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