Ingersoll-Rand FA5T K5C2 Control Valve Disassembly, Crankshaft Disassembly, Handle Removal

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NOTICE

Do not disassemble planetary gear 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).

2.Remove rotary valve housing (247) by pulling it out of motor housing (217) as an assembly with exhaust flange

(253)or (254).

CAUTION

Do not remove the exhaust flange (254) until rotary valve (250) has been removed from rotary valve housing (247).

3.Remove rotary valve (250) by pulling it out from assembly through the motor housing end of rotary valve housing (247).

4.Remove exhaust flange (254) and throttle valve assembly (260) by removing capscrews (255) and (257), respectively.

5.Remove each cylinder head (201) by removing four capscrews (200). Remove head gasket (209).

6.Pull cylinder liner (208) straight out.

7.Position piston (204) at top of its stroke. In this position, with cylinder liner pulled out in step 7, wrist pin (203) can be removed. Remove one retainer ring (205) from either side of piston (204). Push wrist pin (203) out by hand from one side. If wrist pin is too tight it is acceptable to carefully heat piston to 200° F (93° C) or less and then push wrist pin out.

NOTICE

If piston, wrist pin, connecting rod or cylinder liner are to be re-assembled, number each set. Also add radial alignment marks for each piston and cylinder liner to motor housing.

8.Remove remaining cylinder liners and pistons as described in steps 7 and 8. To remove crank assembly, all pistons and cylinder liners must be removed.

9.Crank assembly (231) can now be removed with oil slinger (230) by pulling straight out from motor housing (217). Use care while guiding connecting rods (206) through inside of motor housing.

Crankshaft Disassembly

1.Remove cotter pin (236) and pin nut (237).

2.Remove lock pin (235) by carefully driving it out of its location. Use care not to damage pin threads.

3.Pull crankshaft valve end (231) off crankshaft.

4.Remove connecting rod rings (234), connecting rod bushing (233), sleeve (232) and connecting rods (206). Record five connecting rod (206) numbers and foot directions so they can be re-installed in same order.

5.Oil slinger (230) does not have to be removed unless damaged. If removal is required, heating of five screws (229) may be necessary to loosen Loctite® connection.

Control Valve Removal and Replacement

Refer to Dwg. MHP2036 on page 50 or MHP0165 on page 54.

Replacement of K5B control valve with K5C2 control valve.

1.Turn off air supply to valve and disconnect main air supply line at motor.

2.Disconnect auxiliary air line(s) from fitting(s) located on control valve.

3.Remove muffler and/or exhaust piping.

4.Remove capscrews (1) and (255), and washers (96) from exhaust flange cap (254). Discard gasket (317).

5.Remove capscrews (257) and washers (96) from control valve.

6.Remove control valve from rotary housing and discard gasket (248).

7.Install gaskets (946) and control valve assembly (900) securing with capscrews (951) and washers (949).

8.Install gasket (970) and exhaust cap (971) to rotary housing on motor.

9.Install fittings (957), (958) and muffler (959) on control valve. These are optional parts.

K5C2 Control Valve Disassembly

Refer to Dwg. MHP2036 on page 50.

Handle Removal

It is not recommended to disassemble handle.

1.Carefully pry off plug (935).

2.Remove capscrew (901) and tablock washer (909).

NOTICE

Observe spring (937) connection during disassembly. This spring is under tension and is required to return handle to neutral position.

3.Carefully pull handle assembly (930) from reverse valve (943). Remove spring (937).

Reverse Valve Removal

1.Remove capscrews (938), (925) and washers (924) from seal bracket (939). Remove seal bracket from housing. Remove and discard ‘O’ rings (941) and (942).

2.Remove capscrews (901) and washers (902) from exhaust flange (955). Remove flange from housing. Remove and discard ‘O’ ring (942).

3.Move reverse valve (943) out exhaust flange side of housing until ball (916) is visible on reverse valve. Allow ball (916) to drop out of bushing (944) and remove ball (916).

4.Remove bushing (944) out exhaust flange side of housing.

NOTICE

Dowel pin (945) allows the bushing to be removed only from the exhaust flange side of housing. Ball (916) retains reverse valve (943) in bushing (944).

Do not remove reverse valve (943), bushing (944) and ball (916) at the same time, damage may occur to bushing.

Take care to not allow ball (916) to drop in motor. If this occurs it may be necessary to disassemble motor to retrieve ball (916).

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MHD56037 - Edition 5

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Contents Model FA5 and FA5T Table of Contents Safety Information Safety SummarySafe Operating Instructions Specifications FA53XX Performance Graphs FA5 Winch FA5T WinchDescription of Operation FA5 FA5TInstallation TraceabilityMounting Minimum and Maximum Wire Rope Size Model Wire RopeWinch Bolt Hole Mounting Dimensions Drum Length inchesSafe Installation Procedures Wire Rope SpoolingSpooling Wire Rope onto Winch Drum Air SupplyMotor Emergency Stop and Overload System Components old style Constant Tension optional featureAir Schematic-Emergency Stop and Overload System old style Constant Tension ComponentsOperation Initial Operating ChecksWinch Controls Remote Pilot Pendant Throttle optional feature Underwound Operation optional featureRemote Live Air Throttle optional feature Winch Mounted Throttle Control Valve Operation old styleEmergency Stop and Overload System Remote Pilot Lever Throttle optional featureEmergency Stop optional feature Pendant Hose and Operating Levers old styleEmergency Stop optional feature Overload DeviceWinch Overload Device optional feature Drum Locking Pin optional featureWinch Brakes Limit Switch optional feature Component Lubrication LubricationRecommended Lubricants Interval Lubrication ChecksDisc Brake optional feature Inspection Records and ReportsFrequent Inspection Periodic Inspection Winches Not in Regular UseNormal Heavy Severe Inspection and Maintenance Report TestingCondition Corrective Component Action Troubleshooting Symptom Cause RemedyAutomatic Drum Brake Automatic Disc Brake Adjustments MaintenanceMaintenance Intervals Interval Maintenance CheckOverload Valve Adjustment old style Overload Valve Adjustment new styleOverload Valve Adjustment optional feature Old style Limit Switch Adjustment optional featureDisassembly Manual or Automatic Drum Brake Disassembly Reduction Gear DisassemblyControl Valve Removal and Replacement K5C2 Control Valve DisassemblyCrankshaft Disassembly Handle RemovalCleaning, Inspection and Repair Assembly K5C2 Control Valve AssemblyK5C2-EX Control Valve Assembly Reduction Gear Assembly Winch Assembly Brake Seal InstallationAutomatic Drum Brake Actuator Assembly Drum AssemblyDrum Brake Assembly FA5 Band Brake ComponentsTesting Operational TestLoad Test FA5 Winch Assembly Drawings Reference Diagram FA5 Winch Drawings and Parts Lists Table of Contents DRUM, Base and Reduction Gear Assembly Drawing Part DRUM, Base and Reduction Gear Assembly Parts ListPart Description Part QtyDrum Assembly Parts List DRUM, Base and Reduction Gear Assembly Parts List CONT’DUpright Assembly Parts List Side Rail Parts ListMuffler Assembly Drawing and Parts List K5B Motor Assembly Drawing K5B Motor Assembly Parts List Disc Brake Assembly Drawing Disc Brake Assembly Parts List Drum Brake Assembly Drawing Drum Brake Assembly Parts List Part NumberParts K5C2 Control Valve Assembly Drawing K5C2 Control Valve Assembly Parts List Part Qty NumberEmergency Stop and Overload K5C2-EX Valve Assembly Drawing Emergency Stop and Overload K5C2-EX Valve Parts List K5B Control Valve Assembly Drawing and Parts List K5C2-SBK Remote Pilot AIR Control Optional Assembly Drawing Remote PilotRemote Pilot AIR Control Optional Assembly Parts List PHS2ERemote Pendant Assembly Drawings Pendant without Emergency StopPendant with Emergency Stop Remote Pendant Assembly Parts List Description Total PartPart Qty With E-Stop Dwg. MHP0141 Drum Locking PIN Optional Assembly Drawing and Parts List Number PartDrum Guard Assembly Drawing and Parts List Dwg. MHP1341 Pendant Control Assembly Drawing and Parts List Service Notes Emergency Stop Overload Assembly Drawing Emergency Stop Overload Assembly Parts List Limit Switch Assembly Drawing Limit Switch Assembly Parts List Pilot AIR Valve Plumbing Assembly Drawing Pilot AIR Valve Plumbing Assembly Parts List Tensioning Manifold Assembly Drawing Tensioning Manifold Assembly Parts List Description of Accessory Accessory Part Number Lubricant AIR Preparation Assembly Drawing and Parts ListAccessories LUBRI-LINK-GREENDwg. MHP1676 Kits Description Part KitDisposal Parts Ordering InformationReturn Goods Policy Ingersoll RandService Notes Concealed Loss or Damage WarrantyVisible Loss or Damage Damage Claims
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Manual 61 pages 8.29 Kb

FA5T, FA5 specifications

The Ingersoll-Rand FA5 and FA5T are cutting-edge air compressor models designed to offer exceptional performance and reliability for a variety of industrial applications. With their robust engineering, these units are ideal for both small-scale and large-scale operations, providing a significant boost to operational efficiency.

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