Ingersoll-Rand FA5T manual Reduction Gear Assembly

Page 34

3.Install two seal rings (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 bearing inner race. With rotary valve housing (247) exhaust flange down, install rotary valve into housing.

4.Install ‘O’ ring (244) into motor housing (217).

5.Install rotary valve housing gasket (243) onto rotary valve housing. With exhaust flange down on bench, install motor housing (217) onto rotary valve housing. Check for any evidence of damage to ‘O’ ring when rotary valve housing is fully engaged. Install and tighten capscrews (1) to 50 ft lbs (68 Nm).

6.If removed, press crank bearing (228) on crank assembly (231). Apply pressure only on inner race of bearing.

7.Place crank assembly on a work bench with oil slinger (230) down and slide the sleeve (232) (with tang up) on crankpin.

8.Slide connecting rod bushing (233) over sleeve (232) and first connecting rod ring (234) with chamfer up.

9.Install connecting rods (206) in same order as removed, with all feet pointing in same direction, using first connecting rod ring (234) to hold one side of connecting rod feet.

10.Slide second connecting rod ring over other side of connecting rod feet with chamfer on ring facing down (toward stem of connecting rod).

11.Slide crank shaft valve end over crank pin while simultaneously aligning tang on sleeve (232) with slot in crank shaft.

12.Rotate and position crank shaft valve end relative to crank pin to allow installation of lock pin (235).

13.Tap lock pin (235) in place and install pin nut (237). Torque nut to 60 ft lbs (81 Nm).

14.Install cotter pin (236) and bend ends over.

15.Install roll pin (240) and bearing (228) into valve end of crank shaft.

16.Check that all connecting rods move freely around crank. Position crank assembly into motor housing (217). Ensure bearing (228) is seated and connecting rods (206) are centered in cylinder holes.

NOTICE

•Make certain roll pin (240) and three lugs on rotary valve (250) line up with corresponding hole and lugs on crank shaft.

•Do not allow rotary valve to slide back in rotary valve housing (247). If rotary valve slides in too far, seal ring (251) will lock-up in internal grooves of rotary valve housing (247) and restrict further assembly.

17.Rotate crank assembly until one connecting rod (206) is at the top of its stroke. Install a piston (204) with its rings (202) and (207) to connecting rod with wrist pin (203) and retaining rings (205).

18.Install a new cylinder head gasket (209) before installing cylinder liner (208).

19.Install cylinder liner over the piston by compressing both piston rings and with a single band ring compressor.

20.Install cylinder head (201) over cylinder and secure cylinder head to motor housing with four capscrews (200). Torque capscrews to 60 ft lbs (81 Nm).

21.Repeat Steps 17 through 20 with remaining cylinders.

22.Rotate motor by hand. Motor should rotate without binding.

23.Install mounting flange (216) and gasket (226) on front of motor housing. Make sure notches on both parts are aligned.

24.Lightly lubricate ‘O’ ring (5) and install in groove on motor adapter (6).

NOTICE

•‘O’ ring, item 5 listed in step 24 refers to part number 51459 as shown on winch assembly Dwg. MHP0157 on page 40. This part must be placed between mounting flange (216) and motor adapter (6).

25.Temporarily install capscrews and nuts finger tight to retain motor adapter (6).

26.Install eye bolts (213) and vent cap assembly (210) in motor housing.

27.Ensure oil drain and level plugs (225) are installed.

Reduction Gear Assembly

Refer to Dwg. MHP0157 on page 40.

NOTICE

•It is important to maintain a clean work area when reduction assemblies are reassembled. During reassembly clean each part thoroughly and lightly coat with appropriate lubricant as described in ‘Recommended Lubricants’ on page 19 of the “LUBRICATION” section.

1.Install bearing (49) and retainer ring (50) in gear carrier (47).

2.Lubricate and install ‘O’ rings (51) on ring gear (53).

3.Align capscrew holes and dowel pins with gear carrier (47) and install ring gear (53). Ensure ‘O’ rings are not damaged during installation.

4.Install planet assembly (54).

5.Install thrust bearing (55) into sun gear (56). Install retainer ring (57) on sun gear and locate in planet assembly (54).

6.Align capscrew and dowel holes and install input housing

(59).Apply a light coating of Loctite® 262 to capscrew (60) threads and install by hand. Equally tighten capscrews in a diametrically opposed pattern to allow for equal compression of housing onto ring gear (53) and gear carrier (47). When ring gear and input housing flanges are flush with gear carrier torque capscrews to 95 ft lbs (128 Nm).

7.Install dowel pins (52) and tap into position until slightly below input housing flange.

8.Install planet assembly (58) onto sun gear (56).

9.Lubricate and install ‘O’ rings (62) on ring gear (63).

10.Install dowel pins (70) in ring gear (63) so they extend an equal distance on both sides of ring gear.

11.Align capscrew holes and dowel pins and install ring gear

(63)on input housing (59). Using a soft hammer or mallet, carefully tap dowel pins and ring gear (63) onto input housing until mating flanges are flush. Ensure ‘O’ rings are not damaged during installation.

12.Place thrust bearing (55) in sun gear (66) and install sun gear into planet assembly (58).

13.Install planet assembly (67) onto sun gear (66).

14.Align capscrew holes and dowel pins and install spacer (71) onto ring gear (63). Using a soft hammer or mallet, carefully tap spacer onto ring gear until mating flanges are flush.

Ensure ‘O’ rings are not damaged during installation.

15.Lubricate and install ‘O’ rings (62) on ring gear (72).

16.Using a soft hammer or mallet, carefully tap ring gear (72) onto spacer (71). Ensure ‘O’ rings are not damaged during installation.

17.Install sun gear (69) in planet assembly (67).

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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 FA5 Specifications3XX Performance Graphs FA5 Winch FA5T WinchDescription of Operation FA5 FA5TTraceability InstallationMounting 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 ComponentsInitial Operating Checks OperationWinch 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 DeviceDrum Locking Pin optional feature Winch Overload Device optional featureWinch Brakes Limit Switch optional feature Component Lubrication LubricationRecommended Lubricants Interval Lubrication ChecksDisc 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 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 ComponentsOperational 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 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 Part Number Drum Brake Assembly Parts ListParts 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 without Emergency Stop Remote Pendant Assembly DrawingsPendant with Emergency Stop Description Total Part Remote Pendant Assembly Parts ListPart 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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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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