Ingersoll-Rand FA5T manual Winch Assembly, Brake Seal Installation

Page 35

18.Align capscrew and dowel holes and install cover (73). Use a soft hammer or mallet to carefully tap the cover until flush with ring gear (72). Apply a light coating of Loctite® 242 to capscrew (75) threads and install by hand. Equally tighten the capscrews in a diametrically opposed pattern to allow for equal compression of cover onto ring gear (72) and spacer (71). When cover, ring gear and spacer flanges are flush torque capscrews to 32 ft lbs (42 Nm).

19.Install dowel pins (74) and tap into position until slightly below cover flange.

20.Place a bead of Loctite® 515 sealant on surface which mates with gear carrier. Sealant location should be inside bolt pattern.

21.Align capscrew and dowel holes and install reduction gear assembly into drum. Apply a light coating of Loctite® 242 to capscrew (45) threads and install capscrews and lockwashers (46). Torque capscrews to 255 ft lbs (346 Nm).

22.Install two dowel pins (87) and tap into position until slightly below gear carrier flange.

23.Apply thin coat of Loctite® 609 to outside of seal (43) and, with seal lip facing out, install in gear carrier (47).

Winch Assembly

Refer to Dwg. MHP0157 on page 40.

1.Clean both mating surfaces on inboard upright (42) and install drum shaft (41) through bore aligning dowel pin holes.

2.Install dowel pins (40) flush or slightly below surface of drum shaft (41).

3.Install eight capscrews (39). Lightly coat capscrew threads with Loctite® 242 and torque to 80 ft lbs (108 Nm).

4.Press bearing (37) onto shaft (35). Lightly coat inner bearing race bore with Loctite® 609. Install retainer ring (38).

5.Install shaft and bearing into drum shaft (41) so smaller splined end enters first. Install retainer ring (36) in bore of drum shaft (41).

Instructions 6 through 17 cover winches with a disc brake. For winches without a disc brake skip to instruction 18.

6.Install spacer (34) on shaft (35). Install splined hub (19) so splined side on outside diameter goes on first. Install capscrew in locking ring (18) and place on shaft (35). Maintain pressure on locking ring to keep it against splined hub (19) and tighten capscrew in locking ring (18).

7.Lubricate and install ‘O’ ring (33) on hub of drum shaft.

8.Install brake housing (21) on drum shaft (41) being careful not to damage ‘O’ ring (33).

9.Position brake housing so brake port is in the 2 o’clock position (as viewed from the motor end). Install drain plug (24) in brake housing at the 6 o’clock position.

10.Install fitting (22) and breather (23) in the top of the brake housing.

11.Lubricate friction plates (16) with a light motor oil (refer to ‘Recommended Lubricants’ on page 19 in “LUBRICATION” section). Install friction plates (16) and drive plates (17) in brake housing. Begin with a friction plate then alternate with drive plates between friction plates. Ensure splined teeth mesh. Do not force plates into place during installation.

12.Lubricate and install seals (11) and (12) in brake piston (10) grooves so seal lips face each other. Do not overstretch seals during this procedure. Refer to Dwg. MHP0139 on page 35.

13.Install brake piston assembly in brake housing so stepped side enters first. Gently tap into position using a soft mallet until seated.

14.Install one brake spring (9) in each brake spring holes.

15.Lubricate and install ‘O’ ring (33) in groove on brake housing (21).

NOTICE

•‘O’ ring, item 33 listed in step 15 refers to part number 51460 as shown on disc brake Dwg. MHP0152 on page 46. This part must be placed between brake housing (21) and motor adapter

(6).

Brake Seal Installation

(Dwg. MHP0139)

17.Install brake reaction plate (8) in motor adapter.

18.Install seal adapter (15) in mounting flange (216), if required.

19.Two threaded holes in motor adapter (6) are centered between mounting bolt holes. Install motor adapter with these two holes in 6 o’clock position.

20.Secure motor adapter with eight capscrews (1) using Loctite® 242. Torque to 125 ft lbs (170 Nm). On winches with a disc brake install capscrews evenly to compress brake springs, and torque to 80 ft lbs (108 Nm). Do not allow plate to become cocked. Evenly hand tighten all capscrews before applying final torque.

21.On disc brake equipped winches install shaft extender (7) on end of shaft (35). On winches without disc brake install seal sleeve (14) on shaft (35).

22.Lubricate and install ‘O’ ring (5) in groove on motor adapter.

23.Ensure seal adapter (15) and oil seal (2) are installed in bore of motor assembly. Seal lip must face into motor assembly.

WARNING

•The air motor weighs approximately 260 lb. (118 kg). Adequately support air motor while installing motor mounting capscrews.

24.If motor assembly is being mounted with winch in a vertical position, install one short bolt and nut to keep motor mounting flange from dropping off. Lower motor assembly carefully onto the shaft. Position throttle assembly at the top. Be careful not to damage oil seal (2). When correctly positioned remove bolt and nut and lower motor assembly the remaining distance.

MHD56037 - Edition 5

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Contents Model FA5 and FA5T Table of Contents Safety Summary Safety InformationSafe Operating Instructions 3XX SpecificationsFA5 FA5T Winch Performance Graphs FA5 WinchFA5 FA5T Description of OperationMounting InstallationTraceability 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 styleWinch Controls OperationInitial Operating Checks 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 featureWinch Brakes Winch Overload Device optional featureDrum Locking Pin optional feature Limit Switch optional feature Interval Lubrication Checks LubricationRecommended Lubricants Component LubricationDisc 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 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 AssemblyLoad 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 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 Parts Drum Brake Assembly Parts ListPart Number 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 with Emergency Stop Remote Pendant Assembly DrawingsPendant without Emergency Stop Part Qty With E-Stop Remote Pendant Assembly Parts ListDescription Total Part 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

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.

The compressors are equipped with a state-of-the-art microprocessor controller that allows for precise monitoring of system performance. This intelligent controller provides real-time data on operating conditions, such as pressure levels and temperature, allowing operators to ensure optimal performance and preemptively address potential issues.

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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.

Ingersoll-Rand has incorporated innovative technologies into the FA5 and FA5T, such as variable speed drive capabilities which allow for greater control of output levels. This feature ensures that the compressor operates only as needed, further enhancing energy efficiency.

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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