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

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Form MHD56332 Edition 1 9
(474). Install connecting rod rings (474) so chamfered side is next to
connecting rod (459).
2. Place sleeve (475) on crankshaft (473), then install the connecting rod (459)
assembly on the crankshaft (473).
3. Secure crankshaft counterbalance to the crankshaft with taper pin (479) and
tighten capscrew (480).
4. Install rotary bushing (466) and attach adapter valve (468) and valve cover
(469) to motor housing (463) with at least two capscrews. This is necessary to
correctly locate bearing (465) when installing crankshaft in motor housing
(463), shifting it as necessary so each connecting rod (459) end will project
through a cylinder hole.
5. Align bearing (465) in bore of motor housing (463) and tap crankshaft assembly
in place until bearing (465) bottoms on the rotary bushing.
6. Check fit of each compression and oil ring by placing one ring at a time in the
cylinder, making sure that it is not canted or tilted in relation to the cylinder
wall. With a feeler gauge, measure the ring gap.
7. Make sure that compression rings, oil rings, and pistons are absolutely clean.
Carefully place oil rings (458) and compression rings (454) in their respective
grooves on the pistons (455).
NOTICE
• Do not interchange the compression and oil rings. The plain compression
ring (454) must be placed nearest the head of the piston (455). The oil ring
(458) (identified by several oil channel grooves) must be placed nearest the
skirt of the piston (455).
8. Compression and oil ring joints (gaps) should be staggered and positioned so
that joints (gaps) do not coincide with wrist pin (457) openings. Refer to Dwg.
MHP0224.
(Dwg. MHP0224)
9. Rotate crankshaft so each connecting rod (459) in succession will project
enough beyond the motor housing (463) to permit inserting wrist pin (457)
through the piston (455) and connecting rod (459).
10. After each piston (455) is assembled to its connecting rod (459), install a gasket
(460) and cylinder (453).
11. Slide each cylinder (453) over the piston (455), guiding it carefully over the
compression and oil rings.
NOTICE
• the cylinder has four tapered ears around the skirt of the piston which serve
as ring compressors to aid in installation. The cylinder should go into place by
tapping lightly. If force is required, there maybe an alignment problem which
must be corrected before continuing.
12. Secure cylinders (453) to motor housing (463) by uniformly tightening
capscrews (451) and lockwashers (452).
13. Remove exhaust cap (469). Install rotary valve (467) in adapter valve (468).
Align the drive pins on the rotary valve (467) with the end of the crank shaft
(473). The three drive pins on the crank shaft end of the rotary valve should fit
in the holes in the crank shaft without appreciable play. If holes in crank shaft
are elongated, crank shaft should be replaced. The drive pins are located so the
rotary valve will always be returned to the correct position.
14. Replace exhaust cap (469) and secure in position with capscrews (364) and
lockwashers (96).
„
Reduction Gear
NOTICE
• It is important to maintain a clean work area when reduction assemblies are
reassembled. During reassembly clean each part thoroughly and lightly coat
with appropriate lubricant as described in ‘Recommended Lubricants’ in the
“LUBRICATION” section of the Product Information Manual.
Refer to Dwg. MHP2773.
1. Lubricate and install ‘0’ rings (62) on ring gear (72). Assemble ring gear (72),
cover (73) and spacer (71). Check dowel and capscrew holes are aligned.
2. Drive dowels (74) into assembly so they are flush with the cover (73).
3. Position assembled parts vertically with the cover (73) down. Install planet
assembly (67) and gear (69) into ring gear (72).
4. Press bushing (55) into sun gear (66) and install sun gear (66) into planet
assembly (67).
5. Lubricate and install ‘0’ rings (51) on ring gear (63). Install ring gear on spacer
(71) being careful not to damage ‘0’ ring. Align dowel and capscrew holes.
6. Tap dowels (52) into ring gear (63) and spacer (71). Leave approximately 0.37
inch (9 mm) exposed for engagement with input housing (59).
7. Install planet assembly (58) so planet gear teeth mesh in the ring gear (63) and
with the sun gear (66).
8. Carefully install input housing (59) so it locates on dowels (70). Tilt assembly on
work bench and install capscrews (75) with Loctite® 242 and torque to 21 ft-lbs
(28 Nm).
9. Return assembly to vertical position. Install bushing (55) and on sun gear (56)
and install sun gear (56) in planet assembly (58).
10. Lubricate and install ‘0’ ring (51) on ring gear (53). Line up dowel and capscrew
holes and install ring gear (53) on input housing (59) being careful not to
damage ‘0 ring (51).
11. Install planet assembly (54) so planet gear teeth mesh with ring gear and sun
gear.
12. Lubricate and install ‘0’ ring (51) on ring gear (53).
13. Install oil plugs (61) in input housing (59).
14. .Press bearing (49) into bore of gear carrier (47). Install retainer ring (50).
15. Install gear carrier (47) on ring gear (53) being careful not to damage ‘0’ ring
(51). Check capscrew and dowel holes are lined up. Install capscrews (60) with
Loctite® 262. Torque capscrews (60) to 33 ft-lbs (44.7 Nm).
16. Tap dowels (52) through ring gear (53), input housing (59) and gear carrier (47)
until they are just below flange surface of gear carrier (47).
„
Drum
Refer to Dwg. MHP2773.
1. Clean surfaces of drum (80) and gear carrier (47). Apply Loctite® 515 gasket
sealant to drum mating surface. Lower reduction gear assembly into drum (80) so
capscrew and dowel pin holes are aligned. On 8 inch long drums ensure a spacer
is used between drum and gear carrier flange.
2. Install capscrews (45) and lockwashers (46) with Loctite® 242 and torque to 61
ft-lbs (82 Nm).
3. Install dowel pins (44) so they are flush with gear carrier (47).
4. Install fill/drain plugs (48) in gear carrier (47).
5. Apply a thin coat of Loctite® 609 to the outside of seal (43) and install in gear
carrier (47).
6. Place drum in an upright position.
„
Winch Assembly
Refer to Dwgs. MHP2773 and MHP2786.
1. Clean both mating surfaces on inboard upright (42) and install drum shaft
(41)through bore aligning dowel pin holes.
2. Install dowel pins (40) flush or slightly below surface of drum shaft (41).
3. Install eight capscrews (39). Lightly coat capscrew threads with Loctite® 242
and torque to 35 ft lbs (47 Nm).
4. Press bearing (37) onto drive shaft (35). Lightly coat inner bearing race bore
with Loctite 609.
5. Install shaft and bearing into drum shaft (41) so smaller splined end enters
first.Install retainer ring (36) in bore of drum shaft (41).
6. Carefully lower inboard assembly into the drum (80) making sure splines on
shaft(35) and drum shaft (41) mesh in the drum and reduction gear assembly.
7. Using a ‘C’ clamp, secure inboard flange assembly to drum flange and position
complete assembly in a horizontal position.
8. Clean seal surface and install oil seal (99) in outboard upright (84) with lip
toward the drum. Pack bearing (87) with grease and install in outboard upright
(84).
9. Install outboard upright (84) on drum end. Ensure assembly is kept centered on
journal during this step.
10. Install bearing retainer (92). Secure by installing two capscrews (94). Lightly
coat capscrew threads with Loctite® 242. Torque to 35 ft lbs (47 Nm).
11. Apply a light coat of Loctite® 515 sealant to mating surface of outboard
upright(84) and install end cover (95). Secure using four capscrews (97) and
lockwashers(96). Lightly coat capscrew threads with Loctite® 242. Torque to 25
ft lbs (34Nm).
12. Install siderails (82) to uprights (42) and (84) and loosely secure using
capscrews(85) and lockwashers (98).
13. Tap dowel pins (86) into position until flush with siderails.
14. Tighten eight capscrews (85) evenly. Torque to 61 ft lbs (82 Nm)
Piston Head
Wrist pin opening
Install one compression
ring on either side of oil ring
Ends of compression rings
must be staggered to avoid
alignment with wrist pin
opening and ends of oil ring
Colored ends of oil ring
must butt together,
and must not overlap
Compression Ring Groove