Ingersoll-Rand FA2.5A Series, Parts, Operation And Maintenance Manual

Page 1: ...ied out by personnel certified by Ingersoll Rand or by Ingersoll Rand Authorized Service Centers Contact the Factory if in doubt about installation operation inspection and maintenance instructions Us...

Page 2: ...o all persons responsible for the installation operation and maintenance of these products WARNING Do not use this winch for lifting supporting or transporting people or lifting or supporting loads ov...

Page 3: ...Constant Tension Manifold Optional Feature 17 Free Spool Optional Feature 18 Inspection Records and Reports 19 Frequent Inspection 19 Periodic Inspection 20 Winches Not In Regular Use 20 Inspection an...

Page 4: ...h a manner that if there were an equipment failure no personnel would be injured This means keep out from under a raised load and keep out of the intended path of any load The Occupational Safety and...

Page 5: ...ed personnel 4 Before each shift the operator should inspect the winch for wear and damage Never use a winch that inspection indicates is worn or damaged 5 Never lift a load greater than the rated cap...

Page 6: ...or damage is found Use only approved rigging methods Do not make unauthorized modifications Use guards to avoid possible hazards Ensure an accessible shut off valve has been installed in the air suppl...

Page 7: ...drum brake G Drum Guard H Open Front frame for horizontal pulling M1 Material Traceability typical material results M2 Material Traceability actual material results M3 Material Traceability actual mat...

Page 8: ...345 FA2 5A LXK1 750 340 FA2 5A LXK2 756 343 FA2 5A LMK1 808 367 FA2 5A LMK2 814 369 FA2 5A LAK1 830 377 FA2 5A LAK2 836 379 FA2 5A LMX1 773 351 N A N A N A FA2 5A LAX1 795 361 FA2 5A LAX2 801 363 FA2...

Page 9: ...are documented to provide traceability Documentation includes chemical and physical properties of raw material heat treating and hardening tensile and charpy tests as required for the part Units with...

Page 10: ...e foundation may cause distortion or twisting of the winch uprights and side rails resulting in winch damage 2 Make sure the mounting surface is flat to within 0 005 inch 0 127 mm per inch of drum len...

Page 11: ...PS 6 X 19 IWRC right lay Note To maintain 5 1 safety factor ratio 1 2 inch 13 mm wire rope must be used Dwg MHP1013 Installing Wire Rope Refer to Dwg MHP0652 on page 11 1 Cut wire rope to length and f...

Page 12: ...e slack This helps achieve level winding and tight spooling Support wire rope spool and have wire rope come off top of spool and over top of winch drum This will prevent damage to wire rope Dwg MHP245...

Page 13: ...ricator The air line lubricator should be replenished daily and set to provide 6 to 9 drops per minute of ISO VG 32 SAE 10W oil A fine mist will be exhausted from throttle control valve when air line...

Page 14: ...d and may require adjustment or repair When control valve senses a preset pressure difference between ports a pilot signal is sent to stop flow of air all winch movement will stop Initial Winch Operat...

Page 15: ...ied as a standard feature on these winches Optional remote pendant controls are also available Reference the model code on the winch nameplate and compare it to the SPECIFICATIONS section on page 6 to...

Page 16: ...alve The winch control valve located on winch motor controls motor speed and direction of drum rotation Direction of rotation is determined by direction in which lever is shifted For distances greater...

Page 17: ...activate overload valve WARNING This adjustment can cause overload device to NOT activate before winch s overload limit is exceeded This procedure should only be done by personnel trained in testing a...

Page 18: ...linder to automatically disengage the brake when the motor is operated in either the haul in or payout directions Air pressure directed to the cylinder overcomes spring pressure to release the brake a...

Page 19: ...ounterclockwise 180 to the UP position 4 Release handle Ensure handle is engaged in slots in detent plate 514 The drum is now in free spool During free spool operations use drum band brake to control...

Page 20: ...tions noted during frequent inspections and the actual condition of wire rope as determined by periodic inspections Frequent Inspection On equipment in continuous service frequent inspection should be...

Page 21: ...ble 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 an...

Page 22: ...existing condition contact the nearest Ingersoll Rand Distributor or the factory for technical assistance COMPONENT CONDITION CORRECTIVE ACTION NOTES Pass Fail Repair Replace Uprights and Side Rails D...

Page 23: ...olume Clean air line filter Emergency Stop Valve engaged Reset Emergency Stop Valve Overload Device engaged Reduce load to within rated capacity of winch and reset Emergency Stop Valve Air leak Check...

Page 24: ...ped with a disc brake the reduction gear is vented through the disc brake breather plug Recommended Lubricant Units are shipped from factory with ISO VG 100 SAE 3 EP lubricant Reduction Gear capacity...

Page 25: ...oil slowly until oil drains from level plug hole CAUTION CAUTION Do not over fill Excess oil will reduce operating efficiency and increase oil temperature The use of unsuitable oil may result in exces...

Page 26: ...ee position Automatic Drum Band Brake optional feature Refer to Dwg MHP2508 on page 46 For adjustments references to clockwise and counterclockwise directions in the text refer to directions as viewed...

Page 27: ...emove capscrews 592 2 Remove brackets 591 and or 595 by sliding out of drum guard 590 3 Carefully remove drum guard 590 from rear drum brake side side rail 64 By design the drum guard attaches to the...

Page 28: ...in and fill plugs are removed When using jacking bolts ensure the cover lifts evenly by turning bolt one full turn and then repeating on the other bolt If cover jams remove jacking bolts and gently ta...

Page 29: ...pscrews 901 and washers 902 from cover 719 underneath valve housing NOTICE Cover 719 retains spring 718 To remove capscrews 901 and washer 902 unscrew in a crisscross pattern 4 Remove adjusting screw...

Page 30: ...erclockwise until disconnected from plunger 2 Disconnect air line from brake cylinder 121 With the aid of a strap wrench remove brake cylinder 121 and components as an assembly by turning brake cylind...

Page 31: ...ed it may be necessary to carefully remove old Loctite from the bushing bores Dry each part using low pressure filtered compressed air Clean the drum brake band using a wire brush or emery cloth Do no...

Page 32: ...202 and 207 to the connecting rod 206 with wrist pin 203 and retainer rings 205 16 Install a new cylinder head gasket 209 before installing the cylinder liner 208 17 Install the cylinder liner 208 ov...

Page 33: ...917 from exhaust flange side ensuring that groove in bushing is aligned with pin 945 3 Lubricate O rings 942 and 722 and place in grooves in exhaust adapter 723 4 Lubricate O rings 942 and place in gr...

Page 34: ...c b If washer 584 locations and quantities were not recorded loosely attach side rail 571 to upright 26 and side rail 573 to upright 68 using capscrews 574 Using washers and bars 570 determine the cor...

Page 35: ...with cotter pin 144 6 Insert pivot nut 134 into brake handle 135 7 Place brake handle 135 into bracket in brake band 136 and tighten screws in handle Slide grip over brake handle 8 Place brake link st...

Page 36: ...ack from band brake Release air pressure The nut should move closer to the end cover 125 and stop 3 Repeat step 1 until the nut stops at approximately 9 16 inch 14 mm from the cover 125 4 Refer to fur...

Page 37: ...to ensure proper operation 1 Check oil level in reduction gear assembly and disc brake is correct Top off levels as required before operation as described in the LUBRICATION section 2 To initially br...

Page 38: ...MHD56114 Edition 4 37 SERVICE NOTES...

Page 39: ...8 MHD56114 Edition 4 WINCH CROSS SECTION DRAWING Dwg MHP1191 Motor Adapter Motor Assembly Drum Disc Brake Assembly Upright Outboard End Reduction Gear Assembly Upright Motor End Control Valve Assembly...

Page 40: ...ssembly Drawings MHP2346 and MHP1677 52 Remote Pendant Assembly Parts List 53 Emergency Stop and Overload K5C2 EX Valve Assembly Drawing MHP2434 54 Emergency Stop and Overload K5C2 EX Valve Parts List...

Page 41: ...40 MHD56114 Edition 4 WINCH ASSEMBLY DRAWING Dwg MHP0950 74 26 27 28 30 29 1 2 18 68 73 70 71 53 29 30 62 81 64 72 67 63 66 66 65 33 61 60 48 58 46 44 47 43 40 42 32 34 33 35 32 39 36 40 74...

Page 42: ...48 25751 64 Side Rail Rear Short Drum 1 24901 1 25424 1 Side Rail Rear Medium Drum 24901 2 25424 2 Side Rail Rear Long Drum 24901 5 25424 3 Side Rail Rear Extra Long Drum 24901 7 25424 4 65 Side Rail...

Page 43: ...HP0690 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 2...

Page 44: ...t Cap Assembly 1 26604 247 Rotary Valve Housing 1 K5B 546 213 Eye Bolt 2 KU 888 250 Rotary Valve Assembly 1 K5B 526EQ RS 216 Mounting Flange 1 K5B 502A 251 Seal Ring 1 Set K5B 607A 217 Motor Housing 1...

Page 45: ...t either the 9 o clock left or the 6 o clock bottom position as viewed from the brake end of the winch On Open Frame Face winches the brake cover release port is located at the 3 o clock right positio...

Page 46: ...um 20 in 24901 5 Long Drum 20 in 24901 3 Extra Long Drum 24 in 24901 7 Extra Long Drum 24 in 24901 8 Brake Hose without Drum Brake Brake Hose with Drum Brake 75 Short Drum 7 in 1 25403 36 75 Short Dru...

Page 47: ...6821 116 Roller 1 23883 75 Hose Assembly 1 25403 39 117 Jam Nut 2 71267413 79 Valve Exhaust 1 71372890 119 Pivot Bar 1 23755 101 Capscrew 3 71264808 120 Capscrew 1 71326805 102 Spacer 3 21899 121 Cyli...

Page 48: ...embly 1 382 29304 138 Pin 1 4303 S Recommended spare for one winch 2 years of normal operation Note 1 Brake Assembly item 151 includes items 131 133 134 136 139 141 144 2 Items 136 and 137 must be pur...

Page 49: ...AWING 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 94...

Page 50: ...y 1 27239 1 959 Muffler 1 52472 935 Plug 1 71348965 960 Label Warning 1 71373229 937 Spring 1 26966 962 Breather 1 51559 Item 917 not sold separately order item 900 Reverse Valve Normal for Standard O...

Page 51: ...mbers 321 322 323 900 738 956 782 To Brake 321 322 255 254 243 Item No Description of Part Total Qty Part Number 243 Gasket 1 K5B 928 254 Exhaust Cover 1 KK5B 276M 255 Capscrew 5 51471 321 Fitting Elb...

Page 52: ...nd Cap Assembly includes items 270 and 271 1 25591 269 Capscrew 8 71030118 270 Adjusting Screw 1 53545 271 Nut 2 50176 272 Shoulder Screw 1 54710 273 Guide 1 71136741 274 Spring 1 71136758 275 Washer...

Page 53: ...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 4...

Page 54: ...1625 447 Pin 1 95790040 448 Setscrew 2 42008607 449 O Ring 2 3 58235329 450 Setscrew 2 3 42008307 451 Protector 2 3 95790107 452 Valve 2 3 95790104 453 Lever 2 95790122 454 Pendant Handle 1 order item...

Page 55: ...ake Fitting 948 920 906 956 912 910 917 711 703 707 706 705 918 919 902 704 703 702 701 700 940 947 901 922 923 921 960 901 909 930 937 938 939 941 942 925 924 935 963 944 955 902 942 721 722 942 723...

Page 56: ...2 71138135 945 Pin 1 71146674 723 Adapter Exhaust 1 27540 946 Gasket 1 set 27115 726 Plug 1 27945 947 Rivet 2 71028849 901 Capscrew 11 71342034 948 Label Throttle Direction 1 71352777 902 Washer 12 7...

Page 57: ...l Qty Part Number 353 Remote Pilot Pendant 1 PHS2E 364 Fitting Hose 3 52179 355 Valve Assembly 1 20993 365 Fitting Tee 1 52181 358 Remote Pilot Lever Throttle 1 71386064 455 Fitting Nipple 3 71078158...

Page 58: ...lve Housing 1 K5B 1101 300 Handle 1 K5B 556 347 Roll Pin 1 71326102 301 Roll Pin 1 K5B 1115 348 Valve Bushing 1 K5B 1101 305 Valve Body Retainer 1 K5B 1110A 350 Fitting Bushing 1 51814 306 Spring Reta...

Page 59: ...46 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 76...

Page 60: ...End 3 51029 769 Fitting Nipple 1 71328249 739 Fitting Elbow 5 52803 771 Washer 4 71320956 741 Fitting Elbow 8 54243 772 Capscrew 4 71320949 742 Capscrew 3 71319073 773 Nut 3 71069132 743 Handle Ball...

Page 61: ...eframe Motor End 1 26332 585 Washer 4 71274807 Bar without Drum Brake Bar with Drum Brake 570 Short Drum 7 in 2 25671 1 570 Short Drum 7 in 2 25671 4 Medium Drum 13 1 2 in 25671 2 Medium Drum 13 1 2 i...

Page 62: ...9 710 711 712 958 Item No Description of Part Total Qty Part Number Motor Muffler and Fittings 710 Muffler 1 50594 711 Fitting Elbow 1 71106439 712 Reducer 1 71057459 Control Valve Muffler and Fitting...

Page 63: ...Capscrew 4 71261739 2 593 Washer As Req d 71296800 595 Bracket 1 26311 596 Extension 1 26312 Drum Guard Assembly without Drum Brake Drum Guard Assembly with Automatic Drum Brake Short Drum 7 in 1 incl...

Page 64: ...asket 2 71262257 511 Plunger 1 HU 566 28 Output Shaft 1 24817 512 Handle 1 HU 565 501 O Ring 1 71137988 513 Capscrew 4 71307284 502 Housing 1 27315 514 Detent Plate 1 26182 503 Shaft Support 1 27314 5...

Page 65: ...62 613 Arm 1 29456 600 Base 1 614 Retainer Ring 2 71053581 602 Retainer Ring 2 53050 615 Bushing 2 71411490 603 Retainer Ring 2 71069322 616 Bushing 2 71337091 604 Bearing 4 71053649 617 Shaft 1 29457...

Page 66: ...1 1 2 FNPT 1 F35 0B C28 577 Regulator 1 1 2 FNPT 1 R40 0B G00 578 Pipe Nipple 1 1 2 FNPT As Req d Contact Factory 580 Lubricator 1 1 2 FNPT 1 L40 0B G00 Liquidator 2 FNPT 1 8834 W1 000 Air preparation...

Page 67: ...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 64 341 342 343 947 948 960 345 346 347 Vie...

Page 68: ...348 Product Label 7 inch Drum 1 71302640 Product Label 13 1 2 inch Drum 71111769 Product Label 20 inch Drum 71111777 Product Label 24 inch Drum 349 I R Logo 7 inch Drum 1 71106231 I R Logo 13 1 2 inch...

Page 69: ...o incorporate changes Always check the manual edition number on the front cover for the latest issue Sections of this manual may not apply to your winch Return Goods Policy Ingersoll Rand will not acc...

Page 70: ...MHD56114 Edition 4 69 SERVICE NOTES...

Page 71: ...70 MHD56114 Edition 4 SERVICE NOTES...

Page 72: ...or otherwise Note Some states do not allow limitations on incidental or conse quential damages or how long an implied warranty lasts so that the above limitations may not apply to you This warranty g...

Page 73: ...and office for the name and address of the distributor in your country or write fax to Canada National Sales Office Regional Warehouse Toronto Ontario 51 Worcester Road Rexdale Ontario M9W 4K2 Phone 4...