03533882

Form P6728
Edition 1
May, 1984

OPERATION AND MAINTENANCE MANUAL

for
SERIES K4U, K4UL, K5U AND KSUL
UTILITY® WINCHES

WARNING
These Winches are not to be used
for lifting or lowering people

Always operate, inspect and maintain this Winch in accordance with American
National Standards Institute Safety Code (ANSI B30.7) and any other applicable
safety codes and regulations

Refer All Communications to the Nearest

Ingersoll-Rant-l Office or Distributor.
© Ingersoll-Rand Company 1984
Printed in U.S.A. AIR WINCHES
 FOR TOP PERFORMANCE AND MAXIMUM DURA-
BILITY OF PARTS, OPERATE THIS WINCH AT 90 psig
(6.2 bar/620 kPa) 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 a 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, including a study of the manufac-
turer’s 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
conditions.
Regular inspection procedures should be set up, rigidly
adhered to and recorded by or under direction of a quali-
fied 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 on Pages4 and 5.
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.
C. WIRE ROPE AND HOOKS: Visually inspect the wire

rope. Replace it AT ONCE if there is indication of fray-

ing, or if it is crushed, cut or otherwise damaged. Follow
cable manufacturer’s recommended practice for proper
use and inspection of wire rope.

Hooks should be checked for wear, increase in throat

opening, and bending.
d. 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 unusual
visual or audible signs which could indicate a defect. Do
not operate the Winch until the defect has been deter-
mined and corrected.
Periodically, depending on the severity of the service:
a. Inspect Brake and Locking Dog components for wear or
damage.
b. Check all bolts or fasteners.
C. Inspect the Winch structure for damage.

Notice: The use of other than genuine Ingersoll-Rand

replacement parts may result in decreased Winch perform-
ance and increased maintenance, and may invalidate all
warranties.

2
 OPERATING INSTRUCTIONS
1. Read the manufacturer’s instructions before operat-
ing the Winch.
2. Never lift a load greater than the rated capacity of the
Winch.
3. Never use the Winch rope as a sling.
4. Always stand clear of the load.
5. Never use the Winch for lifting or lowering people,
and never stand on a suspended load.
6. Never carry loads over people.
7. Before each shift, check the Winch for wear or
damage. Check brakes, locking dog, etc.
8. Periodically inspect the Winch thoroughly and replace
worn or damaged parts.
9. Follow the lubrication instructions.
10. Do not disengage clutch with a load on the Winch. Be
sure clutch is fully engaged before operating Winch.
Il. Do not “side pull” or “yard”.
12. Always rig the Winch properly and carefully.
13. Never operate a Winch with twisted, kinked or
damaged wire rope.
14. Be sure cable winds properly on drum.
15. Ease the slack out of the wire rope and sling when
starting a lift. Do not jerk the load.
16. Be certain there are no objects in the way of a load or
hook when operating the Winch.
17. Be certain the air supply is shut off before performing
maintenance work on the Winch.
18. Shut off air supply while Winch is unattended.
19. Properly secure the Winch before leaving it unat-
tended.
20. 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.
21. Do not allow unqualified personnel to operate a
Winch.
22. Do not swing a suspended load.
23. Do not operate a Winch if you are not physically fit
to do so.
24. Do not do anything you believe may be unsafe.
25. Do not use the Winch rope as a ground for welding.
Do not attach a welding electrode to a Winch or sling
chain.
26. Do not divert your attention from the load while
operating a Winch.
27. Engage locking dog before leaving load suspended.

3
 OPERATING INSTRUCTIONS
(Continued)
28. Do not engage locking dog while drum is in opera-
tion.
29. Do not leave a load suspended for any extended
period-never unattended.
30. Never splice a sling chain by inserting a bolt between
links.
31. Do not force a chain or hook into place by hammer-
ing. Do not insert the point of the hook into a chain
link.
32. Do not expose the sling chain to freezing tempera-
tures, and do not apply sudden loads to a cold chain.

Warning: Lubricate the motor before using the Winch.

To avoid leakage during shipment, the oil was drained from
the motor. 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

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. Unscrew the Vent Cap (4) and pour a sufficient
quantity of the recommended oil through this opening to
bring the oil level, 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 re-
plenish the oil as above. Should this procedure be imprac-
tical, drain the entire contents of the Motor Case immed-
iately after operation ceasesand pour the oil back into the
Motor Case before resuming operation. If not drained, a
sufficient quantity of water will eventually accumulate so
that the Oil Splasher (37), which is attached to the Crank
(36) will freeze fast.
For temperatures 30° to 80° F (-lo 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 or
10W 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 ap-
pear to lack lubrication, add about l/2 pound (.23 kg) of
the recommended grease.When reassembling a Winch, three
pounds (1.4 kg) of greaseare 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 greasemay be used.
For extremely low temperatures, Ingersoll-Rand Medium
Gear Grease No. 75, low temperature greaseor a heavy gear
oil may be used. Note: Leakage will probably be experi-
enced if heavy gear oil is used for normal temperatures.
Lubricate the Drum Gear occasionally by pushing a
piece of hard stick or block grease3/4” 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 prolong the life of the motor.

HOSE AND HOSE CONNECTIONS

Use l-1/2” (38 mm) hose with a suitable hose fitting for
attaching it to the inlet. Use of smaller hose and fittings will
reduce 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 Drum more than 10° from horizontal will result in
lubrication difficulties and the Wire Rope will tend to pile
up on the low end of the Drum.
 MOUNTING (Continued)

On all 4-cylinder Winches, the Motor Case (1) can be

rotated on the Motor Mounting Bracket (66) to any one of
eight different 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 with the Vent Cap (4) more than 25° off top
vertical center. To change the position of the Motor Case:
1. Drain the oil.
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. Fill with oil.
On Model KSUL or K5U, the Motor Case (1) can be
rotated on the Motor Mounting Bracket (66) to any one of
five different 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 with the 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 bring the Drain Plug as near
bottom vertical center as possible.
4. Replace the Cap Screws.
5. Fill with oil.
The 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 re-
quired 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).

6
 MAINTENANCE (Continued)
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 replace-
ment of the Rotary Valve Bushing (12) or Reverse Valve
Bushing (13) is necessary:
1. Unscrew the Valve Chest Screws (18) and remove the
Valve Chest Cover (17).
2. Screw a 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 a little 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 (l), and press out the old Bushings
with an arbor that will clear the Bushing Keys (11).
Caution: Failure to use an arbor that will clear the
Bushing Keys, or pressing the Bushings in the oppo-
site direction than instructed, will destroy the Keys.
6. Support the face of the Valve Chest (10) that con-
tacts the Valve Chest Cover (17); align the keyslot in
the new Reverse Valve Bushing with the Bushing Key
(11), and press the Bushing into the Chest until the
leading face of the Bushing is flush with the sup-
ported 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 flush with the supported face of the Chest.
7. Insert the No. 23470 Throttle Valve Stem Reamer or
a .505” (12.8 mm) hand reamer through the throttle
valve chamber in the Valve Chest and ream the hole
through the wall of the new Reverse Valve Bushing.

7
 MAINTENANCE (Continued)
8. Check the fit of the Rotary Valve (25) in the new
Rotary Valve Bushing. If the 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. Remove all trace 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 lit is too tight, ream the
Bushing 1.875” (47.625 mm).
Caution: The Reverse Valve is chrome-plated; do not
lap.
10. Rotate the Reverse Valve in the Reverse Valve Bush-
ing until the arrows on the two parts align, and in-
stall 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 protruding 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 AA17, CC21, xX19, etc.
Only sections bearing identical marking can be used toge-
ther. If more 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
crank 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 assembling the Crank (36).

8
Model K4U Utility Winch (Typical of Model K5UL
 MOTOR PARTS
PART NUMBER FOR ORDERING

1 Motor Case
for K4U or K4UL. KU-501
for K5U or KSUL.. K5M-501
2 Drain Plug (2) D02-402
Motor Eyebolt (2 for K5U or KSUL; 1 for others). KU-888
* l-1/4” Pipe Plug (for K5U or KSUL). E5UD-947
4 vent cap D02-303A
5 S-Hook. D02-421
6 Vent Cap Chain D02-891
7 vent cap Screen D02-889
8 Vent Cap Screen Retainer 6CND-233-112
vent cap Cotter. D02-893
10 Valve Chest
for K4U or K4UL. KU-545A
for K5U or K5UL. KK5UM-545
11 Bushing Key (2). HU-538
12 Rotary Valve Bushing
for K4U or K4UL. KU-525s
for K5U or K5UL. K5M-525s
13 Reverse Valve Bushing KU-94%
14 Grease Fitting (2) 23-188
15 Throttle Lever Spring Stop Pin D02-553
16 Brake Inlet Plug (2). D02-402
17 Valve Chest Cover KU-546A
18 Valve Chest Screw (4) KU-548
19 l/2” Lock Washer (4) DlO-322
20 Poppet Throttle Valve KU-940
21 Poppet Throttle Valve Spring. HU-942
22 Poppet Throttle Valve Ball . DlO-280
23 Poppet Throttle Valve Cap KU-943
24 Reverse Valve
for Winch with standard brake KU-944
for Winch with automatic brake. KU-744
25 Rotary Valve
for overwinding Winch KU-526A
for underwinding Winch KU-526RA
26 Large Valve Drive Pin. KU-527
21 Small Valve Drive Pin (2) HU-527
28 Throttle Control Arm KU-555A
29 Throttle Lever Spring Stop Pin D02-553

* Not illustrated.
For Valve Chest (10) with Poppet-Type Throttle Valve (20), used beginning serial 7000
and illustrated in the sectional views. Parts for the superseded Valve Chest with taper-
plug type Throttle Valve that was used under serial 7000 are no longer available. When
any part is required for the superseded Valve Chest, order the listed Valve Chest Assem-
bly. It can be used as a replacement for the assembly with taper-plug type Valve, pro-
vided a new Throttle Control Arm (28) is also used.
l To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We
recommend that you stock one (pair or set) of each part indicated by a bullet (0) for
every four tools in service
 MOTOR PARTS (Continued)
PART NUMBER FOR ORDERING

30 throttle Lever ........................ HU-556

31 Throttle Lever Latch. .................. [IU-869
32 Throttle Lever Latch Spring. .............. HU-567
33 Throttle Lever Setscrew ................. HU-842
34 throttle Lever Pin ...................... HU-870
* throttle Lever Pin Cotter (2). ............... D02-524
35 throttle Lever Spring .................... KU-412
crank Assembly
for K4U or K4UL ............... KU-A5 16
for K5U or K5UL. .............. K5M-A516
36 Crank Bare (consists of 2 matched parts which are
not sold separately). ................... KU-540
31 Oil Splasher ...................... KU-640
38 Oil Splasher Long Rivet (2) ........... KU-54 1
* Oil Splasher Short Rivet (2). .......... KU-542
l 39 Crank Pin Sleeve ................... KU-519
40 Crank Lock Pin .................... KU-520
41 Crank Lock Pin Nut ............... D02-3 17
42 Crank Lock Pin Cotter. ............. D02-330
l 43 Connecting Rod
for K4U or K4UL (4). ............ KU-509
for K5U or K5UL (5). ............ K5M-509
44 Connecting Rod Ring (2) ................ KU-510
l 45 Connecting Rod Bushing. ................ KU-51 1
l 46 Crank Valve End Bearing. ................ KU-518
l 41 Crank Pin End Bearing. ................. KU-895
cylinder Assembly (5 for K5U or K5UL; 4 for
others). ............................ KU-A505A
48 Cylinder Head. ...................... KU-H505A
48A Cylinder Sleeve ...................... KU-L505A
49 piston Assembly (5 for K5U or K5UL; 4 for others). .. K5W-A5 13A
l 50 Piston Ring (1 for each Piston) ............. KU-337
51 Oil Regulating Ring (1 for each Piston) ........ KU-338
51A Wrist Pin Retaining Ring (2 for each Piston). ..... ILA902A9-589
52 Piston Wrist Pin (5 for K5U or K5UL; 4 for others) K5W-514
l 53 Cylinder Gasket (5 for K5U or K5UL; 4 for others). KU-507
54 cylinder Cap Screw (4 for each Cylinder). . . . 215-13

* Not illustrated.
l To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We
recommend that you stock one (pair or set) of each part indicated by a bullet (l) for
every four tools in service.
 MOTOR PARTS (Continued)
PART NUMBER FOR ORDERING-\

55 Cylinder Cap Screw Washer (4 for each Cylinder) KU-504

l 56 Motor Case Gasket
for K4U or K4UL. . . . . KU-592
for K5U or K5UL. . . K5M-592
57 Motor Case Screw (10 for K5U or K5UL; 8 for
others). . . 215-36
58 5/8” Lock Washer (10 for K5U or K5UL; 8 for
others). . . A-67
Motor Nameplate. . . . . K5W-99
Nameplate Screw (4). . . R4K-302
Winch Nameplate. . . . . . DU-301
Nameplate Screw (4). . . . . R4K-302
Caution Plate. . . . . . . . . . . . . . TA-147A
Caution Plate Screw (4). . . . . . . R4K-302

BASE, ROPE DRUM AND GEAR PARTS

PART NUMBER FOR ORDERING

65 Base
for K4U or K5U. K4U-564A
for K4UL or K5UL. K4UL-564A
66 Motor Mounting Bracket K4U-502
67 Rope Drum
for K4U or K5U. K5U-324
for K4UL or K5UL. KSUL-32
68 Wire Rope Setscrew (2) 215-140
69 Drum Shaft
for K4U or K5U. K4U-459
for K4UL or K5UL. K4UL-459
* Drum Shaft Oil Seal (2). K4UL-271
70 Drum Packing. 207-l 36
71 Drum Bearing (2) (Hyatt
CW99212 or equivalent). K4U-466
73 Drum Bearing Plate (4) . K4U-469
74 Drum Shaft Short Setscrew. HU-867
75 Drum Shaft Long Setscrew HU-868
76 Motor Shaft
for K4U or K5U. K4U-3 16C
for K4UL or K5UL, K4UL-316C
77 Motor Pinion Key. EEG-76 8

* Not illustrated
To keep downtime to a minimun, it is desirable to have on hand
certain repair parts. We recommend that you stock one (pair or
set) of each part indicated by a bullet (0) for every four tools in
service.
BASE, ROPE DRUM AND GEAR PARTS (Continued)

PART NUMBER FOR ORDERING

78 Motor Shaft Pinion. K4U-319B

l 79 Motor Shaft Bearing. K4U-589B
* Motor Shaft Bearing Seal RlOV-310
80 Intermediate Gear K4U-364
81 Intermediate Gear Bushing K4U-36 3
82 Intermediate Gear Bushing
Retainer. K4U-362
83 Fiber Washer K4U-871
84 Gear Case K4U-353A
85 Gear Case Screw (10) 215-148
86 Lock Washer (10) DlO-322
87 Gear Cover K4U-352
88 Grease Fitting 23-188
89 Drive Shaft K4U-358
90 Clutch Jaw Lock Ball. G601-65
91 Clutch Jaw Lock Spring K4U-863
92 Clutch Jaw Lock Plug HU-864
l 93 Drive Shaft Inner Bearing 2325-41
l 94 Drive Shaft Outer Bearing. 215-63
95 Clutch Jaw K4U-568
96 Clutch Eccentric Shaft. HU-857
97 Clutch Eccentric Roller HU-858
98 Clutch Eccentric Pin . HU-859
99 Eccentric Pin Lock Screw HU-860
100 Clutch Lever HU-565
101 Clutch Latch HU-566
102 Latch Spring HU-567
103 Clutch Lever Pin HU-86 1
104 Eccentric Shaft Lock Screw. HU-865
105 Base Bolt (3/4” -10 thd.
3-l/2” long [8]) K4U-775
106 Base Bolt Nut (8). DU-56 2
107 Base Bolt Lock Nut Washer (8) DO1692
108 Grease Plug (2) 22SR-165
109 3/8” Lock Washer D02-321
110 Drive Shaft Nut, 215-73
111 Drive Shaft Nut Lock 215-74
112 Drum Bearing Retainer (2) K4U-340
Grease Gun P25-228
* Wire Rope Setscrew Wrench K-27
* Valve Chest Jack Bolt (2). HU-932
* Piston Ring Compressor KU-933
* Throttle Valve Stem Reamer 23470
* Throttle Valve Seat Reamer. 25670

* Not illustrated
l To keep downtime to a minimum, it is desirable to have on
hand certain repair parts. We recommend that YOU stock one
(pair or set) of each part indicated by a bullet (0) for every
four tools in service.
 BRAKE PARTS

PART NUMBER FOR ORDERING

K4U K5U
K4UL KSUL

Brake Band Assembly .............. K4LJ-A152 K5U-A152A

l 115 Brake Band .................. K4U-152 K5U-152A
116 Brake Lining. ............... K4U-155 K4U-155
117 Brake Lining Short Rivet (16). ... K4U-156 K4U-156
118 Brake Lining Long Rivet (17) .... 235-98 235-98
119 Brake Support Spring Bracket. ..... K4U-161A K4U-161A
120 Spring Bracket Rivet (2) ....... 107-153 107-153
120 Brake Shoe Rivet (13) .......... 107-153 107-153
l 121 Brake Shoe. .................. K4U-145 K5U-145
122 Brake Shoe Rivet (9). .......... 107-153 KU-542
118 Brake Lining Long Rivet (12) ...... 235-98 235-98
123 Brake Lever Bracket ............. K4U-193 K5U-193
124 Brake Lever Bracket Rivet (5). ..... 107-153 107-153
125 Brake Lining Long Rivet (5). ...... 235-98 235-98
l 126 Brake Handle ................... 107-151 107-151
127 BrakeHandle Pin. ................ 107-149 107-149
128 BrakeHandle Pm Cotter (2) .......... 107-146 107-146
129 BrakeYoke. ................... 107-159 107-159
130 BrakeAdjusting Screw. ............. 107-158 107-158
131 BrakeShoe Long Pin. .............. 107-147 107-147
132 BrakeShoe Pin Cotter (2). ........... DOZ-330 D02-330
133 BrakeAnchor. .................. K4U-206 K4U-206
134 BrakeAnchor Nut ................ HU-776 HU-776
135 BrakeAnchor Lock Washer, .......... 4-67 A-67
136 BrakeSupport Screw .............. Y4U-162 K4U-162
137 BrakeSupport Screw Jam Nut ......... ;7-18 G7-18
138 BrakeSupport Screw Washer. ......... <4u-343 K4U-343
139 BrakeSupport Spring .............. l-03-1 19 T03-119
140 BrakeLever Bracket Pin. ............ 107-148 107-148
* Bracket Pin Cotter. ............... LO7-146 107-146

* Not illustrated.
l To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We
recommend that you stock one (pair or set) of each part indicated, by a bullet (0) for
every four tools in service.
 WARNING
DISENGAGING CLUTCH PARTS
For reasons of safety, it is emphatically recommended
that Automatic Brake and Disengaging Clutch features not
be used on 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 is the responsibility of the
user to make provision to prevent accidental operation of
the Winch motor with the clutch disengaged. Opera-
tion of the motor with the 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 be ordered and installed if conversion
from manual to automatic brake is made on a Winch
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 Gear (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 Eccentric
Shaft.
REMOTE CONTROL PARTS

(Dwg. TPD206)
Remote Control Valve Chest Assembly

PART NUMBER FOR ORDERING

IRemote Control Block Assembly

for Winch with Standard
Brake. . . . . KU-A685
for Winch with Automatic
Brake. . . . . KU-B685
200 Remote Control Block. . KU-685
201 3/8” Lock Washer (2) . D02-321
202 Control Arm Retainer
.
Screw (2). . . . . . . HI-J-865
203 Control Arm Retainer . . . HU-687
204 Control Block Valve Chest. . KU-876A
205 Bushing Key. . HU-538
* Brake Inlet Plug. . . . . . D02-402
206 Throttle Lever Spring
Stop Pin . . . D02-553
208 Control Block Reverse
Valve Bushing . KU-945
* Grease Fitting (2). . . 23-188
209 Control Block Reverse Valve
for Winch with Standard
Brake. KU-944
for Winch with Automatic
Brake. . . . -- KU-744
* Not illustrated
 REMOTE CONTROL PARTS (Continued)

PART NUMBER FOR ORDERING

210 Control Block Throttle Lever

Spring . . . . . . . . KU-4 12
211 Control Block Throttle Arm. . KU-555A
212 Throttle Lever Spring
Stop Pin . . . . . . . D02-553
213 Control Block Throttle Valve
Cap................. KU-943
215 Control Block Throttle Valve
Spring . . . . . . . . . . . . . . HU-942
216 Control Block Poppet Throttle
Valve . . . , . . . . . . . . KU-940
217 Control Block Throttle Valve
Ball . . . . . . . . . DlO-280
218 Control Block Valve Chest
Cover. . . . . . . . . . KU-546A
223 Control Block Throttle Lever . . HU-556
224 Throttle Lever Latch. . . HU-869
225 Latch Spring. . . . . . . HU-567
226 Throttle Lever Setscrew . . HU-842
227 Throttle Lever Pin . . . HU-870
* Throttle Lever Pin Cotter (2) D02-5 24
230 Remote Control Valve Chest
for K4U or K4UL.. . . . KX-545
for K5U or K5UL. . . . K5M-545
231 Rotary Valve Bushing
for K4U or K4UL.. . . KU-525s
for K5U or K5UL.. . . K5M-525s
232 Bushing Key. . . . . . . HU-538
233 rotary Valve
for overwinding Winch . . KU-526A
for underwinding Winch KU-526RA
234 Large Valve Drive Pin. . . . KU-527
--
235 Small Valve Drive Pin (2) . . HU-51’~
236 remote Control Valve Chest
cover . . . . KX-546
* valve Chest Screw (4) . . . KU-54S
* 1/2” Lock Washer (4) . DlO-322

* Not illustrated.
AUTOMATIC BRAKE PARTS

(Dwg. TPA742-1)
PART NUMBER FOR ORDERING

+ 251 Clutch Jaw Spacer .......... K4U-7 12

+ 252 Gear Cover Plug ........... HI-J-728
-f 253 Gear Cover Plug Seal. ........ HU-730
l 254 Brake Cylinder Assembly ...... HU-720A
255 Brake Cylinder Yoke ....... HU-7 19
* Brake Cylinder Bushing ..... HU-771
256A Eye Bracket ............ HU-717
256B Street Elbow. ........... HUS-912
257 Brake Cylinder Bracket ....... K4U-721
258 Brake Cylinder Bracket Cap
Screw (2) ............... HU-723
259 Brake Cylinder Bracket Pin ..... HU-870
260 Bracket Pin Cotter (2) ...... D02-524
261 Brake Spring (2) ........... K4U-726
262 Yoke Pin ............... 22-720
* Not illustrated.
l To keep downtime to a minimum, it is desirable to have on hand
certain repair parts. We recommend that you stock one (pair or
set) of each part indicated by a bullet (0) for every four tools in
service.
* Refer to paragraph 2 of DISENGAGING CLUTCH PARTS on
Page 15.
 AUTOMATIC BRAKE PARTS
(Continued)
PART NUMBER FOR ORDERING

263 Yoke Pin Cotter . . . . . D02-330

264 Automatic Brake Lever . K4U-718
265 Brake Pipe
for K4U or K5U. . . K4U-401
for K4UL or K5UL. . K4UL-401
266 Brake Pipe Elbow (2) . . . K4U-400
261 Brake Pipe Strap (2) . . . . . HU-727
268 Strap Screw (2). . . . . . . J-376
269 1/4” Lock Washer (2) . . . LO167
272 1/2” Lock Washer . . . . . . . DlO-322
273 Automatic Brake Reverse Valve KU-744
* Reverse Valve O-ring . . . R18-311
274 Motor Mounting Bracket . . . K4U-502
* Brake Cylinder Bracket Bolt
(3/4” -10 thd. x 4” long). .. . K6U-775

* Not illustrated.

BRAKE EXHAUST VALVE PARTS

281 282 283

(Dwg. TPD214-1
285

PART NUMBER FOR ORDERING

Brake Exhaust Valve Assembly. . K4U-A733

280 Brake Exhaust Valve . . HU-733
281 Exhaust Valve Elbow. HU-745
282 Brake Air Strainer Assembly. . . ROB2-A565
283 Brake Connection. . . . . . K4U-7 11
284 1/4” Pipe Plug. . . . . . . D62-402
285 Orifice Plug . . . . . . . . HU-732
286 Exhaust Valve Pipe . . . K4U-731
287 Exhaust Valve Cap Screw (2) . . R55H-413
288 5/16” Lock Washer (2). . . Tll-58
t 266 Brake Pipe Elbow. . . K4U-400

t Illustrated on Page 18.

PULL CHAIN THROTTLE PARTS

307

306

(Dwg. TPCllZ)

PART NUMBER FOR ORDERING

300 Pull Chain Throttle Lever. . HU-559

301 Throttle Chain Bolt (2) . . . . D02-3 12
302 Throttle Chain Bolt Nut (2). . . D02-4 18
303 3/8" Lock Washer (2) . . . . . D02-321
304 3/8" Plain Washer (2) . . D02-419
305 Throttle Lever Cotter . . . . 215-124
306 Throttle Lever Chain (2) (length
as specified). . . . . . . DU-413
307 S-Hook (4) . . . . . . . . . . DOl-221
308 Throttle Handle (2) . . . . . MR.415
AIR STRAINER

(Dwg. TPDl22-

PART NUMBER FOR ORDERING--,

400 Air Strainer Assembly ........ K4U-A267AT

401 Air Strainer Screen ........ K4U-6 1 AT
403 Air Strainer Plug ......... 22SR-165
404 Air Strainer Cap. ......... K4U-268AT
* Air Strainer Nipple
(l-1/4” x 2-l/2.3. .......... KKM-286

* Not illustrated.
 WIRE ROPE AND FITTINGS

PART NUMBER FOR ORDERING

For Use With For Use With For Use With For Use With
3/8” Dia. 1/2” Dia. 9/16” Dia. 5/8” Dia.
Wire Rope Wire Rope Wire Rope Wire Rope

420 Wire Rope (specify length) . . . . . EU-372 215-372 K4U-372 235-372

Wire Rope Fitting Assembly . . . . EU-AS601 K4U-AS601-l/2 K4U-AS601-9116 K4U-AS601-5/8
421 Wire Rope Clamp (3). . . . . . . D04-464 D20-375 D20-375 235-375
422 Rope Thimble. . . . . . . . . . . DlO-721 215-602 K4U-602 K4U-602
423 Swivel Hook. . . . . . . . . . DOlC-S377 K4U-S601 K4U-S601 K4US601
423A Hook Latch Kit (individual
parts not sold separately) . . . . DOl-S4055 D02S4055 - - - - - -
Hook Block Assembly. . . . . . . . D02-AS463A DM-AS463A
424 Hook Block . . . . . . . . . . . . D02-463A DO4-463A
425 Hook. . . . . . . . . . . . . . D02-S377 D04-S377
425A Hook Latch Kit. . ___. D02-S123 DO4,-S123
425B Hook Nut . . . . . . . . . . . D02-305B HRA60A-jbS
426 Hook Bearing . . . . . . . . . D02-379A DO4-379A
427 Roll Pin . . . . . . . . . . . . 20QDM-330 D02-374
428 Wire Rope Clamp. . . . . . . DO4464 D20-375 - - -
429 Wire Rope Wedge. . . . . . . D02-373 D02-373

22
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