03523966 SERIES K4U, K4UL, KSU AND KS5UL UTILITY® WINCHES WARNING These Winches are not to be used for lifting or lowering people Always operate and maintain this Winch in accordance with American National Standards Institute Safety Code (ANSI B30.7) and any other applicable safety codes and regulations. FOR TOP PERFORMANCE AND MAXIMUM DURABILITY OF PARTS, OPERATE THIS WINCH AT 90 psig (6.2 bar/620 kPs) AIR PRESSURE WITH 1-1/2” (38 mm) DIAMETER HOSE. OPERATING PRACTICES The two most important aspects of Winch operation are: (1) Allow only qualified people to operate « Winch and (2) Subject each Winch to a regular inspection and maintenance procedure. ‘A qualified operator must be physically competent. He must have no health condition which might affect his ability to react, and he must have good hearing, vision and depth perception. The qualified Winch ‘operator must be carefully instructed in his duties and must understand the operation of the Winch, includ. ing a study of the manufacturers literature, He must thoroughly understand proper methods of hitching, loads, He should have a good attitude regarding safety and should refuse to operate under unsafe cond tions. Regular inspection procedures should be set up, rigidly adhered to and recorded by or under direction of 4 quilified person, On Winches in continuous service, inspection should be made at the beginning of each shift. The items to be checked include, but are not limited to: a. LUBRICATION: See lubrication instructions on Page 3, b, BRAKES: Visually check for proper adjustment. Lift a capacity or near capacity load a few inches off the floor and check ability of braking system to stop and hold the load without excessive drift ¢. WIRE ROPE AND HOOKS: Visually inspect the wire rope. Replace it AT ONCE if there is indication of fraying, or if it is crushed, cut or otherwise damaged. Follow cable manufacturer's recommended practice for proper use and inspection of wite rope. Hooks should be checked for wear, increase in throat opening, and bending. 4. CONTROLS: See that controls function properly and return to neutral when released, e. GENERAL: Check to see that mounting fastenings are secure, unworn and undamaged. Be alert for un- usual visual or audible signs which could indicate a defect. Do not operate the Winch until the defect has been determined and corrected. Periodically, depending on the severity of the service: Inspect Brake and Locking Dog components for wear or damage. b. Check all bolts or fasteners , Inspect the Winch structure for damage. Notice: The use of other than genuine Ingersoll-Rand replacement parts may result in decreased tool performance and increased maintenance, and may, at the Company's option, invalidate all warranties Refer All Communications to the Nearest INGERSOLL-RAND. Ingersoll-Rand Office or Distributor. Pace cone AIR HOISTS & WINCHES Form P5893 Edition 6 March, 1981 Onan Zaesnerraw21 23. 24. 26. 2 28. 29 30. 31 32, OPERATING INSTRUCTIONS, Read the manufacturer's instructions before operating the Winch, Never lift a oad greater than the rated capacity of the Winch. Never use the Winch rope as a sling. Always stand clear of the load Never use the Winch for lifting or lowering people, and never stand on a suspended load Never carry Toads over people. Before each shift, check the Winch for wear or damage. Check brakes, locking dog, ete Periodically inspect the Winch thoroughly and replace worn or damaged parts. Follow the lubrication instructions. Do not disengage clutch with a load on the Winch. Be sure clutch is fully engaged before operating Winch, Do not “side pull” or * Always rig the Winch properly and carefully. Never operate a Winch with twisted, kinked or damaged wire rope. Be sure cable winds properly on deur, Ease the slack out of the wire rope and sling when starting a lift. Do not jerk the load. Be certain there are no objects in the way of a load or hook when operating the Winch, Be certain the air supply is shut off before performing maintenance work on the Winch, Shut off air supply while Winch is unattended, Properly secure the Winch before leaving it unattended. [Be certain the load is properly seated in the saddle of the hook. Do not tipload the hook as this leads to spreading and eventual failure of the hook, Do not allow unqualified personnel to operate a Winch. Do not swing a suspended load. Do not operate a Winch if' you are not physically fit to do so Do not do anything you believe may be unsafe. Do not use the Winch rope as a ground for welding, Do not attach a welding electrode to a Winch or sting chain. Do not divert your attention from the load while operating a Winch, Engage locking dog before leaving load suspended. Do not engage locking dog while drum isin operation, Do not leave a load suspended for any extended period—never unattended. Never splice a sling chain by inserting a bolt between links. Do not force a chain or hook into place by hammering. Do not insert the point of the hook into a chain link. Do not expose the sling chain to freezing temperatures, and do not apply sudden loads to a cold chain.LUBRICATION ‘Warning: Lubricate the motor before using the Winch. To avoid leakage during shipment, the oll was drained from the mo: tor. A quantity of oil sufficient for one filling is contained in the can packed with the Winch. Before using the Winch, make sure the Drain Plugs (2) are screwed securely into place, then unscrew the Vent Cap (4) and pour the entire contents of the can into the opening in the top of the Motor Case (1). Motor Lubrication ‘Check oil daily and maintain level with opening in the side of the Motor Case When the Winch is subjected to temperatures above freezing: After the Winch has been idle for several hours or overnight, loosen the Drain Plug (2) located at the bottom of the Motor Case (1) and allow the accumulated water to drain out. After draining the water, tighten the Plug in the bottom and remove the Plug (2) on the side of the Motor Case. Unserew the Vent Cap (4) and pour a sufficient quantity of the recommended oil through this opening to bring the oil evel, within the Motor Case, up to the side opening. Replace the Plug and Vent Cap. When the Winch is subjected to freezing temperatures: Allow the Winch to remain idle long enough for the water content in the Motor Case (1) to separate from the oil, but not long enough for it to freeze, Drain the water and replenish the oil as above. Should this procedure be impractical, drain the entire contents of the Motor Case immediately after operation ceases. and pour the oil back into the Motor Case before resuming operation. If not drained, a sufficient quantity of water will even: tually accumulate so that the Oi Splasher (37), which is attached to the Crank (36) will freeze fas. For temperatures 30° to 80° F (-1° C to 26° C), use Ingersoll-Rand Pneu-Lube® Medium Oil No. 50 or SAE 20 or 20W motor oil, For temperatures below 30° F (-1° C), use SAE 10 oF LOW motor oil. For temperatures above 80° F (26° C), use SAE 30 motor oil. Throttle Valve Lubrication Weekly, insert a small quantity of Ingersoll-Rand Light Grease No. 28 or a good quality No. 2 cup grease into the Grease Fittings (14) located in the Valve Chest (10). Two or three strokes from the No. P25-228 Grease Gun is ample for each Fitting, Gearing Lubrication Every sixty to ninety days, remove the Grease Plug (108) from the Gear Case (84) and note if the visible portion of the ‘gears is coated with grease. If the gears appear to lack lubrication, add about 1/2 pound (.23 ke) of the recommended grease. When reassembling a Winch, three pounds (1.4 kg) of grease are required. Use Ingersoll-Rand Heavy Gear Grease No. 70. As a substitute, Ingersoll-Rand Light Grease No, 28 or a good quality No. 2 ‘cup grease may be used. For extremely low temperatures, Ingersoll-Rand Medium Gear Grease No. 75, low temperature grease ora heavy gear oil may be used. Note: Leakage will probably be experienced if heavy gear oil is used for normal temperatures, Lubricate the Drum Gear occasionally by pushing @ piece of hard stick or block grease 3/4" to 1” (19 mm to 25 mm) long through the hole above the Drum Shaft Long Set Screw (75). ‘An Air Line Lubricator is recommended for use with Utility Winch, It will improve the efficiency of the Winch and pro long the life of the motor.HOSE AND HOSE CONNECTIONS Use 1-1/2" (38 mm) hose with a suitable hose fitting for attaching it to the inlet. Use of smaller hose and fittings will re duce the efficiency of the Winch. MOUNTING Mount the Winch so that the axis of the Rope Drum (67) is horizontal. Operation of the Winch with the axis of the Drumm ‘more than 10° from horizontal will result ia lubrication difficulties and the Wire Rope will tend to pile up on the low end of the Drum, On all d-cylinder Winches, the Motor Cas (1) can be rotated on the Motor Mounting Bracket (66) to any one of eight di ferent postions. When Winch is shipped from the factory, the Motor Case is positioned for operation when the Winch is ‘mounted upright on its base. Therefore, the Motor Case must be repositioned if the Winch is to be mounted with the Vent Cap (4) more than 25° off top vertical center. To change the postion of the Motor Case: Lain the wil 2 Unscrew the eight Motor Case Screws (57) 3. Rotate the Motor Case to bring the Vent Cap as near top vertical center as possible. 4. Replace the Cap Screws. 5. Fillwith oil (On Model KSUL or KSU, the Motor Case (1) can be rotated on the Motor Mounting Bracket (66) to any one of five differ end positions. When a Winch is shipped from the factory, the Motor Case is positioned for operation when the Winch is ‘mounted upright on its base. Therefore, the Motor Case must be repositioned if the Winch is to be mounted withthe Drain Plug 2) more than 25° off bottom vertical center. To change the position of the Motor Case: 1. Drain the oil 2. Unscrew the Motor Case Screws (57). 3. Rotate the Motor Case to being the Drain Plug as near bottom vertical center as possible, 4. Replace the Cap Screws. 5. Fill with oi ‘Tho Winch should not be operated with one of the Cylinders at bottom vertical centerMAINTENANCE Apply the Wire Rope to wind on the Rope Drum in the direction indicated by the instruction plate on the Winch, ‘Adjust the brake so that considerable pressure is required to push the Brake Handle (126) past center for locking, Make adjustment by removing the Brake Shoe Long Pin (131) and rotating the Brake Adjusting Screw (130) Remove the Throttle Valve Spring (21), Poppet Throttle Valve (20) and Throttle Valve Ball (22) from the Valve Chest (10) before attempting to withdraw the Reverse Valve (24) from the Reverse Valve Bushing (13). ‘The following procedure is recommended when replacement of the Rotary Valve Bushing (12) or Reverse Valve Bushing (13) is necessary: 1. Unserew the Valve Chest Screws (18) and remove the Valve Chest Cover (17). 2. Screw 3 No. HU-932 Jack Bolt into each tapped lug on the Valve Chest (10) until the Jack Bolts contact the Motor Case (1). Turn each Bolt alittle at a time to jack the Chest with assembled parts from the Motor Case 3. Unscrew the Throttle Valve Cap (23) and remove the Spring (21), Poppet Throttle Valve (20) and Ball (22) from the Valve Chest (10). 4. Withdraw the Rotary Valve (25) and Reverse Valve (24), and remove the Throttle Lever Spring (35) 5. Support the face of the Valve Chest (10) that contacts the Motor Case (1), and press out the old Bushings with an arbor that will clear the Bushing Keys (11). Caution: Failure to use an atbor that will clear the Bushing Keys, or pressing the Bushings inthe opposite direction than instructed, will destroy the Keys 6. Support the face of the Valve Chest (10) that contacts the Valve Chest Cover (17):align the keystot in the new Reverse Valve Bushing with the Bushing Key (11), and press the Bushing into the Chest until the leading face ofthe Bushing is flush with the supported face of the Chest. Align the Keyslot in the new Rotary Valve Bushing with the Bushing Key and press the Bushing into the Chest until the bushing shoulder is fash with the supported face of the Chest, 7. Insert the No, 23470 Throttle Valve Stem Reamer or a 50S" (12.8 mm) hand reamer through the throttle valve cham- ber in the Valve Chest and ream the hole through the wall of the new Reverse Valve Bushing. 8. Check the fit of the Rotary Valve (25) in the new Rotary Valve Bushing. Ifthe Valve is tighter than a good running fit in the Bushing, lap in the Valve, using a fine grain lapping compound whose abrasive agent will break up rapidly. Re: move all trae of the compound after obtaining the desired fit 9. Check the fit of the Reverse Valve (24) in the new Reverse Valve Bushing, If the fit is too tight, ream the Bushing 1.875” (47.625 mm). Caution: The Reverse Valve is chromo-plated; do not lap. 10. Rotate the Reverse Valve in the Reverse Valve Bushing until the arrows on the two parts align, and install the Throttle Valve Ball, Poppet Throttle Valve, Spring and Cap. 11, Install the Throttle Lever Spring (35) and Throttle Control Arm (28). 12. Align the holes through the Valve Chest (10) with those in the face of the Motor Case (1) and squarely start the pro- truding end of the Rotary Valve Bushing into the Case, Place a hardwood block on the chest face and press or drive in the Bushing until the Valve Chest contacts the Motor Case. ‘The two sections of the Crank (36) are matched before final machining, and the web of each section is stamped with an identification mark as AAI7, C21, XX19, ete. Only sections bearing identical marking can be used together. If mote than ‘one Crank is disassembled at one time, be sure only matched parts are assembled together Slide the Crank Pin Sleeve (39), plain end first, onto the eranic pin when assembling the Crank (36). Install the Connecting Rod Rings (44) so that the internally beveled ends are toward the Connecting Rods (43) when as sembling the Crank (36).138 105; 10 134) 106. 130 SECTION THRU VENT CAP 126 123, 124 MOTOR CASE END VIEW 96 1 Ho on 120 6 —i39 138 9a. 137 WH 136 or ef ema 2 SEC. AA (Dwg. TPA254-2) ‘Model K4U Utility Winch (Typical of Model KUL)MOTOR PARTS. PART NUMBER FOR ORDERING a) PART NUMBER FOR ORDERING 7 1 Jatotor case 35 |Throtte Lever Spring. - : Kuta foe KAU or KAUL. G KU-so1 (Crank Assembly for KSU of KSUL, 5 SMSO} for KAU or KAUL. Ku-asi6 2 | Drain Pug @) 02-402 for kSU or KSUL. KSM-ASIS| * | Motcr Eyebolt Q for KSU or KSUL; 1 for other). | KU-888 36 | Crank Baro (onssts of matched parts which are + | re” Pipe Plog (for KSU or KSUL). . ESUb-947 not sold sepamtely)- Ku-sao 4 |vent Cap ‘ 02303, 37 Oil Splasher D] Kuso 5 | SHook 02-421 35 Oil Splshor Long Rivet (2) KUSH 6 | Vent cap Chain DIIIL | pozest . Oil Spsher Short Rivet 2) KUSsa2 7 | Vent Cap Sereen » 02-889 9 ‘Crank Pin Sleeve KUSI9 8 | Vent Cap Screen Retainer S6CND-233.1/2 oo Crank Lock Pin Ku520 9 | Vent Cap Cater Do. | pone9s a ‘Crank Lock Pin Nut 02-317 410 [vate chest 2 rank Lock Pin Cotter 20212011227] o2-330 for KAU of KAUL, KUsasa 943 | connecting Rod for KSU or KSUL. ce KKSUMSas {for KAU or KAUL (4) KU-s09 + 11 | Bushing Key 0) D) HUs38: for kSU or KSULIS), KSn-309 412 | Rotary Vale Bushing 44° | Connecting Rod Ring (2) EIT] kusie for KAU oF KAUL. vee Ku-s2ss 245 | Connecting Rod Bushing. 2) kus {or KSU or KSUL. K5ws2ss, 946 | Crank Valve End Bearing. KUSIs 1 Reverse Valve Bushing KU94SS 047 | Cranepin End Bearing KU-95 ' Grease Fitting (2). ao 23-188 lcytinder assembly (5 for KSU or KSUL! 4 for t Throttle Lever Spring Stop Pin SII.) pons Jother). see KU-ASOSA i Brake Init Plug (2) 02-402 48 | Cylinder Hose Ba60 KUHSOSA i Valve Chest Cover KU-s46a, 48a | Cylinder Slee KULSDSA } 18 Vale Chest Screw (4) KUSA8 49° piston Assembly (S for KSU or KSUL:4 for 419/12" Lock Washer (4) 10322 others KSW-ASI3A, 420 [Poppet Throttle Vale er) Piston Ring (foreach Pision) Kuss? 0} 21 poppet Throttle Vale Spring. > 2] Husa (Oil Rogulatne Ring (1 For each Piston) =| KU238 + 22. |Poppet Throttle Vale Ball. : Dio-260 Wrist Pin Retaining Ring (2 for each Pistoa. TLA902A9-589 {23 [Poppet Throttle Valve Cap Kuss piston Wrist Pin(S for KSU or KSUL;4 for others) KSw-si¢ 424 [Revere Vabe Cylinder Gasket(S for KSU oF KSUL:4 for others)... | KU-S07 Tor Winch with standard brake Kus4e [Cinder Cap Sevew (4 foreach Cylinder)... 215-13 for Winch with automat brake. KUT |Cyliner Cap Screw Washer (8 for each Cylinder) Kusos 425 | Rory Vane IMotor Case Gasket Tor overwinding Winch KU-s26a forkAUorKAUlLs oe. . cc eee eee | RUS92 for underwinding Winch KU-S26RA forKSUor KSUL | LL] Ksmso2 21 26 | Large Vane Dive Pin KUS27 51 |etotor Case Semw (10 for KSU or KSUL; 8 tor 04027 | Small Valve Drive Pin (2) a US? others. 21536 + 28 [rote Control Arm : KUSSSA 58 {5/8 Lock Washer (10 for KSU or KSUL; 8 for $29. |! "Throttle Lever Spring Stop Pin 02-553 others. ast 930 Thyotte Lever HUSS6 + PMotor Nimepiat Ksw99 31 | Throte Lever Lateh Ll | Hues) + [Nameplate Serov ca), R&K-302 932. | Throttle Lever Lateh Spring HU-s67 + [Winch Nameplate. SLI] pusor 33. | Throttle Lever Set Serew. usa? + [Nameplate Stew cd, : TI] RaK-302 34 [throttle Lever Pin HUT + [eeution Piste TAAISTA # _}iworte Lever Pin Cotter (2) 902-524 + [caution Pate Saew (4) RAK 302 + Not itustrace. + For Valve Chest (10) with Poppet-Type Throttle Valve (20), used beginning serial 7000 and illystrated inthe sectional views. Prts fr the superseded Valve Chest with taperpus ¢yp= ‘Throttle Vale that was used under sera 7000 are no longer avalable. When gny parti tequired Tor the superseded Vale Chest, order the sted Valve Chest Assembly. It can be used 98 4 replacement forthe asembly with taper ple type Valve, provided a new Throttle Control Arm (28) is also used 4@- To heep downtime to.a minimum, tte desiable to have on hand certain repair pasts. We recommend that you stock one (pair or set) ofeach past indicated by a bullet (for every {our tools in serviceBASE, ROPE DRUM AND GEAR PARTS PART NUMBER FOR ORDERING 7 for KAU of KSU. coven KAU-S64A, for KAUL oF KSUL, K4UL-S64a, 65 | Motor Mounting Bracket Kavs02 67 [Rope Drum Jor KAU or KSU. dbobocopeccans ksuaad for KAUL of KSUL. 5 7 KsuLa24 68 | Wire Rope Set Serew (2). . 215-140 69 {Drum shat, for KAU or KSU, Kav-4s9 for KAUL or SUL. - Sroosesnncopdn KauL-459 + {Drum shaft Oi Seal 2) . kauLa7t 70 | Deum Packing. : Dt 207-136 oon Drum Bening) iva €W59212 or aout) 40-456 73. | Drum Bearing Plate (4) Secugcabocaond KaU-469 14 [Drum Shate Short Set Screw | a0 HUS67 18 |Drum Shaft Long Set Screw HU-868 16 [Motor Shat for K4U or KSU, Kau-si6c for KAUL of KSUL es < | KauLstec 17 | Motor Pinion Key. o-oo. eee n EEG-768 78 [Motor Shaft Pinion. ca ST K4U-3198 © 79 [Motor Shat Bearing K4U-S898, + | Motor shaft Bearing Seal nt RIOV-310 ‘30 [Intermediate Gear SI K4U-364 ‘81 [Intermediate Gear Bushing Kau 363 82 | Intermediate Gear Bushing Retainer Kav-362 83 [Fier Washer Kaun 84 [Gear Case : a0 : | Kavss3a 85 [Gear Cate Sew 10) aco 215-148 85 | Lock Washer (10) : SIT] piosaz 87 [Gear Cover : : k4U352 88 | “Greate Fitting : 23.188 89 Drive Shatt Kau-358 90 | Cluten Jaw Lock fal uo : Go01-65 dt | Ciuteh Jaw Lock Spring K4U.863 92 | Cluten Jaw Lock Plug co HU-864 © 93 [Drive Shaft loner Bearing a 2325-41 © 54 [Drive Shalt Outer Bearing. 21563 9s |ctutch Jaw - : LL] kau-ses 96 [Clutch Eecentle Shaft... : sc] Hust 97 | Clutch Fecemtie Roller a : HUBS 98 | Cluteh Fecentre Pin HU-859 99 | Recentric Pin Lock Screw HU860 100 HUs6s 101 a HUS66 102 [Latch Spring ll] user ; 103 |ctutch Lever Pin DE HUS6I od | Recentie Shaft Lock Serew SS Huss 10S |ase Bolt (3/4"-10 thd. 3-1/2" lone (8). Kaus ' 105 | Bae Bolt Nut). Ly) pussea’ 107 | Base Bott Lock Nut Washer (8) oe Do1-692 108 |Grease Plug 2) 228R-165 109 |3/8" Lock Washer DS Dor-321 110 [Drive Shaft Nut qpobedae SOL) ansr3 111 [Drive Shaft Nut Look «> 5 S| asa 112 [Drum Bearing Retainer (2) E Kau-340 + [Grease Gun ano5q00 Si] pes228 + |Wire Rope Set Serew Wrench. Ka + [Valve Chest Jack Bolt (2 required)... eee muss + [Piston Ring Compressor Bqocnsaoag KU933 + [Throttle Valve Stem Reamer os : uo fi} B70 + [throttle Vale Seat Reamer banoncae 25670 = Not ilustrated © To keep downtime to a minimum, tis desirable to have on hand cert each part indicated by a bullet (® for evry four tools in service in repair parts. We recommend that you stock one (pair or set) ofBRAKE PARTS. PART NUMBER FOR ORDERING Kau Ksu aut, SUL Brake Band Assembly Kauais2 KSU-ALS2A ers | Brake Band Kav-is2 116 Brake Lining. a Kavss ny ‘Brake Lining Short Rivet (16). Kav-is6 118 Brake Lining Long Rivet (17). : 23598 ng Bake Support Spring Bracke. KaUAGIA KSU-IIA 120 Spring Bracket Rivet (2) q 17183 07-133) 120 Brake Shoe Rivet (13) 107153, 107-183 e121 | Brake Shoe kav-ias Ksu-145 2 ‘Brake Shoe Rivet (9) 107-153 Ku-s42 ne Brake Lining Long Rivet (12). 23598 23598 123 | Brake Lever Bracket : ct Kavass KsU-193 124 ‘Brake Lover Bracket Rivet (8). 107-153 107.153, 1s Brake Lining Long Rivet (5). - oo sc] 23598 23898 9125 {brake Handte 107-181 107-131 127 | Brake Handle Pin 5 oe 107-149 128 Brake Handte Pin Cotter Q) 107-146 129 [Brake Yoke 5 ‘i 107-159 130 [rake Adjusting Screw, : : 107158 107-158 131 [Brake Shoe Long Pia 107-147 10747 132, [Brake Shoe Pin Cotter (2). i 02-330 02-330 133 [Brake Anchor : : K4U-206 Kav.2n 134 [Brake Anchor Nut ot HU-776 HU-776 135 [Brake Anchor Lock Washer Ast Ast 136 [Brake Support Screw Kav-162 Kau-62 137 [Brake Support Serew Jam Nut sbobdno0sauoodeoue ors Gri 138 [Brake Support Screw Washer Kau383 Ksuse3 139 [Brake Suppore Spring 60 TO3119 703119 140 Brake Lever Bracket Pins a LL] orgs 107-48 [Bracket Pin Cott 1046 107-146 Nor illustrated © To keep downtime to a minimum, itis desirable to have on hand certain repair parts We recommend that you stock ope (pair ost) oF cach part indicated by a bullet (® fr every four tools in service. WARNING DISENGAGING CLUTCH PARTS For reasons of safety, itis emphatically recommended that Automatic Brake and Disengaging Clutch features not be used con any Winch used for hoisting or otherwise subjected to an overhauling load. If for any reason the Disengaging Clutch is left ‘operative in a Winch used under either of the above conditions, it isthe responsibility of the user to make provision to pre- vent accidental operation of the Winch motor withthe clutch disengased. Operation of the motor withthe clutch disengaged ‘while holding a suspended load will allow the load to drop. Because the combination of Automatic Brake and Disengaging Clutch is not sanctioned, the three parts marked “#* should bee ordered and installed if conversion from manusl to automatic brake is made on aWinch equipped with the engaging clutch Use the parts as follows: Install the Clutch Jaw Spacer (251) between the Drive Shaft Outer Bearing (94) and the Clutch Jaw (95) on the Drive Shaft (89) to lock the Clutch Jaw in engagement with the Intermediate Geas (80). Remove the Clutch Eccentric Shaft (96) and included parts along with the Clutch Lever (100). Insert the Gear Cover Plug Seal 253) and Plug (252) into the hole in the Gear Cover (87) previously occupied by the Becentric ShaREMOTE CONTROL PARTS Remote Control Block Assembly Remote Control Valve Chest Assembly (wg, TPO201) (Dwg. TPD 206) PART NUMBER FOR ORDERING 7 Remote Control Block Assembly {or Winch with Standard Brake KU-AGSS for Wineh with Automatic Brake KU-B68S 200 | Remote Contia! Block KU-685 201 53/8" Lock Washer (2) o2321 202 Contyol Arm Retainer Screw (2) HU-865 203, Control Arm Retainer : HU-687 204 | Conto! Block Valve Chest KU-BT6A, 20s Bushing Key. HUS38 * Brake Inlet Plug 02-402 206 ‘Throttle Lever Spring Stop Pin g2-ss3 208 Control Block Reverse Valve Bushing KUs4s ‘ Grease Fitting 2). 23188 209 | Conttol Block Reverse Vale for Winch with Standard Brake Kusas for Winch with Automatic Brake Kurs Control Block Throttle Lever Spring Kua Control Block Throttle Arm KUsS5a Throttle Lever Spring Stop Pin 02-553 Control Block Throttle Valve Cap KU943, Control Block Throttle Valve Spring HU942 ‘Control Block Poppet Throttle Valve, Ku9a0 Conti Block Throttle Valve Bal Dio-280 KUS@5A, HUSS6 “Throttle Lever Latch HU-569 Lateh Spring. HU-567 ‘Throttle Lover Set Sere. HU-862 ‘Throttle Lever Pin HUS70 ‘Throttle Lever Pin Cotter (2) poas2 Remote Control Valve Chest, for KAU of KAUL, kxss5 Tot KSU or KSUL. KsMsas 231 | Rotary Valve Bushing Tor KaU or KAUL. Ku-s2ss for KSU or KSUL. KSMS255 232 | Bushing Key : HUS38 233 |Rotary Valve for overwinding Winch KUss26a for underwinding Winch - KU-526RA 234 | Lange Valve Drive Pin. KUs27 235 | Small Vale Drive Pin (2) HUS27 236 [Remote Control Vale Chest Cover KXS46 + |Walve Chest Serew (4). KU-Saa + [1/2 Lock Washer (4) 10-322AUTOMATIC BRAKE PARTS 268, aes | ase - lars age \ \ 253 ase | 4 oe \ : ST it . aN 267 aie 288 ee (Dwg, TPA742-1) PART NUMBER FOR ORDERING 7 $251 [Clutch Jaw Spacer Kaur? $252 [Gear Cover Plug HU-728 $253, [Gear Cover Plug Seat. HU-730 © 254 [Brake Cylinder Assembly HU-7208 255 Brake Cylinder Yoke HU-719 * Brake Cylinder Bushing HUTT 2560 Eye Bracket HU-717 2568 Street Elbow. Hus912 257 | Brake Cylinder Bracket : Kau-721 258 {Brake Cylinder Bracket Cap Screw (2). HU-723 259 [Brake Cylinder Bracket Pin : HU-870 260, racket Pin Cotter (2) Do2-s24 261 rake Spring (2) KAUI26 262 |Yoke Pin 22720 263 | Yoke Pin Cotter 02-330 264 | Automatic Brake Lever K4U718 265 | Brake Pipe for KAU or KSU. kau-401 for KAUL or KSUL. KAUL-401 266 | Brake Pipe Elbow (2) K4U-400 2 267 [Brake Pipe Strap (2). HU-727 268 trap Serew (2). 4316 4 269 ‘Lock Washer (2) 101-67 ° 272 Lock Washer 10-322 273 | Automatic Brake Reverse Valve KU-746 ce Reverse Valve O-ring RIg3i 274 | Motor Mounting Bracket... : K4U-s02 2 Brake Cylinder Bracket Bolt (3/4"-10 thd. x 4" Long). K6u-75 + Not ilstated. ‘To keep downtime to a minimum, itis desirable to have on hand certain rep each par indicated by a bullet (® fr every four tools in service. Refer paragraph 2 of DISENGAGING CLUTCH PARTS on Page 9. " parts. We recommend that you stock one (pur or set) ofBRAKE EXHAUST VALVE PARTS «\ i [ ah es (Owg. TPD214-1) PART NUMBER FOR ORDERING 7 [Brake Exnaust Vane Aveombiy es KavATSS any | Brake Exhaust Vane HUTS 281 ‘Exhaust Vale Elbow Hu-74s 382 | brake AirStainer Asembiy. ROBD-ASES 283 | Brake Connection Keuait a 1/4" Pipe Pu | o2-402 as | Once Pug } wors2 286 | Exhaust Vate Pipe | suai 287 | Extaust Vale Cap Sccw (2) | Rssia7s ase | 5/16" Lock Washer 2). + | tits 1266 | BukePipeebow.. oss xav-400 F tuwrated on Page 1 a (Ow. Tec112) PART NUMBER FOR ORDERING 7 300 [Putt Chain Tartu Laver 5650 HUSS9 301 [Throttle Chsin Bolt 2)» : por3i2 302 {Mitte Cain Bott Nut). = : : Sy ozs 303 | 3/8" Look Washer 2) 02321 308 —_|3/8" Pain Waster) — oe : Do2-419 305 [Throe Leer Cotter 215.124 305 Thzotue Lever Chain (2) Genathas speci) «= SE puis 307 |sHook a) Dor-221 308 [Thnotde male) v2 oes wt MRIS 2AIR STRAINER, PART NUMBER FOR ORDERING 7 400 [Air Strainer Asembly KAU-A267AT gor | AieStaine Seren Kau-siaT 403, | ie Stainer Pus 225R-165, 408 | Air Strainer Cop. Kau2esar + (air Stainer Nipple lier x 2/2, KKM-286 * Notitustrated. (Dwg. TPD122-1) WIRE ROPE AND FITTINGS 423 4238 422. 42i 420-—— (ws, TC146-2), PART NUMBER FOR ORDERING ~ | For Use With For Use With For Use With For Use With 378" Oi, We" Oi 9116" Dia 5/8" Dia, Wire Rope Wire Rope Wire Rope we 420 |wice Rope specify length) rus nissan xauar2 23872 Wire Rope Fitting Assay EU-AS6O1 KaUeasoory2 | KAU-AS6019/16 | KAU-ASGOL-S/8 421, | Wire Rope Clamp (3). DOt68 20-375 20375 235.378 422 | Rope Thimble pio721 215-602 Kav-602 Kavio2 423. | swivel Hook pores377 Kavseot KsuS601 405601 423a | Hook Latch Kit individual alts not sold separately) or-sdoss o2s40ss a — Hook Block Asiembly DO2-ASASSA Og ASK634 eee Bee 424 | Hook Block 02-4634 DO+463A = ess 25 Hook 02-8377 088377 | 4358 Hook Lateh Kit o2si23 o#s123, : a 4258 | Hook Nut 023058 HRAGOA305 : 46 Hook Bearing 023794 DOs379A —— - an Roll Pin 200041330 orst8 BS ae 48 Wire Rope Clamp Dotea 20.375 ae es 49 Wire Rope Wedge 02373 02373 13DRUM GUARDS rt crew sermon ate {S'stome To necouuonaTe INE Fore te ya ug Ea (Dwg. TPBSES) PART NUMBER FOR ORDERING 7. 600 [Drum Guana = for KAU or KSU, . 6 Kav.298 for KAUL or KSUL. : KsuL298 601 5/811 thd. Nut). SI a Kous 602 Plated) oven : K6v.299 MUFFLER PART NUMBER FOR ORDERING 7 Mutfier KU-674 ; 4 Muffler Nipple. KKBE-256 + _Redueing Coupling HU-677 1 + Not required except when Winch is equipped for Remote Contra 4Rese, “bar. ae Shs setae 7 ower Too! Division SETI inane comnts tansy aie ore ene co tome Noe Meee pee — PERCE: orrag HOSE SP Aes opts Sa ‘test Sons pay x TRE MER aw paris warms “Eee, “Ew aimee. EN sonmags tre Ong ton 8g “Hichee,., “SEEE, Sep tert ater arr Sar Pa eter TSAR as rate aritnne we Teac nn oee ptnin, Boones hiss Tt Meine Cras 2412, Cara Cra “Treat tan Non tt Aca ag, eden, 314 700 owner Hevse, Reighmbr ge ‘pei 4128 nn and on 8 Reteewteshree $18:215/2/5 ren oreeny, tae tatoaee, Trowltang Sind Com. Ponto a6 CBee 31 ree peau 2Es cee, ted x3k09 ARETE a Testes ‘Picea Crd teaser cer ae nice Ms cepee tn at Seesoes vi te eae oa sete Semin Rea Kenna, Nai na SBA iia = ae “em “ppathts o Bers Tryeornd Sowin NV. 8 "ton 33 Zotomuce Meta Rand AB PB Box 14 Sera: Tartan co ot Pen 5 ‘etipia, Mata Rat 3177 apg Southam ae Pm Sin gear tangs SA, Prepay) ‘ede ast Seta Medes i nl Rand, SA ‘outs 518 Sedan, Bran Teed a0 ea Aien Trl Sede Veranale SA ‘barsde 10508 or sew. ruts pcp! esp wel Cane mrt ge eden ha ood SET TT 2 Ta ingen nr, Won aa Hw my AUTHORIZED I-R SALES AND SERVICE INGERSOLL-RAND