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

30

2.

Inspect all remaining parts for evidence of damage.
Replace or repair any part which is in questionable
condition. The cost of the part is often minor in comparison
with the cost of redoing the job.

3.

Smooth out all nicks, burrs, or galled spots on shafts,
bores, pins, or bushings.

4.

Examine all gear teeth carefully, and remove nicks or
burrs.

5.

Polish the edges of all shaft shoulders to remove small
nicks which may have been caused during handling.

6.

Remove all nicks and burrs caused by lockwashers.

Assembly

General instructions

•

use all new gaskets and seals.

•

replace worn parts.

•

assemble parts using match marks applied during
disassembly. Compare replacement parts with originals
to identify installation alignments.

•

lubricate all internal parts with rust and oxidation
inhibiting lubricant, ISO VG 100 (30W).

Thermoplastic Coated Parts Assembly

CAUTION

• During application of thermoplastic coating to assemblies
use a flame to localize the heat. Do not heat entire assembly.
Assemblies contain gaskets, ‘O’ rings and other components
that may be damaged by exposure to excessive heat.

1.

When assembling parts already coated, the mating areas can
be heated to soften the coating enough to flow together and
seal the parts.

2.

When installing a new component in an assembly, remove
coating from existing parts as necessary to ensure parts
mate correctly.

3.

Install fasteners and torque as required. Apply coating to
bare areas as described in ‘Thermoplastic Coating’
repairing surfaces instructions in the “MAINTENANCE”
section for areas larger than 1/16 inch (1.6 mm).

4.

Allow the repaired area to cool. Quenching with water is
acceptable. Rough spots, minor scorching and excess
coating deposits can be wet sanded to remove the
imperfections. To return the gloss finish, reheat the surface
carefully.

Motor Assembly

Refer to Dwg. MHP0690.
1.

Install two seal rings (251) on each end of rotary valve
(250). Place bearing (252) onto the rear of rotary valve
(250) and press into position. Press only on the bearing
inner race. With the rotary valve housing (247) exhaust
flange side down, install rotary valve into housing.

2.

Install ‘O’ ring (244) into motor housing (217).

3.

Install the rotary valve housing gasket (243) onto rotary
valve housing (247). With the exhaust flange down on the
bench, install motor housing (217) onto rotary valve
housing (247). Check for any evidence of damage to ‘O’
ring (244) when the rotary valve housing is fully engaged.
Install exhaust flange (254) and tighten capscrews (255) to
50 ft lbs (68 Nm).

4.

If removed, press crank bearing (228) on crank assembly
(231). Press only on the inner race of the bearing.

5.

Place crank assembly (231) on a work bench with the oil
slinger (230) down and slide the sleeve (232), with tang up,
on the crankpin.

6.

Slide connecting rod bushing (233) over the sleeve (232)
and first connecting rod ring (234) with the chamfer up.

7.

Install the connecting rods (206) in the same order as
removed, with all feet pointing in the same direction, using
the first connecting rod ring (234) to hold one side of the
connecting rod feet.

8.

Slide the second connecting rod ring (234) over the other
side of the connecting rod feet with the chamfer on the ring
facing down (toward the stem of the connecting rod).

9.

Slide the crank shaft valve end over the crank pin while
simultaneously aligning the tang on the sleeve (232) with
the slot in the crank shaft.

10. Rotate and position the crank shaft valve end relative to the

crank pin to allow installation of the lock pin (235).

11. Tap the lock pin (235) into place and install the pin nut

(237). Torque nut to 60 ft lbs (81 Nm).

12. Install cotter pin (236).
13. Install roll pin (240) and bearing (228) into the valve end of

the crank shaft.

14. Check that all connecting rods move freely around the

crank. Position the crank assembly (231) into the motor
housing (217). Ensure the bearing (228) is seated and
connecting rods (206) are centered in the cylinder holes.

NOTICE

• Make certain that the roll pin (240) and the three lugs on
the rotary valve (250) line up with  the corresponding hole
and lugs on the crank shaft.
• Do not allow the rotary valve (250) to slide back in rotary
valve housing (247). If the rotary valve slides in too far, the
rotary valve and crankshaft will not align properly and will
restrict further assembly.

15. Rotate the crank assembly until one connecting rod (206) is

at the top of its stroke. Install a piston (204) with its rings
(202 and 207) to the connecting rod (206) with wrist pin
(203) and retainer rings (205).

16. Install a new cylinder head gasket (209) before installing

the cylinder liner (208).

17. Install the cylinder liner (208) over the piston (204) by

compressing both piston rings (202) and (207) with a single
band ring compressor.

18. Install cylinder head (201) over the cylinder and secure

cylinder head to motor housing (217) with four capscrews
(200). Torque capscrews to 60 ft lbs (81 Nm).

19. Repeat Steps 15 through 18 with the remaining cylinders.

NOTICE

• When installing the two lowest cylinder heads (201), use
seal washers on capscrews (200).

20. Rotate motor by hand. Motor should rotate without

binding.

21. Install mounting flange (216) and gasket (226) on the front

of the motor housing (217). Make sure notches on both
parts are aligned.

22. Lightly lubricate ‘O’ ring (70) and install in groove on

motor adapter (71).

23. Install eye bolts (213), vent cap assembly (210) and pipe

plug (218) in the motor housing (217). From the rotary
valve housing end of the motor, ensure plug (218) is
installed in the left oil fill hole of the motor.