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PARTS, OPERATION AND MAINTENANCE MANUAL
THIRD GENERATION
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance infor-
mation. Make this manual available to all persons responsible for the
operation, installation and maintenance of these products.
Do not use this winch for lifting, supporting, or transporting people or lifting or supporting
loads over people.
Always operate, inspect and maintain this winch in accordance with American National
Standards Institute Safety Code (ASME B30.7) and any other applicable safety codes and
regulations.
Refer all communications to the nearest Ingersoll-Rand Material Handling Office or
Distributor.
Form MHD56087
Edition 3
April 1997
71146690
© 1997 Ingersoll-Rand Company
MODEL FA5A
WARNING
1
™
AIR WINCHES
Form MHD56087
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Summary of Contents for Ingersoll-Rand force5 FA5A-SXK1
- Page 1 Always operate, inspect and maintain this winch in accordance with American National Standards Institute Safety Code (ASME B30.7) and any other applicable safety codes and regulations. Refer all communications to the nearest Ingersoll-Rand Material Handling Office or Distributor. Form MHD56087...
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Page 2: Table Of Contents
CONTENTS Page Safety Information Danger, Warning, Caution and Notice ................................3 Safe Operating Instructions ....................................4 Warning Labels and Tag ....................................4 Specifications Description ......................................... 5 Model Code Explanation ....................................5 General Specifications ....................................... 6 Winch Weight and Wire Rope Capacities ................................. 6 Performance Graph ...................................... -
Page 3: Safety Information
10018. information which is important but not hazard-related. This manual has been produced by Ingersoll-Rand to provide dealers, mechanics, operators and company personnel with the Safety Summary information required to install, operate, maintain and repair the products described herein. -
Page 4: Safe Operating Instructions
11. Always ensure that you, and all other people, are clear of the path of the load. Do not lift a load over people. Ingersoll-Rand recognizes that most companies who use 12. Never use the winch for lifting or lowering people, and winches have a safety program in force at their facility. -
Page 5: Specifications
Remote throttles are provided with 6 feet (1.8 metres) of hose. Specify hose lengths greater than 6 feet. Contact your Ingersoll-Rand distributor or the factory for control acceptability for hose lengths greater than 60 feet (18.3 metres). Metric lengths are provided for reference only, order lengths in feet. -
Page 6: General Specifications
General Specifications Rated Operating Pressure 90 psig (6.3 bar/630 kPa) Air System Air Consumption 600 scfm 17 cu.m/min (at rated pressure and load) Mid Drum Line Pull 10,000 lbs. 4,536 kg. Rated Performance (at rated pressure / volume) Mid Drum Line Speed 60 fpm 18.3 m/min 1.5 inch... -
Page 7: Installation
INSTALLATION Prior to installing the winch, carefully inspect it for possible Tighten mounting bolts evenly and torque to 380 ft lbs. shipping damage. Winches are supplied fully lubricated from the (515 Nm) for dry thread fasteners. If the fasteners are factory. -
Page 8: Wire Rope
Installing Wire Rope Refer to Dwg. MHP0652. Cut wire rope to length and fuse end to prevent fraying of strands in accordance with the wire rope manufacturer's instructions. Feed the end of the wire rope into the wire rope anchor hole in the drum and pull through approximately three feet (1 metre) of wire rope. -
Page 9: Air Supply
Air Lines The inside diameter of the winch air supply lines must be at least 1-1/2 inch (38 mm). Before making final connections, all air supply lines should be purged with clean, moisture free air or nitrogen before connecting to winch inlet. Supply lines should be as short and straight as installation conditions will permit. -
Page 10: Motor
Motor When first operating the winch it is recommended that the motor be driven slowly in both directions for a few For optimum performance and maximum durability of parts, minutes. provide an air supply of 600 scfm (17 cu. m/m) at 90 psig (6.3 bar/630 kPa). -
Page 11: Brakes
* To ensure accurate winch control when remotely operating the winch at distances greater than 60 feet (18 metres) contact Ingersoll-Rand Technical Sales for control suitability. Overload Device (optional feature) An overload device is available on winches provided with the emergency shut-off valve. -
Page 12: Free Spool
Adjustments to the cylinder clevis can be made to compensate Engaging the Free Spool: for normal brake lining wear. The drum brake must be kept Engage the drum band brake to lock drum in position. properly adjusted to hold the required load. Refer to Pull out the plunger (508). -
Page 13: Inspection
INSPECTION Inspection information is based in part on American National WIRE ROPE. Visually inspect all wire rope which can be expected to be in use during the day’s operations. Inspect Standards Institute Safety Codes (ASME B30.7). for wear and damage indicated by distortion of wire rope such as kinking, “birdcaging,”... -
Page 14: Winches Not In Regular Use
FASTENERS. Check retainer rings, split pins, capscrews, BRAKES. Individually test brakes installed to ensure nuts, and other fasteners on winch, including mounting proper operation. Brakes must hold a 100% rated load at bolts. Replace if missing or damaged and tighten if loose. mid drum without slipping. -
Page 15: Inspection Report Form
Refer to the Parts, Operation and Maintenance Manual "INSPECTION" section for general inspection criteria. Also, refer to appropriate National Standards and codes of practice. If in doubt about an existing condition contact the nearest Ingersoll-Rand distributor or the factory for technical assistance. -
Page 16: Troubleshooting
TROUBLESHOOTING This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common winch symptoms, probable causes and remedies. SYMPTOM CAUSE REMEDY... -
Page 17: Lubrication
Other lubricants may affect the performance of the winch. Approval for the use of other lubricants must be Recommended Grease obtained from your Ingersoll-Rand distributor. Failure to observe this precaution may result in damage to the winch and/ Temperature Type Grease or its associated components. - Page 18 Recommended Motor Lubricant specified by the wire rope manufacturer. Temperature Recommended Viscosity Apply a wire rope lubricant, Ingersoll-Rand LUBRI- Under 32° F (0° C) ISO VG 46 (10W) LINK-GREEN or ISO VG 100 (30W) lubricant. Brush, drip or spray lubricant weekly, or more frequently, 32°...
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Page 19: Maintenance
450º F (232º C). Optimum temperature is 300º F Maintenance if damaged. (149º C) for best results. A small propane torch (Ingersoll-Rand Personnel) Part No. 71308886) or heat gun (Ingersoll-Rand Part No. Operate the winch at low RPM in both 71308894) can be used. -
Page 20: Adjustments
Adjust band assembly using capscrew (120). and then apply thermoplastic coating powder To loosen band brake, turn capscrew (120) in the (Ingersoll-Rand Part No. 71308902 [2 oz. (56.7 g)] to fill counterclockwise direction. the area. Continue heating until coating liquefies and flows To tighten band brake, turn capscrew (120) in the together with the existing coating. - Page 21 Thermoplastic Coated Parts Disassembly CAUTION Thermoplastic coating on capscrew heads, nuts, housings and other components can be removed as follows: • There are a total of eight capscrews securing the brake cover to the brake housing. Two of these capscrews hold the CAUTION brake assembly together, but do not attach to the outboard upright.
- Page 22 16. Screw two 1/2 - 13 UNC x 1-1/2 inch capscrews into the Drive out pin (409) from valve shaft (401) to remove clevis threaded holes in the reducer housing (59). Turn both (446). screws evenly until housing is separated from drum. Attach To disassemble rear poppet assembly: suitable lifting eyes to the capscrews and remove housing Remove pin (406) and shims (444) from valve shaft...
- Page 23 Disconnect tubing at fittings and remove capscrews (528). 10. Crank assembly (231) can now be removed with the oil Separate emergency stop valve as an assembly from valve slinger (230) by pulling straight out from the motor housing body (410). (217).
- Page 24 Disconnect air line from brake cylinder (121). With the aid Reduction Gear of a strap wrench, remove brake cylinder (121) and Refer to Dwg. MHP0649. components as an assembly by turning brake cylinder Place the reduction gear assembly on a clean work bench counterclockwise until disconnected from brake bracket such that reducer housing (59) with oil seal (58) is down.
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Page 25: Cleaning, Inspection And Repair
Assembly NOTICE General instructions • use all new gaskets and seals. • If gear clearance is not within specification (0.005 to 0.032 • replace worn parts. inch [0.1 to 0.8 mm]) as determined in Step 4a., correct • assemble parts using match marks applied during location/quantity of washers (84), (85) and (86) must be disassembly. - Page 26 12. Install cotter pin (236). Shuttle Valve Assembly 13. Install roll pin (240) and bearing (228) into the valve end of Refer to Dwgs. MHP0653, MHP0654, MHP0764 and the crank shaft. MHP1228. 14. Check that all connecting rods move freely around the For winches equipped with dual automatic brakes or with an crank.
- Page 27 Lubricate ‘O’ ring on poppet valve (423). NOTICE Lubricate ‘O’ ring (427) and place it on poppet seat (428). Place this assembly on poppet valve (423). • Pendant Pilot Valves do not use cotter pin (414). For these Lubricate ‘O’ ring (426) and place it on poppet valve units, use a suitable cotter pin to temporarily contain (423).
- Page 28 (Dwg. MHP1027) With an allen wrench inserted through sleeve (408) slot, tighten setscrew (407) until secure against the far wall of sleeve. This locks the sleeve in position. (Dwg. MHP1024) To check brake valve operation: Refer to Dwg. MHP1026. For units with dual air brakes, repeat step 2 for second Press shaft (401) in the direction causing the sleeve to shift valve assembly (413).
- Page 29 Slide spring (462) over handle and onto pin. NOTICE Insert this assembly up through the bottom of cross shaft (461). ‘The bottom’ is the side with the groove for locating • Prior to installing a new spring (452), fully compress the pin (463).
- Page 30 Freespool Assembly Place an output planet gear (43) assembly into the Refer to Dwg. MHP0927. output carrier (35). Verify end clearance. Align the Assemble shaft support (505) to output shaft (28) and hole in output planet pin (36) in line with the hole in the intermediate carrier (35).
- Page 31 If equipped with drum band brake, attach band brake Manual Drum Band Brake: assembly (104) as described in the ‘Drum Band Brake Coat the bearings with “LubriPlate” MO-LITH No. 2 or Assembly’ section. equivalent lubricant and install bearings (138) and (140) in brake bracket (106).
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Page 32: Testing
Install assembly on support plate (19). 12. Install brake shaft (25) and place assembly on outboard Install twelve springs (17) in holes on inside of support (opposite motor end) upright (26). Align capscrew holes plate (19). such that the breather (8) is slightly off top dead center. Install gasket (18) and pressure plate (15). -
Page 33: Winch Parts Drawings And Parts Lists Table Of Contents
WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS Page Winch Cross Section Drawing (MHP1224) ..............................33 Winch Assembly Parts Drawing (MHP0649) ..............................34 Winch Assembly Parts List ....................................35 Motor Assembly Parts Drawing (MHP0690) ..............................36 Motor Assembly Parts List ....................................37 Disc Brake Assembly Parts Drawing (MHP1230) ............................ -
Page 34: Winch Parts Drawings And Parts Lists
WINCH ASSEMBLY PARTS DRAWING... -
Page 35: Winch Assembly Parts List
WINCH ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Capscrew (1) 71266613 Bearing 71113187 • End Cover (1) 24381 Oil Seal 71113179 • Gasket (1) 71262257 Reducer Housing 20672 Upright, Outboard End 25566 Shaft Coupling 50775... -
Page 36: Motor Assembly Parts Drawing (Mhp0690)
MOTOR ASSEMBLY PARTS DRAWING... -
Page 37: Motor Assembly Parts List
MOTOR ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER • Motor Assembly K5B-546LP Oil Seal K5B-270 Lockwasher 71268213 Crank Bearing 51066 Capscrew 71268205 Button Head Screw Washer 71274815 Oil Slinger Motor Assembly ** K5B-546LP Crank Assembly Capscrew... -
Page 38: Disc Brake Assembly Parts Drawing (Mhp1230)
DISC BRAKE ASSEMBLY PARTS DRAWING... -
Page 39: Disc Brake Assembly Parts List
DISC BRAKE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Disc Brake Assembly * 24140 Separator Plate 22033 Capscrew 71264717 Pressure Plate 24137 • End Cover ** 23605 Sprag Clutch *** 71044853 •... -
Page 40: Drum Band Brake Assembly Parts Drawing (Mhp0631)
DRUM BAND BRAKE ASSEMBLY PARTS DRAWING... -
Page 41: Drum Band Brake Assembly Parts List
DRUM BAND BRAKE ASSEMBLY PARTS LIST PART NUMBER ITEM DESCRIPTION OF PART TOTAL Automatic Brake Manual Brake Hose Assembly 24403-39 - - - Exhaust Valve 71047898 - - - Brake Assembly * 23890 21890 Capscrew 71264808 Spacer 21899 Spacer Tube 21891 Band Assembly 24367... -
Page 42: Lever Operated Control Valve Assembly Parts Drawing (Mhp0654)
LEVER OPERATED CONTROL VALVE ASSEMBLY PARTS DRAWING... -
Page 43: Lever Operated Control Valve Assembly Parts List
LEVER OPERATED CONTROL VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER - - - Valve Assembly * Poppet Seat 23518 Single Air Brake 24801 Retainer Ring 53833 • Single Air Brake - CE * 25451 ‘O’... -
Page 44: Pendant Operated Pilot Control Valve Assembly Parts Drawing (Mhp0653)
PENDANT OPERATED PILOT CONTROL VALVE ASSEMBLY PARTS DRAWING... -
Page 45: Pendant Operated Pilot Control Valve Assembly Parts List
PENDANT OPERATED PILOT CONTROL VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER • Valve Assembly: * - - - ‘O’ Ring 52573 Single Air Brake 25440 Valve Piston 23519 Single Air Brake - CE * 25439 Retainer Ring 71138010... -
Page 46: Remote Pendant Assembly Parts Drawing (Mhp0934) And Parts List
Pendant Assembly includes items 620 through 645. Pendant Extension Assembly (item 646) must be ordered in feet. Example: 15 feet = Part Number 24259-15. Lengths available up to 54 feet. Contact your distributor or the nearest Ingersoll-Rand office for assistance on lengths greater than 54 feet. -
Page 47: Freespool Assembly Parts Drawing (Mhp0927) And Parts List
FREESPOOL ASSEMBLY PARTS DRAWING AND PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Cover 24381 Capscrew 71138267 Plug 71069009 Shaft Support 22257 • Gasket 71262257 Shifter Assembly ** 22259 Outboard Upright 25566 Free Spool Shifter 22258 Output Shaft... -
Page 48: Shuttle Valve Assembly Parts Drawing (Mhp0764)
SHUTTLE VALVE ASSEMBLY PARTS DRAWING... -
Page 49: Shuttle Valve Assembly Parts List
SHUTTLE VALVE ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Pendant Operated Pilot Air Valve: Tubing (Hose) * 71261374 Nipple Fitting 24242 Tubing Fitting 71262083 Plug 71262141 Fitting 71268536 Short Tubing 24241-1 Hose 71261366... -
Page 50: Emergency Stop And Overload Assembly Parts Drawing (Mhp1188)
EMERGENCY STOP AND OVERLOAD ASSEMBLY PARTS DRAWING... -
Page 51: Emergency Stop And Overload Assembly Parts List
EMERGENCY STOP AND OVERLOAD ASSEMBLY PARTS LIST PART NUMBER ITEM DESCRIPTION Pendant with Manual Lever with Pendant with NUMBER OF PART TOTAL Emergency Stop and Overload Device Emergency Stop Overload Device Spring 71053730 Setscrew 71266589 Plug 23745 - - - - - - Label, E-Stop Instructions 71320279... -
Page 52: Open Frame (Face) Winch Assembly Parts Drawing (Mhp1231)
OPEN FRAME (FACE) WINCH ASSEMBLY PARTS DRAWING... -
Page 53: Open Frame Winch Assembly Parts List
OPEN FRAME (FACE) WINCH ASSEMBLY PARTS LIST ITEM DESCRIPTION PART ITEM DESCRIPTION PART OF PART TOTAL NUMBER OF PART TOTAL NUMBER Upright, Outboard End 25566 Sideframe, Outboard End 25548 Upright, Motor End 25567 Capscrew 71306450 Capscrew 71264709 Sideframe, Motor End 25549 Corner Bar 21882... -
Page 54: Muffler Assembly Parts Drawing (Mhp1189) And Parts List
MUFFLER ASSEMBLY PARTS DRAWING AND PARTS LIST ITEM DESCRIPTION QUANTITY PART OF PART TOTAL NUMBER Motor Muffler and Fittings: Muffler 50594 Elbow Fitting 71106439 Reducer 71057459 Control Valve Muffler and Fittings: Nipple Fitting 71311260 Elbow Fitting 54299 Muffler 71264360... -
Page 55: Drum Guard Assembly Parts Drawing (Mhp0658) And Parts List
DRUM GUARD ASSEMBLY PARTS DRAWING AND PARTS LIST ITEM DESCRIPTION QUANTITY PART NUMBER OF PART TOTAL NUMBER Drum Guard - Short Drum (12 and 15 inch) 23836 Drum Guard - Long Drum (24 and 27 inch) 23506 Bracket 23608 Capscrew 71261739 Washer As Required... -
Page 56: Air Preparation Assembly Parts Drawing (Mhp0233) And Parts List
AIR PREPARATION ASSEMBLY PARTS DRAWING AND PARTS LIST ITEM DESCRIPTION QUANTITY PART NUMBER OF PART TOTAL NUMBER Filter F42-0B-000 Pipe Nipple 51670 Regulator R30-0B-G00 Pipe Nipple 51704 Pipe Bushing Contact factory Lubricator L40-0B-G00 Air preparation components for 1-1/2 inch NPT system. Items 578 and 579 depend on required size for customer application. ACCESSORIES AND KITS DESCRIPTION PART... -
Page 57: Winch Label/Tag Location Drawing (Mhp1229) And Parts List
WINCH LABEL/TAG LOCATION AND PART NUMBER REFERENCE DRAWING... -
Page 58: Parts Ordering Information
The use of other than Ingersoll-Rand Material Handling Return Goods Policy replacement parts may adversely affect the safe operation and Ingersoll-Rand will not accept any returned goods for warranty performance of this product. or service work unless prior arrangements have been made and... -
Page 59: Warranty
WARRANTY HOIST AND WINCH LIMITED WARRANTY Ingersoll-Rand Company (I-R) warrants to the I-R makes no other warranty, and all implied original user its Hoists and Winches (Products) to be warranties including any warranty of free of defects in material and workmanship for a merchantability or fitness for a particular purpose period of one year from the date of purchase. -
Page 60: Office Locations
Fax: (310) 948-1828 Fax: (416) 213-4510 Order Desk Asia Pacific Operations Fax: (416) 213-4605 Ingersoll-Rand (Japan) Ltd. Philadelphia, PA P.O. Box 425 Shin-Yokohama Square Bldg. 900 E. 8th Ave., Suite 103 Regional Sales Offices Floor) King of Prussia, PA 19406...
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