PARTS, OPERATION AND MAINTENANCE MANUAL
MODEL FA5 AND FA5T
TABLE OF CONTENTS
Safety Information
Specifications
Installation
SAFETY INFORMATION
Safety Summary
Danger, Warning, Caution and Notice
SAFE OPERATING INSTRUCTIONS
WARNING LABEL
SPECIFICATIONS
Series Capacity FA5 = Air Powered Winch 5 metric ton / 11,000 lbs
Model Code Explanation
Example FA5-24MK320P
Performance Graphs FA5 Winch
Dwg. MHP1890
FA5T Winch
Dwg. MHP1891
General Specifications
Drum Wire Rope
Description of Operation
Model
INSTALLATION
Winch Bolt Hole Mounting Dimension Drawing
Traceability
Mounting
Wire Rope
Table 2-Winch Bolt Hole Mounting Dimensions
Maintain at least 3 tight wraps of wire rope on drum at all times
Wire Rope Selection
Installing Wire Rope
Safe Wire Rope Handling Procedures
Wire Rope Spooling
Spooling Wire Rope onto Winch Drum
Emergency Stop and Overload System optional feature
Motor
Air Lines
Table 4-Minimum Allowable Air Supply Line Sizes
Constant Tension optional feature
Air Schematic-Emergency Stop and Overload System old style
Air Schematic-Constant Tension Winches
Emergency Stop and Overload System Components old style
OPERATION
Winch Mounted Air Throttle standard feature New Style
Initial Operating Checks
Winch Controls
Underwound Operation optional feature
Remote Live Air Throttle optional feature
Remote Pilot Pendant Throttle optional feature
Winch Mounted Throttle Control Valve Operation old style
Remote Pilot Lever Throttle optional feature
Emergency Stop optional feature
Dwg. MHP2036 on page Emergency Stop Reset
Emergency Stop Reset
Emergency Stop optional feature
Checking Overload Valve Setting
Setting the Overload
Overload Valve Reset
Winch Overload Device optional feature
Constant Tension optional feature
Drum Locking Pin optional feature
Automatic Drum Brake optional feature
Limit Switch optional feature
To Disengage
LUBRICATION
Recommended Lubricants
Component Lubrication
INTERVAL
Disc Brake optional feature
Wire Rope
Reduction Gear Assembly
K5B Motor Lubrication Locations
INSPECTION
Drum Locking Pin optional feature
Wire Rope Reports
Records and Reports
Periodic Inspection
Winches Not in Regular Use
NORMAL HEAVY SEVERE
INSPECTION AND MAINTENANCE REPORT
TESTING
Ingersoll-Rand Force 5 Series FA5 and FA5T Air Winches
Model Number
TROUBLESHOOTING
SYMPTOM
CAUSE
REMEDY
SYMPTOM
CAUSE
REMEDY
Automatic Disc Brake
MAINTENANCE
Maintenance Intervals
Adjustments
Never perform maintenance on winch while it is supporting a load
Overload Valve Adjustment new style
Overload Valve Adjustment optional feature old style
Checking Overload Valve Setting
Setting the Overload
Disassembly
Constant Tension Adjustment optional feature
Regulator Adjustment Procedure
Setting with test load
Note position of all brake parts for reassembly
Manual or Automatic Drum Brake Disassembly
Reduction Gear Disassembly
Instructions 11 through 17 apply only to winches with a disc brake
K5C2 Control Valve Disassembly
K5B Motor Disassembly
Crankshaft Disassembly
Control Valve Removal and Replacement
Cleaning, Inspection and Repair
K5B Control Valve Disassembly old style
Match mark throttle valve parts to ensure proper re- assembly
K5C2-E Control Valve Disassembly
Assembly
K5C2 Control Valve Assembly
Reverse Valve Assembly
Pilot Valve Assembly
K5C2-EX Control Valve Assembly
K5B Control Valve Assembly old style
During assembly align parts using match marks made during disassembly
Reverse Valve Assembly
Reduction Gear Assembly
Winch Assembly
Brake Seal Installation
Drum Assembly
Drum Brake Assembly
Automatic Drum Brake Actuator Assembly
FA5 Band Brake Components
Testing
Limit Switches
Operational Test
Load Test
FA5 WINCH ASSEMBLY DRAWINGS REFERENCE DIAGRAM
Dwg. MHP1493
MHD56037 - Edition
FA5 WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS
Description
DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING
Dwg. MHP0157
MHD56037 - Edition
DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST
Description
Part
Description
DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST CONT’D
UPRIGHT ASSEMBLY PARTS LIST
DRUM ASSEMBLY PARTS LIST
SIDE RAIL PARTS LIST
MUFFLER ASSEMBLY DRAWING AND PARTS LIST
K5B MOTOR ASSEMBLY DRAWING
K5C2 Valve
K5B MOTOR ASSEMBLY PARTS LIST
K5B Motor Assembly Kit List
Description
Part
DISC BRAKE ASSEMBLY DRAWING
Dwg. MHP0152
Note Tee fitting for use on units with Disc and Auto Band Brake only
MHD56037 - Edition
DISC BRAKE ASSEMBLY PARTS LIST
Description
Part
of Part
DRUM BRAKE ASSEMBLY DRAWING
Dwg. MHP0153
MHD56037 - Edition
DRUM BRAKE ASSEMBLY PARTS LIST
Description
Part Number
of Part
K5C2 CONTROL VALVE ASSEMBLY DRAWING
Dwg. MHP2036
K5C2 CONTROL VALVE ASSEMBLY PARTS LIST
Description
Part
Description
EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE ASSEMBLY DRAWING
Dwg. MHP2180
EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE PARTS LIST
Description
Part
Description
K5B CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST
old style
Description
Part
FULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST
Description
Part
of Part
REMOTE PILOT AIR CONTROL OPTIONAL ASSEMBLY DRAWING
To Brake
Remote Pilot
Remote Pilot
REMOTE PILOT AIR CONTROL OPTIONAL ASSEMBLY PARTS LIST
Description
Part
of Part
REMOTE PENDANT ASSEMBLY DRAWINGS
Pendant without Emergency Stop
Pendant with Emergency Stop
MHD56037 - Edition
REMOTE PENDANT ASSEMBLY PARTS LIST
Description
Total
Part
PILOT AIR CONTROL VALVE OPTIONAL ASSEMBLY DRAWING AND PARTS LIST
Service Kit
Description
Part Number
DRUM LOCKING PIN OPTIONAL ASSEMBLY DRAWING AND PARTS LIST
Description
Part
Description
DRUM GUARD ASSEMBLY DRAWING AND PARTS LIST
Drum Guard Assembly includes items 3, 96 and 150 through
Description
Part Number
EMERGENCY STOP VALVE, OVERLOAD ASSEMBLY DRAWING AND PARTS LIST
old style
Description
Part
PENDANT CONTROL ASSEMBLY DRAWING AND PARTS LIST
old style
Description
Part
SERVICE NOTES
MHD56037 - Edition
EMERGENCY STOP OVERLOAD ASSEMBLY DRAWING
Dwg. MHP1488
MHD56037 - Edition
EMERGENCY STOP OVERLOAD ASSEMBLY PARTS LIST
Description
Part
Description
LIMIT SWITCH ASSEMBLY DRAWING
Dwg. MHP2027
MHD56037 - Edition
LIMIT SWITCH ASSEMBLY PARTS LIST
Description
Part
of Part
PILOT AIR VALVE PLUMBING ASSEMBLY DRAWING
Dwg. MHP1679
MHD56037 - Edition
PILOT AIR VALVE PLUMBING ASSEMBLY PARTS LIST
Description
Part
of Part
TENSIONING MANIFOLD ASSEMBLY DRAWING
Dwg. MHP2028
MHD56037 - Edition
TENSIONING MANIFOLD ASSEMBLY PARTS LIST
Description
Part
of Part
AIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST
ACCESSORIES
Description of Accessory
Accessory Part Number
Description
Part
Description
Part
KITS
K5C2-X and K5C2-EX Control Valve Service Kits
Description
Part
PARTS ORDERING INFORMATION
Return Goods Policy
Sections of this manual may not apply to your winch
Disposal
SERVICE NOTES
MHD56037 - Edition
WARRANTY
LIMITED WARRANTY
IMPORTANT NOTICE
Visible Loss or Damage