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

Page: 36 / 68

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NOTICE
• Refer to ‘ADJUSTMENT’ section for adjusting brake.
9. Lift up brake handle (135) until hole in brake link stud
(141) and bracket in brake band (137) are aligned. Insert
pin (138) and secure with cotter pin (139).
10. Push brake handle (135) down to the lock position.
11. Tighten capscrews (112).
Automatic Drum Band Brake Assembly
Optional feature. Refer to Dwg. MHP1281.
For ease of assembly install bracket (106), cylinder (121)
assembly to motor end upright (68) prior to assembling upright
to drum.
1.
Assemble the brake cylinder (121) as follows:
a.
Install ‘O’ ring (122) on piston (123).
b. Heavily coat the piston and cylinder rod with
“LubriPlate” MO-LITH No. 2 or equivalent lubricant.
Install ‘O’ rings (109) and (110) on cylinder rod (108).
Place cylinder rod (108) into piston (123) and secure
in place using retainer ring (111).
c. Install piston assembly in brake cylinder (121).
d. Install washer (128) and springs (124) and (127).
DANGER
• Springs (124) and (127) exert a considerable force on cover
(125) when assembled . Extreme care must be taken when
assembling and installing cover (125) and retainer ring (126).
e. Using a press, slowly compress cover (125) and
springs until the retainer ring groove is accessible.
Install retainer ring (126). To ensure that retainer ring
is properly installed, tap the end of the retainer ring
with a punch until the entire retainer ring rotates in
brake cylinder groove. Slowly release press and ensure
retainer ring securely holds cover in place.
2. If not accomplished during ‘Winch Assembly’ steps, install
bracket (106) to inside of motor end upright (68) and
secure in place using capscrews (107) and (112). Torque
capscrews to 85 ft lbs (115 Nm).
3. Assemble roller (116) in plunger (114) and secure using
dowel pin (115). Heavily coat the plunger assembly with
“LubriPlate” MO-LITH No. 2 or equivalent lubricant.
Install spring (113) and plunger assembly in brake bracket
(106). Align groove in plunger towards hole in motor end
(68) upright.
4. Align cylinder rod roller surface to groove in plunger. Turn
cylinder (121) clockwise until snug. Adjust cylinder (121)
such that the air hose connection port is horizontal and
towards the motor.
Conduct the following when the winch is assembled, but
prior to mounting to the foundation. The motor end of the
winch should be raised enough to allow access to the brake
components located on the inside surface of the inboard
(motor end) upright (68).
5. Place spacer (105) between upper brake band flange and
bracket. Attach band assembly (104) to bracket (106) using
three capscrews (101), spacers (102) and spacer tubes
(103). Torque capscrews to 55 ft lbs (75 Nm).
6. Install pivot bar (119) and capscrew (120) through lower
flange of brake band assembly (104). At lowest point of
threads, place a bead of Loctite
®
680 and install jam nut
(117) fully. Jam nut threads must become coated with
sealant. Install second jam nut (117) to approximately the
middle of the thread length. Thread capscrew (120) into
bottom of plunger (114) a minimum of five thread lengths.
Lock in place, against plunger, using jam nut (117). Adjust
brake as described in the ‘Drum Band Brake Adjustment’
section.
Adjusting Automatic Drum Band Brake
Optional Feature. Refer to Dwg. MHP1281.
CAUTION
• This adjustment is done after a rebuild. It is only a rough
adjustment intended to remove major slack prior to
adjusting with a load.
This procedure can be done at a work bench using a 50 psig air
supply applied to the brake cylinder. After completion of this
procedure the brake must further be adjusted using the
recommended air supply and a test load.
1.
Insert a length of 3/8 inch NC threaded rod, fully into the
cylinder rod (108). With the brake band slack and no air
supplied to the brake, push the end of the threaded rod to
position the plunger all the way inside the brake bracket
(106). Place a nut on the threaded rod, and locate nut until
it is just touching the cover (125). Apply air to the brake.
The threaded rod should move out from the cylinder
approximately 1 inch (25 mm).
2. Tighten capscrew (120) in plunger (114) to remove slack
from band brake. Release air pressure. The nut should
move closer to the end cover (125) and stop.
3. Repeat step 1 until the nut stops at approximately 9/16 inch
(14 mm) from the cover (125).
4. Refer to further adjusting in ‘Automatic Drum Brake
Adjustment’.
Disc Brake Assembly
Refer to Dwg. MHP1230.
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. MHP1197.
NOTICE
• Correct sprag clutch installation prevents clockwise
rotation (brake engages) and allows counterclockwise
rotation when viewed from the 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).