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