Benutzeranleitung / Produktwartung FA5T des Produzenten Ingersoll-Rand
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Form MHD56037 P AR TS, OPERA TION AND MAINTENANCE MANU AL MODEL F A5 AND FA5T (Dwg. MHP2107) Form MHD56037 Edition 5 May 20 06 71062103 © 2006 Ingersoll Rand Company READ THIS MANU AL BE FORE USING THESE PROD UCTS. This man ual contains impor tant safety , instal lation, operation and maintenance inf ormation.
2 MHD56037 - Edition 5 T ABLE OF CONTENTS Description Page No. Safety Information Danger , Caution, W arning a nd Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MHD56037 - Edition 5 3 SAFETY INFORMATION This manual provides important information for all personnel involved with the safe inst allation, opera tion and proper maintenance of this product. Ev en if you feel you are familiar with this or simila r equipment, you shoul d read this manual before operating the winch.
4 MHD56037 - Edition 5 SAFE OPERATING INSTRUCTIONS The following warnings and oper ating instructions have been adapted in part from Am erican Society of Me chanical Engi neers (Safety) Standard ASME B3 0.7 and are intended to avoid unsafe operating practices which might lead to injury or property damage.
MHD56037 - Edition 5 5 SPECIFICATIONS Model Code Explanation Example: F A5-24MK320P FA 5 - 24 M K 320 P Series (Capacity) FA 5 = Air Powered Wi nch (5 metric ton / 1 1,000 lbs.
6 MHD56037 - Edition 5 Performance Graphs F A5 Winch (Dwg. MHP1890) F A5T Winch (Dwg. MHP1891).
MHD56037 - Edition 5 7 Description of Operation FA 5 winches are air powered, planet ary gear ed units designed for lifting and pulling applications. FA 5 winches are available with either an internal aut o ma tic disc brake, a manual or automatic band brake, or a combination of both.
8 MHD56037 - Edition 5 T raceability Load bearing parts are documente d to provide traceability . The documentation includes chemical and physical properties of raw material, heat treating, hardeni ng, tensile and charpy tests as required for the part.
MHD56037 - Edition 5 9 T able 2–Winch Bolt Hole Mounting Dimensions (Dwg. MHP2123) ‘A ’ = 1.6 feet (0.5 metre) per inch of drum length: ‘A ’ = 19.2 feet (5.85 metres) for 12 inch d rum. ‘A ’ = 25.6 feet (7.80 metres) for 16 inch d rum. ‘A ’ = 38.
10 MHD56037 - Edition 5 Installing W ire Rope CAUTION • T o avoid disc brake damage when installing wire r ope pressurize brake with a minimum of 60 psi (4.1 bar) air from an auxiliary sour ce. Refer to Dwg. MHP0166 on page 10. 1. Cut wire rope to length in accordance with wire rope manufacturer ’ s instructions.
MHD56037 - Edition 5 11 Air Lines Inside diameter of winch air suppl y lines must not be less than sizes shown in T a ble 4 on page 11 . Before making final connections, all air s upply lines should be purged with clean, moisture free air or nitrogen be f ore connecting to winch inlet.
12 MHD56037 - Edition 5 Emergency S top and Overload System Components (old style) (Dwg. MHP1492) Air Schematic–Emergency S top and Overload System (old style) (Dwg. MHP1491) Constant T ension (opt ion al feature) Refer to Dwg. MHP1865 on page 12 and Dwg.
MHD56037 - Edition 5 13 Initial Operating Checks W i nches are tested for proper operation prior to leaving factory . Before winch is placed into service the foll owing ini tial operating checks should be performed. 1. When first run ning motor inject some light oil into i nlet connection to provide initial lubrication.
14 MHD56037 - Edition 5 Winc h Mounted Thr ottle Contr ol V alve Operation (old style) Dwg. MHP0566) Underwound Operation (optional featur e) Underwound operation is where wire ro pe haul-in or payout is off the bottom of drum. This is a special operation and requires a winch specifically design ed for this usage.
MHD56037 - Edition 5 15 Pendant Hose and Ope rat ing Levers (old style) (Dwg. MHP131 1) * For distances greater than 50 feet (15 metres) contact Ingersoll Rand T echnical Sales for control sui tability . Remote Pilot Lever Throttle (optional feature) Refer to Dwg.
16 MHD56037 - Edition 5 Overload Device An overload device is availabl e on winches with the emergency shutoff option. Overload device operation is based on differential pressure betw een air motor in let and exhaust. The overload device is factory preset to actuat e at 150% (± 25%) of winch rated capacity .
MHD56037 - Edition 5 17 Remote Pendant Emergenc y S top V alve Operation (Dwg. MHP1892) Winch Overload De vice (optional feature) The overload device is integrated into winch air motor control air system and prevents winch from lifting a load greater than overload value.
18 MHD56037 - Edition 5 pull rod and ensure locking pin e ngages and is seated in drum hole and gland deep groove. W ARNING • Ensure that all braking me chanisms ar e engaged and all personnel ar e clear of winc h load and rigging befor e disengaging locking pin.
MHD56037 - Edition 5 19 LUBRICATION T o ensure continued satisfactory operation of winch, all points requiring lubrication must be serviced with correct lubrican t at proper time interval as indi cated for each assembly .
20 MHD56037 - Edition 5 K5B Motor Lubrication Locations (Dwg. MHP2126) Air Throttle Refer to Dwg. MHP0165 on page 54. Periodically , depending on winch usage and severity of e nvironment, lubr icate lever air throttle (local and remote) with recommended grease at grease fitting (246).
MHD56037 - Edition 5 21 Drum Locking Pin (optional feature) Refer to Dwg. MHP0155 on page 61. Lubricate at least once every m onth, depending on environmen t and duty cycle, through grease fit ting (139) located in gland (138) with 2 or 3 pumps of a gr ease gun.
22 MHD56037 - Edition 5 10. MOTOR. During operation chec k motor housing for excess heat build up. Housing should not be hot to touch. Listen for grinding or knocking noises. En sure lubricated air supply provides 6 to 9 drops per minute of ISO VG 32 (SAE 10W) oil when winch is operated at rated capacity .
MHD56037 - Edition 5 23 INSPECTION AND MAINTENANCE REPORT Ingersoll-Rand Force 5 Series F A5 and F A5T Air Winches Model Number: Date: Serial Numb er: Inspected by: Reason for Inspection: (Check Applic able Box) 1.
24 MHD56037 - Edition 5 T R OUBLESHOOTING This section provides basic troubleshooting in formation. Determina tion of specific causes to problems are best ide n ti fie d by th orough inspections performed by personne l instructed in safety , operation and maintenanc e of this equipment.
MHD56037 - Edition 5 25 SYMPT O M CAUSE REMEDY Automatic Disc Brake: Brake fails t o release. Low air supply pressure. Ensure air pressure at inlet to disc brake is at least 50 psig (3.4 bar/340 kPa). Leaking piston seals. Inspect brake breather . If air escapes from brake bre at her when attempting to release brake, rep lace brake seals.
26 MHD56037 - Edition 5 MAINTENANCE W ARNING • Never perfor m maintenance on winch while it is supportin g a load. • Before performing main tenance, tag c ontrols : W ARNING - DO NOT OPERA TE - EQUIPMENT BEING REP AIRED. • Only allow service personne l trained in safety and service on this winch to perform maintenance.
MHD56037 - Edition 5 27 3. Rotating adjustment screw counterclockwise will decrease pressure required to activate overload valve. Overload V alve Adjustment (new style) (Dwg. MHP2216) Overload V alve Adjustment (optional feature) old style Refer to Dwg.
28 MHD56037 - Edition 5 5. Hold cam adjustment screw in position (venting air) and tighten red setscrew . 6. If required, adjust payout lim it switch. T est winch set points by operating winch through three co mplete cycles to ensure consistent limit swi tch operat ion within + /- 2 fee t (2/3 me tre) of set points.
MHD56037 - Edition 5 29 7. Drain oil from reduction gear assembly by removing one plug (48) when positioned at it ’ s lowest point, and one plug (48) from it’ s highest point to vent. Refer to Dwg. MHP0140 on page 20 in “LUBRICA TION” se ction.
30 MHD56037 - Edition 5 NOTICE • Do not disassemble planetary ge ar assemblies (54), (58) and (67). K5B Motor Disassembly Refer to Dwg. MHP2093 on page 44. 1. Remove five capscrews (1) from exhaust flange (253) or (254). Do not remove the two capscrews (255) from throttle valve assembly (260).
MHD56037 - Edition 5 31 Piston Removal 1. Remove capscrews (901) a nd washers (902) from piston cover (919). Remove cover and discard gasket (918). 2. Remove capscrews (901) and washers (902) from poppet cover (903). Remove cover and discard gasket (904).
32 MHD56037 - Edition 5 5. Inspect drum band brake lining fo r oil, grease and glazing. If drum band brake lining is oil-soaked replace brake bands as a set. Remove gl azed areas of band brake lining by sanding lightly with a fine grit emery cloth. 6.
MHD56037 - Edition 5 33 2. Place handle assembly ove r re verse valve end. Slide handle will have to be lifted slightly to allow pin to fit into slot in seal bracket. 3. Secure handle assembly (930) to reverse valve with tab lock washer (909) and capscrew (901), torque to 15 ft lbs.
34 MHD56037 - Edition 5 3. Install two seal ri ngs (251) on each end of rotary valve (250). Place bearing (252 ) onto the rear of rotary valve (250) and press into position. Press only on beari ng inner race. W i th rotary valve housing (247) exhaust flange down, install rotary valve into housing.
MHD56037 - Edition 5 35 18. Align capscrew and dowel hole s and install cover (73). Use a soft hammer or mallet to care fully tap the cover until flush with ring gear (72). Apply a light coating of Loctite ® 242 to capscrew (75) threads and in stall by hand .
36 MHD56037 - Edition 5 25. Install the motor assembly to motor mounting plate using capscrews (4) and lockwashers (3). Lightly coa t capscrew threads with Loctite ® 242 and torque to 85 ft lbs (1 15 Nm). 26. On winches with a disc brake install fitting (31) in dump valve (30) and screw into brak e rele as e port.
MHD56037 - Edition 5 37 Te s t i n g Operational T est Prior to initi al use, all new or re paired winches shal l be tested to ensure proper operation. 1. Check oil level in motor , re duction gear assembly and disc brake are correct. T op off leve ls as required before operation as described in the “LUBRICA TION” section.
38 MHD56037 - Edition 5 F A5 W INCH ASSEMBLY DRAWINGS REFERE NCE DIAGRAM (Dwg. MHP1493).
MHD56037 - Edition 5 39 F A5 WINCH DRAWINGS AND PARTS LISTS T ABLE OF CONTENTS Description Page No. Drum, Base and Reduction Gear Assembly Drawing (Dwg. MHP0157) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 MHD56037 - Edition 5 DRUM, BASE AND REDUCTION GEAR ASSEMBLY DRAWING (Dwg. MHP0157).
MHD56037 - Edition 5 41 DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST Item No. Description of Part To t a l Qty Part Number Item No. Description of Part To t a l Qty Part Number •2 Oil Seal 1 51.
42 MHD56037 - Edition 5 DRUM, BASE AND REDUCTION GEAR ASSEMBLY PARTS LIST (CONT’D) UPRIGHT ASSEMBL Y P ARTS LIST Inboard Upright (Item 42) To t a l Qty Part Number Outboard Upright (Item 84) To t a .
MHD56037 - Edition 5 43 MUFFLER ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2090) 165 169 170 162 161 169 165 170 K5B Motor Muffler and K5B Control V alve with Long Exhaust Manif old K5C2 Control V alve .
44 MHD56037 - Edition 5 K5B MOTOR ASSEMBLY DRAWING (Dwg. MHP2093) 200 216 228 205 203 201 202 204 205 208 207 213 206 210 209 206 213 229 230 226 225 225 231 232 233 234 237 3 217 4 236 235 231 240 24.
MHD56037 - Edition 5 45 K5B MOTOR ASSEMBLY PARTS LIST Item No. Description of Part To t a l Qty Part Number Item No. Description of Part To t a l Qty Part Number 199 Motor Assembly 230 Oil Slinger 1 K.
46 MHD56037 - Edition 5 DISC BRAKE ASSEMBLY DRAWING (Dwg. MHP0152) Note: T ee fitting for us e on u nit s with Di s c a nd A u to B a nd Br a ke only .
MHD56037 - Edition 5 47 DISC BRAKE ASSEMBLY PARTS LIST Item No. Description of Part To t a l Qty Part Number 64 Brake Assembly (includes items 1, 7 through 32 and 44) 1 11 3 6 6 1 Capscrew (with Disc .
48 MHD56037 - Edition 5 DRUM BRAKE ASSEMBLY DRAWING (Dwg. MHP0153).
MHD56037 - Edition 5 49 DRUM BRAKE ASSEMBLY PARTS LIST Item No. Description of Part To t a l Qty Part Number Manual Brake Automatic Bra ke 80 Drum with band brake 1 Refer to page 42 82 Side Rail, Righ.
50 MHD56037 - Edition 5 K5C2 CONTROL V ALVE ASSEMBLY DRAWING (Dwg. MHP2036) * Item 920 is not sold with any valve parts, must be purchased separately .
MHD56037 - Edition 5 51 K5C2 CONTR OL V ALVE ASSEMBLY PARTS LIST Note 1: For service kit descriptions and additi onal informati on on related publication(s) refer to T ables on page 76. Note 2: Item 922 not sold separately , in cludes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
52 MHD56037 - Edition 5 EMERGENCY S TOP AND OVERLOAD K5 C2-EX V ALVE ASSEMBLY DRAWING (Dwg. MHP2180) 9 3 5 906 956 912 910 917 711 70 3 707 706 705 704 70 3 702 701 700 940 947 955 902 721 722 916 901.
MHD56037 - Edition 5 53 EMERGENCY S TOP AND OVERLOAD K5C2-EX V ALVE PARTS LIST Note 1: For service kit descriptions a nd additional information on related publication(s) refer to T ables 75. Note 2: Item 922 not sold separately , in cludes items (6) each of 901 and 902, items 904-907, 918, 921 and 923.
54 MHD56037 - Edition 5 K5B CONTROL V ALVE ASSEMBLY DRAWING AND PARTS LIST (old style) (Dwg. MHP0165) Item No. Description of Part To t a l Qty Part Number 260 V alve Assembly (Includes item 96, 246 a.
MHD56037 - Edition 5 55 FULL FLOW REMOTE CONTROL V ALVE ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP2092) Item No. Description of Part To t a l Qty Part Number 1 Capscrew 5 51471 113 Hose End 2 51029 115.
56 MHD56037 - Edition 5 REMOTE PILOT AIR CONTROL (OPTIONAL) ASSEMBLY DRAWING (Dwg. MHP0167) 552 552 113 113 113 97 96 335 355 334 333 357 115 Remote Pilot Lever Thr ottle 348 358 343 115 115 To Brake .
MHD56037 - Edition 5 57 REMOTE PILOT AIR CONTROL (OPTIONAL) ASSEMBLY PARTS LIST Item No. Description of Part To t a l Qty Part Number 96 Lockwasher 4 50200 97 Capscrew 4 51780 113 Fitting, Hose End .
58 MHD56037 - Edition 5 REMOTE PENDANT ASSEMBLY DRAWINGS Pendant without Emergency S top (Dwg. MHP2346) Pendant with Emergency Stop (Dwg. MHP1677) 445 446 444 440 456 447 453 448 449 451 470 452 443 4.
MHD56037 - Edition 5 59 REMOTE PENDANT ASSEMBLY PARTS LIST Item No. Descript ion of Part To t a l Qty Part Number Wit h E- S to p Without E-Stop 353 Pendant Assembly* 1 PHS2E PHS 2E-U 440 Lifting Eye .
60 MHD56037 - Edition 5 PILOT AIR CONTROL V ALVE (OPTIONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP0141) Item No. Description of Part To t a l Qty Part Number 510 size 355 V alve Assembly (includes .
MHD56037 - Edition 5 61 DRUM LOCKING PIN (OPT IONAL) ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP0155) 135 135 80 84 137 138 246 140 136 403 135 140 404 138 137 136 304 401 84 OLD STYLE Item No.
62 MHD56037 - Edition 5 DRUM GUARD ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP0154) Item No. Description of Part To t a l Qty Part Number S tandar d Flange T all Flange 149 Drum Guard Assembly (includes.
MHD56037 - Edition 5 63 EMERGENCY S TOP V ALVE, OVERLOAD ASSEMBLY DRAWING AND PARTS LIST (old style) (Dwg. MHP1341) Item No. Description of Part To t a l Qty Part Number Item No.
64 MHD56037 - Edition 5 PENDANT CONTROL ASSEMBLY DRAWING AND PARTS LIST (old style) (Dwg. MHP0168) Item No. Description of Part To t a l Qty Part Number 348 Fitting, Adapter 3 71048268 352 Pendant Ass.
MHD56037 - Edition 5 65 SERVICE NOTES.
66 MHD56037 - Edition 5 EMERGENCY S TOP OVERLOAD ASSEMBLY DRAWING (Dwg. MHP1488).
MHD56037 - Edition 5 67 EMERGENCY S TOP OVERLOAD ASSEMBLY PARTS LIST Item No. Description of Part To t a l Qty Part Number Item No. Description of Part To t a l Qty Part Number 26 Fitting, T ee 1 5218.
68 MHD56037 - Edition 5 LIMIT SWITCH ASSEMBLY DRAWING (Dwg. MHP2027).
MHD56037 - Edition 5 69 ( LIMIT SWITCH ASSEMBL Y P AR TS LIST Item No. Description of Part To t a l Qty Part Number 93 Capscrew 3 51086 96 Lockwasher 6 50200 97 Capscrew 6 51780 115 Hose As Req’d 50.
70 MHD56037 - Edition 5 PILOT AIR V ALVE PLUMBING ASSEMBLY DRAWING Note: This drawing is for Pilot Air V alve Assembly wit h Limit Swit ch. For Remote Pilot Air installation refer to Dwg.
MHD56037 - Edition 5 71 PILOT AIR V ALVE PLUMBING ASSEMBLY PARTS LIST Item No. Description of Part To t a l Qty Part Number 96 Wa s h e r 4 50200 97 Capscrew 4 51780 113 Fitting, Hose End 5 51029 115 .
72 MHD56037 - Edition 5 T ENSIONING MANIFOLD ASSEMBLY DRAWING (Dwg. MHP2028).
MHD56037 - Edition 5 73 T ENSIONING MANIFOLD ASSEMBLY PARTS LIST Item No. Description of Part To t a l Qty Part Number 11 3 Fitting, Hose End 3 51029 11 5 Hose (bulk) As Req’d 50923 248 Gasket 2 K5B.
74 MHD56037 - Edition 5 AIR PREPARATION ASSEMBLY DRAWING AND PARTS LIST (Dwg. MHP0223) Note : Drawing for reference only; components ma y not resemble those shown in drawing.
MHD56037 - Edition 5 75 LABELS AND T AGS (Dwg. MHP1676) Item No. Description of Part To t a l Qty Part Number Item No. Description of Part To t a l Qty Part Number 650 Label and T ag Kit * 1 22261-4-S 654 Product Label 12-16 in. long drum 1 711 11777 22261-5-S Product Label 24 in.
76 MHD56037 - Edition 5 KITS Description of Kit Part Number Automatic Brake Kit (converts ma nual band brake to automatic band brake). Refer to Dwg. MHP0153on page 48 ; includes items 102, 105 through 1 15, 1 17 throu gh 120, 129 and 134. F A5-ABK Disc Brake Kit (adds disc brake to winch).
MHD56037 - Edition 5 77 PARTS ORDERING INFORMATION Use of other than Ingersoll Rand replacement parts may adversely affect th e safe opera tion and performance of this product. For your convenience and future re ference it is recommended that the following inform ation be recorded.
78 MHD56037 - Edition 5 SERVICE NOTES.
MHD56037 - Edition 5 79 W ARRANT Y LIMITED W ARRANTY Ingersoll Rand Company ( I-R ) warrants to the original user its Hoists and Winches (Pro ducts) to be free of defects in material and workmanship for a period of one year from the date of purchase.
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Wenn Sie Ingersoll-Rand FA5T noch nicht gekauft haben, ist jetzt ein guter Moment, um sich mit den grundliegenden Daten des Produkts bekannt zu machen. Schauen Sie zuerst die ersten Seiten der Anleitung durch, die Sie oben finden. Dort finden Sie die wichtigsten technischen Daten für Ingersoll-Rand FA5T - auf diese Weise prüfen Sie, ob das Gerät Ihren Wünschen entspricht. Wenn Sie tiefer in die Benutzeranleitung von Ingersoll-Rand FA5T reinschauen, lernen Sie alle zugänglichen Produktfunktionen kennen, sowie erhalten Informationen über die Nutzung. Die Informationen, die Sie über Ingersoll-Rand FA5T erhalten, werden Ihnen bestimmt bei der Kaufentscheidung helfen.
Wenn Sie aber schon Ingersoll-Rand FA5T besitzen, und noch keine Gelegenheit dazu hatten, die Bedienungsanleitung zu lesen, sollten Sie es aufgrund der oben beschriebenen Gründe machen. Sie erfahren dann, ob Sie die zugänglichen Funktionen richtig genutzt haben, aber auch, ob Sie keine Fehler begangen haben, die den Nutzungszeitraum von Ingersoll-Rand FA5T verkürzen könnten.
Jedoch ist die eine der wichtigsten Rollen, die eine Bedienungsanleitung für den Nutzer spielt, die Hilfe bei der Lösung von Problemen mit Ingersoll-Rand FA5T. Sie finden dort fast immer Troubleshooting, also die am häufigsten auftauchenden Störungen und Mängel bei Ingersoll-Rand FA5T gemeinsam mit Hinweisen bezüglich der Arten ihrer Lösung. Sogar wenn es Ihnen nicht gelingen sollte das Problem alleine zu bewältigen, die Anleitung zeigt Ihnen die weitere Vorgehensweise – den Kontakt zur Kundenberatung oder dem naheliegenden Service.
