Ingersoll-Rand ManRider force5 FA5AMR-LAK1, Parts, Operation And Maintenance Manual

Page: 24 / 68

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Repairing Surfaces
For minor repairs to the thermoplastic coating conduct the
following:
1.
If the under laying surface is not corroded and the scratch is
less than 1/16 inch (1.6 mm) wide the surrounding
thermoplastic coating can be heated until the material flows
together. For clean surfaces with damage greater than 1/16
inch (1.6 mm) heat the area and then apply thermoplastic
coating powder (Ingersoll-Rand Part No. 71308902 [2 oz.
(56.7 g)] to fill the area. Continue heating until coating
liquefies and flows together with the existing coating.
2. Corrosion in damaged area must be removed. Sandblast or
wire brush the area to remove corrosion. If corrosion exists,
ensure the corrosion has not penetrated below the surface of
existing thermoplastic coating. This can usually be easily
determined by checking to see if the coating is loose around
the corroded area. Cut away coating as necessary to expose
corrosion for removal. If the damaged area is less than 1/16
inch (1.6 mm) wide the surrounding thermoplastic coating
can be heated until the material flows together. For surfaces
with damage greater than 1/16 inch (1.6 mm) heat the area
and then apply thermoplastic coating powder,
Ingersoll-Rand Part No. 71308902 [2 oz. (56.7 g)], to fill
the area. Continue heating until coating liquefies and flows
together with the existing coating.
3. Allow the repaired area to cool. Quenching with water is
acceptable. Inspect the repair. Rough spots, minor
scorching and excess coating deposits can be wet sanded to
remove the imperfections. To return the gloss finish, reheat
the surface carefully.
For large bare surfaces or new parts:
Coating these components can be done more economically and
with better end results by using an electrostatic powder
application process or flamespray process. Contact
Ingersoll-Rand Technical Assistance for more information.
For specific disassembly and assembly information refer to
‘Assembly’ or ‘Disassembly’ in the “MAINTENANCE” section.
Adjustments
Disc Brake
Brake adjustment is not required. If the disc brake does not hold
100% of rated load at mid drum, disassemble and repair.
NOTICE
• Winches are provided with a breather plug located at the
top of the disc brake housing. If the brake assembly is
removed or repaired ensure the breather is installed and
located at the top of the brake housing during reassembly.
Manual Drum Band Brake
Optional feature. Refer to Dwg. MHP1448.
1.
Release wire rope tension on the drum.
2. Raise handle (135) to free brake bands (136 and 137).
3. Remove cotter pin (139) and pin (138).
4. Rotate brake link stud (141) clockwise to increase brake
torque.
5. Install pin (138) and check adjustment.
NOTICE
• If brake band cannot be adjusted to hold the rated load,
replace the brake band assembly.
6. Adjust brake so when brake handle locks (goes over-
center), brake will hold rated load.
7. Install cotter pin (139) when adjustment is complete.
Automatic Drum Band Brake
Optional feature. Refer to Dwg. MHP1281.
For adjustments, references to “clockwise” and
“counterclockwise” directions, in the text, refer to directions as
viewed from the head end of capscrew (120).
NOTICE
• If brake band cannot be adjusted to hold rated load, replace
the brake band assembly.
1. Loosen jam nut (117) closest to plunger (114).
2. Adjust band assembly using capscrew (120).
a.
To loosen band brake, turn capscrew (120) in the
counterclockwise direction.
b. To tighten band brake, turn capscrew (120) in the
clockwise direction.
NOTICE
• If the capscrew (120) is not accessible, the jam nut (117)
[located closest to the head of capscrew (120)] may be used to
adjust the band brake. Ensure capscrew turns with nut.
3. When adjustments are complete tighten jam nut (117)
closest to plunger (114).
Disassembly
General Disassembly Instructions
The following instructions provide the necessary information to
disassemble, inspect, repair, and assemble the winch. Parts
drawings are provided in the Parts Section.
If a winch is being completely disassembled for any reason,
follow the order of the topics as they are presented.
It is recommended that all maintenance work on the winch be
performed in a clean dust free work area.
In the process of disassembling the winch, observe the
following:
1.
Never disassemble the winch any further than is necessary
to accomplish the needed repair. A good part can be
damaged during the course of disassembly.
2. Never use excessive force when removing parts. Tapping
gently around the perimeter of a cover or housing with a
soft hammer, for example, is sufficient to break the seal.
3. Do not heat a part with a flame to free it for removal,
unless the part being heated is already worn or damaged
beyond repair and no additional damage will occur to other
parts.
In general, the winch is designed to permit easy disassembly and
assembly. The use of heat or excessive force should not be
required.
4. Keep the work area as clean as practical, to prevent dirt and
other foreign matter from getting into bearings or other
moving parts.
5. All seals, gaskets and ‘O’ rings should be discarded once
they have been removed. New seals, gaskets and ‘O’ rings
should be used when assembling the winch.