Ingersoll-Rand FA2A, Parts, Operation And Maintenance Manual

Page: 33 / 65

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5. To install planet gear assemblies on the input carrier (47)
conduct the following:
a.
Ensure pin (49) is securely attached to input carrier
(47). If loose, carefully remove pin. Clean pin and
mating surface on carrier. Coat end of pin and carrier
mating surface with Loctite
®
620 and install pin.
Allow to cure.
b. Install washer (39) and input planet gear (51) on pin
(49).
c. Lubricate roller bearings (50) and install sixteen
bearings in input planet gear (51).
d. Install second washer (39) on pin (49). Secure parts on
pin using retainer ring (53).
6. Install intermediate sun gear (45) in input carrier assembly.
Place retainer rings (46) on each side of carrier (47) to
secure sun gear in place.
7. Place thrust washers (55) and thrust bearing (56) on input
sun gear (54). Place assembly in input carrier assembly (47)
by aligning gear teeth of planet gears (51) with gear teeth
on input sun gear.
8. Install input carrier assembly in reducer housing (59).
9. Install output carrier assembly in reducer housing. Ensure
gear teeth of planet gears (43) align with intermediate sun
gear (45) gear teeth.
10. Install thrust washer (34).
11. With drum standing on end, place reduction gear assembly
into drum. Place Loctite
®
515 on mating surfaces of
housing (59) and cover (33). Align the two recessed cutouts
in the housing with the fill and drain plug ports in the
cover. Secure in place by evenly installing six capscrews
(32). Torque capscrews to 60 ft lbs (81 Nm).
12. Cover the reduction gear to prevent dirt and contaminants
from entering assembly and place in a safe position until
ready for assembly to winch uprights.
Winch Assembly
Refer to Dwg. MHP1248 and 1324.
NOTICE
• Unless otherwise stated capscrew torque values listed are
for lubricated or plated threads. This assembly uses “blue
bolts” in numerous locations. These are plated and should
not be lubricated.
1. Using a hoist, support the drum.
2. Install bearing (30) in inboard (motor end) upright (68).
With oil seal (29) lip facing towards the motor, install oil
seal in inboard upright.
3. Install output shaft (28), bearing (30) and oil seal (29) in
outboard upright (26). Oil seal lip must face toward the
brake. Install the outboard upright onto drum by aligning
splines of output shaft to reduction gear output carrier
assembly splines.
4. If equipped with automatic drum brake, install the drum
band brake bracket and piston assemblies. Do not attach the
brake band assembly (104). Refer to the ‘Drum Band
Brake’ section for instructions.
5. Install coupling (60) on drive shaft (61) and install on end
of the input sun gear (54), located in the reduction gear
assembly.
6. If equipped with automatic drum brake, place brake band
assembly (104) onto drum brake flange. Place inboard
(motor end) upright (68) on drum.
7. For standard winch: loosely attach the sideframes (64)
and (65) to the uprights (26) and (68) using four capscrews
(66) for each sideframe. Tighten capscrews and torque to
75 ft lbs (102 Nm) for dry threads, or 55 ft lbs (75 Nm) if
thread lubrication is used.
8. For Open Frame (Face) winch: Refer to Dwg. MHP1324.
Loosely attach the rear sideframe (64), using four
capscrews (66) to uprights (26) and (68).
a.
If noted during disassembly, place washers (584), in
quantities and locations recorded, and bars (571)
between sideframes (571) and (573). Secure using
capscrews (572) and torque to 150-175 ft lbs (203-237
Nm). Go to step 8.c.
b. If washer (584) locations and quantities were not
recorded, loosely attach sideframe (571) to upright
(26) and sideframe (573) to upright (68) using
capscrews (574). Using washers and bars (570),
determine the correct arrangement of washers required
to ensure sideframes are even with drum (62) flange
edge. The washers (584) must be evenly distributed
with an equal number located on each end of the bars.
Once quantities are determined, remove the sideframes
and reassembly as described in step 8.a.
c. Place open frame assembly onto uprights (26) and
(68). Ensure sideframe (571) is located on upright (26)
and sideframe (573) is located on upright (68). Place
washers (585) on capscrews (574) and secure frame
assembly to uprights. Torque capscrews to 75 ft lbs
(102 Nm).
d. Secure rear sideframe (64) to uprights, torque
capscrews (66) to 75 ft lbs (102 Nm).
9. Align holes in motor adapter (71) and install on upright.
Secure with six washers (74) and capscrews (73). Torque
capscrews to 125 ft lbs (170 Nm) for dry threads, or 95 ft
lbs (129 Nm) if thread lubrication is used.
10. If equipped, attach band brake assembly (104) as described
in the ‘Drum Band Brake Assembly’ section.
Disc Brake Assembly
Refer to Dwg. MHP0947.
1.
Install bearing (21) into support plate (19) and secure with
retainer ring (22).
2. In this order, place spacer (11), sprag clutch (16), outer race
(12) and spacer (11) on inner race (10). Test sprag clutch
operation. Refer to Dwg. MHP0667.
NOTICE
• Correct sprag clutch installation prevents clockwise
rotation (brake engages) and allows counterclockwise
rotation when viewed from the end cover (2) end of the brake
assembly.
WARNING
• Incorrect assembly of the sprag clutch will adversely affect
winch operation. In haul-in operation, sprag clutch will be
engaged resulting in restricted winch operation. In neutral
and payout positions, the sprag clutch can rotate resulting in
brake not holding load. Ensure the sprag clutch is correctly
installed.
3. Install assembly on support plate (19).
4. Install twelve springs (17) in holes on inside of support
plate (19).
5. Install gasket (18) and pressure plate (15).