Ingersoll-Rand FA5T manual K5C2 Control Valve Assembly

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5.Inspect drum band brake lining for oil, grease and glazing. If drum band brake lining is oil-soaked replace brake bands as a set. Remove glazed areas of band brake lining by sanding lightly with a fine grit emery cloth.

6.Measure thickness of drum band brake lining. If drum brake band linings are less than 0.062 inch (2 mm) thick anywhere along edges replace brake bands (128) as a set.

7.Inspect cylinder bores. Minor scratches in bore lining may be repaired by lightly honing to remove. Refer to tolerances listed below for acceptable clearances. Replace liner if deep scratches or gouges are apparent. Measure inside diameter of liner. If measurement is greater than 4.764 inches (121 mm) replace liner. ‘Ring Gap’ may also be used to determine wear; place compression ring into liner, using a piston, push ring until approximately half way in liner and measure ‘Gap’

— 0.003 inch (0.076 mm) is normal; replace rings, or liner, if ‘Gap’ exceeds 0.020 inch (0.51 mm).

Repair

Actual repairs are limited to removal of small burrs and other minor surface imperfections from gears and shafts. Use a fine stone or emery cloth for this work.

1.Worn or damaged parts must be replaced. Refer to the applicable parts listing for specific replacement parts information.

2.Inspect all remaining parts for evidence of damage. Replace or repair any part which is in questionable condition. Cost of the part is often minor in comparison with cost of redoing job.

3.Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings.

4.Examine all gear teeth carefully, and remove nicks or burrs.

5.Polish edges of all shaft shoulders to remove small nicks which may have been caused during handling.

6.Remove all nicks and burrs caused by lockwashers.

Assembly

General instructions

•Use all new gaskets and seals.

•Replace worn parts.

•Assemble parts using match marks attached during disassembly. Compare replacement parts with originals to identify installation alignments.

•Lubricate all internal parts with rust and oxidation inhibiting lubricant, ISO VG 100 (SAE 30W).

K5C2 Control Valve Assembly

Refer to Dwg. MHP2036 on page 50.

Reverse Valve Assembly

1.Insert reverse valve (943) into bushing (944) with ball slot oriented UP, approximately 2-1/2 in. (64 mm).

2.Insert bushing (944) and reverse valve (943) into valve housing (917) from exhaust flange side, ensuring that groove in bushing is aligned with pin (945).

3.Insert ball (916) onto reverse valve platform. With finger, push ball (916) in housing until ball hits end of reverse valve.

4.Holding ball (916) in position on reverse valve platform, rotate reverse valve from neutral position to approximately 45 degrees in either direction. Ball will ‘walk’ up side of reverse valve platform and move in ball hole in bushing.

NOTICE

•Do not rotate reverse valve past a 90 degree position, it may result in the ball (916) falling in motor.

5.Slowly push reverse valve, while still in the 45 degree position, the rest of the way in housing until flush with surface. From other side of valve rotate reverse valve back to neutral position, ball should be seated in ball slot at that time.

6.Lubricate ‘O’ ring (942) and place it in groove in exhaust flange (955).

7.Secure exhaust flange (955) to valve housing with capscrews

(901)and washers (902).

8.Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’ ring (942) and place into groove in seal bracket.

9.Place seal bracket over end of reverse valve. Using finger pressure, press until seal is seated on reverse valve and seal bracket is seated on valve housing. Secure with washers

(924)and capscrews (925) and (938).

Pilot Valve Assembly

NOTICE

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

1.Install pilot valve assembly (910).

2.Apply thread sealant Loctite 567® to pilot valve assembly (910), place pilot valve assembly into valve housing. Use a large flat tipped screw driver to engage slots in pilot seat and tighten until pilot assembly is 1/8 in. (3.175 mm) from housing bore.

3.Insert plug (912) and tighten.

Piston Assembly

1.Lubricate and install ‘O’ rings (921) and (923) on piston (922).

2.Insert assembled piston into valve housing (917) from handle side.

3.Secure with gasket (918), piston cover (919), washers (902) and capscrews (901).

4.Place poppet seal (907) into poppet cap (906). Place this assembly into valve housing and seat on piston (922).

5.Place spring (905) over this assembly.

6.Secure with gasket (904), poppet cover (903), washers (902) and capscrews (901).

Handle Assembly

1.Place spring (937) over reverse valve handle end in seal bracket.

NOTICE

•Spring (937) will have to be ‘Cocked’ over stud in seal bracket. This will ensure handle returns to neutral.

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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 3XX SpecificationsFA5 Performance Graphs FA5 Winch FA5T WinchDescription of Operation FA5 FA5TMounting InstallationTraceability Wire Rope Winch Bolt Hole Mounting DimensionsMinimum and Maximum Wire Rope Size Model Drum Length inchesWire Rope Spooling Spooling Wire Rope onto Winch DrumSafe Installation Procedures Air SupplyMotor Constant Tension optional feature Air Schematic-Emergency Stop and Overload System old styleEmergency Stop and Overload System Components old style Constant Tension ComponentsWinch Controls OperationInitial Operating Checks Underwound Operation optional feature Remote Live Air Throttle optional featureRemote Pilot Pendant Throttle optional feature Winch Mounted Throttle Control Valve Operation old styleRemote Pilot Lever Throttle optional feature Emergency Stop optional featureEmergency Stop and Overload System Pendant Hose and Operating Levers old styleEmergency Stop optional feature Overload DeviceWinch Brakes Winch Overload Device optional featureDrum Locking Pin optional feature Limit Switch optional feature Lubrication Recommended LubricantsComponent Lubrication Interval Lubrication ChecksDisc Brake optional feature Frequent Inspection InspectionRecords and Reports Normal Heavy Severe Periodic InspectionWinches Not in Regular Use Condition Corrective Component Action Inspection and Maintenance ReportTesting Automatic Drum Brake TroubleshootingSymptom Cause Remedy Automatic Disc Brake Maintenance Maintenance IntervalsAdjustments Interval Maintenance CheckOverload Valve Adjustment new style Overload Valve Adjustment optional feature Old styleOverload Valve Adjustment old style Limit Switch Adjustment optional featureDisassembly Manual or Automatic Drum Brake Disassembly Reduction Gear DisassemblyK5C2 Control Valve Disassembly Crankshaft DisassemblyControl Valve Removal and Replacement Handle RemovalCleaning, Inspection and Repair Assembly K5C2 Control Valve AssemblyK5C2-EX Control Valve Assembly Reduction Gear Assembly Winch Assembly Brake Seal InstallationDrum Assembly Drum Brake AssemblyAutomatic Drum Brake Actuator Assembly FA5 Band Brake ComponentsLoad Test TestingOperational Test FA5 Winch Assembly Drawings Reference Diagram FA5 Winch Drawings and Parts Lists Table of Contents DRUM, Base and Reduction Gear Assembly Drawing DRUM, Base and Reduction Gear Assembly Parts List Part DescriptionPart Part QtyDRUM, Base and Reduction Gear Assembly Parts List CONT’D Upright Assembly Parts ListDrum 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 Parts Drum Brake Assembly Parts ListPart Number 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 PHS2EPendant with Emergency Stop Remote Pendant Assembly DrawingsPendant without Emergency Stop Part Qty With E-Stop Remote Pendant Assembly Parts ListDescription Total Part 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 AIR Preparation Assembly Drawing and Parts List AccessoriesDescription of Accessory Accessory Part Number Lubricant LUBRI-LINK-GREENDwg. MHP1676 Kits Description Part KitParts Ordering Information Return Goods PolicyDisposal Ingersoll RandService Notes Warranty Visible Loss or DamageConcealed Loss or Damage Damage Claims
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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.

One of the main features of the FA5 series is its advanced rotary screw design, which ensures a continuous supply of compressed air while minimizing energy consumption. This energy-efficient design not only reduces operational costs but also makes the models environmentally friendly. The FA5T variant introduces enhanced technology for higher performance, targeting industries that require a greater air flow.

The compressors are equipped with a state-of-the-art microprocessor controller that allows for precise monitoring of system performance. This intelligent controller provides real-time data on operating conditions, such as pressure levels and temperature, allowing operators to ensure optimal performance and preemptively address potential issues.

Another notable characteristic of the FA5 and FA5T is their quiet operation. These compressors incorporate sound-dampening technology, making them suitable for installation in noise-sensitive environments. The reduced noise levels help maintain a comfortable work atmosphere while also adhering to regulatory standards.

The FA5 series features durable construction with high-quality materials that enhance the longevity and reliability of the compressors. The robust design minimizes wear and tear, ensuring that the units remain operational even under demanding conditions. Additionally, maintenance is simplified, thanks to easily accessible components and straightforward service procedures, which help minimize downtime.

The FA5 and FA5T also offer flexibility in installation. Their compact design enables them to fit in limited spaces, making them ideal for various industrial settings. Users appreciate the versatility of these compressors, as they can be integrated into existing systems without significant modifications.

Ingersoll-Rand has incorporated innovative technologies into the FA5 and FA5T, such as variable speed drive capabilities which allow for greater control of output levels. This feature ensures that the compressor operates only as needed, further enhancing energy efficiency.

Overall, the Ingersoll-Rand FA5 and FA5T represent a perfect balance of high performance, energy efficiency, and operational reliability. Their advanced features make them a top choice for industries looking to improve productivity while reducing environmental impact.
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