Ingersoll-Rand force5 FA5A-LAK1, Parts, Operation And Maintenance Manual

21

Thermoplastic Coated Parts Disassembly
Thermoplastic coating on capscrew heads, nuts, housings and
other components can be removed as follows:

CAUTION

• Separate parts using proper tools. Ensure machined
surfaces are not damaged during disassembly.

1.

Fasteners:
a.

Push tool into or over fastener, forcing coating off of
the fastener.

b.

If coating is too thick, then heat the fastener to soften
coating. Socket or wrench will push softened coating
off, allowing removal of part.

c.

For socket head capscrews, setscrews, etc., heat the
component until coating is softened. Use a small
screwdriver or similar tool to remove coating to allow
access for wrench.

2.

For housings, plates and other coated mating components
use a sharp knife or similar tool to cut through coating
around mating area of components.

Winch Disassembly
Refer to Dwgs. MHP0649 and MHP0690.
1.

Remove the wire rope from the drum. Remove wire rope
anchor (63) and store for reassembly.

2.

Relieve pressure in the air lines and winch air components
by operating the winch control several times after the air
supply has been turned off.

WARNING

• Shut off, bleed down and disconnect the air supply line
before performing any disassembly procedures.

3.

Disconnect and tag the air lines.

4.

To drain oil refer to “LUBRICATION” section.

5.

Remove the capscrews and nuts securing winch to its
foundation and move to a suitable work area before
beginning disassembly.

WARNING

• The air motor weighs approximately 260 lbs. (118 kg).
Adequately support the air motor before removing the motor
mounting capscrews.

6.

Remove the ten capscrews (197), lockwashers (196) and
washer (198) securing the motor assembly to the motor
adapter (71). Using a hoist to support the motor, pull the
motor straight away from the winch.  Refer to the ‘Motor
Disassembly’ section if motor disassembly is required.

7.

Remove drive shaft (61) and coupling (60).

8.

Disconnect the drum band brake. Refer to Dwg. MHP0631.
Remove capscrews (101), spacers (102) and (103),
capscrew (120), the two nuts (117) and the pivot bar (119)
to disconnect drum band assembly (104) from brake
bracket (106). Remove and save spacer (105). To further
disassemble the drum band brake assembly, refer to Dwg.
MHP0631 and the ‘Drum Band Brake Disassembly’
section.

9.

Remove drum guard and any other externally mounted
winch attachments.

CAUTION

• There are a total of eight capscrews securing the brake
cover to the brake housing. Two of these capscrews hold the
brake assembly together, but do not attach to the outboard
upright. One capscrew attaching the brake assembly is
located directly beneath the brake air line fitting connection;
the other is located 180 degrees from the air fitting. The
heads of these two capscrews sit deeper into the counterbores
of the brake cover. Do not remove these two capscrews until
the brake has been separated as an assembly from the winch
and the directions in the ‘Disc Brake Disassembly’ section
have been reviewed.

10. Disconnect and remove brake hose (75). Remove six

capscrews (1) attaching disc brake assembly to outboard
upright (26). Remove disc brake assembly by tapping
around housing with a soft hammer or mallet while pulling
out and away from upright in a horizontal direction.
Remove dowel pin (20) and store until reinstallation. To
further disassemble the disc brake assembly, refer to Dwg.
MHP1230 and the ‘Disc Brake Disassembly’ section.

11. Using a hoist to support the drum, remove sideframes (65),

one at a time, by removing four capscrews (66) attaching
each sideframe to uprights (26) and (68).

12. Remove the inboard (motor end) upright (68) by pulling

straight away from drum (62) in a horizontal direction.
Remove oil seal (29) and bearing (30) from upright.
Discard oil seal. Discard bearing if inspection indicates
replacement.

13. Remove the drum band brake assembly (104) by sliding

over the end of the drum (62) flange.

14. Outboard upright (26) removal:

a.

For units without disc brake: remove cover (2) by
removing six capscrews (1). Pry cover and gasket (18)
from upright. Pull upright away from drum (62) in a
straight horizontal direction. Remove output shaft
(28), oil seal (29) and bearing (30) from upright.
Discard oil seal. Discard bearing if inspection
indicates replacement. Note the condition of capscrews
(27) located in output shaft. Note positions for
reinstallation.

b.

For units with a disc brake: pull upright away from
drum (62) in a straight horizontal direction. Remove
output shaft (28), oil seal (29) and bearing (30) from
upright. Discard oil seal. Discard bearing if inspection
indicates replacement.

CAUTION

• Ensure the reduction gear oil is drained before disassembly
and that the drain and fill plugs are removed. When using
jacking bolts, ensure the cover lifts evenly by turning bolt
one full turn and then repeating on the other bolt. If cover
jams, remove jacking bolts and gently tap around the cover
to reseat it before starting over. Careful prying of the cover
along its diameter during jacking, using a soft material
wedge, to guide the cover is acceptable. Care must be taken
not to scar, gouge or damage the machined finishes on the
cover and the reducer housing mating surfaces during parts
separation.

15. Stand drum on end with reduction gear on top. Remove

reduction gear assembly from drum (62) by removing six
capscrews (32) attaching end cover (33) to drum. Screw
two 7/16 - 20 UNF x 1-1/2 inch capscrews into the
threaded holes in cover (33). Turn both screws evenly until
cover is separated from housing. Remove cover.