Ingersoll-Rand FA5T manual Maintenance Intervals, Adjustments, Equipment Being Repaired

Page 26

MAINTENANCE

WARNING

•Never perform maintenance on winch while it is supporting a load.

•Before performing maintenance, tag controls:

WARNING - DO NOT OPERATE -

EQUIPMENT BEING REPAIRED.

•Only allow service personnel trained in safety and service on this winch to perform maintenance.

•After performing any maintenance on winch, test winch to 125% of its rated capacity before returning to service. Testing to more than 125% of rated capacity may be required to comply with standards outside the USA.

•Shut off air system and depressurize air lines before performing any maintenance.

Maintenance Intervals

The Maintenance Interval chart is based on intermittent operation of winch eight hours each day, five days per week. If winch operation exceeds eight hours per day, or use is under HEAVY or SEVERE conditions, more frequent maintenance should be performed. Refer to ‘Periodic Inspection’ on page 22 in “INSPECTION” section for interval guidance.

INTERVAL

MAINTENANCE CHECK

 

 

 

 

Start of each shift

Make a thorough visual inspection of winch

 

(Operator or

for damage. Do not operate winch if

 

damaged.

 

Maintenance

 

 

Operate winch at low RPM in both

 

Personnel)

 

directions. Winch must operate smoothly

 

 

 

 

without sticking, binding or abnormal

 

 

noises. Check operation of brake(s)

 

 

 

 

3 Months

Inspect drum brake friction linings. Clean or

 

(Maintenance

replace parts as required. Adjust drum brake

 

Personnel)

as necessary.

 

 

 

 

Yearly

Inspect winch gearing, shafts and bearings

 

(Maintenance

for wear and damage. Repair or replace as

 

necessary.

 

Personnel)

 

 

Check all supporting members, including

 

 

 

 

foundation, fasteners, nuts, sheaves and

 

 

rigging, etc. for indications of damage or

 

 

wear. Repair or replace as required.

 

 

 

 

 

 

 

 

Adjustments

 

 

 

 

Disc Brake Adjustment (optional feature)

Refer to Dwg. MHP0152 on page 46.

Disc brake adjustment is not required. If disc brake does not hold rated load disassemble and repair.

If brake assembly is removed or disassembled ensure breather (23) is installed and located at top of brake housing during reassembly.

Manual Drum Brake Adjustment

Refer to Dwg. MHP0153 on page 48.

1.Release wire rope tension on drum.

2.Raise handle (104) to free brake bands (128).

3.Remove cotter pin (102) and pin (101).

4.Rotate link stud (103) clockwise to increase brake torque.

5.Install pin (101) and check adjustment.

6.Brake should be adjusted until brake lever over center position can be attained with 50 to 100 lb. (23 to 45 kg) force on handle (104).

7.Install cotter pin (102) when adjustment is completed. Bend ends of cotter pin over.

CAUTION

•When any part of brake lining measures 0.062 inch (2 mm) or less, brake bands (128) or linings must be replaced.

Automatic Drum Brake Adjustment (optional feature)

Refer to Dwg. MHP0153 on page 48.

1.Remove cotter pin (102) and washer (129) at adjustment clevis (107).

2.Apply air to brake cylinder (110) and remove pin (106) and second washer (129) to disconnect clevis from brake lever

3.Turn adjustment clevis (107) clockwise to increase cylinder rod extension. Turn clevis counterclockwise to decrease cylinder rod extension.

4.Assemble clevis (107) to brake lever (105) with washer

(129)and pin (106). Release air to brake cylinder (110).

5.Measure cylinder rod extension. Length should be 1 to 1-1/2 inches (25 to 37 mm). Readjust if necessary.

6.Install cotter pin (102) and second washer (129) to secure clevis to brake lever when adjustment is complete.

7.With brake “On”, adjust screw (127) to just touch arm (124).

Pilot Air Control Valve Adjustment (optional feature)

Refer to Dwg. MHP0141 on page 60.

If winch operating speeds differ from performance specifications pilot air control valve may require adjustment. Loosen nut (271) and adjust adjusting screw (270), located in valve end cap (268), until drum speed for no-load haul-in equals drum speed for full load payout. Rotate screw (270) ‘out’ to increase drum speed and ‘in’ to decrease drum speed. It is suggested that a chalk mark be placed on drum flange so that drum rpm can be accurately counted.

Overload Valve Adjustment (optional feature)

new style

Refer to Dwg. MP2216 on page 27

5/16 in. or 8 mm open ended wrench required.

1.Adjust overload valve by turning adjustment screw located at bottom of control valve.

2.Rotating adjustment screw clockwise will increase pressure required to activate overload valve.

WARNING

•This adjustment can cause overload device to NOT activate before winch’s safety limit is exceeded. This procedure should only be done by personnel trained in testing and servicing this winch.

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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 3XX SpecificationsFA5 Performance Graphs FA5 Winch FA5T WinchDescription of Operation FA5 FA5TMounting InstallationTraceability Minimum and Maximum Wire Rope Size Model Wire RopeWinch Bolt Hole Mounting Dimensions Drum Length inchesSafe Installation Procedures Wire Rope SpoolingSpooling Wire Rope onto Winch Drum Air SupplyMotor Emergency Stop and Overload System Components old style Constant Tension optional featureAir Schematic-Emergency Stop and Overload System old style Constant Tension ComponentsWinch Controls OperationInitial Operating Checks Remote Pilot Pendant Throttle optional feature Underwound Operation optional featureRemote Live Air Throttle optional feature Winch Mounted Throttle Control Valve Operation old styleEmergency Stop and Overload System Remote Pilot Lever Throttle optional featureEmergency Stop optional feature Pendant Hose and Operating Levers old styleEmergency Stop optional feature Overload DeviceWinch Brakes Winch Overload Device optional featureDrum Locking Pin optional feature Limit Switch optional feature Component Lubrication LubricationRecommended Lubricants Interval Lubrication ChecksDisc Brake optional feature Frequent Inspection InspectionRecords and Reports Normal Heavy Severe Periodic InspectionWinches Not in Regular Use Condition Corrective Component Action Inspection and Maintenance ReportTesting Automatic Drum Brake TroubleshootingSymptom Cause Remedy Automatic Disc Brake Adjustments MaintenanceMaintenance Intervals Interval Maintenance CheckOverload Valve Adjustment old style Overload Valve Adjustment new styleOverload Valve Adjustment optional feature Old style Limit Switch Adjustment optional featureDisassembly Manual or Automatic Drum Brake Disassembly Reduction Gear DisassemblyControl Valve Removal and Replacement K5C2 Control Valve DisassemblyCrankshaft Disassembly Handle RemovalCleaning, Inspection and Repair Assembly K5C2 Control Valve AssemblyK5C2-EX Control Valve Assembly Reduction Gear Assembly Winch Assembly Brake Seal InstallationAutomatic Drum Brake Actuator Assembly Drum AssemblyDrum Brake Assembly FA5 Band Brake ComponentsLoad Test TestingOperational Test FA5 Winch Assembly Drawings Reference Diagram FA5 Winch Drawings and Parts Lists Table of Contents DRUM, Base and Reduction Gear Assembly Drawing Part DRUM, Base and Reduction Gear Assembly Parts ListPart Description Part QtyDrum Assembly Parts List DRUM, Base and Reduction Gear Assembly Parts List CONT’DUpright 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 Parts Drum Brake Assembly Parts ListPart Number 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 PHS2EPendant with Emergency Stop Remote Pendant Assembly DrawingsPendant without Emergency Stop Part Qty With E-Stop Remote Pendant Assembly Parts ListDescription Total Part 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 Description of Accessory Accessory Part Number Lubricant AIR Preparation Assembly Drawing and Parts ListAccessories LUBRI-LINK-GREENDwg. MHP1676 Kits Description Part KitDisposal Parts Ordering InformationReturn Goods Policy Ingersoll RandService Notes Concealed Loss or Damage WarrantyVisible Loss or Damage Damage Claims
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FA5T, FA5 specifications

The Ingersoll-Rand FA5 and FA5T are cutting-edge air compressor models designed to offer exceptional performance and reliability for a variety of industrial applications. With their robust engineering, these units are ideal for both small-scale and large-scale operations, providing a significant boost to operational efficiency.

One of the main features of the FA5 series is its advanced rotary screw design, which ensures a continuous supply of compressed air while minimizing energy consumption. This energy-efficient design not only reduces operational costs but also makes the models environmentally friendly. The FA5T variant introduces enhanced technology for higher performance, targeting industries that require a greater air flow.

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The FA5 series features durable construction with high-quality materials that enhance the longevity and reliability of the compressors. The robust design minimizes wear and tear, ensuring that the units remain operational even under demanding conditions. Additionally, maintenance is simplified, thanks to easily accessible components and straightforward service procedures, which help minimize downtime.

The FA5 and FA5T also offer flexibility in installation. Their compact design enables them to fit in limited spaces, making them ideal for various industrial settings. Users appreciate the versatility of these compressors, as they can be integrated into existing systems without significant modifications.

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Overall, the Ingersoll-Rand FA5 and FA5T represent a perfect balance of high performance, energy efficiency, and operational reliability. Their advanced features make them a top choice for industries looking to improve productivity while reducing environmental impact.
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