches long) 382-30720-1L Drum (12 inches long) 382-30698-2 Drum (12 inches long) 382-30720-2 Drum (12 inches long) 382-30698-2L Drum (12 inches long) 382-30720-2L Drum (16 inches long) 382-30698-3 Drum (16 inches long) 382-30720-3 Drum (16 inches long) 382-30698-3L Drum (16 inches long) 382-30720-3L Drum (20 inches long) 382-30698-4 Drum (20 inches long) 382-30720-4 Drum (20 inches long) 382-30698-4L Drum (20 inches long) 382-30720-4L Drum (24 inches long) 382-30698-5 Drum (24 inches long) 382-30720-5 Drum (24 inches long) 382-30698-5L Drum (24 inches long) 382-30720-5L Drum (30 inches long) 382-30698-6 Drum (30 inches long) 382-30720-6 Drum (30 inches long) 382-30698-6L Drum (30 inches long) 382-30720-6L Drum (36 inches long) 382-30698-7 Drum (36 inches long) 382-30720-7 Drum (36 inches long) 382-30698-7L Drum (36 inches long) 382-30720-7L Siderail ( 82) with Band Siderail ( 82) w/out Band ** with 8 inch Drum 382-30624-1 with 8 inch Drum 382-30628-1 with 12 inch Drum 382-30624-2 with 12 inch Drum 382-30628-2 with 16 inch Drum 382-30624-3 with 16 inch Drum 382-30628-3 with 20 inch Drum 382-30624-4 with 20 inch Drum 382-30628-4 with 24 inch Drum 382-30624-5 with 24 inch Drum 382-30628-5 with 30 inch Drum 382-30624-6 with 30 inch Drum 382-30628-6 with 36 inch Drum 382-30624-7 with 36 inch Drum 382-30628-7 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 382-30698-2 as part number 382-30698-2CH. 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) 382-30858-2 Drum (12 inches long) 382-31472 Drum (12 inches long) 382-30858-2L Drum (12 inches long) 382-30887-2L Drum (16 inches long) 382-30858-3 Drum (16 inches long) 382-30887-3 Drum (16 inches long) 382-30858-3L Drum (16 inches long) 382-30887-3L Drum (20 inches long) 382-30858-4 Drum (20 inches long) 382-30887-4 Drum (20 inches long) 382-30858-4L Drum (20 inches long) 382-30887-4L Drum (24 inches long) 382-30858-5 Drum (24 inches long) 382-30887-5 Drum (24 inches long) 382-30858-5L Drum (24 inches long) 382-30887-5L Drum (30 inches long) 382-30858-6 Drum (30 inches long) 382-30887-6 Drum (30 inches long) 382-30858-6L Drum (30 inches long) 382-30887-6L Drum (36 inches long) 382-30858-7 Drum (36 inches long) 382-30887-7 Drum (36 inches long) 382-30858-7L Drum (36 inches long) 382-30887-7L Siderail ( 82) with Band Siderail ( 82) w/out Band ** with 12 inch Drum 382-30823-2 with 12 inch Drum 382-30824-2 with 16 inch Drum 382-30823-3 with 16 inch Drum 382-30824-3 with 20 inch Drum 382-30823-4 with 20 inch Drum 382-30824-4 with 24 inch Drum 382-30823-5 with 24 inch Drum 382-30824-5 with 30 inch Drum 382-30823-6 with 30 inch Drum 382-30824-6 with 36 inch Drum 382-30823-7 with 36 inch Drum 382-30824-7 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) 382-31207-2 Drum (12 inches long) 382-31540 Drum (12 inches long) 382-31207-2L Drum (12 inches long) 382-31540-L Drum (16 inches long) 382-31207-3 Drum (16 inches long) 382-31243-3 Drum (16 inches long) 382-31207-3L Drum (16 inches long) 382-31243-3L Drum (20 inches long) 382-31207-4 Drum (20 inches long) 382-31243-4 Drum (20 inches long) 382-31207-4L Drum (20 inches long) 382-31243-4L Drum (24 inches long) 382-31207-5 Drum (24 inches long) 382-31243-5 Drum (24 inches long) 382-31207-5L Drum (24 inches long) 382-31243-5L Drum (30 inches long) 382-31207-6 Drum (30 inches long) 382-31243-6 Drum (30 inches long) 382-31207-6L Drum (30 inches long) 382-31243-6L Drum (36 inches long) 382-31207-7 Drum (36 inches long) 382-31243-7 Drum (36 inches long) 382-31207-7L Drum (36 inches long) 382-31243-7L Siderail ( 82) with Band Siderail ( 82) w/out Band ** with 12 inch Drum 382-30823-2 with 12 inch Drum 382-30824-2 with 16 inch Drum 382-30823-3 with 16 inch Drum 382-30824-3 with 20 inch Drum 382-30823-4 with 20 inch Drum 382-30824-4 with 24 inch Drum 382-30823-5 with 24 inch Drum 382-30824-5 with 30 inch Drum 382-30823-6 with 30 inch Drum 382-30824-6 with 36 inch Drum 382-30823-7 with 36 inch Drum 382-30824-7 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 382-30858-2 as part number 382-30858-2CH. 8 Form MHD56287 Edition 2
SERVICE NOTES Form MHD56287 Edition 2 9
MOTOR ASSEMBLY DRAWING 216 200 201 2 15 228 205 203 202 204 201 200 206 205 207 208 213 206 210 205 203 204 202 229 213 214 209 207 205 208 K5C2 Control Valve 209 230 225 244 243 226 217 3 4 225 246 247 231 232 233 234 235 236 237 243 251 250 251 252 231 240 228 165 169 171 170 253 211 (Dwg. MHP2693) 10 Form MHD56287 Edition 2
of MOTOR ASSEMBLY PARTS LIST of Motor Assembly 214 Pipe Plug 1 71263297 199 with Control Valve * K5B-546M-S 216 Mounting Flange 1 K5B-502A 1 without Control Valve * K5B-546LM-S 217 Motor Housing (Note 1) 1 382-30415-S 2 Oil Seal ** 1 51873 225 Pipe Plug (Drain) 3 54912 3 Lockwasher 10 50181 226 Gasket 1 K5B-592 4 Capscrew 10 52379 228 Bearing 2 51066 15 Seal Adapter ** 1 16354 229 Buttonhead Screw 5 K5B-541 165 Reducer Bushing 1 71057459 230 Oil Slinger 1 K5B-540 169 Pipe, Elbow 1 71057434 231 Crank Assembly 1 K5B-A516 170 Muffler 1 50594 232 Sleeve 1 K5B-519 171 Pipe Nipple 1 51704 233 Connecting Rod Bushing 1 K5B-511 200 Capscrew 20 71434260 234 Connecting Rod Ring 2 K5B-510 201 Cylinder Head 5 K5B-H505 235 Lock Pin 1 HU-520 202 Compression Ring 1 Set K5B546-KRING 236 Cotter Pin 1 53456 203 Wrist Pin 5 HU-514A 237 Pin Nut 1 D02-394 204 Piston 5 *** 240 Roll Pin 1 54257 205 Retainer Ring 10 902A45-632 243 Gasket 2 K5B-928 206 Connecting Rod 5 K5B-509 244 O Ring 1 20A11CM248 207 Oil Ring Order 202 246 Grease Fitting 1 53095 208 Cylinder Liner 5 K5B-L505-47 247 Rotary Valve Housing 1 K5B-545 209 Head Gasket 1 Set K5B-507-5 250 Rotary Valve Assembly 1 K5B-526EQ-RS 210 Vent Cap Assembly 1 26604 251 Seal Ring Assembly 1 set K5B-607A 211 Capscrew 5 71452536 252 Bearing 1 50138 213 Eye Bolt 2 71431506 253 Exhaust Flange 1 KK5B-276M Recommended spare for one winch, 2 years of normal operation. * K5B-546M-S includes items 2-4, 93, 200-210, 213, 214, 216, 217, 225, 226, 228-237, 240, 243, 244, 246, 247, 250-253, with K5C2 style control valve. * K5B-546LM-S includes items 2-4, 93, 200-210, 213, 214, 216, 217, 225, 226, 228-237, 240, 243, 244, 246, 247, 250-253. ** 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-A516 250 Rotary Valve Assembly (includes items 251 and 252) 1 K5B-526EQ-RS 261 Piston Assembly (includes items 202 through 205 and 207) 1 K5B-A513-47 --- Motor Gasket Kit (includes items 209, 226, 243, 244 and 248) 1 26823 --- Air Motor Service Kit (includes items 3, 4, 200, 202, 207-209, 226, 243, 244, and 251) 1 71390181 Form MHD56287 Edition 2 11
DISC BRAKE ASSEMBLY DRAWING (Dwg. MHP2674) 12 Form MHD56287 Edition 2
DISC BRAKE ASSEMBLY PARTS LIST of of 7 Shaft 1 10594 25 Fitting, Nipple 1 50859 8 Reaction Plate 1 10597 26 Dump Valve 1 50276 9 Spring 15 50751 27 Fitting, Vented 1 20770 10 Piston 1 382-31002 28 Fitting, Reducer 1 51803 11 Seal 1 51462 29 Breather 1 51857 12 Seal 1 71444822 30 O Ring 1 51458 13 Collar 1 71039333 31 Level/Drain Plug 2 55013 17 Housing 1 382-31000 44 Hose Assembly 1 50923 18 Drive Plate 6 382-31004 64 Tubing Assembly Contact Factory 19 Friction Plate 5 71126874 93 Capscrew 8 51471 20 Reaction Disc 1 382-31080 * Label Plate, LP 1 71465942 21 Gear 1 382-31707 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 10594 as part number 10594CH. Certification Type Example To Order ABS --- 10594-2CHA DNV 10594-2CH --- Form MHD56287 Edition 2 13
DRUM BAND BRAKE ASSEMBLY DRAWING (Dwg. MHP2694) 14 Form MHD56287 Edition 2
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 3 50890 50203 Contact Factory 101 Pin 2 382-31615 382-31615 382-31615 102 Cotter Pin See ( ) 51996 (5) 51996 (7) 51996 (5) 51996 (7) 51996 (5) 103 Link Stud 1 2448 4115 4115 104 Lever - Manual 1 382-31264 - - - 4127 - - - 382-31371 105 Lever - Automatic 1 11498 21158 106 Pin 1 8609 8609 107 Clevis 1 6237-2 8586 108 Nut 1 50159 50152 109 Breather 1 52384 52384 110 Cylinder 1 4575-1 8575 - - - - - - --- 111 Fitting, Bushing 1 52006 52006 Contact Factory 112 Dump Valve 1 51954 51954 113 Hose End 2 52385 51029 114 Fitting, Elbow 1 52181 54272 115 Hose (bulk) As Req d 50923 50923 116 Capscrew 3 52014 52014 117 Washer See ( ) 71293005 (3) 51008 (4) 51008 (5) 71293005 (4) 118 Bracket 1 - - - 382-30728 - - - 11329 --- 119 Capscrew See ( ) 71128193 (3) 71128193 (4) 71128193 (4) 120 Nut 1 54661 54661 54661 121 Pin 3 3704-S 382-31614 382-31614 122 Pivot Bracket 1 382-30630 10881 10881 124 Arm 1 11147 382-31610 382-31617 125 Connecting Link 1 11144 10882 10882 126 Stop Plate 1 382-30629 10879 10879 127 Screw, Adjusting 1 HU-775 71033104 71033104 128 Band 1 Set 382-29303 382-31948 382-31948 134 Pin 1 - - - 382-30729 --- 11497 --- 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 10881 should be ordered as part number 10881CH. Certification Type Example To Order ABS --- 10881CHA DNV 10881CH --- Form MHD56287 Edition 2 15
CONTROL VALVE ASSEMBLY DRAWING (Dwg. MHP2696) 16 Form MHD56287 Edition 2
CONTROL VALVE ASSEMBLY PARTS LIST of of 900 Control Valve Assembly 1 K5C2-ELP 937 Spring 1 26966 89 Rivet 2 71028849 938 Buttonhead Screw 2 71394407 214 Plug 1 71263297 939 Seal Bracket (Note 2) 1 28733-S 901 Capscrew 9 71342034 940 Tag, No FA2B 1 71392757 902 Washer 8 71303408 941 O Ring 1 71357198 903 Poppet Cover 1 26997 942 O Ring 2 51651 904 Poppet Gasket 1 27064 Reverse Valve Kit (Normal)** 27925-SX 905 Poppet Spring 1 71351068 943 Reverse Valve (Reverse Bias)** 1 28002 906 Poppet Cap 1 28734 Reverse Valve (Unbiased) **** 907 Poppet Seal 1 26991 Bushing (Normal)*** 26686 909 Washer, Tablock 1 71398051 944 Bushing (Reverse Bias)*** 1 27450 910 Pilot Valve Assembly 1 28696 Bushing (Unbiased) **** 912 Plug 1 71267561 945 Dowel Pin 1 71146674 916 Ball 1 D10-280 946 Gasket Set 27115 917 Valve Housing 1 * 948 Label, Throttle Direction 1 71352777 918 Cover Gasket 1 26999 949 Washer 4 71413355 919 Piston Cover 1 26998 950 Plug 1 71366348 920 IR Pilot Valve Tool 1 28690 951 Capscrew 4 71431365 921 O Ring 1 52537 955 Exhaust Flange 1 26691 922 Piston (Note 1) 1 28735-S 956 Fitting, Elbow 1 71367932 923 O Ring 1 71355796 957 Fitting, Elbow 1 71273676 924 Washer 2 71271985 958 Fitting, Nipple 1 71057483 925 Capscrew 2 71348338 959 Muffler 1 52472 930 Handle Assembly 1 27239-1 960 Label, Warning 1 71373229 935 Plug 1 71348965 962 Breather 1 51559 * 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 904-907, 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) 1 27240 782 Handle Assembly Kit (includes items 901, 902 and 930; 1 each) 1 27239 784 Reverse Valve Kit (includes items 943 and 956) 1 27925-SX 786 Overload Valve Service Kit 1 27995-X 788 Emergency Stop Service Kit* 1 27994-X 789 Emergency Stop Kit (Optional Feature)* 1 28026 910 Pilot Valve Assembly Kit 1 28696 922 Piston Kit 1 28735-S 939 Seal Bracket Kit (includes items 901, 902, 924, 925, 935, 937-939, 941 and 942 1 28733-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
EMERGENCY STOP AND OVERLOAD CONTROL VALVE ASSEMBLY DRAWING (Dwg. MHP2697) 18 Form MHD56287 Edition 2
EMERGENCY STOP AND OVERLOAD CONTROL VALVE ASSEMBLY PARTS LIST of of 908 Control Valve Assembly 1 K5C2-EXLP 918 Cover Gasket 1 26999 89 Rivet 2 71028849 919 Piston Cover 1 26998 214 Plug 1 71263297 920 IR Pilot Valve Tool 1 28690 700 Cap 1 27491 921 O Ring 1 52537 701 Grommet 1 71365779 922 Piston (Note 1) 1 28735-S 702 Plunger 1 27490 923 O Ring 1 71355796 703 O Ring 6 71127039 924 Washer 2 71271985 704 Label, Stop 1 95790099 925 Capscrew 2 71348338 705 Button, E-Stop 1 71372601 930 Handle Assembly 1 27239-1 706 Adapter 1 27488 935 Plug 1 71348965 707 Plunger 1 27489 937 Spring 1 26966 711 Spring 1 71365787 938 Buttonhead Screw 2 71394407 712 Piston 1 27964 939 Seal Bracket (Note 2) 1 28733-S 713 O Ring 1 51768 940 Tag, No FA2B 1 71392757 714 Gasket 1 27493 941 O Ring 1 71357198 715 Plate 1 27624 942 O Ring 3 51651 716 O Ring 1 71365795 Reverse Valve Kit (Normal)** 27925-XLP 717 Adjustment Nut 1 24374 943 Reverse Valve (Reverse Bias)** 1 ** 718 Spring 1 71053730 Reverse Valve (Unbiased) **** 719 Cover 1 27494 Bushing (Normal)*** 382-29739 720 Screw, Adjusting 1 27571 944 Bushing (Reverse Bias)*** 1 *** 721 Capscrew 2 71398879 Bushing (Unbiased) **** 722 O Ring 2 71138135 945 Dowel Pin 1 71146674 723 Exhaust Adapter 1 27540 946 Gasket Set 27115 724 Label Plate, LP (Note 3) 1 71465959 948 Label, Throttle Direction 1 71352777 726 Plug 1 27945 949 Washer 4 71413355 901 Capscrew 11 71342034 951 Capscrew 4 71431365 902 Washer 12 71303408 955 Exhaust Flange 1 26691 903 Poppet Cover 1 26997 956 Fitting, Elbow 1 71367932 904 Poppet Gasket 1 27064 957 Fitting, Elbow (refer to Dwg. MHP2696) 1 71273676 905 Poppet Spring 1 71351068 958 Fitting, Nipple (refer to Dwg. MHP2696) 1 71057483 906 Poppet Cap 1 28734 959 Muffler (refer to Dwg. MHP2696) 1 52472 907 Poppet Seal 1 26991 960 Label, Warning 1 71373229 909 Washer, Tablock 1 71398051 963 Plug 3 28628 910 Pilot Valve Assembly 1 28696 964 Manifold Block 1 382-31727 912 Plug 1 71267561 965 Gasket 1 382-31762 916 Ball 1 D10-280 966 Washer 4 71271985 917 Valve Housing 1 * 967 Capscrew 4 71348338 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 904-907, 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
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 50923 93 Capscrew 5 51471 243 Gasket 1 K5B-928 253 Exhaust Cover 1 KK5B-276M 321 Fitting, Elbow 4 54270 322 Hose End 4 54738 323 Hose (bulk) As Req d 54737 956 Fitting, Elbow 1 71367932 20 Form MHD56287 Edition 2
PENDANT OPERATED OVERLOAD (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP0698) of 369 Adapter 1 24373 386 Setscrew 1 71266589 387 Piston 1 24372 388 Plug, Orifice 1 382-31313 389 O Ring 1 50557 713 O Ring 2 51768 717 Adjustment Nut 1 24374 718 Spring 1 71053730 Form MHD56287 Edition 2 21
PENDANT OPERATED PILOT CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING (Dwg. MHP2778) 22 Form MHD56287 Edition 2
of PENDANT OPERATED PILOT CONTROL VALVE (OPTIONAL) PARTS LIST of 96 Washer (2) 4 71376370 362 Retainer Ring 2 53833 Valve Assembly: PTV 363 O Ring 2 52573 Single Air 364 Valve Piston 2 23519 330 Single Air -E Option 1 365 Retainer Ring 2 71138010 Contact Factory Dual Air s 366 Capscrew 4 71138069 Dual Air s -E Option 367 Valve Cap (Note 4) 2 23598 331 Valve Shaft 1 23522 368 Capscrew 4 71138077 332 Restrictor, Poppet 1 23523 Adapter, Standard 23514 369 1 333 Restrictor, Seat 1 23524 Adapter,-E Option 24373 334 O Ring 1 71137988 370 Capscrew 4 71138085 335 Pin 2 71293179 371 Shims (3) 71138119 336 Pin 2 71293161 372 Cylinder (Note 4) 2 28432 337 Setscrew 1 71138093 373 Spring (Note 4) 2 71386627 338 Sleeve 1 23606 374 O Ring (Note 4) 2 51554 339 Valve Body 1 * 375 Piston (Note 4) 2 23596 340 Gasket 2 23592 376 O Ring (Note 4) 2 71145650 Pin (Note 1) 1(2) 377 Seal Cup (Note 4) 2 23597 341 Valve Assembly (Note 1) 1(2) 23594 378 O Ring (Note 4) 2 71138234 O Ring (Note 1) 2(4) 379 Setscrew (Note 4) 2 71148779 342 Manifold 1 382-31755 380 Retainer, Spring (Note 4) 2 24041 343 Spring Clip 1 24793 381 Capscrew (Note 4) 3 53807 344 Washer 1 50899 382 Pin (Note 4) ** 2 71136923 345 Capscrew 2 71261747 383 Capscrew 2 71261713 346 Gasket 1 382-31761 384 Pedant Bracket 1 24442 347 Pin 1(2) 71146195 385 Valve Cap Assembly 2 28433 354 Exhaust Poppet 1 23516 386 Capscrew 2 71303671 355 Plug 1 51897 387 Seal Washer 2 71303838 356 Spring 2 71138028 388 Shuttle Valve Body (Note 3) 1 24146 357 Inlet Poppet 2 23517 389 Elbow Fitting 2 51768 358 Gasket 1 71264725 713 O Ring 2 51768 359 Fitting, Elbow (Note 3) 1 71262299 924 Washer 8 71271985 360 O Ring 2 52662 951 Capscrew 4 71431365 361 Poppet Seat 2 23518 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 25439 or 25440) use quantity of 1 Pin (347) and 1 Valve Assembly (341). Winches with disc and automatic drum band brakes (Valve Assemblies 25441 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 28433. Form MHD56287 Edition 2 23
REMOTE PENDANT (OPTIONAL) ASSEMBLY DRAWINGS Pendant without Emergency Stop (Dwg. MHP2346) Pendant with Emergency Stop 442 348 440 444 443 453 448 446 447 445 446 449 451 441 456 455 454 449 443 443 452 451 452 457 458 (Dwg. MHP1677) 24 Form MHD56287 Edition 2
REMOTE PENDANT (OPTIONAL) ASSEMBLY PARTS LIST of With E-Stop Without E-Stop 353 Pendant Assembly* 1 PHS2E PHS2E-U 348 Fitting 3(5) 71048268 440 Lifting Eye 1 64222332 441 Emergency Stop Valve 1 95790108 442 Valve 1 95790106 - - - 443 O Ring 2(5) 58209229 444 Plug 2(4) 65107741 445 Spring 2(4) 69128541 446 Ball 2(5) 69401625 447 Pin 1 95790040 448 Setscrew 2 42008607 449 O Ring 2(3) 58235329 451 Protector 2(3) 95790107 452 Valve 2(3) 95790104 453 Lever 2 95790122 454 Pendant Handle 1 order item 353 455 Setscrew 3(5) 71078158 456 Label Kit 1 95790111 457 Exhaust Washer 1 67600303 458 Retainer Ring 1 47713030 470 Plug 1 - - - 65129541 Recommended spares for one winch, 2 years of normal operation. * PHS2E includes items 440-449 and 451-458. * PHS2E-U includes items 440, 443-449, 451-458 and 470. Form MHD56287 Edition 2 25
DRUM LOCKING PIN (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2675) of FA2.5i FA5i/FA5Ti 300 Drum Locking Assembly 1 382-30722 382-30723 141 Handle Grip 1 71436851 301 Handle 1 382-30639 302 Capscrew 1 71445654 303 Locknut 1 71069132 304 Shaft 1 382-30705 305 Capscrew 2 71328744 306 Washer 2 51833 307 Cover 1 382-30704 308 Housing 1 382-30558 309 Grease Fitting 1 71111942 310 Spring 1 71436869 311 Bushing 1 71316616 312 Drum Lock Pin 1 382-30633 382-30706 Note 1: Not available for Man Rider applications. 26 Form MHD56287 Edition 2
PRESS ROLLER ASSEMBLY (OPTIONAL) DRAWING AND PARTS LIST (Dwg. MHP2695) FA2.5i of 12 w/o Band 12 w/ Band 400 Press Roller Assembly * 1 382-31043-2 382-31043-2B 402 Roller 2 382-30962-2 403 Roller Shaft 1 382-31044-2 407 Arm 1 382-30966-2 of 24 w/o Band 24 w/ Band 400 Press Roller Assembly * 1 382-31043-5 382-3043-5B 402 Roller 2 382-30962-5 403 Roller Shaft 1 382-31044-2B 382-31044-5 407 Arm 1 382-30966-5 16 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 1 382-30961-2 382-30961-2B 382-30961-3 382-30961-3B 382-30961-4 382-30961-4B 402 Roller 2 382-30966-2 382-30966-3 403 Roller Shaft 1 382-30970-2 382-30970-2B 382-30970-3 382-30970-3B Contact Factory 407 Arm 1 382-31263-2 382-31263-3 of 24 w/o Band 24 w/ Band 400 Press Roller Assembly 1 382-30961-5 382-30961-5B 402 Roller 2 382-30966-5 403 Roller Shaft 1 382-30970-5 382-30970-5B 407 Arm 1 382-31263-5 30 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 2 71443980 405 Spring, Left Side 1 382-30968 406 Spring, Right Side 1 382-30969 408 Capscrew 4 71371652 409 Washer 4 51009 410 Bushing 2 71443816 Form MHD56287 Edition 2 27
LIMIT SWITCH (OPTIONAL) ASSEMBLY DRAWING (Dwg. MHP2677) 28 Form MHD56287 Edition 2
of LIMIT SWITCH (OPTIONAL) PARTS LIST 475 Limit Switch Assembly (Includes items 450, 476-481, 484-486 and 488-509 1 382-32134-S 96 Washer 4 71376370 97 Capscrew 4 52160 450 Adapter, Limit Switch 1 382-30831 476 Upper Support Block 1 96150556 477 Capscrew 2 41332006 478 Control Valve 2 68558741 479 Fitting, Hose Tee 1 58255860 480 Connection Block 1 382-31427 481 Fitting, Pipe 1 54242 482 Dump Valve 1 71302673 484 Pin 1 46503420 485 O Ring 1 58237529 486 Housing 1 382-31036 488 Washer 2 45001104 489 Capscrew 1 41311906 490 Gasket 2 69761541 491 Fitting, Cap 1 71111975 492 Washer 5 45201006 493 Capscrew 2 41020301 494 Hose Assembly (37 in. [940 mm]) standard hose 382-31423-8 1 Hose Assembly (37 in. [940 mm]) stainless steel hose 382-31426-8 495 Hose Assembly (42 in. [1067 mm]) standard hose 382-31423-10 1 Hose Assembly (42 in. [1067 mm]) stainless steel hose 382-31426-10 496 Hose Assembly (42.5 in. [1080 mm]) standard hose 382-31423-9 1 Hose Assembly (42.5 in. [1080 mm]) stainless steel hose 382-31426-9 497 Fitting, Hose 4 51814 498 Cap Assembly 1 96150662 499 Capscrew 3 71324115 500 Lower Support Block 1 96150555 501 Spindle Switch Assembly 1 * 502 Rod 4 382-31037 503 Washer 4 45201008 504 Nut 4 43003511 505 Cover, Housing 1 96150566 506 Capscrew 2 41313606 507 Fitting, Hose Tee 1 71457519 508 Tube 1 68045328 509 Fitting, Adapter 4 71457485 510 Label, Limit Switch Configuration 1 71459929 511 Label, Limit Switch Instructions, Underwind Winches Only 1 71462337 Label, Limit Switch Instructions, Overwind Winches Only 1 71446439 Recommended spare for one winch, 2 years of normal operation. * not sold separately. Order Limit Switch Assembly, 475. Form MHD56287 Edition 2 29
WINCH GUARD ASSEMBLY DRAWING (Dwg. MHP2676) 30 Form MHD56287 Edition 2
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 382-31122-1 382-31122-2 382-31122-3 382-31122-4 382-31122-5 382-31122-6 382-31122-1L 382-31122-2L 382-31122-3L 382-31122-4L 382-31122-5L 382-31122-6L 382-31122-1B 382-31122-2B 382-31122-3B 382-31122-4B 382-31122-5B 382-31122-6B 382-31122-1BL 382-31122-2BL 382-31122-3BL 382-31122-4BL 382-31122-5BL 382-31122-6BL 382-31122-1AB 382-31122-2AB 382-31122-3AB 382-31122-4AB 382-31122-5AB 382-31122-6AB 382-31122-1ABL 382-31122-2ABL 382-31122-3ABL 382-31122-4ABL 382-31122-5ABL 382-31122-6ABL 2 382-31123 1 382-31123 1 382-31123-L 2 328-31123 1 382-31123 1 382-31123-L 2 382-31123 802 2 382-31124 1 382-31123 801 Frame 1 382-31123-L w/ Auto Band w/ Drum Lock 802 2 382-31124 805 Panel w/o Band w/o Drum Lock 5 Panel w/o Band w/ Drum Lock 4 382-31125-1 382-31125-2 382-31125-3 382-31125-4 382-31125-5 382-31125-6 805 Panel 2 382-31125-1B 382-31125-2B 382-31125-3B 382-31125-4B 382-31125-5B 382-31125-6B 807 w/ Manual Band w/o Drum Lock * 1 382-31127-1 382-31127-2 382-31127-3 382-31127-4 382-31127-5 382-31127-6 805 Panel 2 382-31125-1B 382-31125-2B 382-31125-3B 382-31125-4B 382-31125-5B 382-31125-6B 807 w/ Manual Band w/ Drum Lock 1 382-31127-1 382-31127-2 382-31127-3 382-31127-4 382-31127-5 382-31127-6 805 Panel w/ Auto Band w/o Drum Lock * 5 382-31125-1B 382-31125-2B 382-31125-3B 382-31125-4B 382-31125-5B 382-31125-6B Panel w/ Auto Band w/ Drum Lock 5 382-31125-1BL 382-31125-2BL 382-31125-3BL 382-31125-4BL 382-31125-5BL 382-31125-6BL Crossbar w/o Band 6 382-31126-1 382-31126-2 382-31126-3 382-31126-4 382-31126-5 382-31126-6 806 Crossbar w/ Manual Band 5 Crossbar w/ Auto Band 7 382-31126-1B 382-31126-2B 382-31126-3B 382-31126-4B 382-31126-5B 382-31126-6B Locknut w/o Band 12 804 Locknut w/ Manual Band 10 71445415 Locknut w/ Auto Band 14 96 Washer 8 71376370 809 Capscrew 8 71445407 * Man Rider application requires a band brake and no drum lock. Form MHD56287 Edition 2 31
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 382-31017-2 382-31017-3 382-31017-4 382-31017-5 382-31017-6 382-31017-7 382-31017-2L 382-31017-3L 382-31017-4L 382-31017-5L 382-31017-6L 382-31017-7L 382-31017-2B 382-31017-3B 382-31017-4B 382-31017-5B 382-31017-6B 382-31017-7B 382-31017-2BL 382-31017-3BL 382-31017-4BL 382-31017-5BL 382-31017-6BL 382-31017-7BL 382-31017-2AB 382-31017-3AB 382-31017-4AB 382-31017-5AB 382-31017-6AB 382-31017-7AB 382-31017-2ABL 382-31017-3ABL 382-31017-4ABL 382-31017-5ABL 382-31017-6ABL 382-31017-7ABL 2 382-30774 1 382-30774-1 1 382-30774 2 382-30774 1 382-30774 1 382-30774-1 2 382-30774 802 1 382-30953 1 382-30774 801 Frame 1 382-30774-1 w/ Auto Band w/ Drum lock 802 2 382-30953 805 Panel w/o Band w/o Drum Lock Panel w/o Band w/ Drum Lock 5 382-31011-3 382-31011-3 382-31011-4 382-31011-5 382-31011-6 382-31011-7 805 Panel 3 382-31011-2B 382-31011-3B 382-31011-4B 382-31011-5B 382-31011-6B 382-31011-7B 807 w/ Manual Band w/o Drum Lock * 1 382-31012-2 382-31012-3 382-31012-4 382-31012-5 382-31012-6 382-31012-7 805 Panel 3 382-31011-2B 382-31011-3B 382-31011-4B 382-31011-5B 382-31011-6B 382-31011-7B 807 w/ Manual Band w/ Drum Lock 1 382-31012-2 382-31012-3 382-31012-4 382-31012-5 382-31012-6 382-31012-7 805 Panel w/ Auto Band w/o Drum Lock * 7 382-31011-2B 382-31011-3B 382-31011-4B 382-31011-5B 382-31011-6B 382-31011-7B Panel w/ Auto Band w/ Drum Lock 7 382-31011-2B 382-31011-3B 382-31011-4B 382-31011-5B 382-31011-6B 382-31011-7B Crossbar w/o Band 7 382-30982-2 382-30982-3 382-30982-4 382-30982-5 382-30982-6 382-30982-7 806 Crossbar w/ Manual Band 7 Crossbar w/ Auto Band 9 382-30982-2B 382-30982-3B 382-30982-4B 382-30982-5B 382-30982-6B 382-30982-7B Locknut w/o Band 14 804 Locknut w/ Manual Band 14 71445415 Locknut w/ Auto Band 18 96 Washer 12 71376370 809 Capscrew 12 71445407 * Man Rider application requires a band brake and no drum lock. 32 Form MHD56287 Edition 2
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 382-31209-2 382-31209-3 382-31209-4 382-31209-5 382-31209-6 382-31209-7 382-31209-2L 382-31209-3L 382-31209-4L 382-31209-5L 382-31209-6L 382-31209-7L 382-31209-2B 382-31209-3B 382-31209-4B 382-31209-5B 382-31209-6B 382-31209-7B 382-31209-2BL 382-31209-3BL 382-31209-4BL 382-31209-5BL 382-31209-6BL 382-31209-7BL 382-31209-2AB 382-31209-3AB 382-31209-4AB 382-31209-5AB 382-31209-6AB 382-31209-7AB 382-31209-2ABL 382-31209-3ABL 382-31209-4ABL 382-31209-5ABL 382-31209-6ABL 382-31209-7ABL 2 382-31208 1 382-31208 1 382-31208-1 2 382-31208 1 382-31208 1 382-31208-1 --- --- 6 382-31011-3 382-31011-3 382-31011-4 382-31011-5 382-31011-6 382-31011-7 4 382-31011-2B 382-31011-3B 382-31011-4B 382-31011-5B 382-31011-6B 382-31011-7B 807 1 382-31421-2 382-31421-3 382-31421-4 382-31421-5 382-31421-6 382-31421-7 4 382-31011-2B 382-31011-3B 382-31011-4B 382-31011-5B 382-31011-6B 382-31011-7B 807 1 382-31421-2B 382-31421-3B 382-31421-4B 382-31421-5B 382-31421-6B 382-31421-7B 805 Panel w/ Auto Band w/o Drum Lock * Panel --- --- w/ Auto Band w/ Drum Lock Crossbar w/o Band 6 382-30982-2 382-30982-3 382-30982-4 382-30982-5 382-30982-6 382-30982-7 806 Crossbar w/ Manual Band 5 382-30982-2B 382-30982-3B 382-30982-4B 382-30982-5B 382-30982-6B 382-30982-7B Crossbar w/ Auto Band --- --- Locknut w/o Band 16 804 Locknut w/ Manual Band 14 71445415 Locknut w/ Auto Band --- --- 96 Washer 8 71376370 809 Capscrew 8 71445407 * Man Rider application requires a band brake and no drum lock. Form MHD56287 Edition 2 33
AIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST 579 580 578 585 581 577 585 581 Lubricator 582 583 584 575 578 587 Regulator Control Valve 586 588 Lubricator Filter (Dwg. MHP2679) of --- Air Preparation Assembly 1 382-31020 575 Filter 1 F35-0B-C28 577 Regulator 1 R40-0B-G00 578 Pipe Nipple 2 71311426 579 Pipe Nipple 1 71057483 580 Lubricator 1 L40-0B-G00 581 U-Bolt 2 71445308 582 Capscrew 4 71391080 583 Washer 4 71445324 584 Nut 4 71445316 585 Bracket 2 382-31021 586 Hose, bulk (4 ft [1.22 mm]) * 1 54737 587 Fitting, Connector 1 71106520 588 Hose Fitting 2 54738 ** Fitting 1 54270 ** Ball Valve 1 71416911 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
LABELS AND TAGS ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2718) of 22261-4S of Product Label 12-16 inch long drum 71111777 650 Label and Tag Kit * 1 654 1 22261-5S Product Label 24 inch and longer drum 71109508 24305-4S Warning Label 71060529 Label and Tag Kit -E * 655 1 24305-5S Warning Label -E 96180100 88 Data (Name) Plate 1 7116967-R 656 Oil Level Label 1 71043616 89 Drive Screw 4 71028849 657 Exhaust Label 1 71042196 651 652 Winding Label 2 71109516 658 Control Valve Operation -E 1 96180102 Winding Label -E 96180103 659 Air Supply Label 1 71046395 IR Logo Label 12-16 inch long drum 71106272 661 Warning Label (Only Non -E) 1 71107130 IR Logo Label 24 inch long and longer drum 1 71109102 662 Check Oil Level Label 1 71107148 663 Underwound Direction Label 1 71110068 653 Label General -E 1 71153464 --- Label Kit 382-31662 * Kits depend on drum length. s ending in -4 are for drums 12-16 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
CONSTANT TENSION (OPTIONAL) ASSEMBLY DRAWING 703 704 702 705 701 706 708 708 To Disc 744 709 743 707 113 745 343 115 742 728 707 113 708 741 708 709 712 711 715 716 717 713 714 709 719 115 113 725 726 718 719 951 K5C2 Valve 746 949 900 946 739 735 709 734 733 736 737 738 732 709 728 709 729 718 719 726 709 727 248 714 709 719 (Dwg. MHP2028) 36 Form MHD56287 Edition 2
CONSTANT TENSION (OPTIONAL) ASSEMBLY PARTS LIST of 900 Control Valve Assembly 1 K5B-REMOTE 113 Fitting, Hose End 3 51029 115 Hose (bulk) As Req d 50923 248 Gasket 1 K5B-547 343 Shuttle Valve 1 50277 701 Washer 4 71320964 702 Capscrew 4 71127054 703 Rivet 6 50915 704 Label, Constant Tension 1 26217 705 Gasket 1 26216 706 Cover 1 26215 707 Fitting, Elbow 2 54869 708 Fitting, Elbow 5 52803 709 Fitting, Elbow 6 54243 711 Capscrew 3 71319073 712 Handle Ball 1 71138051 713 Valve 1 71316434 714 Plug 2 71069017 715 Fitting, Elbow 1 51001 716 Spacer 3 14998-8B 717 Handle 1 26149 718 Hose (bulk) As Req d 51003 719 Fitting, Hose End 4 51002 725 Fitting, Bushing 1 51705 726 Fitting, Nipple 2 71308258 727 Fitting, Elbow 1 50928 728 Fitting, Nipple 2 50933 729 Manifold, Control Valve 1 25874 732 Union 1 71328330 733 Fitting, Nipple 1 71328314 734 Check Valve 1 71320915 735 Fitting, Nipple 1 71328249 736 Washer 4 71320956 737 Capscrew 4 71320949 738 Nut 3 71069132 739 Bracket 1 26095 741 Fitting, Nipple 1 71320907 742 Fitting, Elbow 1 26057 743 Regulator and Gauge * 1 71325047 744 Fitting, Connector 1 54943 745 Fitting, Tube Extension 1 71325591 746 Fitting, Elbow 1 71149975 946 Gasket 2 27115 949 Washer 4 51581 951 Capscrew 4 71328199 * s not sold separately. Form MHD56287 Edition 2 37
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 321 324. with 10 feet (3.05 metres) hose 19999-1S with 20 feet (6.1 metres) hose 19999-2S 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 24375 ACCESSORIES of Accessory Lubricant Accessory LUBRI-LINK-GREEN 38 Form MHD56287 Edition 2
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