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