Ingersoll Rand MHD56298 - Manuals

4 MHD56087 - Edition 4 REVIEW COPY 6-21-02 SAFE OPERATING INSTRUCTIONS The following warnings and operating instructions have been adapted in part from American National (Safety) Standard ASME B30.7 and are intended to avoid unsafe operating practices which might lead to injury or property damage. I...

MHD56087 - Edition 4 5 REVIEW COPY 6-21-02 SPECIFICATIONS Model Code Explanation: (Example FA5A-LXK1G) FA 5 A - L X K 1 G Series FA = Force 5 Air Powered Capacity: (Based on wire rope at mid drum) 5 = (5 tons (10,000 lbs [4,536 kg]) Generation: A = Third Generation Drum Length: S = Short without Dru...

MHD56087 - Edition 4 7 REVIEW COPY 6-21-02 FA5A Performance Curve (Dwg. MHP0895) Description of Operation FA5A winches are air powered, planetary geared units designed for lifting and pulling applications. FA5A winches are supplied with either an internal automatic disc brake, a manual or automatic ...

8 MHD56087 - Edition 4 REVIEW COPY 6-21-02 INSTALLATION Prior to installing the winch, carefully inspect it for possible shipping damage. Winches are supplied fully lubricated from the factory. Check oil levels and adjust as necessary before operating winch. Refer to “LUBRICATION” section for recomm...

10 MHD56087 - Edition 4 REVIEW COPY 6-21-02 Wire Rope and Drum Diagram (Dwg. MHP0498) ‘A’ = 1.6 feet (0.5 metre) per inch of drum length: ‘A’ = 19.2 feet (5.85 metres) for 12 inch drum. ‘A’ = 24.0 feet (7.31 metres) for 15 inch drum. ‘A’ = 38.4 feet (11.7 metres) for 24 inch drum. ‘A’ = 43.2 feet (1...

12 MHD56087 - Edition 4 REVIEW COPY 6-21-02 OPERATION The four most important aspects of winch operation are:1. Follow all safety instructions when operating the winch. 2. Allow only people trained in safety and operation of this winch to operate this equipment. 3. Subject each winch to a regular in...

MHD56087 - Edition 4 13 REVIEW COPY 6-21-02 Remote Pilot Pendant Control (optional feature) Refer to Dwg. MHP2233 on page 13.Provides for remote winch control at distances of up to 50* feet (15 metres) away from winch. The pendant pilot control throttle is a two lever movable control station for win...

MHD56087 - Edition 4 15 REVIEW COPY 6-21-02 Winch Brakes Automatic Disc Brake The automatic disc brake is spring applied, air released. When the winch is operated in payout direction, air pressure acting on the diaphragm overcomes spring pressure and releases brake. The brake automatically engages w...

16 MHD56087 - Edition 4 REVIEW COPY 6-21-02 • To avoid damage to mounting structure and winch, the winch drum must be stationary and there must be no load on wire rope during Free Spool operation. Free Spool Position: 1. Engage drum band brake to lock drum in position. 2. Pull handle (512) out. 3. R...

MHD56087 - Edition 4 17 REVIEW COPY 6-21-02 Frequent Inspection On equipment in continuous service, frequent inspection should be made by operators at the beginning of each shift. In addition, visual inspections should be conducted during regular operation for indications of damage or evidence of ma...

18 MHD56087 - Edition 4 REVIEW COPY 6-21-02 6. BRAKES. Individually test brakes installed to ensure proper operation. Brakes must hold a 125% rated load at mid drum without slipping. If indicated by poor operation or visual damage, disassemble and repair brake(s). Check all brake surfaces for wear, ...

MHD56087 - Edition 4 19 REVIEW COPY 6-21-02 INSPECTION AND MAINTENANCE REPORT Ingersoll-Rand Force 5 Series FA5A Air Winch Model Number: Date: Serial Number: Inspected by: Reason for Inspection: (Check Applicable Box) 1. Scheduled Periodic Inspection:(_____ Quarterly _____ Semiannually _____ Yearly)...

20 MHD56087 - Edition 4 REVIEW COPY 6-21-02 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 ...

MHD56087 - Edition 4 21 REVIEW COPY 6-21-02 TROUBLESHOOTING (CONTINUED) LUBRICATION To ensure continued satisfactory operation of the winch, all points requiring lubrication must be serviced with correct lubricant at the proper time interval as indicated for each assembly. Lubrication intervals reco...

MHD56087 - Edition 4 23 REVIEW COPY 6-21-02 Motor Fill and Drain Procedures Refer to Dwg. MHP2126 on page 22. To Fill: 1. Remove fill cap and level plug. Fill with oil slowly until oil drains from level plug hole. CAUTI ON • Do not over fill. Excess oil will reduce operating efficiency and increase ...

24 MHD56087 - Edition 4 REVIEW COPY 6-21-02 MAINTENANCE WARN ING • Never perform maintenance on the winch while it is supporting a load.• Before performing maintenance, tag controls: WARNING - DO NOT OPERATE - EQUIPMENT BEING REPAIRED. • Only allow personnel trained in safety and service on this win...

MHD56087 - Edition 4 25 REVIEW COPY 6-21-02 the corroded area. Cut away coating as necessary to expose corrosion for removal. If the damaged area is less than 1/16 inch (1.6 mm) wide the surrounding thermoplastic coating can be heated until the material flows together. For surfaces with damage great...

26 MHD56087 - Edition 4 REVIEW COPY 6-21-02 Regulator Adjustment Procedure: Refer to Dwg. MHP2416 on page 48.1. Attach test load of desired weight to load line, or connectload line to scale. • Ensure load line is connected to load and excessive slack istaken up before activating auxiliary valve. Whe...

MHD56087 - Edition 4 27 REVIEW COPY 6-21-02 3. Disconnect and tag air lines. 4. To drain oil refer to “LUBRICATION” section. 5. Remove capscrews and nuts securing winch to its foundation and move to a suitable work area before beginning disassembly. WARN ING • The air motor weighs approximately 260 ...

MHD56087 - Edition 4 29 REVIEW COPY 6-21-02 pin (203) can be removed. Remove one retainer ring (205) from either side of piston (204). Push the wrist pin (203) out by hand from one side. If the wrist pin is too tight it is acceptable to carefully heat the piston to 200° F (93° C) or less and then pu...

30 MHD56087 - Edition 4 REVIEW COPY 6-21-02 3. Rotate brake link stud (141) counterclockwise until free from brake handle. 4. Remove grip from brake handle (135). Loosen screws in brake handle until handle can be freed from brake band bracket, remove brake handle. Remove pivot nut (134). 5. Remove c...

MHD56087 - Edition 4 31 REVIEW COPY 6-21-02 Thermoplastic Coated Parts Assembly CAUTI ON • During application of thermoplastic coating to assemblies use a flame to localize the heat. Do not heat entire assembly. Assemblies contain gaskets, ‘O’ rings and other components that may be damaged by exposu...

34 MHD56087 - Edition 4 REVIEW COPY 6-21-02 5. Place washer (142) over pin in adapter plate (145) and secure with cotter pin (144). Bend cotter pin ends apart. 6. Insert pivot nut (134) into brake handle (135). 7. Place brake handle (135) into bracket in brake band halves (136) and (137) and tighten...

MHD56087 - Edition 4 35 REVIEW COPY 6-21-02 WARN ING • Incorrect assembly of the sprag clutch will adversely affect winch operation. In haul-in operation, sprag clutch will be engaged resulting in restricted winch operation. In neutral and payout positions, the sprag clutch can rotate resulting in b...

36 MHD56087 - Edition 4 REVIEW COPY 6-21-02 WINCH CROSS SECTION DRAWING (Dwg. MHP1224) Inboard Upright Control Valve Assembly Motor Adapter Disc Brake Assembly Outboard Upright Reduction Gear Assembly Motor Assembly Drum

MHD56087 - Edition 4 37 REVIEW COPY 6-21-02 WINCH DRAWINGS AND PARTS LISTS TABLE OF CONTENTS Page Winch Cross Section Drawing (MHP1224) ..................................................................................................................................................... 36 Drum, Base ...

38 MHD56087 - Edition 4 REVIEW COPY 6-21-02 DRUM, BASE AND REDUCTION GEAR PARTS DRAWING (Dwg. MHP0649) 68 69 71 70 73 82 66 74 81 30 72 65 29 64 67 81 82 33 63 62 66 74 61 60 48 58 46 44 47 43 40 42 2 18 26 1 82 81 29 27 28 30 32 34 33 35 32 39 36 40

MHD56087 - Edition 4 39 REVIEW COPY 6-21-02 DRUM, BASE AND REDUCTION GEAR PARTS LIST Item No. Descriptionof Part Total Qty Part Number Item No. Descriptionof Part Total Qty Part Number 1 Capscrew (1) 6 71266613 61 Drive Shaft - Long Drum(24 and 27 inch) 1 23902 2 End Cover (1) 1 21732 • 18 Gasket 1 ...

40 MHD56087 - Edition 4 REVIEW COPY 6-21-02 MOTOR ASSEMBLY DRAWING (Dwg. MHP0690) 216 227 228 213 210 206 213 230 226 217 196 197 225 243 250 251 251 252 254 255 218 205 203 201 200 205 209 225 244 243 946 247 246 208 207 204 202 231 232 233 234 237 236 235 231 240 228 200 205 203 201 202 204 205 20...

MHD56087 - Edition 4 41 REVIEW COPY 6-21-02 MOTOR ASSEMBLY PARTS LIST Motor Assembly Kit List: Item No. Descriptionof Part Total Qty Part Number Item No. Descriptionof Part Total Qty Part Number 190 Motor Assembly ** 1 K5B-546LP 229 Button Head Screw 5 * 196 Lockwasher 10 71268213 230 Oil Slinger 1 ...

42 MHD56087 - Edition 4 REVIEW COPY 6-21-02 DISC BRAKE ASSEMBLY DRAWING (Dwg. MHP1230) 13 14 15 16 11 17 18 19 21 22 23 25 20 65 75 12 11 10 80 79 41

MHD56087 - Edition 4 43 REVIEW COPY 6-21-02 DISC BRAKE ASSEMBLY PARTS LIST Item No. Descriptionof Part Total Qty Part Number Item No. Descriptionof Part Total Qty Part Number 320 Disc Brake Assembly * 1 24140 15 Pressure Plate 1 24137 1 Capscrew 6 71264717 16 Sprag Clutch Kit *** 1 27724 2 End Cover...

44 MHD56087 - Edition 4 REVIEW COPY 6-21-02 MANUAL DRUM BRAKE ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP1448) Item No. Descriptionof Part Total Qty Part Number Item No. Descriptionof Part Total Qty Part Number 147 Brake Assembly (includes items 131 through 145) 1 26377 137 Front Brake Band Assembly (...

MHD56087 - Edition 4 45 REVIEW COPY 6-21-02 AUTOMATIC DRUM BRAKE ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2433) Note: See certification type cold weather chart on page 44 for example of part number to order. 104 119 120 101 102 103 105 107 106 110 79 111 109 113 112 108 116 114 115 117 149 126 125 1...

46 MHD56087 - Edition 4 REVIEW COPY 6-21-02 K5C2-X CONTROL VALVE ASSEMBLY DRAWING (Dwg. MHP2427) Note: (956) Brake Fitting 909 Optional 948 949 902 903 901 955 951 218 942 943 944 912 907 906 904 905 917 916 918 956 919 921 922 902 901 945 946 935 901 930 937 939 941 938 925 924 942 923 962 950 960 ...

MHD56087 - Edition 4 47 REVIEW COPY 6-21-02 K5C2-X CONTROL VALVE ASSEMBLY PARTS LIST * Kits can be installed to K5C2-X control valve for emergency stop option. Item No. Descriptionof Part Total Qty Part Number Item No. Descriptionof Part Total Qty Part Number 900 Control Valve Assembly 1 K5C2-X 938 ...

48 MHD56087 - Edition 4 REVIEW COPY 6-21-02 PILOT AIR CONTROL VALVE (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2416) 276 277 278 279 272 273 269 265 266 267 271 266 280 268 269 264 270 274 275 Item No. Descriptionof Part Total Qty Part Number 510 size 355 Valve Assembly (includes items 265 ...

MHD56087 - Edition 4 49 REVIEW COPY 6-21-02 FULL FLOW REMOTE CONTROL VALVE ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2432) Note: To convert live air control to remote live air control contact factory for kit part numbers. 321 322 323 900 738 956 782 To Brake 321 322 255 254 243 Item No. Descriptionof...

50 MHD56087 - Edition 4 REVIEW COPY 6-21-02 EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE ASSEMBLY DRAWING (Dwg. MHP2434) Note: Brake Fitting 948 920 906 956 912 910 917 711 703 707 706 705 918 919 902 704 703 702 701 700 940 947 901 922 923 921 960 901 909 930 937 938 939 941 942 925 924 935 963 944 95...

MHD56087 - Edition 4 51 REVIEW COPY 6-21-02 EMERGENCY STOP AND OVERLOAD K5C2-EX VALVE PARTS LIST Note 1: Item 922 not sold separately, includes items (6) each of 901 and 902, items 904-907, 918, 921 and 923. Note 2: Item 939 not sold separately, includes items (1) each of 901 and 909, items 924, 925...

52 MHD56087 - Edition 4 REVIEW COPY 6-21-02 TENSIONING MANIFOLD ASSEMBLY DRAWING (Dwg. MHP2436) 946 67 732 731 783 739 784 739 736 734 735 737 738 777 779 739 737 738 739 741 743 742 748 744 745 746 747 741 751 752 753 782 738 756 758 749 751 785 741 761 775 769 741 767 766 771 772 773 774 741 765 7...

MHD56087 - Edition 4 53 REVIEW COPY 6-21-02 TENSIONING MANIFOLD ASSEMBLY PARTS LIST Item No. Descriptionof Part Total Qty Part Number Item No. Descriptionof Part Total Qty Part Number 67 Rivet 6 50915 756 Fitting, Bushing 1 50934 248 Gasket 1 K5B-547 758 Fitting, Nipple 2 71308258 731 Washer 4 71320...

54 MHD56087 - Edition 4 REVIEW COPY 6-21-02 REMOTE PENDANT ASSEMBLY DRAWINGS Pendant without Emergency Stop (Dwg. MHP2346) Pendant with Emergency Stop (Dwg. MHP1677) 445 446 444 455 440 456 447 453 448 449 451 470 452 443 450 454 457 458 445 446 444 442 443 455 440 446 447 453 448 456 449 451 441 45...

MHD56087 - Edition 4 55 REVIEW COPY 6-21-02 REMOTE PENDANT ASSEMBLY PARTS LIST Item No. Descriptionof Part Total Qty Part Number Without E-Stop With E-Stop 353 Pendant Assembly* 1 PHS2E PHS2E-U 440 Lifting Eye 1 64222332 441 Emergency Stop Valve 1 --- 95790108 442 Plug 1 95790106 • 443 ‘O’ Ring 2(5)...

MHD56087 - Edition 4 57 REVIEW COPY 6-21-02 OPEN FRAME (FACE) WINCH ASSEMBLY PARTS LIST Item No. Descriptionof Part Total Qty Part Number Item No. Descriptionof Part Total Qty Part Number 26 Upright, Outboard End 1 25566 571 Sideframe, Outboard End 1 25548 68 Upright, Motor End 1 25567 572 Capscrew ...

58 MHD56087 - Edition 4 REVIEW COPY 6-21-02 REMOTE PILOT AIR CONTROL (OPTIONAL) PARTS DRAWING (Dwg. MHP2444) Remote Pilot Lever Throttle Remote Pilot Pendant Throttle 951 364 365 355 782 363 949 362 949 361 360 738 455 353 359 358

MHD56087 - Edition 4 59 REVIEW COPY 6-21-02 REMOTE PILOT AIR CONTROL (OPTIONAL) PARTS LIST Item No. Descriptionof Part Total Qty Part Number 353 Remote Pilot Pendant 1 PHS2E 355 Valve Assembly 1 20993-P 358 Remote Pilot Lever Throttle 1 71386064 359 Fitting, Nipple 1 71048268 360 Fitting, Elbow 2 51...

60 MHD56087 - Edition 4 REVIEW COPY 6-21-02 MUFFLER ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP1189) 713 714 715 712 711 710 Item No. Descriptionof Part Total Qty Part Number Motor Muffler and Fittings: 710 Muffler 1 50594 711 Elbow Fitting 1 71106439 712 Reducer 1 71057459 Control Valve Muffler and F...

MHD56087 - Edition 4 61 REVIEW COPY 6-21-02 FREE SPOOL ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2414) 18 2 1 506 902 501 510 502 505 507 512 514 515 508 513 509 511 518 517 516 503 518 504 18 28 Item No. Descriptionof Part Total Qty Part Number Item No. Descriptionof Part Total Qty Part Number 500 F...

62 MHD56087 - Edition 4 REVIEW COPY 6-21-02 DRUM GUARD ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP0658) * Drum Guard Assemblies include items 109, 591-592.* Contact factory for drum and guard assemblies with drum band brake. 591 109 590 109 592 591 109 596 595 592 594 Manual Drum Brake Item No. Descri...

64 MHD56087 - Edition 4 REVIEW COPY 6-21-02 WINCH LABEL/TAG LOCATION PARTS DRAWING (Dwg. MHP1229) Install over wire rope anchor hole with arrow toward operator Oil Drain Label Oil Drain Label Oil Drain Label Oil Level/Fill Label Oil Level/Fill Label Oil Level/Fill Label 67 64 341 342 343 947 948 960...

MHD56087 - Edition 4 65 REVIEW COPY 6-21-02 WINCH LABEL/TAG LOCATION PARTS LIST Item No. Descriptionof Part Total Qty Part Number 300 Label Kit (Short)** 1 23510-1-S Label Kit (Long)*** 23510-2-S 50 Label, Disc Instructions 1 71306518 64 Label, Wire Rope Cover 1 71148282 67 Rivet 8 50915 341 Label, ...

66 MHD56087 - Edition 4 REVIEW COPY 6-21-02 CONSTRUCTION CAGE ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2438) 564 566 567 560 568 601 600 948 563 562 561 565 Item No. Descriptionof Part Total Qty Part Number 560 Construction Cage (Short) 1 CC-FA5A-SM Construction Cage (Long) CC-FA5A-LM 561 Capscrews ...

MHD56087 - Edition 4 67 REVIEW COPY 6-21-02 SERVICE NOTES

70 MHD56087 - Edition 4 REVIEW COPY 6-21-02 PARTS ORDERING INFORMATION The use of other than Ingersoll-Rand replacement parts may adversely affect the safe operation and performance of this product. For your convenience and future reference it is recommended that the following information be recorde...

MHD56087 - Edition 4 71 REVIEW COPY 6-21-02 WARRANTY LIMITED WARRANTY Ingersoll-Rand Company ( I-R ) warrants to the original user its Hoists and Winches (Products) to be free of defects in materialand workmanship for a period of one year from the date ofpurchase. I-R will repair, without cost, any ...

Printed in USA REVIEW COPY 6-21-02 United States Office Locations International Office Locations For Order Entry andOrder Status Ingersoll-RandDistribution Center P.O. Box 618510 Hester DriveWhite House, TN 37188Phone: (615) 672-0321Fax: (615) 672-0801 For Technical Support Ingersoll-Rand P.O. Box 2...