Ingersoll-Rand FORCE5i FA2i-MRA, Информация по техническому обслуживанию продукции

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Form MHD56332 Edition 1 7
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Limit Switch
Refer to ‘Limit Switch Adjustment’ procedure in Product Information Manual.
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Wire Rope Line Speed Monitor and Overspeed Alarm Adjustment
Line speed monitor adjustments are limited to placement of sensor. Adjustments to
indicator set points established at factory should not be attempted. To change line
speed monitor set points contact your nearest
Ingersoll Rand distributor or the
factory.
1. The sensor attaches to assembly bracket and faces the drum reduction gear
mounting capscrews.
2. Install sensor and adjust to ensure a clearance of 0.2 inch (+/- 0.1 inch) [5 mm
(+/- 2.5 mm)] between sensor and drum reduction gear mounting capscrew
heads. Refer to Dwg. MHP0602 on page 7.
(Dwg. MHP0602)
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Disassembly
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General Disassembly Instructions
The following instructions provide necessary information to disassemble, inspect,
repair, and assemble winch. Parts drawings are provided in Product Parts Information
Manual.
If a winch is being completely disassembled for any reason, follow the order of
topics as they are presented. It is recommended that all maintenance work on winch
be performed in a clean dust free work area. In the process of disassembling winch,
observe the following:
1. Never disassemble winch any further than is necessary to accomplish needed
repair. A good part can be damaged during the course of disassembly.
2. Never use excessive force when removing parts. Tapping gently around 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 part being heated is
already worn or damaged beyond repair and no additional damage will occur to
other parts.
NOTICE
• In general, winch is designed to permit easy disassembly and assembly. The
use of heat or excessive force should not be required.
4. Keep 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 and ‘O’ rings should be used when assembling winch.
6. When grasping a part in a vise, always use leather-covered or copper-covered
vise jaws to protect the surface of part and help prevent distortion. This is
particularly true of threaded members, machined surfaces and housings.
7. Do not remove any part which is a press fit in or on a subassembly unless
removal of that part is necessary for repairs or replacement.
8. When removing ball bearings from shafts, it is best to use a bearing puller. When
removing bearings from housings, drive out bearing with a sleeve slightly smaller
than outside diameter of bearing. The end of sleeve or pipe which contacts
bearing must be square. Protect bearings from dirt by keeping them wrapped in
clean cloths.
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Winch Disassembly
Refer to Dwgs. MHP0210 and MHP2773.
1. Remove wire rope from drum.
2. Operate winch to position reduction gear drain plug at its lowest position.
3. Relieve pressure in air lines by operating winch control several times after air
supply has been turned off.
WARNING
• Shut off, bleed down and disconnect air supply line before performing any
disassembly procedures.
4. Disconnect and tag the air lines.
5. Remove winch from its mounting and take to a suitable work area before
beginning disassembly.
6. Remove lower case drain plug (464) in motor housing (463) and allow oil to
drain into a suitable container. Loosen fill cap (462) to vent motor housing.
7. Drain oil from gear reduction assembly by removing pipe plug (48) when
positioned at its lowest point.
8. Remove pipe plug (25) in brake housing (17) to drain brake oil. If winch is
equipped with a drum band brake the winch outboard end (opposite motor end)
must be elevated to prevent draining oil from contaminating brake band lining.
WARNING
• The motor weighs approximately 117 lbs. (53 kg). Adequately support motor
before removing motor mounting capscrews.
9. Remove drum guard. Refer to ‘Drum Guard’ disassembly on page 6.
10. Remove drum band brake and any other externally mounted winch attachments.
11. Remove capscrews (97) and lockwashers (96) securing motor assembly to the
motor adapter (6). Using a hoist to support the motor, pull motor straight away
from winch. Reference applicable ‘Motor Disassembly’ section if motor
disassembly is required.
12. Alternately and evenly loosen capscrews (93). Remove capscrews and motor
adapter (6).
13. Remove brake housing (17). If brake housing sticks, tap it with a brass hammer
until pieces separate. Note position of all brake pieces for reassembly.
14. Remove friction plates (19) and drive plates (18).
15. Remove springs (9) from brake piston (10).
16. Remove brake piston (10) from brake housing (17). Tap lightly with a plastic
mallet to separate parts if necessary.
17. Remove seals (11) and (12) from brake piston (10).
18. Remove gear (21) from shaft (35).
19. Remove retainer ring (36) from bore of drum shaft (41).
20. Pull shaft and bearing assembly from drum shaft (41).
21. Support drum (80) and remove capscrews (39) from drum shaft (41). Pry drum
shaft (41) from inboard upright (42).
22. Remove capscrews (85) and lockwashers (98) which secure siderails (82) to
inboard upright (42) and drive out dowel pins (86).
23. Remove inboard upright (42).
24. Remove end cover (95), capscrews (97) and lockwashers (96) from outboard
upright (84).
25. Remove capscrews (94) and bearing retainer (92) from drum (80).
26. Remove drum and reduction gear assembly.
27. Remove remaining capscrews (85) and lockwashers (98) that attach siderails
(82) to outboard upright (84)and drive out dowel pins (86).
28. Remove bearing (86) and seal (99) from outboard upright (84).
29. Remove capscrews (45) and lockwashers (46) from gear carrier (47). Lift
reduction gear assembly from drum (80). To disassemble reduction gear refer to
“Reduction Gear” disassembly section on page 9.
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Drum Guard
Refer to Dwg. MHP2676.
1. Remove capscrews (90) and washers (91) securing lifting lugs (83) to uprights.
2. Remove panels (805) one section at a time, by removing nuts (804) and
crossbars(806).
3. Remove capscrews (809) and washers (96) that secure frames to winch uprights.
4. Remove frames.
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Motor
Refer to Dwg. MHP0210.
1. Remove capscrews (364), lockwashers (96) and exhaust cover (469). Pull out
rotary valve (467) and rotary valve bushing (466). Remove adapter valve (468).
2. Remove capscrews (451), lockwashers (452) and cylinders (453) from motor
housing (463).
3. Rotate crankshaft assembly (473) to bring each wrist pin (457) above the motor
housing (463), then push out wrist pin (457) and remove piston (455). Plugs
(456) pressed into ends of wrist pins (457) should not be removed. To avoid
breakage use extreme care when removing compression rings (454).
4. Pull crankshaft assembly (473) with attached connecting rods (459) out of
motor housing (463) by shifting connecting rods (459) to clear cylinder holes.
Connecting rods (459) are joined through a common journal on the crankshaft
and are held in place by connecting rod rings (474) on each side of main rib.
Reduction Gear
Assembly
Capscrew
Head
Inboard
Upright
Maintain Clearance of
0.2 inch (+/- 0.1 inch)
[5 mm (+/- 2.5 mm]
bewteen sensor and
capscrew head
Overspeed Indicator Sensor Clearance
Drum