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Ingersoll-Rand FA5T manual Service Notes, MHD56037 - Edition

Models: FA5

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SERVICE NOTES

MHD56037 - Edition 5

Page 65

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Ingersoll-Rand FA5T manual Service Notes, MHD56037 - Edition

Contents

MODEL FA5 AND FA5T PARTS, OPERATION AND MAINTENANCE MANUALSafety Information TABLE OF CONTENTSSpecifications InstallationDanger, Warning, Caution and Notice SAFETY INFORMATIONSafety Summary WARNING LABEL SAFE OPERATING INSTRUCTIONSSeries Capacity FA5 = Air Powered Winch 5 metric ton / 11,000 lbs SPECIFICATIONSModel Code Explanation Example FA5-24MK320PDwg. MHP1890 Performance Graphs FA5 WinchFA5T Winch Dwg. MHP1891Drum Wire Rope General SpecificationsDescription of Operation ModelWinch Bolt Hole Mounting Dimension Drawing INSTALLATIONTraceability MountingTable 2-Winch Bolt Hole Mounting Dimensions Wire RopeMaintain at least 3 tight wraps of wire rope on drum at all times Wire Rope SelectionSafe Wire Rope Handling Procedures Installing Wire RopeWire Rope Spooling Spooling Wire Rope onto Winch DrumMotor Emergency Stop and Overload System optional featureAir Lines Table 4-Minimum Allowable Air Supply Line SizesAir Schematic-Emergency Stop and Overload System old style Constant Tension optional featureAir Schematic-Constant Tension Winches Emergency Stop and Overload System Components old styleWinch Mounted Air Throttle standard feature New Style OPERATIONInitial Operating Checks Winch ControlsRemote Live Air Throttle optional feature Underwound Operation optional featureRemote Pilot Pendant Throttle optional feature Winch Mounted Throttle Control Valve Operation old styleEmergency Stop optional feature Remote Pilot Lever Throttle optional featureDwg. MHP2036 on page Emergency Stop Reset Emergency Stop ResetChecking Overload Valve Setting Emergency Stop optional featureSetting the Overload Overload Valve ResetConstant Tension optional feature Winch Overload Device optional featureDrum Locking Pin optional feature Automatic Drum Brake optional featureTo Disengage Limit Switch optional featureTemperature LUBRICATIONTemperature TemperatureWire Rope Disc Brake optional featureReduction Gear Assembly K5B Motor Lubrication LocationsDrum Locking Pin optional feature INSPECTIONWire Rope Reports Records and ReportsNORMAL HEAVY SEVERE Periodic InspectionWinches Not in Regular Use TESTING INSPECTION AND MAINTENANCE REPORTIngersoll-Rand Force 5 Series FA5 and FA5T Air Winches Model NumberSYMPTOM TROUBLESHOOTINGCAUSE REMEDYCAUSE SYMPTOMREMEDY Automatic Disc BrakeMaintenance Intervals MAINTENANCEAdjustments Never perform maintenance on winch while it is supporting a loadOverload Valve Adjustment optional feature old style Overload Valve Adjustment new styleChecking Overload Valve Setting Setting the OverloadConstant Tension Adjustment optional feature DisassemblyRegulator Adjustment Procedure Setting with test loadManual or Automatic Drum Brake Disassembly Note position of all brake parts for reassemblyReduction Gear Disassembly Instructions 11 through 17 apply only to winches with a disc brakeK5B Motor Disassembly K5C2 Control Valve DisassemblyCrankshaft Disassembly Control Valve Removal and ReplacementK5B Control Valve Disassembly old style Cleaning, Inspection and RepairMatch mark throttle valve parts to ensure proper re- assembly K5C2-E Control Valve DisassemblyK5C2 Control Valve Assembly AssemblyReverse Valve Assembly Pilot Valve AssemblyK5B Control Valve Assembly old style K5C2-EX Control Valve AssemblyDuring assembly align parts using match marks made during disassembly Reverse Valve AssemblyReduction Gear Assembly Brake Seal Installation Winch AssemblyDrum Brake Assembly Drum AssemblyAutomatic Drum Brake Actuator Assembly FA5 Band Brake ComponentsLimit Switches TestingOperational Test Load TestMHD56037 - Edition FA5 WINCH ASSEMBLY DRAWINGS REFERENCE DIAGRAMDwg. MHP1493 Description FA5 WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTSMHD56037 - Edition DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWINGDwg. MHP0157 Description DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LISTPart DescriptionUPRIGHT ASSEMBLY PARTS LIST DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST CONT’DDRUM ASSEMBLY PARTS LIST SIDE RAIL PARTS LISTMUFFLER ASSEMBLY DRAWING AND PARTS LIST K5C2 Valve K5B MOTOR ASSEMBLY DRAWINGK5B Motor Assembly Kit List K5B MOTOR ASSEMBLY PARTS LISTDescription PartDwg. MHP0152 DISC BRAKE ASSEMBLY DRAWINGNote Tee fitting for use on units with Disc and Auto Band Brake only MHD56037 - EditionDescription DISC BRAKE ASSEMBLY PARTS LISTPart of PartMHD56037 - Edition DRUM BRAKE ASSEMBLY DRAWINGDwg. MHP0153 Description DRUM BRAKE ASSEMBLY PARTS LISTPart Number of PartDwg. MHP2036 K5C2 CONTROL VALVE ASSEMBLY DRAWINGDescription K5C2 CONTROL VALVE ASSEMBLY PARTS LISTPart DescriptionDwg. MHP2180 EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE ASSEMBLY DRAWINGDescription EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE PARTS LISTPart Descriptionold style K5B CONTROL VALVE ASSEMBLY DRAWING AND PARTS LISTDescription PartDescription FULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LISTPart of PartTo Brake REMOTE PILOT AIR CONTROL OPTIONAL ASSEMBLY DRAWINGRemote Pilot Remote PilotDescription REMOTE PILOT AIR CONTROL OPTIONAL ASSEMBLY PARTS LISTPart of PartPendant without Emergency Stop REMOTE PENDANT ASSEMBLY DRAWINGSPendant with Emergency Stop MHD56037 - EditionDescription REMOTE PENDANT ASSEMBLY PARTS LISTTotal PartService Kit PILOT AIR CONTROL VALVE OPTIONAL ASSEMBLY DRAWING AND PARTS LISTDescription Part NumberDescription DRUM LOCKING PIN OPTIONAL ASSEMBLY DRAWING AND PARTS LISTPart DescriptionDrum Guard Assembly includes items 3, 96 and 150 through DRUM GUARD ASSEMBLY DRAWING AND PARTS LISTDescription Part Numberold style EMERGENCY STOP VALVE, OVERLOAD ASSEMBLY DRAWING AND PARTS LISTDescription Partold style PENDANT CONTROL ASSEMBLY DRAWING AND PARTS LISTDescription PartMHD56037 - Edition SERVICE NOTESMHD56037 - Edition EMERGENCY STOP OVERLOAD ASSEMBLY DRAWINGDwg. MHP1488 Description EMERGENCY STOP OVERLOAD ASSEMBLY PARTS LISTPart DescriptionMHD56037 - Edition LIMIT SWITCH ASSEMBLY DRAWINGDwg. MHP2027 Description LIMIT SWITCH ASSEMBLY PARTS LISTPart of PartMHD56037 - Edition PILOT AIR VALVE PLUMBING ASSEMBLY DRAWINGDwg. MHP1679 Description PILOT AIR VALVE PLUMBING ASSEMBLY PARTS LISTPart of PartMHD56037 - Edition TENSIONING MANIFOLD ASSEMBLY DRAWINGDwg. MHP2028 Description TENSIONING MANIFOLD ASSEMBLY PARTS LISTPart of PartACCESSORIES AIR PREPARATION ASSEMBLY DRAWING AND PARTS LISTDescription of Accessory Accessory Part NumberPart DescriptionDescription PartK5C2-X and K5C2-EX Control Valve Service Kits KITSDescription PartReturn Goods Policy PARTS ORDERING INFORMATIONSections of this manual may not apply to your winch DisposalMHD56037 - Edition SERVICE NOTESLIMITED WARRANTY WARRANTYIMPORTANT NOTICE Visible Loss or Damage