Ingersoll-Rand FA5T manual Recommended Lubricants, Component Lubrication

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LUBRICATION

To ensure continued satisfactory operation of winch, all points requiring lubrication must be serviced with correct lubricant at proper time interval as indicated for each assembly.

The lubrication intervals recommended in this manual are based on intermittent operation of winch eight hours each day, five days per week. If winch is operated almost continuously or more than the eight hours each day, more frequent lubrication will be required. Also, lubricant types and change intervals are based on operation in an environment relatively free of dust, moisture, and corrosive fumes. Use only those lubricants recommended. Other lubricants may affect winch performance. Approval for use of other lubricants must be obtained from your Ingersoll Rand distributor. Failure to observe this precaution may result in damage to winch and/or its associated components.

INTERVAL

LUBRICATION CHECKS

 

 

Start of each shift

Check flow and level of air line lubricator

 

(approximately 6 to 9 drops per minute

 

required at maximum motor speed).

 

 

 

Check winch motor oil level.

 

 

Monthly

Lubricate components supplied by grease

 

fittings.

 

 

 

Inspect and clean or replace air line filter.

 

 

 

Check reduction gear oil level.

 

 

Yearly

Drain and refill winch reduction gear oil.

 

 

 

Drain and refill winch motor oil.

 

 

Note: Intervals are based on winch operation in a normal environment as described in the “INSPECTION” section. In ‘Heavy’ or ‘Severe’ operating conditions adjust lubrication intervals accordingly.

Recommended Lubricants

Reduction Gear Recommended Lubricant

Temperature

Type Oil

 

 

Below 32° F (0° C)

ISO VG 68 (2 EP)

 

 

32° to 80° F (0° to 27° C)

ISO VG 100 (3 EP) *

 

 

Above 80° F (27° C)

ISO VG 150 (4 EP)

 

 

*Units are shipped from factory with ISO VG 100 (3 EP) lubri- cant. Reduction gear capacity is approximately 2 quarts (1.9 litres).

Air Motor and Disc Brake Recommended Lubricant

Temperature

Type Oil

 

 

Below 32° F (0° C)

ISO VG 32 (SAE 10W)

 

 

32° to 80° F (0° to 27° C)

ISO VG 68 (SAE 20W) *

 

 

Above 80° F (27° C)

ISO VG 100 (SAE 30W)

 

 

*Units are shipped from factory with ISO VG 68 (SAE 20W) lubricant. Motor oil capacity is approximately 3 quarts (2.8 litres).

Recommended Grease

Temperature

Type Oil

 

 

-20° to 50° F

EP 1 multipurpose

(-30° to 10° C)

lithium based grease

 

 

30° to 120° F

EP 2 multipurpose

(-1° to 49° C)

lithium based grease

 

 

NOTICE

Do NOT use synthetic lubricants in air motor. Synthetic lubricants will result in oil blowing by piston rings.

Component Lubrication

General Lubrication

Correct lubrication is one of the most important factors in maintaining efficient winch operation.

1.The recommended grade of oil must be used at all times. Use of unsuitable oil may result in excessive temperature rise, loss of efficiency and possible damage to lubricated components. Refer to ‘Recommended Lubricants’ section.

2.Drain and replace oil in motor, disc brake and reduction gear after the first 50 hours of initial winch operation. Thereafter, drain and replace oil according to operating environment (yearly in NORMAL and HEAVY; quarterly in SEVERE), or more frequently if desired.

3.Always inspect removed oil for evidence of internal damage or contamination (metal shavings, dirt, water, etc.). If indications of damage are noted, investigate and correct before returning winch to service.

4.After winch operation, allow oil to settle before topping off.

5.Always collect lubricants in suitable containers and dispose of in an environmentally safe manner.

Motor

Refer to Dwg. MHP2126 on page 20.

The motor is splash lubricated by oil in motor housing and has no other means of lubrication. It is therefore important to use only good quality, non-detergent motor oil to ensure maximum performance and minimum downtime for repairs. Refer to ‘Recommended Lubricants’ section.

Oil capacity for the K5B-546 motor is 3 quarts (2.8 litres). Add oil through filler opening until oil flows from level plug hole. Add oil slowly to prevent spilling.

The motor should be level-checked daily or at the start of each shift after any accumulated water has been drained off. When motors are operated in temperatures below freezing, wait long enough at end of shift for water to separate from oil but not long enough for it to freeze. Drain water then refill to level plug (225), located on side of motor housing (217). If desired, all oil may be drained at end of shift and motor refilled with new oil.

MHD56037 - Edition 5

19

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Contents Model FA5 and FA5T Table of Contents Safety Summary Safety InformationSafe Operating Instructions FA5 Specifications3XX FA5T Winch Performance Graphs FA5 WinchFA5 FA5T Description of OperationTraceability InstallationMounting Drum Length inches Wire RopeWinch Bolt Hole Mounting Dimensions Minimum and Maximum Wire Rope Size ModelAir Supply Wire Rope SpoolingSpooling Wire Rope onto Winch Drum Safe Installation ProceduresMotor Constant Tension Components Constant Tension optional featureAir Schematic-Emergency Stop and Overload System old style Emergency Stop and Overload System Components old styleInitial Operating Checks OperationWinch Controls Winch Mounted Throttle Control Valve Operation old style Underwound Operation optional featureRemote Live Air Throttle optional feature Remote Pilot Pendant Throttle optional featurePendant Hose and Operating Levers old style Remote Pilot Lever Throttle optional featureEmergency Stop optional feature Emergency Stop and Overload SystemOverload Device Emergency Stop optional featureDrum Locking Pin optional feature Winch Overload Device optional featureWinch Brakes Limit Switch optional feature Interval Lubrication Checks LubricationRecommended Lubricants Component LubricationDisc Brake optional feature Records and Reports InspectionFrequent Inspection Winches Not in Regular Use Periodic InspectionNormal Heavy Severe Testing Inspection and Maintenance ReportCondition Corrective Component Action Symptom Cause Remedy TroubleshootingAutomatic Drum Brake Automatic Disc Brake Interval Maintenance Check MaintenanceMaintenance Intervals AdjustmentsLimit Switch Adjustment optional feature Overload Valve Adjustment new styleOverload Valve Adjustment optional feature Old style Overload Valve Adjustment old styleDisassembly Reduction Gear Disassembly Manual or Automatic Drum Brake DisassemblyHandle Removal K5C2 Control Valve DisassemblyCrankshaft Disassembly Control Valve Removal and ReplacementCleaning, Inspection and Repair K5C2 Control Valve Assembly AssemblyK5C2-EX Control Valve Assembly Reduction Gear Assembly Brake Seal Installation Winch AssemblyFA5 Band Brake Components Drum AssemblyDrum Brake Assembly Automatic Drum Brake Actuator AssemblyOperational Test TestingLoad Test FA5 Winch Assembly Drawings Reference Diagram FA5 Winch Drawings and Parts Lists Table of Contents DRUM, Base and Reduction Gear Assembly Drawing Part Qty DRUM, Base and Reduction Gear Assembly Parts ListPart Description PartSide Rail Parts List DRUM, Base and Reduction Gear Assembly Parts List CONT’DUpright Assembly Parts List Drum Assembly Parts ListMuffler Assembly Drawing and Parts List K5B Motor Assembly Drawing K5B Motor Assembly Parts List Disc Brake Assembly Drawing Disc Brake Assembly Parts List Drum Brake Assembly Drawing Part Number Drum Brake Assembly Parts ListParts K5C2 Control Valve Assembly Drawing Part Qty Number K5C2 Control Valve Assembly Parts ListEmergency Stop and Overload K5C2-EX Valve Assembly Drawing Emergency Stop and Overload K5C2-EX Valve Parts List K5B Control Valve Assembly Drawing and Parts List K5C2-SBK Remote Pilot Remote Pilot AIR Control Optional Assembly DrawingPHS2E Remote Pilot AIR Control Optional Assembly Parts ListPendant without Emergency Stop Remote Pendant Assembly DrawingsPendant with Emergency Stop Description Total Part Remote Pendant Assembly Parts ListPart Qty With E-Stop Dwg. MHP0141 Number Part Drum Locking PIN Optional Assembly Drawing and Parts ListDrum Guard Assembly Drawing and Parts List Dwg. MHP1341 Pendant Control Assembly Drawing and Parts List Service Notes Emergency Stop Overload Assembly Drawing Emergency Stop Overload Assembly Parts List Limit Switch Assembly Drawing Limit Switch Assembly Parts List Pilot AIR Valve Plumbing Assembly Drawing Pilot AIR Valve Plumbing Assembly Parts List Tensioning Manifold Assembly Drawing Tensioning Manifold Assembly Parts List LUBRI-LINK-GREEN AIR Preparation Assembly Drawing and Parts ListAccessories Description of Accessory Accessory Part Number LubricantDwg. MHP1676 Description Part Kit KitsIngersoll Rand Parts Ordering InformationReturn Goods Policy DisposalService Notes Damage Claims WarrantyVisible Loss or Damage Concealed Loss or Damage
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FA5T, FA5 specifications

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