Ingersoll-Rand FA5T manual Cleaning, Inspection and Repair

Page 31

Piston Removal

1.Remove capscrews (901) and 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).

3.Remove the following items from housing poppet bore: spring (905), poppet cap (906) and poppet seal (907).

4.From poppet side, push piston (922) out of housing. Remove ‘O’ rings (921) and (923) and discard.

Pilot Valve Removal

NOTICE

For easier removal it is recommended to use IR pilot valve tool (920). This must be purchased separately.

If pilot valve is not damaged it is not necessary to disassemble completely.

1.Remove plug (912).

2.Remove pilot valve assembly (910) as an assembly.

3.Discard and replace pilot valve assembly (910) if necessary.

K5B Control Valve Disassembly (old style)

Refer to Dwg. MHP0165on page 54.

NOTICE

Match mark throttle valve parts to ensure proper re- assembly.

1.Remove two capscrews (302) and lockwashers (96) that hold the valve body retainer (305).

2.Mark square end on valve body (316) and handle (300) to ensure correct orientation during reassembly.

3.Drive out pin (301) and remove handle (300).

4.Make note on how spring (303) is positioned before removing it. Pull valve body (316) out of valve bushing (314) while disconnecting spring (303).

5.Remove seal rings (315) from valve body (316).

6.Check parts for score marks or wear.

7.Measure clearance between valve bushing (314) and valve body (316). Clearance between valve bushing and valve body should not exceed 0.002 inch (0.05 mm) or excessive air leakage will occur.

K5C2-E Control Valve Disassembly

Refer to Dwg. MHP 2180 on page 52.

Handle Removal

Follow disassembly instructions for K5C2 Control Valve.

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 (721) and washers (902) from exhaust flange (955) and exhaust adapter (723). Remove and discard ‘O’ rings (942) and (722).

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.

Piston Removal

Follow disassembly instructions for K5C2 Control Valve.

Pilot Valve Removal

Follow disassembly instructions for K5C2 Control Valve.

Emergency Stop Removal

1.Remove adapter (706) and E-Stop button (705).

2.Remove plunger (707). Remove and discard ‘O’ rings (703).

3.Pull spring (711) out of valve housing and discard.

Overload Valve Removal

1.Remove cap (700). Remove and discard grommet (701).

2.Pull out plunger (702), remove and discard ‘O’ rings (703).

3.Remove capscrews (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 (720).

Cleaning, Inspection and Repair

Clean all winch component parts in solvent (except drum brake bands and disc brake friction plates). The use of a stiff bristle brush will facilitate removal of accumulated dirt and sediments on housings, frame and drum. If bushings have been removed it may be necessary to scrape old Loctite® from bushing bores. Dry each part using low pressure, filtered compressed air. Clean drum brake band using a wire brush or emery cloth. Do not wash drum brake band in solvent. If drum brake band lining is oil soaked, it must be replaced.

Inspection

All disassembled parts should be inspected to determine their fitness for continued use. Pay particular attention to the following:

1.Inspect all gears for worn, cracked, or broken teeth.

2.Inspect all bushings for wear, scoring, or galling.

3.Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent on shafts, replace shaft.

4.Inspect all threaded items and replace those having damaged threads.

MHD56037 - Edition 5

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Contents Model FA5 and FA5T Table of Contents Safety Summary Safety InformationSafe Operating Instructions FA5 Specifications3XX FA5T Winch Performance Graphs FA5 WinchFA5 FA5T Description of OperationTraceability InstallationMounting Drum Length inches Wire RopeWinch Bolt Hole Mounting Dimensions Minimum and Maximum Wire Rope Size ModelAir Supply Wire Rope SpoolingSpooling Wire Rope onto Winch Drum Safe Installation ProceduresMotor Constant Tension Components Constant Tension optional featureAir Schematic-Emergency Stop and Overload System old style Emergency Stop and Overload System Components old styleInitial Operating Checks OperationWinch Controls Winch Mounted Throttle Control Valve Operation old style Underwound Operation optional featureRemote Live Air Throttle optional feature Remote Pilot Pendant Throttle optional featurePendant Hose and Operating Levers old style Remote Pilot Lever Throttle optional featureEmergency Stop optional feature Emergency Stop and Overload SystemOverload Device Emergency Stop optional featureDrum Locking Pin optional feature Winch Overload Device optional featureWinch Brakes Limit Switch optional feature Interval Lubrication Checks LubricationRecommended Lubricants Component LubricationDisc Brake optional feature Records and Reports InspectionFrequent Inspection Winches Not in Regular Use Periodic InspectionNormal Heavy Severe Testing Inspection and Maintenance ReportCondition Corrective Component Action Symptom Cause Remedy TroubleshootingAutomatic Drum Brake Automatic Disc Brake Interval Maintenance Check MaintenanceMaintenance Intervals AdjustmentsLimit Switch Adjustment optional feature Overload Valve Adjustment new styleOverload Valve Adjustment optional feature Old style Overload Valve Adjustment old styleDisassembly Reduction Gear Disassembly Manual or Automatic Drum Brake DisassemblyHandle Removal K5C2 Control Valve DisassemblyCrankshaft Disassembly Control Valve Removal and ReplacementCleaning, Inspection and Repair K5C2 Control Valve Assembly AssemblyK5C2-EX Control Valve Assembly Reduction Gear Assembly Brake Seal Installation Winch AssemblyFA5 Band Brake Components Drum AssemblyDrum Brake Assembly Automatic Drum Brake Actuator AssemblyOperational Test TestingLoad Test FA5 Winch Assembly Drawings Reference Diagram FA5 Winch Drawings and Parts Lists Table of Contents DRUM, Base and Reduction Gear Assembly Drawing Part Qty DRUM, Base and Reduction Gear Assembly Parts ListPart Description PartSide Rail Parts List DRUM, Base and Reduction Gear Assembly Parts List CONT’DUpright Assembly Parts List Drum Assembly 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 Part Number Drum Brake Assembly Parts ListParts K5C2 Control Valve Assembly Drawing Part Qty Number K5C2 Control Valve Assembly Parts ListEmergency 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 Remote Pilot AIR Control Optional Assembly DrawingPHS2E Remote Pilot AIR Control Optional Assembly Parts ListPendant without Emergency Stop Remote Pendant Assembly DrawingsPendant with Emergency Stop Description Total Part Remote Pendant Assembly Parts ListPart Qty With E-Stop Dwg. MHP0141 Number Part Drum Locking PIN Optional Assembly Drawing and Parts ListDrum 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 LUBRI-LINK-GREEN AIR Preparation Assembly Drawing and Parts ListAccessories Description of Accessory Accessory Part Number LubricantDwg. MHP1676 Description Part Kit KitsIngersoll Rand Parts Ordering InformationReturn Goods Policy DisposalService Notes Damage Claims WarrantyVisible Loss or Damage Concealed Loss or Damage
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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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