Ingersoll-Rand FA2A, Parts, Operation And Maintenance Manual

33

6.

Determine correct alignment of end cover (2), housing (6)
and support plate (19) by checking matchmarks placed
during disassembly, or by placing housing on support plate
and matching capscrew holes.

(Dwg. MHP0667)

7.

Correctly align with dowel slots on the housing (6) and
install six separator plates (14) and five friction plates (13)
in the following order:
a.

Place two separator plates, two friction plates, two
separator plates, three friction plates and two separator
plates. Refer to Dwg. MHP0946.

WARNING

• Failure to correctly arrange friction and separator plates
will result in irratic brake operation. Sudden brake
applications may cause winch and/or wire rope damage
resulting in a falling load.

8.

Install the three dowel pins (9) in housing (6). Apply
Loctite

®

 515 sealant on mating surfaces of housing and end

cover (2). Install housing by aligning dowel pins with
separator (14) and friction plate (13) grooves and, also
aligning capscrew holes in housing with holes in end cover.

9.

Install ring (4), and diaphragm support plate (5). Support
plate radius must be next to diaphragm (3).

10. Install diaphragm (3) and end cover (2).
11. Locate as shown on Dwg. MHP0947 and install two

capscrews (1). Evenly and alternately tighten capscrews to
compress springs. Torque capscrews to 18 ft lbs (24 Nm).

12. Install brake shaft (25) and place assembly on outboard

(opposite motor end) upright (26). Align capscrew holes
such that the breather (8) is slightly off top dead center.
Install six capscrews (1). Torque capscrews to 18 ft lbs (24
Nm). Install exhaust valve (79), elbow fitting (80) and
connect air hose (75) to elbow fitting.

13. Winch drum may rotate in the haul-in direction and must

not rotate in the payout direction, unless air is applied to
the brake, when assembled properly.

(Dwg. MHP0946)

Manual Drum Band Brake Assembly

Optional feature. Refer to Dwg. MHP1372.
1.

Press bushings (143) into brake band pivot brackets.
Bushing flanges must be to the motor upright side.

2.

Attach adapter plate (145) to upright (68) loosely with
capscrews (112) (apply Loctite

®

 242 to threads) and

washers (131).

3.

Place brake band (136) onto drum and rotate around drum
(close to mounting position). Spread brake band (136) apart
slightly and slide in over drum flange. Place brake band
pivot bracket over pin in adapter plate (145).

4.

Repeat this procedure for brake band (137).

5.

Place washer (142) over pin in adapter plate (145) and
secure with cotter pin (144).

6.

Insert pivot nut (134) into brake handle (135).

7.

Place brake handle (135) into bracket in brake band (136)
and tighten screws in handle. Slide grip over brake handle.

8.

Place brake link stud (141) into pivot nut (134) and rotate
clockwise until approximately 1 in. (25 mm) of threads are
exposed.

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).
12. Adjust cam stop (132). Refer to ‘ADJUSTMENT’ section

for adjusting brake.

Automatic Drum Band Brake Assembly

Optional feature. Refer to Dwg. MHP1281.
For ease of assembly install bracket (106), cylinder (121)
assembly and brake handle stop 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).