Ingersoll-Rand FA5 Air Supply, Installing Wire Rope, Safe Wire Rope Handling Procedures, Rigging

Installing Wire Rope

CAUTION

•To avoid disc brake damage when installing wire rope pressurize brake with a minimum of 60 psi (4.1 bar) air from an auxiliary source.

Refer to Dwg. MHP0166 on page 10.

1.Cut wire rope to length in accordance with wire rope manufacturer’s instructions.

2.Feed end of wire rope into wire rope anchor hole in drum and pull through approximately one foot (305 mm) of wire rope.

(Dwg. MHP0166)

3.Wrap wire rope with wire a distance from the end equal to wedge length plus one inch (25 mm).

4.Slide sleeve over end of wire rope so larger diameter of taper bore is nearest the end of wire rope.

5.Spread end strands of wire rope and insert split wedge until it is below the end of wire rope.

6.Pull sleeve over wire rope end until tight. Check that wire rope strands stay in the slots located on split wedge.

7.Pull wire rope anchor into position in drum anchor pocket.

CAUTION

•Make sure first wrap of wire rope is tight and lays flush against drum flange.

Safe Wire Rope Handling Procedures

1.Always use gloves when handling wire rope.

2.Never use wire rope which is frayed or kinked.

3.Never use wire rope as a sling.

4.Always ensure wire rope is correctly spooled and the first layer is tight against drum.

5.Always follow wire rope manufacturers’ recommendation on use and maintenance of wire rope.

Wire Rope Spooling

Refer to Dwg. MHP2125 on page 10.

To compensate for uneven spooling and decrease in line pull capacity as drum fills up, use as short a wire rope as practical. When rewinding apply tension to the end of wire rope to eliminate slack. This helps achieve level winding and tight spooling.

Support wire rope spool and have wire rope come off top of spool and over top of winch drum. This will prevent damage to wire rope.

Spooling Wire Rope onto Winch Drum

(Dwg. MHP2125)

Rigging

Make sure all wire rope blocks, tackle and fasteners have a sufficient safety margin to handle required load under all conditions. Do not allow wire rope to contact sharp edges or make sharp bends which will cause damage to wire rope, use a sheave. Refer to wire rope manufacturer’s handbook for proper sizing, use and care of wire rope.

Safe Installation Procedures

1.Do not use wire rope as a ground (earth) for welding.

2.Do not attach a welding electrode to winch or wire rope.

3.Never run wire rope over a sharp edge. Use a correctly sized sheave.

4.When a lead sheave is used, it must be aligned with center of drum. The diameter of lead sheave must be at least 18 times diameter of wire rope. Refer to Dwg. MHP2123 on page 9.

5.Always maintain at least three full, tight wraps of wire rope on drum.

Air Supply

The air supply must be clean, free from moisture and lubricated to ensure optimum motor performance. Foreign particles, moisture and lack of lubrication are the primary causes of premature motor wear and breakdown. Using an air filter, lubricator and moisture separator will improve overall winch performance and reduce unscheduled down time.

Air consumption for the FA5 and FA5T air motor is 700 scfm (20 cu. m/min.) at rated operating pressure of 90 psig (6.3 bar) at winch motor inlet. If air supply varies from recommended, then winch performance will change.

10 MHD56037 - Edition 5