Product Parts

Information
Model
FA5i-DCOKR
(Dwg. MHP2787)
Save These Instructions
Form MHD56334
Edition 1
October 2005
71468854
2005 Ingersoll-Rand Company
2 Form MHD56334 Edition 1
Only allow Ingersoll-Rand trained Service Technicians to perform maintenance on this winch. For additional information contact Ingersoll-Rand
factory or nearest Distributor.
Refer to Table for Product Safety, Information and Maintenance Manuals Form Numbers.
Manuals can be downloaded from www.winchandhoistsolutions.com
The use of other than genuine Ingersoll-Rand replacement parts may result safety hazards, decreased performance and increased maintenance and may invalidate all
warranties.
The original language of this manual is English.
Refer all communications to the nearest Ingersoll-Rand Office or Distributor.
TABLE OF CONTENTS
Description Page No. Dwg. Name Page No.
Parts Ordering Information............................................................................. 3
Drum, Base and Reduction Gear Assembly Drawing............................................. 4 (Dwg. MHP2670) ......................................................................................... 4
Drum, Base and Reduction Gear Assembly Parts List ........................................... 5
K5B Motor Assembly Drawing ......................................................................... 6 (Dwg. MHP2693) ......................................................................................... 6
K5B Motor Assembly Parts List........................................................................ 7
Disc Brake Assembly Drawing.......................................................................... 8 (Dwg. MHP2674) ......................................................................................... 8
Disc Brake Assembly Parts List........................................................................ 9
Drum Band Brake Assembly Drawing .............................................................. 10 (Dwg. MHP2790) ....................................................................................... 10
Drum Band Brake Assembly Parts List ............................................................ 11
K5C2 Control Valve (Optional) Assembly Drawing ............................................. 12 (Dwg. MHP2696) ....................................................................................... 12
K5C2 Control Valve (Optional) Assembly Parts List ........................................... 13
Drum Locking Pin (Optional) Assembly Drawing and Parts List ........................... 14 (Dwg. MHP2675) ....................................................................................... 14
Press Roller Assembly Drawing and Parts List .................................................. 15 (Dwg. MHP2695) ....................................................................................... 15
Winch Guard Assembly Drawing..................................................................... 16 (Dwg. MHP2676) ....................................................................................... 16
Winch Guard Parts List ................................................................................ 17
Warranty ................................................................................................... 19
Publication Part/Document Number Publication Part/Document Number
Product Safety Information (Non-Man Rider) MHD56250 Product Maintenance Information MHD56335
Product Information MHD56333
Form MHD56334 Edition 1 3
PARTS ORDERING INFORMATION
These winches 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 Number ____________________________________________________
Serial Number ____________________________________________________
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. Part 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.
Winches 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 winch is provided inside the back cover of this
manual.
Disposal
When the life of the winch 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
4 Form MHD56334 Edition 1
DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING
(Dwg. MHP2670)
Form MHD56334 Edition 1 5
DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
Item
No.
Description
of Part
Total
Qty
Part
Number
2 Oil Seal 1 51873 62 O Ring 4
Order Item 34
3 Lockwasher 10 50181 63 Ring Gear 1
4 Capscrew 10 52379 66 Sun Gear 1
5 O Ring 1 51459 67 Planetary Assembly 1
6 Motor Adapter 1 14227 69 Sun Gear 1
15 Seal Adapter 1 16354 70 Dowel Pin 4
33 O Ring 1 51460 71 Spacer 1
34 Reduction Gear Assembly * 1 18288 72 Ring Gear 1
35 Drive Shaft 1 28738 73 Cover 1
36 Retainer Ring 1 52298 74 Dowel Pin 4
37 Bearing 1 71458418 75 Capscrew 8
38 Retainer Ring 1 51872
80
Drum w/o Drum Lock
1
382-30858-3
39 Capscrew 8 52380 Drum with Drum Lock 382-30858-3L
40 Dowel Pin 2 52334 81 Wire Rope Anchor 5/8 inch (16 mm) 1 52306
41 Drum Shaft 1 14020 82 Siderail 2 382-30823-3
42 Upright, Inboard 1 382-30770-1 83 Lifting Lug 2 382-30773
43 Seal 1 51464
84
Upright, Outboard (w/o Drum Lock)
1
382-30771-3
45 Capscrew 12 52829 Upright, Outboard (with Drum Lock) 382-30771-1
46 Lockwasher 12 51012 85 Capscrew 8 50872
47 Gear Carrier 1 15418 86 Dowel Pin 14 71266670
48 Pipe Plug 2 51467 87 Bearing 1 71440002
49 Bearing 1 51455 88 Data (Name) Plate 1 Note 1
50 Retainer Ring 1 71018196 89 Screw, Drive 4 71028849
51 O Ring 2
Order Item 34
90 Capscrew 8 71316491
52 Dowel Pin 3 91 Washer 8 52915
53 Ring Gear 1 92 Bearing Retainer 1 382-30646
54 Planetary Assembly 1 93 Capscrew (no Disc Brake) 8 50910
55 Thrust Bearing 2 94 Capscrew 2 50964
56 Sun Gear 1 95 End Cover (w/o Limit Switch) 1 382-30830
57 Retainer Ring 1 96 Washer 4 71376370
58 Planetary Assembly 1 97 Capscrew 4 52160
59 Input Housing 1 98 Washer 8 50203
60 Capscrew 12 71068605 --- O Ring Kit (includes items 51 & 62) 1 27347
61 Plug 4 71068571
Recommended spare for one winch, 2 years of normal operation.
Note 1: Contact factory, model and serial number required.
* Reduction Gear Assembly includes items 51 - 53, 66, 67, 69, 70 - 75.
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) part number 382-30858-3 as part number 382-30858-3CH.
Certification Type Example Part Number To Order
ABS --- 382-30858-2CHA
DNV 382-30858-2CH ---
6 Form MHD56334 Edition 1
K5B MOTOR ASSEMBLY DRAWING
(Dwg. MHP2693)
Form MHD56334 Edition 1 7
K5B MOTOR ASSEMBLY PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
Item
No.
Description
of Part
Total
Qty
Part
Number
199
Motor Assembly 214 Pipe Plug 1 71263297
with Control Valve *
1
K5B-546M-S 216 Mounting Flange 1 K5B-502A
without Control Valve * K5B-546LM-S 217 Motor Housing 1 K5B-501A
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
93 Capscrew 5 51471 230 Oil Slinger 1 K5B-540
165 Reducer Bushing 1 71057459 231 Crank Assembly 1 K5B-A516
169 Pipe, Elbow 1 71057434 232 Sleeve 1 K5B-519
170 Muffler 1 50594 233 Connecting Rod Bushing 1 K5B-511
171 Pipe Nipple 1 51704 234 Connecting Rod Ring 2 K5B-510
200 Capscrew 20 71434260 235 Lock Pin 1 HU-520
201 Cylinder Head 5 K5B-H505 236 Cotter Pin 1 53456
202 Compression Ring 1 Set K5B546-KRING 237 Pin Nut 1 D02-394
203 Wrist Pin 5 HU-514A 240 Roll Pin 1 54257
204 Piston 5 *** 243 Gasket 2 K5B-928
205 Retainer Ring 10 902A45-632 244 O Ring 1 20A11CM248
206 Connecting Rod 5 K5B-509 246 Grease Fitting 1 53095
207 Oil Ring Order Item 202 247 Rotary Valve Housing 1 K5B-545
208 Cylinder Liner 5 K5B-L505-47 250 Rotary Valve Assembly 1 K5B-526EQ-RS
209 Head Gasket 1 Set K5B-507-5 251 Seal Ring Assembly 1 set K5B-607A
210 Vent Cap Assembly 1 26604 252 Bearing 1 50138
213 Eye Bolt 2 KU-888 253 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).
*** Parts not sold separately. Refer to K5B Motor Assembly Kit List.
K5B Motor Assembly Kit List:
Item
No.
Description
of Part
Total
Qty
Part
Number
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
8 Form MHD56334 Edition 1
DISC BRAKE ASSEMBLY DRAWING
(Dwg. MHP2674)
Form MHD56334 Edition 1 9
DISC BRAKE ASSEMBLY PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
Item
No.
Description
of Part
Total
Qty
Part
Number
7 Brake Shaft 1 10594 25 Fitting, Nipple 1 50859
8 Brake Reaction Plate 1 10597 26 Dump Valve 1 50276
9 Spring 15 50751 27 Fitting, Vented 1 20770
10 Brake 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 Brake 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 Brake 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.
*
Item not illustrated.

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 Brake Shaft item (7) part number 10594 as part number 10594CH.
Certification Type Example Part Number To Order
ABS --- 10594-2CHA
DNV 10594-2CH ---
10 Form MHD56334 Edition 1
DRUM BAND BRAKE ASSEMBLY DRAWING
(Dwg. MHP2790)
Form MHD56334 Edition 1 11
DRUM BAND BRAKE ASSEMBLY PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
80 Drum with band brake 1 Refer to Drum, Base
and Reduction Gear
Parts List on page 5.
82 Siderail 2
98 Washer 3 50203
101 Pin 2 382-31615
102 Cotter Pin 7 51996
103 Link Stud 1 4115
105 Brake Lever 1 21158
106 Pin 1 8609
107 Clevis 1 8586
108 Nut 1 50152
109 Breather 1 52384
110 Cylinder 1 8575
111 Fitting, Bushing 1 52006
112 Dump Valve 1 51954
113 Hose End 2 51029
114 Fitting, Elbow 1 54272
115 Hose (bulk) As Reqd 50923
117 Washer 5 51008
118 Bracket 1 11329
119 Capscrew 4 71128193
120 Nut 1 54661
121 Pin 3 382-31614
122 Pivot Bracket 1 10881
124 Brake Arm 1 382-31610
125 Connecting Link 1 10882
126 Stop Plate 1 10879
127 Screw, Adjusting 1 71033104
128 Brake Band 1 Set 382-31948
134 Pin 1 11497
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 Part Number To Order
ABS --- 10881CHA
DNV 10881CH ---
12 Form MHD56334 Edition 1
K5C2 CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING
(Dwg. MHP2696)
Form MHD56334 Edition 1 13
K5C2 CONTROL VALVE (OPTIONAL) ASSEMBLY PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
Item
No.
Description
of Part
Total
Qty
Part
Number
900 Control Valve Assembly 1 K5C2-LP 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
943
Reverse Valve Kit (Normal)**
1
27925-SX
905 Poppet Spring 1 71351068 Reverse Valve (Reverse Bias)** 28002
906 Poppet Cap 1 28734 Reverse Valve (Unbiased) ****
907 Poppet Seal 1 26991
944
Bushing (Normal)***
1
26686
909 Washer, Tablock 1 71398051 Bushing (Reverse Bias)*** 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
* Item 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: Item 922 not sold separately, includes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
Note 2: Item 939 not sold separately, includes items (1) each of 901 and 902, items 924, 925, 935, 937, 938 and 940.
K5C2-XLP and K5C2-EXLP Control Valve Service Kits
Item
No.
Kit Description
Total
Qty
Part
Number
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.
Items not illustrated.
14 Form MHD56334 Edition 1
DRUM LOCKING PIN (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST
(Dwg. MHP2675)
Item
No.
Description
of Part
Total
Qty
Part
Number
300 Drum Locking Assembly 1 382-30723
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 1 382-30706
Form MHD56334 Edition 1 15
PRESS ROLLER ASSEMBLY DRAWING AND PARTS LIST
(Dwg. MHP2695)
Item
No.
Description
of Part
Total
Qty
Part
Number
400 Press Roller Assembly 1 382-30961-3B
402 Roller 2 382-30966-3
403 Roller Shaft 1 382-30970-3B
404 Shaft Collar 2 71443980
405 Spring, Left Side 1 382-30968
406 Spring, Right Side 1 382-30969
407 Arm 1 382-31263-3
408 Capscrew 4 71371652
409 Washer 4 51009
410 Bushing 4 71443816
16 Form MHD56334 Edition 1
WINCH GUARD ASSEMBLY DRAWING
(Dwg. MHP2676)
Form MHD56334 Edition 1 17
WINCH GUARD PARTS LIST
Item
No.
Description
of Part
Total
Qty
Part
Number
---
Winch Guard Assembly w/o Drum Lock
1
382-31017-3AB
Winch Guard Assembly with Drum Lock 382-31017-3ABL
801
Frame w/o Drum Lock
2 382-30774
802 1 382-30953
801
Frame with Drum Lock
1 382-30774
1 382-30774-1
802 2 382-30953
805
Panel w/o Drum Lock 7 382-31011-3B
Panel with Drum Lock 7 382-31011-3B
806 Crossbar 9 382-30982-3B
804 Locknut 18 71445415
96 Washer 12 71376370
809 Capscrew 12 71445407
18 Form MHD56334 Edition 1
SERVICE NOTES
Form MHD56334 Edition 1 19
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-Rs 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 carriers agent immediately.
DAMAGE CLAIMS
You must file claims for damage with the carrier. It is the transportation companys
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.
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