Ingersoll-Rand FA5T manual Troubleshooting, Symptom Cause Remedy, Automatic Drum Brake

Page 24

TROUBLESHOOTING

This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common winch symptoms, probable causes and remedies.

SYMPTOM

CAUSE

REMEDY

Winch will not operate.

No air supply to winch.

Check air supply line connections and hoses.

 

Winch is overloaded.

Reduce load to within rated capacity.

 

Disc brake does not release.

Pressurize disc brake release port and check for leakage. Replace brake

 

 

piston seals if leakage is found. Ensure air pressure at inlet to disc brake is

 

 

at least 50 psig (3.4 bar/340 kPa).

 

 

 

 

Shipping plugs may still be in

Remove shipping plugs in valve and motor exhaust ports.

 

place.

 

 

Drum brake does not release.

Disengage manual drum brake, or refer to ‘Automatic Drum Brake

 

 

Adjustment’ on page 26.

 

 

 

Load continues to move when

Drum brake is slipping.

Check drum brake adjustment on page 26 and brake band lining wear.

winch is stopped.

 

 

Winch is overloaded.

Reduce load to within rated capacity.

 

Winch motor controls sticking.

Check pendant/throttle levers spring return to normal (neutral) positions

 

 

when released.

 

 

 

Winch does not lift load or

Motor may be damaged.

Remove and disassemble motor as described in the “MAINTENANCE”

does not lift rated capacity.

 

section on page 30. Examine all parts and replace any that are worn or

 

 

damaged.

 

 

 

 

Insufficient air supply.

Verify air supply pressure and volume at winch inlet meets requirements

 

 

listed in the “SPECIFICATIONS” section on page 5. Clean air line filter.

Throttle or pendant lever

Motor may be damaged.

Disassemble and clean motor and replace any broken or damaged parts.

moves but winch does not

 

 

Insufficient air supply.

Ensure air pressure at winch inlet is at least 90 psig (6.3 bar/630 kPa) at

operate.

 

rated volume. Clean air line filter.

 

 

 

 

Air leak.

Check hose and fitting connections. Inspect hose(s) for breaks. Tighten

 

 

fittings and repair or replace hoses as necessary.

Motor runs hot or makes

Low oil level.

Check oil level in motor. Add oil as required to obtain proper level.

excessive noise during

 

 

Improper lubrication.

Replace oil with type recommended in “LUBRICATION” section on

operation.

 

page 19. Set lubricator to provide 6 to 9 drops of oil per minute at

 

 

maximum winch operating capacity.

 

 

 

 

Water in oil.

Drain and refill with recommended oil. Operate winch with no load

 

 

slowly, in both directions. If noise still exists or motor overheats

 

 

disassemble and repair motor.

 

 

 

 

Damaged or broken piston or

Disassemble and repair motor.

 

connecting rod.

 

 

 

 

Winch runs slow.

Improper hose or fitting sizes.

Check fittings, connections and hoses for correct size and length. Replace

 

 

parts that may cause restricted air flow. Inspect air line filter.

 

 

 

 

Motor may be damaged.

Remove and disassemble motor as described in the “MAINTENANCE”

 

 

section on page 30. Inspect all parts and replace all worn or damaged

 

 

parts.

 

 

 

 

Brake(s) not releasing.

Refer to brakes in “MAINTENANCE” section on page 26.

Air lines freeze.

Water in air supply.

Install or drain air system moisture traps, moisture collecting air receivers

 

 

and compressor aftercoolers. After corrective action has been taken,

 

 

disconnect lines at winch inlet and purge with clean, dry air or nitrogen.

 

 

 

Throttle lever hard to actuate,

Valve body sticking in

Lubricate valve through grease fitting with recommended lubricant. Refer

or lever does not spring return

bushing.

to ‘Air Throttle’ on page 19 in “LUBRICATION” section.

to neutral.

 

 

 

 

 

Automatic Drum Brake:

 

 

Brake cylinder will not

Drum brake out of adjustment.

Adjust drum brake to maintain correct cylinder stroke.

release.

 

 

Leaking cylinder seals.

If air is noticed escaping from cylinder breather when attempting to

 

 

release brake, replace or repair cylinder.

 

 

 

 

Dirty filter in air supply.

Clean or replace filter.

 

Faulty dump valve.

Check dump valve exhaust port. Air should exhaust when control valve

 

 

handle is in neutral. If no air escapes, replace dump valve.

 

 

 

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MHD56037 - Edition 5

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Contents Model FA5 and FA5T Table of Contents Safety Information Safety SummarySafe Operating Instructions Specifications FA53XX Performance Graphs FA5 Winch FA5T WinchDescription of Operation FA5 FA5TInstallation TraceabilityMounting Wire Rope Winch Bolt Hole Mounting DimensionsMinimum and Maximum Wire Rope Size Model Drum Length inchesWire Rope Spooling Spooling Wire Rope onto Winch DrumSafe Installation Procedures Air SupplyMotor Constant Tension optional feature Air Schematic-Emergency Stop and Overload System old styleEmergency Stop and Overload System Components old style Constant Tension ComponentsOperation Initial Operating ChecksWinch Controls Underwound Operation optional feature Remote Live Air Throttle optional featureRemote Pilot Pendant Throttle optional feature Winch Mounted Throttle Control Valve Operation old styleRemote Pilot Lever Throttle optional feature Emergency Stop optional featureEmergency Stop and Overload System Pendant Hose and Operating Levers old styleEmergency Stop optional feature Overload DeviceWinch Overload Device optional feature Drum Locking Pin optional featureWinch Brakes Limit Switch optional feature Lubrication Recommended LubricantsComponent Lubrication Interval Lubrication ChecksDisc Brake optional feature Inspection Records and ReportsFrequent Inspection Periodic Inspection Winches Not in Regular UseNormal Heavy Severe Inspection and Maintenance Report TestingCondition Corrective Component Action Troubleshooting Symptom Cause RemedyAutomatic Drum Brake Automatic Disc Brake Maintenance Maintenance IntervalsAdjustments Interval Maintenance CheckOverload Valve Adjustment new style Overload Valve Adjustment optional feature Old styleOverload Valve Adjustment old style Limit Switch Adjustment optional featureDisassembly Manual or Automatic Drum Brake Disassembly Reduction Gear DisassemblyK5C2 Control Valve Disassembly Crankshaft DisassemblyControl Valve Removal and Replacement Handle RemovalCleaning, Inspection and Repair Assembly K5C2 Control Valve AssemblyK5C2-EX Control Valve Assembly Reduction Gear Assembly Winch Assembly Brake Seal InstallationDrum Assembly Drum Brake AssemblyAutomatic Drum Brake Actuator Assembly FA5 Band Brake ComponentsTesting Operational TestLoad Test FA5 Winch Assembly Drawings Reference Diagram FA5 Winch Drawings and Parts Lists Table of Contents DRUM, Base and Reduction Gear Assembly Drawing DRUM, Base and Reduction Gear Assembly Parts List Part DescriptionPart Part QtyDRUM, Base and Reduction Gear Assembly Parts List CONT’D Upright Assembly Parts ListDrum Assembly Parts List Side Rail 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 Drum Brake Assembly Parts List Part NumberParts K5C2 Control Valve Assembly Drawing K5C2 Control Valve Assembly Parts List Part Qty NumberEmergency 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 AIR Control Optional Assembly Drawing Remote PilotRemote Pilot AIR Control Optional Assembly Parts List PHS2ERemote Pendant Assembly Drawings Pendant without Emergency StopPendant with Emergency Stop Remote Pendant Assembly Parts List Description Total PartPart Qty With E-Stop Dwg. MHP0141 Drum Locking PIN Optional Assembly Drawing and Parts List Number PartDrum 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 AIR Preparation Assembly Drawing and Parts List AccessoriesDescription of Accessory Accessory Part Number Lubricant LUBRI-LINK-GREENDwg. MHP1676 Kits Description Part KitParts Ordering Information Return Goods PolicyDisposal Ingersoll RandService Notes Warranty Visible Loss or DamageConcealed Loss or Damage Damage Claims
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FA5T, FA5 specifications

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