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Ingersoll-Rand FA5T manual

Models: FA5

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Ingersoll-Rand FA5T manual

Contents

PARTS, OPERATION AND MAINTENANCE MANUAL MODEL FA5 AND FA5TTABLE OF CONTENTS Safety InformationSpecifications InstallationDanger, Warning, Caution and Notice SAFETY INFORMATIONSafety Summary SAFE OPERATING INSTRUCTIONS WARNING LABELSPECIFICATIONS Series Capacity FA5 = Air Powered Winch 5 metric ton / 11,000 lbsModel Code Explanation Example FA5-24MK320PPerformance Graphs FA5 Winch Dwg. MHP1890FA5T Winch Dwg. MHP1891General Specifications Drum Wire RopeDescription of Operation ModelINSTALLATION Winch Bolt Hole Mounting Dimension DrawingTraceability MountingWire Rope Table 2-Winch Bolt Hole Mounting DimensionsMaintain at least 3 tight wraps of wire rope on drum at all times Wire Rope SelectionInstalling Wire Rope Safe Wire Rope Handling ProceduresWire Rope Spooling Spooling Wire Rope onto Winch DrumEmergency Stop and Overload System optional feature MotorAir Lines Table 4-Minimum Allowable Air Supply Line SizesConstant Tension optional feature Air Schematic-Emergency Stop and Overload System old styleAir Schematic-Constant Tension Winches Emergency Stop and Overload System Components old styleOPERATION Winch Mounted Air Throttle standard feature New StyleInitial Operating Checks Winch ControlsUnderwound Operation optional feature Remote Live Air Throttle optional featureRemote Pilot Pendant Throttle optional feature Winch Mounted Throttle Control Valve Operation old styleRemote Pilot Lever Throttle optional feature Emergency Stop optional featureDwg. MHP2036 on page Emergency Stop Reset Emergency Stop ResetEmergency Stop optional feature Checking Overload Valve SettingSetting the Overload Overload Valve ResetWinch Overload Device optional feature Constant Tension optional featureDrum Locking Pin optional feature Automatic Drum Brake optional featureLimit Switch optional feature To DisengageLUBRICATION TemperatureTemperature TemperatureDisc Brake optional feature Wire RopeReduction Gear Assembly K5B Motor Lubrication LocationsINSPECTION Drum Locking Pin optional featureWire Rope Reports Records and ReportsNORMAL HEAVY SEVERE Periodic InspectionWinches Not in Regular Use INSPECTION AND MAINTENANCE REPORT TESTINGIngersoll-Rand Force 5 Series FA5 and FA5T Air Winches Model NumberTROUBLESHOOTING SYMPTOMCAUSE REMEDYSYMPTOM CAUSEREMEDY Automatic Disc BrakeMAINTENANCE Maintenance IntervalsAdjustments Never perform maintenance on winch while it is supporting a loadOverload Valve Adjustment new style Overload Valve Adjustment optional feature old styleChecking Overload Valve Setting Setting the OverloadDisassembly Constant Tension Adjustment optional featureRegulator Adjustment Procedure Setting with test loadNote position of all brake parts for reassembly Manual or Automatic Drum Brake DisassemblyReduction Gear Disassembly Instructions 11 through 17 apply only to winches with a disc brakeK5C2 Control Valve Disassembly K5B Motor DisassemblyCrankshaft Disassembly Control Valve Removal and ReplacementCleaning, Inspection and Repair K5B Control Valve Disassembly old styleMatch mark throttle valve parts to ensure proper re- assembly K5C2-E Control Valve DisassemblyAssembly K5C2 Control Valve AssemblyReverse Valve Assembly Pilot Valve AssemblyK5C2-EX Control Valve Assembly K5B Control Valve Assembly old styleDuring assembly align parts using match marks made during disassembly Reverse Valve AssemblyReduction Gear Assembly Winch Assembly Brake Seal InstallationDrum Assembly Drum Brake AssemblyAutomatic Drum Brake Actuator Assembly FA5 Band Brake ComponentsTesting Limit SwitchesOperational Test Load TestMHD56037 - Edition FA5 WINCH ASSEMBLY DRAWINGS REFERENCE DIAGRAMDwg. MHP1493 FA5 WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS DescriptionMHD56037 - Edition DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWINGDwg. MHP0157 DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST DescriptionPart DescriptionDRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST CONT’D UPRIGHT ASSEMBLY PARTS LISTDRUM ASSEMBLY PARTS LIST SIDE RAIL PARTS LISTMUFFLER ASSEMBLY DRAWING AND PARTS LIST K5B MOTOR ASSEMBLY DRAWING K5C2 ValveK5B MOTOR ASSEMBLY PARTS LIST K5B Motor Assembly Kit ListDescription PartDISC BRAKE ASSEMBLY DRAWING Dwg. MHP0152Note Tee fitting for use on units with Disc and Auto Band Brake only MHD56037 - EditionDISC BRAKE ASSEMBLY PARTS LIST DescriptionPart of PartMHD56037 - Edition DRUM BRAKE ASSEMBLY DRAWINGDwg. MHP0153 DRUM BRAKE ASSEMBLY PARTS LIST DescriptionPart Number of PartK5C2 CONTROL VALVE ASSEMBLY DRAWING Dwg. MHP2036K5C2 CONTROL VALVE ASSEMBLY PARTS LIST DescriptionPart DescriptionEMERGENCY STOP AND OVERLOAD K5C2-EX VALVE ASSEMBLY DRAWING Dwg. MHP2180EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE PARTS LIST DescriptionPart DescriptionK5B CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST old styleDescription PartFULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST DescriptionPart of PartREMOTE PILOT AIR CONTROL OPTIONAL ASSEMBLY DRAWING To BrakeRemote Pilot Remote PilotREMOTE PILOT AIR CONTROL OPTIONAL ASSEMBLY PARTS LIST DescriptionPart of PartREMOTE PENDANT ASSEMBLY DRAWINGS Pendant without Emergency StopPendant with Emergency Stop MHD56037 - EditionREMOTE PENDANT ASSEMBLY PARTS LIST DescriptionTotal PartPILOT AIR CONTROL VALVE OPTIONAL ASSEMBLY DRAWING AND PARTS LIST Service KitDescription Part NumberDRUM LOCKING PIN OPTIONAL ASSEMBLY DRAWING AND PARTS LIST DescriptionPart DescriptionDRUM GUARD ASSEMBLY DRAWING AND PARTS LIST Drum Guard Assembly includes items 3, 96 and 150 throughDescription Part NumberEMERGENCY STOP VALVE, OVERLOAD ASSEMBLY DRAWING AND PARTS LIST old styleDescription PartPENDANT CONTROL ASSEMBLY DRAWING AND PARTS LIST old styleDescription PartSERVICE NOTES MHD56037 - EditionMHD56037 - Edition EMERGENCY STOP OVERLOAD ASSEMBLY DRAWINGDwg. MHP1488 EMERGENCY STOP OVERLOAD ASSEMBLY PARTS LIST DescriptionPart DescriptionMHD56037 - Edition LIMIT SWITCH ASSEMBLY DRAWINGDwg. MHP2027 LIMIT SWITCH ASSEMBLY PARTS LIST DescriptionPart of PartMHD56037 - Edition PILOT AIR VALVE PLUMBING ASSEMBLY DRAWINGDwg. MHP1679 PILOT AIR VALVE PLUMBING ASSEMBLY PARTS LIST DescriptionPart of PartMHD56037 - Edition TENSIONING MANIFOLD ASSEMBLY DRAWINGDwg. MHP2028 TENSIONING MANIFOLD ASSEMBLY PARTS LIST DescriptionPart of PartAIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST ACCESSORIESDescription of Accessory Accessory Part NumberDescription PartDescription PartKITS K5C2-X and K5C2-EX Control Valve Service KitsDescription PartPARTS ORDERING INFORMATION Return Goods PolicySections of this manual may not apply to your winch DisposalSERVICE NOTES MHD56037 - EditionWARRANTY LIMITED WARRANTYIMPORTANT NOTICE Visible Loss or Damage