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

25

6.

When grasping a part in a vise, always use leather-covered
or copper-covered vise jaws to protect the surface of the
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 the 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 the bearing with a sleeve slightly smaller than the
outside diameter of the bearing. The end of the sleeve or
pipe which contacts the bearing must be square. Protect
bearings from dirt by keeping them wrapped in clean
cloths.

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.

Drum Guard Disassembly

Refer to Dwg. MHP1450.
1.

Separate capscrew (597), washer (74) and nut (598).

2.

Pull bracket (595) straight away from drum guard (590).
Note how many washers (593) there are for assembly.

3.

Pull drum guard (590) away from bracket (592). By design
the drum guard attaches to the sideframe by tabs. The
smaller, upper tabs are visible on the top of the sideframe.
The longer, lower tab is located under the sideframe.
During removal take care not to bend the tabs. Push the
drum guard away from the sideframe, towards the drum. Do
not pull ‘up’ or ‘down’ as the tabs may become deformed.

4.

Note how many washers (593) there are on bracket (592)
for assembly.

NOTICE

• Washers should be distributed equally on both sides of
drum guard (590).

Winch Disassembly

Refer to Dwg. MHP1410.
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.
Manual Drum Brake:
Refer to Dwg. MHP1448.
a.

Remove cotter pin (139) and pin (138).

b.

To disassemble further, refer to ‘Manual Band Brake
Disassembly’ and Dwg. MHP1448.

Automatic Drum Brake:
 Refer to Dwg. MHP1281.
a.

Remove capscrews (101), spacers (102) and (103).

b.

Remove and save spacer (105).

c.

Loosen nut (117) that is locking plunger (114).

d.

Rotate capscrew (120) until free from plunger (114).

NOTICE

• Lower nut (117) is bonded to capscrew (120) and should not
be removed.

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.