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DIRECTIONAL CONTROL VALVE MAINTENANCE

Removing Control Valve from Winch

Remove brake air line.

Remove muffler or exhaust hose.

Disconnect inlet air line.

Using a pipe wrench, remove inlet hose adapter.

Loosen capscrews (442) and flatwashers (434). Take valve
assembly to clean work bench. Capscrews (442) cannot be
removed until end caps or adapter are removed.

(Dwg. MHP1121)

Separation of Components

Remove capscrews (441) and separate valve adapter (440)
from valve body (410), discard gasket (424). Remove
capscrews (442) and flatwashers (434).

Remove capcrews (439 and 437) and washers (433) from valve
cap (438). Using a soft face hammer remove valve cap (438)
and discard gasket (411).

Remove the plug (447) from valve cap (450). Pin (445) has
internal threads. Install an 8-32 x 2 inch screw into pin. Pull
out pin (445).

Lift up valve handle assembly slightly, to remove pressure on
pin (463). Press handle assembly out of valve cap (450).

Remove capcrews (439 and 437) and washers (433) from valve
cap (450). Using a soft face hammer remove valve cap (450).

Remove capscrews (418) from shuttle valve body (479) and
remove shuttle valve.

Remove fittings (this depends on the winch options).

Remove gasket (419) and discard.

(Dwg. MHP1145)

Disassembly of Valve Body

Press out pin (409) from clevis (446) and slide clevis off shaft
(401).

Entering from air inlet.

Remove capscrew (465), washer (417) and spring clip (416).

Lift out brake release valve assembly (413) or pin (412)
depending on winch options.

(Dwg. MHP1146)

Section 4

Read these instructions completely before working on the
Directional Control Valve.

NOTICE

The directional control valve is
comprised of components that
have very close tolerances. The

valve components should only be disassembled to
make a repair. Disassembly of good components can
cause additional damage.

Viewed from

Left Side

Viewed from

Front

Viewed from

Right Side

Viewed from

Rear

Handle

Shuttle
Valve

Plug

Gasket

Adapter

Valve Cap

Capscrew

Brake Release
Valve

Clevis

Содержание FA5A

Страница 1: ...intenance information Make this manual available to all persons responsible for the service and maintenance of these products Always operate inspect and maintain this winch in accordance with American...

Страница 2: ...operating the winch Danger Warning Caution and Notice Throughout this manual there are steps and procedures which if not followed may result in an injury The following signal words are used to identif...

Страница 3: ...gether engaging the brake The one way clutch rides on inner and outer races The one way clutch s inner race rotates in a bearing inside the support plate and connects through the brake shaft to the ge...

Страница 4: ...dump valve If no air is detected replace the orifice and dump valve assembly The disc brake is not properly lubricated The wrong amount or type of oil is in the disc brake and gearbox Remove the disc...

Страница 5: ...to use a soft hammer to loosen the disc brake housing The splined brake shaft 34 might come out with the disc brake assembly If it does remove it from the brake assembly and set it aside Dwg MHP0840 5...

Страница 6: ...pport plate bearing for signs of wear Bearing should rotate freely without sticking or binding If sticking or binding is present replace bearing 2 Inspect the one way clutch and its inner and outer ra...

Страница 7: ...CE Before reassembling the brake make sure that all gasket surfaces as well as the diaphragm and corresponding surfaces of the housing and cover are clean and dry Disc Brake Assembly and Installation...

Страница 8: ...ter race Dwg MHP0847 8 Use the loose dowel pins 8 to help line up the three notches on the steel separator plates Dwg MHP0849 9 Place a new gasket 19 on the mating surface of the support plate 10 Set...

Страница 9: ...Using a crossing pattern torque the capscrews to 25 Nm 18 ft lbs 17 Reinstall the air fitting and air line and refill the disc brake with oil until the oil runs out of the oil level plug hole Refer to...

Страница 10: ...10 DISC BRAKE PARTS DRAWING Dwg MHP0667 Dwg MHP0630 One Way Clutch Detail Section 1...

Страница 11: ...1 11 One way Clutch 1 71044853 12 Pressure Plate 1 24137 13 Friction Plate 5 71126874 14 Separator Plate 6 22033 15 Spacer 2 19007 16 Inner Race 1 24038 17 Outer Race 1 22032 19 Gasket 2 71262257 21 S...

Страница 12: ...and a manually operated engagement and release mechanism Dwg MHP1043 Operation The winch operator can engage the brake band at any time whether the winch drum is turning in the haul in direction stati...

Страница 13: ...67 105 Spacer 1 23029 106 Brake Bracket 1 21884 107 Capscrew 2 71264832 112 Capscrew 2 71264824 117 Jam Nut 2 71264790 119 Pivot Bar 1 23755 120 Capscrew 1 71288039 129 Locking Pellet 1 23737 130 Caps...

Страница 14: ...ustment bolt is a specially treated high strength fastener permanently attached to the jam nut Do not remove the adjustment bolt from the end of the band brake unless the threads have been damaged or...

Страница 15: ...essing it out Removal of the larger needle bearing 138 is only required if the bearing housing is cracked or chipped or if the rollers are damaged Removal in this case can be accomplished using a punc...

Страница 16: ...t the eccentric shaft bearing surfaces for galling and flat spots 3 Make sure the two bearings in the brake bracket allow the eccentric shaft to move smoothly and easily Replace the bearings if any of...

Страница 17: ...bolt at least 10 mm 3 8 inch into the cam plate This ensures that the locking pellet will contact the adjustment bolt and hold it in place Insert the locking pellet inside the threaded hole in the si...

Страница 18: ...ver center or if there is excessive resistance reduce the tension by turning the adjustment bolt in the counterclockwise direction There must be slack in the band brake when the handle is in the relea...

Страница 19: ...19 Section 2 SERVICE NOTES...

Страница 20: ...20 MANUAL BAND BRAKE PARTS DRAWING 104 120 117 119 103 102 101 105 142 143 130 142 145 137 138 140 141 112 106 107 130 129 131 132 133 134 135 Section 2 Dwg MHP1079...

Страница 21: ...117 Jam Nut 2 71264790 119 Pivot Bar 1 23755 120 Capscrew 1 71288039 129 Locking Pellet 1 23737 130 Capscrew 2 52160 131 Cam Plate 1 21893 132 Retainer Ring 1 71145122 133 Washer 1 71137905 134 Sleev...

Страница 22: ...y Section 3 Cylinder Cylinder Rod Piston Springs Cover Retainer Dwg MHP0984 B Brake bracket and plunger assembly The brake bracket and plunger assembly is bolted to the drum side of the winch upright...

Страница 23: ...ot returning to neutral Refer to the manual for instructions on troubleshooting and adjusting the brake actuation components in the winch control valve The orifice and dump valve assembly are not reli...

Страница 24: ...easy access to the band brake assembly 2 Thread a piece of 3 8 NC threaded rod approximately 36 cm 14 inches long fully into the tapped hole in the cylinder rod inside the cylinder Make sure the thre...

Страница 25: ...to remove the two socket head capscrews closest to the brake surface The 3 8 inch allen wrench has enough clearance to turn near the drum flange Dwg MHP0979 8 Pull the plunger 114 out of the brake br...

Страница 26: ...washer over the threaded rod and then thread a nut all the way down to the cover Tighten the nut until the cover moves far enough to uncover the retainer ring and remove the ring Use a 12 mm approxima...

Страница 27: ...ld measure at least 203 mm 8 0 inches long Replace them if they have collapsed or become bent 6 Ensure that the spring 113 has not collapsed or become bent It should measure at least 203 mm 8 0 inches...

Страница 28: ...rcise caution can cause mechani cal damage and or injury Dwg MHP0982 4 Insert the piston and cylinder rod assembly into the cylinder and drop the washer 128 into the open end of the piston Dwg MHP0978...

Страница 29: ...50 Nm 33 36 ft lbs 3 Gently spread the ends of the brake band and slip it over the flange and onto the brake surface Dwg MHP1099 4 Place the small spring 113 in the end of the plunger and slip the plu...

Страница 30: ...one of the lock nuts onto the adjustment bolt so that it holds the adjustment bolt on the brake band with very little slack 10 Loosely thread the adjustment bolt into the plunger 11 Install the rubbe...

Страница 31: ...inch from the cylinder cover Tighten the jam nuts closest to the plunger to fasten the adjustment bolt in position Finally remove the 3 8 NC threaded rod from the cylinder rod Dwg MHP0983 Testing the...

Страница 32: ...32 AUTOMATIC BAND BRAKE PARTS DRAWING 104 120 119 103 102 101 105 121 122 123 128 124 127 125 126 107 106 112 116 115 117 114 113 108 111 110 109 Dwg MHP1080 Section 3...

Страница 33: ...08 Cylinder Rod 1 23885 109 O Ring 1 71049423 110 O Ring 1 52662 111 Retainer Ring 1 54136 112 Capscrew 2 71264824 113 Spring 1 71126643 114 Plunger 1 23886 115 Dowel Pin 1 71144968 116 Roller 1 23883...

Страница 34: ...vots on a cross shaft running through an end cap bolted to the valve body The lever is spring loaded so that the control valve returns and automatically locks into the neutral position A clevis attach...

Страница 35: ...to common direction control valve symptoms probable causes and remedies Symptom Cause Remedy No drum movement when control valve actuated in Payout direction No air supply Check air lines for rips or...

Страница 36: ...andle assembly out of valve cap 450 5 Remove capcrews 439 and 437 and washers 433 from valve cap 450 Using a soft face hammer remove valve cap 450 6 Remove capscrews 418 from shuttle valve body 479 an...

Страница 37: ...14 Remove retainer 432 and seperate piston valve 431 from inlet poppet remove O ring 430 from outside of valve piston and O ring 426 from inside of valve piston 15 Seperate poppet seat 428 from inlet...

Страница 38: ...ighten to 24 to 30 inch lb 8 9 3 0 Nm Dwg MHP1150 Handle Assembly 1 Apply Loctite 242 on threads of valve handle 449 Screw handle ball 469 onto valve handle 449 and tighten 2 Slide O ring 460 onto val...

Страница 39: ...e inlet poppet 7 Slide O ring over inlet poppet and into the groove Press O ring into groove all around and wipe excess Loctite 4212 from poppet surface Allow Loctite 4212 to cure Wear rubber gloves w...

Страница 40: ...20 over shaft 401 from the front of the valve body Push into valve body followed by spring 422 16 Slide poppet assembly on to shaft 401 Use fingers to press poppet seat into valve body 17 Install reta...

Страница 41: ...ghten capscrews to 54 to 60 inch lbs 20 to 22 Nm NOTICE The slotted pin grooves in the clevis where clevis and shaft 401 are joined make alignment of the cross shaft and clevis difficult To prevent bi...

Страница 42: ...g MHP1158 13 Insert capscrews 442 and flatwashers 434 into adapter 440 These capscrews cannot be removed without a Removing end caps or b Removing adapter from valve body 14 Apply Loctite 242 on threa...

Страница 43: ...peration Dwg MHP1024 6 Insert capscrew 465 through flatwasher 417 and spring retainer 416 into valve body and tighten 7 Adjusting brake valve 413 Ensure that long portion of sleeve 408 is on the botto...

Страница 44: ...65 464 450 448 433 437 446 444 430 431 409 439 445 447 443 460 433 434 442 410 411 424 431 432 438 436 433 439 437 420 417 416 413 421 470 471 Single Air Brake Qty 1 each of Item 412 and Item 413 Dual...

Страница 45: ...ndle 1 23747 418 Capscrew 2 71261747 450 Valve Cap 1 23607 419 Gasket 1 23744 460 O Ring 1 71146963 420 Exhaust Poppet 1 23516 461 Cross Shaft 1 23746 421 Plug 1 51897 462 Spring 1 71146948 422 Spring...

Страница 46: ...et gears in the second stage which are connected to the planet carrier The planet carrier in the second stage is connected to the outboard upright through the output shaft This prevents planet carrier...

Страница 47: ...rbox Removal Section 5 REDUCTION GEAR MAINTENANCE 1 Rotate gearbox until drain plug is in lowest position refer to LUBRICATION Section 2 Drain lubricant into a clean container and observe for particle...

Страница 48: ...disassembly check planet gear side clearance 0 005 to 0 032 inches 0 13 to 0 81 mm Spin gears gears should rotate freely If gears are tight or clearance is incorrect disassemble planet assembly Dwg M...

Страница 49: ...hers 52 55 and 64 are used in combination to achieve clearance all three might not be present or quantities may vary 4 Tap roll pin 50 out of intermediate planet pin 46 Dwg MHP1187 Inspection 1 Check...

Страница 50: ...6 Measure the side clearance and adjust the thrust washers 52 55 or 64 to provide 0 005 0 032 inches 0 13 0 81 mm Spin gears gears should rotate freely Dwg MHP1169 8 Measure the distance that roll pin...

Страница 51: ...edle bearings 6 Place another thrust washer on top of assembly Carefully slide assembly right into the output carrier 37 Dwg MHP1161 7 Align the bores and push out the pin tool using the output planet...

Страница 52: ...gear 54 followed by thrust washer 63 and then next thrust washer 65 Dwg MHP1163 5 Place retainer ring 53 on end of output sun gear 45 Slide this assembly into intermediate carrier assembly and fasten...

Страница 53: ...hrust washer 36 inside of cover 33 use some EP grease to hold in place 14 Align the two threaded holes in cover 33 with the grooves in housing 44 15 Insert capscrews 32 through cover and into housing...

Страница 54: ...54 REDUCTION GEAR ASSEMBLY PARTS DRAWING Dwg MHP1221 Section 5...

Страница 55: ...ll 3 71113302 67 Bearing Needle 1 71113187 39 Gear Output Planet 3 23893 68 Capscrew 6 71113161 40 Thrust Washer 6 71126478 69 Housing 1 20672 41 Bearing Roller 126 71113286 71 Oil Seal 1 71113179 42...

Страница 56: ...r arrangements have been made and written authorization has been provided from the location where the goods were purchased NOTICE Continuing improvement and advancement of design may cause changes to...

Страница 57: ...57 SERVICE NOTES...

Страница 58: ...58 SERVICE NOTES...

Страница 59: ...59 SERVICE NOTES...

Страница 60: ...ond B C V7C 5C7 Phone 604 278 0459 Fax 604 278 1254 Latin America Operations Ingersoll Rand Production Equipment Group 730 N W 107 Avenue Suite 300 Miami FL 33172 3107 USA Phone 305 559 0500 Fax 305 5...

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