Product Parts

Information

Stationary Piston Air Motor

Models
KK5B546 and KK5B550

(Dwg. MHP2892)

Save These Instructions

Form MHD56311
Edition 1
August 2008
71455976
© 2008 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.
Manuals can be downloaded from www.irtools.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.
The original language of this manual is English.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.

Table 1: Product Manuals

Publication Part/Document Number Publication Part/Document Number
Product Safety Information Manual MHD56312 Product Maintenance Manual P6957
Product Information Manual MHD56310

TABLE OF CONTENTS

Description Page No.

Parts Ordering Information........................................................................................................................................................................................................3

Motor Assembly Drawing...........................................................................................................................................................................................................4

Motor Assembly Parts List .........................................................................................................................................................................................................5

Pilot Air Control Valve (Optional) Assembly Drawing and Parts List ..................................................................................................................................................6

Remote Pilot Air Control Assembly Drawing and Parts List ..............................................................................................................................................................7

Control Valve Assembly Drawing.................................................................................................................................................................................................8

Control Valve Assembly Parts List ...............................................................................................................................................................................................9

Remote Pendant Assembly Drawing and Parts List ....................................................................................................................................................................... 10

Panel Control Assembly Drawing and Parts List ........................................................................................................................................................................... 11

Motor (NEMA) Shaft Kit Drawing and Parts List........................................................................................................................................................................... 12

Motor Shaft Kit Drawing and Parts List...................................................................................................................................................................................... 13

Foot Mount Kit Drawing and Parts list....................................................................................................................................................................................... 14

MOTOR Labels and Tags........................................................................................................................................................................................................... 14

Warranty .............................................................................................................................................................................................................................. 15

2 Form MHD56311 Edition 1

 PARTS ORDERING INFORMATION

The use of other than genuine Ingersoll Rand replacement parts may result in
decreased performance, and may invalidate the warranty. „ Return Goods Policy
For prompt service and genuine Ingersoll Rand replacement parts, provide your
nearest Distributor with the following: Ingersoll Rand will not accept any returned goods for warranty or service unless
1. Complete model number and serial number as it appears on the data (name) prior arrangements have been made and written authorization has been provided
plate. from the location the goods were purchased.
2. Part number(s) and part description as shown in this manual. Products which have been modified without Ingersoll Rand approval, mishandled or
3. Quantity required. 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
For your convenience and future reference it is recommended that the following manual.
information be recorded.

Model Number ________________________________________________________

„ Disposal
Serial Number ________________________________________________________
When the life of the product has expired, it is recommended that it
Date Purchased _______________________________________________________
be disassembled, degreased and parts separated as to materials so
NOTICE that they may be recycled.

• Continuing improvement and advancement of design may cause changes to

this product which are not included in this manual. Manuals are periodically
For additional information contact:
revised to incorporate changes. Always check the manual edition number on the
front cover for the latest issue. Ingersoll Rand
• Sections of this manual may not apply to your product. US, Canada and Latin America
• Using other than genuine Ingersoll Rand parts may invalidate the warranty. Phone: 1-206-624-0466
or 1-866-273-3278
Fax: 1-206-624-6265

or

Ingersoll Rand
Europe, Middle East and Africa
Phone: 33-03-27-93-08-08
Fax: 33-03-27-93-08-00

or

Ingersoll Rand
Asia Pacific
Phone: 65-6861-1555

www.irtools.com

Form MHD56311 Edition 1 3

 MOTOR ASSEMBLY DRAWING

KK5B546 KK5B550
216 200 201
2

202
228
205
203 204
264
202
205
205
204
207 206 203

206 208 200

213 210
209 213 201

214
207 205
229

208

209

244
225 243

230

226

225 247

217
3 246
4

237 236

251

231 232
233
252
243
234
251 250
169
165 235
240
171
231 228
170 253

(Dwg. MHP2424)

4 Form MHD56311 Edition 1

 MOTOR ASSEMBLY PARTS LIST
Item Description Qty Part Number
No. of Part Total KK5B546 KK5B550
1 Capscrew (Metric Thread) (Note 1) 5 71452536
1 Capscrew (Standard English Thread) 5 51471
2 Oil Seal 1 51873 K5B-270
3 Lockwasher 10 71268213
4 Capscrew 10 71268205
165 Fitting, Pipe Nipple (Optional) 1 71057459
169 Pipe Fitting, Elbow (Optional) 1 71057434
170 Muffler (Optional) 1 50594
171 Pipe Fitting, Nipple (Optional) 1 51704
172 Data (Name) Plate 1 Contact Factory
200 Capscrew (Metric Thread) (Note 1) 20 71434260
200 Capscrew (Standard English Thread) 20 52317
201 Cylinder Head 5 K5B-H505 K5B-505
202 Compression Ring (Includes Item 207) 1 Set K5B546-KRING K5B550-KRING
203 Wrist Pin 5 HU-514A
204 Piston (Includes Items 202 through 205 and 207) 5 K5B-A513-47 K5B-A513-50
205 Retainer Ring (Pack of 10) 1 Pack 902A45-632-10
206 Connecting Rod 5 K5B-509
207 Oil Ring 1 Set Order Item 202
208 Cylinder Liner 5 K5B-L505-47 ---
209 Head Gasket 1 Set K5B-507-5
210 Vent Cap Assembly 1 26604
213 Eye Bolt (Metric Thread) (Note 1) 2 71431506
213 Eye Bolt (Standard English Thread) 2 KU-888
214 Pipe Plug 1 71263297
216 Mounting Flange 1 K5B-276SAE
217 Motor Housing (Note 2) 1 382-30415-S
225 Pipe Plug (Drain) 3 (2) 54912
226 Gasket 1 K5B-592
228 Bearing 2 51066
229 Button Head Screw 5 K5B-541
230 Oil Slinger 1 K5B-540
231 Crank Assembly (Includes Items 206, 228 - 240) 1 KK5B-A516
232 Sleeve 1 K5B-519
233 Bushing 1 K5B-511
234 Connecting Rod Ring 1 K5B-510
235 Lock Pin
236 Cotter Pin 1 Set HU-K520
237 Pin Nut
240 Roll Pin 1 54257
243 Gasket 2 K5B-928
244 ‘O’ Ring 1 20A11CM248
246 Grease Fitting 1 53095
247 Rotary Valve Housing 1 382-30414
250 Rotary Valve Assembly 1 K5B-526EQ-RS
251 Seal Ring Assembly 1 Set K5B-607A
252 Bearing 1 K5B-97
253 Exhaust Flange 1 KK5B-276M
264 Flat Head Screw 2 71262810
Note 1: Use CAUTION when ordering items 1, 200, 213, 247 and any Kits with hardware;
Note 2: Housing (217and 247) have metric thread holes for items 1, 200, 211 and 213; Use CAUTION.
Note 3: Refer to Kits prior to placing orders to avoid duplicate parts.

Motor serial numbers MOØØØ649 and lower use standard English thread capscrews.
Motor Assembly Service Kit(s)
Item Description Part Number
No. of Part KK5B546 KK5B550
• --- Full Service Kit (Includes Items 3, 4, 200, 202, 207-209, 226, 243, 244, and 251) 71390181 71404289
--- Gasket Kit (Includes Items 209, 226, 243, 244) 26823

• Recommended spare

Form MHD56311 Edition 1 5

 PILOT AIR CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST

269 265
266

267
271

266
272
280
273
268
269

274
275
276 271

270

277
278
279

(Dwg. MHP0141)
Item Description Total Part Number
No. of Part Qty 510 size
355 Valve Assembly (includes items 265 through 280) 1 20993
265 End Cap 1 71136725
266 Gasket 2 71136733
267 Valve Body 1 Order item 355
268 End Cap Assembly (includes items 270 and 271) 1 25591
269 Capscrew 8 71030118
270 Adjusting Screw 1 53545
271 Nut 2 50176
272 Shoulder Screw 1 54710
273 Guide 1 71136741
274 Spring 1 71136758
275 Washer 1 71136774
276 Spacer 1 71136766
277 ‘O’ Ring (only available in Pilot Air Control Valve Service Kit) 1 Order Kit
278 Valve Sleeve 1
Order item 355
279 Valve Spool 1
280 Washer 1 71332324

Pilot Air Control Valve Service Kit

Description
Item No. Part Number
of Part
• Service Kit [(Includes Items 266 (qty 2) and 277 (qty 6)] 71356406

• Recommended spare .

6 Form MHD56311 Edition 1

 REMOTE PILOT AIR CONTROL ASSEMBLY DRAWING AND PARTS LIST
Forward

Air Supply

Reverse

355

263
226
225
262

261

258
259

257

(Dwg. MHP2896)

Item Description Total Part Item Description Total Part

No. of Part Qty Number No. of Part Qty Number
225 Hose, Bulk As req’d 50923-XX 261 Lockwasher 4 50200
226 Fitting, Hose End As req’d 51029 262 Capscrew (Metric Thread) 4 71431365
257 Capscrew 4 54681 263 Fitting, Elbow 3 52182
258 Lockwasher 4 50893 355 Valve Assembly 1 20993
259 Manifold 1 13881
XX Order in even feet increments; i.e., 50923-02 = 2 feet (0.6 meters). Meters listed for reference only.

Note: Motor serial number MOØØØ649 and lower use the following items:
Item Description Total
Part Number
No. of Part Qty
261 Lockwasher 4 71380133
262 Capscrew (Standard English Thread) 4 71355895

Form MHD56311 Edition 1 7

 CONTROL VALVE ASSEMBLY DRAWING

903
902
904 901
905
955
906 901
956 Brake 912 907
947
Fitting 950
940 910
918 962
917
902
919

902
942
901

916 944
960
921 943
922
923
954

951

949

948
924
945
925

946

942
935 941
957
939
958 Muffler
938 Optional
930 937 959
909
901
920

NOTE: IR tooling
not included with
valve.
(Dwg. MHP2696)

* Item 920 is not sold with any valve parts. Must be purchased separately.

8 Form MHD56311 Edition 1

 CONTROL VALVE ASSEMBLY PARTS LIST
Item Description Total Part Item Description Total Part
No. of Part Qty Number No. of Part Qty Number
900 Control Valve Assembly (Note 1) 1 K5C2-X 940 Tag, No FA2B 1 71392757
901 Capscrew 9 71342034 941 ‘O’ Ring 1 71357198
902 Washer 8 71303408 942 ‘O’ Ring 2 51651
903 Cover, Poppet 1 26997 Reverse Valve Kit (Normal)** 27925-SX
904 Gasket, Poppet 1 27064 943 Reverse Valve (Reverse Bias)** 1 28002
905 Spring, Poppet 1 71351068 Reverse Valve (Unbiased) ****
906 Cap, Poppet 1 28734 Bushing (Normal)*** 26686
907 Seal, Poppet 1 26991 944 Bushing (Reverse Bias)*** 1 27450
909 Washer, Tablock 1 71398051 Bushing (Unbiased) ****
910 Pilot Valve Assembly 1 28696 945 Pin 1 71146674
912 Plug 1 71414817 946 Gasket Set 27115
916 Ball 1 D10-280 947 Rivet 2 71028849
917 Valve Housing 1 Order Item 900 948 Label, Throttle Direction 1 71352777
918 Gasket, Cover 1 26999 949 Washer (Use with Metric Thread Capscrew) 4 71413355
919 Cover, Piston 1 26998 949 Washer 4 71376370
920 Pilot Valve Tool (Ingersoll Rand) 1 28690 950 Plug 1 71366348
921 ‘O’ Ring 1 52537 951 Capscrew (Metric Thread) (Note 4) 4 71431365
922 Piston (Note 2) 1 28735-S 951 Capscrew (Standard English Thread) 4 71369276
923 ‘O’ Ring 1 71355796 954 Plug 1 71263297
924 Washer 2 71271985 955 Exhaust Flange 1 26691
925 Capscrew 2 71348338 956 Fitting 1 71367932
930 Handle Assembly 1 27239-1 957 Fitting, Elbow 1 71273676
935 Plug 1 71348965 958 Fitting, Nipple 1 71057483
937 Spring 1 26966 959 Muffler 1 52472
938 Buttonhead Screw 2 71394407 960 Label, Warning 1 71373229
939 Seal Bracket (Note 3) 1 28733-S 962 Breather 1 51559
** 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: Do not use valve assembly on FA2B products.
Note 2: Item 922 not sold separately, includes (6) each of items 901 and 902, items 904 through 907, 918, 921, 923 and 940.
Note 3: Item 939 not sold separately, includes (1) each of items 901 and 902, items 924, 925, 935, 937, 938 and 941.
Note 4: Use CAUTION when ordering items 949 and 951. Motor serial number MOØØØ649 and lower use Standard English Thread hardware.

Service Kit
Item Total Part
Kit Description
No. Qty Number
Control Valve Service Kit (Includes Items 901, 902, 904, 905, 907, 909, 916, 918, 921, 923 - 925, 935, 937, 938, 941, 946, 949
• 780 1 27240
and 950)

• Recommend spare.

Form MHD56311 Edition 1 9

 REMOTE PENDANT ASSEMBLY DRAWING AND PARTS LIST

455
444
440 453 448

447

445
446
449
456
451
470
450
454

443

452

457

458

(Dwg. MHP2346)

Item Description Total Part Item Description Total Part

No. of Part Qty Number No. of Part Qty Number
353 Pendant Assembly 1 PHS2E 451 Protector 2 95790107
440 Lifting Eye 1 64222332 452 Valve 2 95790104
• 443 ‘O’ Ring 2 58209229 453 Lever 2 95790122
444 Plug 2 65107741 454 Pendant Handle 1 Order Item 353
445 Spring 2 69128541 455 Fitting 3 71078158
446 Ball 2 69401625 456 Label Kit 1 95790111
447 Pin 1 95790040 457 Exhaust Washer 1 95790114
448 Setscrew 2 42008607 458 Retainer Ring 1 47713030
• 449 ‘O’ Ring 2 95790107 470 Plug 1 65129541
450 Setscrew 2 42008307

Pendant Service Kits

Item Total Part
Kit Description
No. Qty Number
• 781 PHS2E Service Kit (includes items 444 to 447, 449, 451, 457, 458 and 470) 1 75790183

• Recommended spare.

10 Form MHD56311 Edition 1

 PANEL CONTROL ASSEMBLY DRAWING AND PARTS LIST

281

282

283

285

Forward
Air Supply Signal
Line Line
284 Supply Port

286

Reverse Signal Line

287 1/8” NPT

285

(Dwg. MHP2010)

Item Description Total Part

No. of Part Qty Number
281 Control Valve 1 UWD-A686
282 Fitting, Elbow 2 71048284
283 Fitting, Hose End 4 51029
As
284 Hose (bulk) * 50923-XX
required
285 Fitting, Tee 1 54678
286 Fitting, Elbow 2 52182
287 Fitting, Connector 2 71048268

Add hose length (feet/meters). Maximum length = 20 ft (6 meters). Contact Technical Sales for information on control applicability for lengths greater than 20
*
feet (6 meters). Meters are for reference only; order quantities in feet.

Form MHD56311 Edition 1 11

 MOTOR (NEMA) SHAFT KIT DRAWING AND PARTS LIST

84
85

67

69

70
71

86

77 68

72

228

216
(Dwg. MHP2895)
Item Description Total Part Item Description Total Part
No of Part Qty Number No. of Part Qty Number
--- NEMA ‘C’ Shaft Kit 1 K5B-NEMA-213 • 77 ‘O’ Ring 1 SM450B-607-1
67 Adapter 1 K5B-749NEMA 84 Capscrew 4 52317
68 Output Shaft 1 K5B-316-213 85 Lockwasher 4 HRA20A-322
69 Oil Seal 1 K5B-270-2 86 Key 1 KK5B-323-1
70 Bearing 1 D10-518 216 Mounting Flange 1 K5B-276SAE
71 Retainer Ring 1 52678 228 Bearing 1 51066
72 Retainer Ring 1 51192

• Recommended spare.

12 Form MHD56311 Edition 1

 MOTOR SHAFT KIT DRAWING AND PARTS LIST

83
81 79
80

78 86

75
82
76

84
85

74
77

228
216
(Dwg. MHP2894)
Item Description Total Part Item Description Total Part
No of Part Qty Number No. of Part Qty Number
--- Keyed Shaft Kit 1 K5B-SHAFT-1.625 81 Oil Seal 1 K5B-270-1
74 Housing 1 K5B-749 82 Plug 1 TC-368
75 Output Shaft 1 K5B-316-1-5/8 83 Retainer Ring 1 51069
76 Bearing 1 D10-518 84 Capscrew 4 52379
• 77 ‘O’ Ring 1 SM450B-607-1 85 Lockwasher 4 HRA20A-322
• 78 Bearing 1 51066 86 Key 1 KK5B-323-2
79 ‘O’ Ring 1 92RMG10-103 216 Mounting Flange 1 K5B-276SAE
80 Holder 1 K5B-271 228 Bearing 1 51066

• Recommended spare.

Form MHD56311 Edition 1 13

 FOOT MOUNT KIT DRAWING AND PARTS LIST

102
103
100

216

3
4

228

(Dwg. MHP2897)

Item Description Total Part

No. of Part Qty Number
3 Washer 10 50181
4 Capscrew 10 52379
100 Foot Mount 1 382-30061
102 Capscrew* (1/2 inch UNC x length as needed) 4 Customer
103 Washer* 4 Supplied

104 Pin ** 2 71001135

216 Mounting Flange 1 K5B-276SAE
228 Bearing 1 51066

* Capscrew (102) and washer (103) shown for reference only.

** Item not Illustrated.

MOTOR LABELS AND TAGS

Item Description Total Part
No. of Part Qty Number
600 Oil Drain Label 1 71042188
601 Exhaust Label 1 71042196
602 Oil Fill Label 1 71042204
603 Oil Level Label 1 71043616
604 Air Supply Label 1 71046395
605 ‘Check Oil Level’ Tag 1 71107148
172 Data (Name) Plate 1 Contact Factory
607 Rivet 4 71028849
608 Customer Service Tag 1 71455455

14 Form MHD56311 Edition 1

 WARRANTY

WARRANTY INFORMATION
Ingersoll Rand Company (IR) warrants to the original user its Hoists and Winches IR makes no other warranty, and all implied warranties including any warranty
(Products) to be free of defects in material and workmanship for a period of one year of merchantability or fitness for a particular purpose are limited to the duration
from the date of purchase. IR will repair, without cost, any Product found to be of the expressed warranty period as set forth above. IR’s maximum liability is
defective, including parts and labor charges, or at its option, will replace such limited to the purchase price of the Product and in no event shall IR be liable
Products or refund the purchase price less a reasonable allowance for depreciation, in for any consequential, indirect, incidental, or special damages of any nature
exchange for the Product. Repairs or replacements are warranted for the remainder of rising from the sale or use of the Product, whether based on contract, tort, or
the original warranty period. otherwise.

If any Product proves defective within its original one year warranty period, it should Note: Some states do not allow limitations on incidental or consequential damages
be returned to any Authorized Hoist and Winch Service Distributor, transportation or how long an implied warranty lasts so that the above limitations may not apply to
prepaid with proof of purchase or warranty card. you.

This warranty does not apply to Products which IR has determined to have been This warranty gives you specific legal rights and you may also have other rights
misused or abused, improperly maintained by the user, or where the malfunction or which may vary from state to state.
defect can be attributed to the use of non-genuine IR parts.

IMPORTANT NOTICE
It is our policy to promote safe delivery of all orders. CONCEALED LOSS OR DAMAGE
When a shipment has been delivered to you in apparent good condition, but upon
This shipment has been thoroughly checked, packed and inspected before leaving opening the crate or container, loss or damage has taken place while in transit,
our plant and receipt for it in good condition has been received from the carrier. Any notify the carrier’s agent immediately.
loss or damage which occurs to this shipment while en route is not due to any action
or conduct of the manufacturer. DAMAGE CLAIMS
You must file claims for damage with the carrier. It is the transportation company’s
VISIBLE LOSS OR DAMAGE responsibility to reimburse you for repair or replacement of goods damaged in
If any of the goods called for on the bill of lading or express receipt are damaged or shipment. Claims for loss or damage in shipment must not be deducted from the
the quantity is short, do not accept them until the freight or express agent makes an Ingersoll Rand invoice, nor should payment of Ingersoll Rand invoice be withheld
appropriate notation on your freight bill or express receipt. 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 MHD56311 Edition 1 15

www.irtools.com