Ingersoll Rand Outboard Motor 92N User Manual

Form P6401  
Edition 6  
October 2005  
CCN 03528635  
Nonreversible and Reversible  
MULTI–VANE® Geared Motors  
92N and 92R Series  
Operations and  
Maintenance Information  
Save These Instructions  
 
than the Vent plug from the upper side of the motor and  
connect an oil line from a gravity feed reservoir. Connect an  
overflow line to the Level Plug opening and run it to a pump  
to return the lubricant to the gravity feed reservoir.  
If the Motor is mounted in any position other than  
that illustrated, contact an Ingersoll-Rand  
Representative for oil level and venting recommendations.  
Direction of Shaft Rotation  
Series 92N Non–reversible Motors are assembled at the  
factory so that the Motor Shaft (36) rotates counterclockwise  
when facing the end of the Shaft. When desired, the direction  
of the shaft rotation can be changed as follows:  
1. Stand the Motor upright on a workbench with the Motor  
Housing Cover (1) upward and secure it in position by  
clamping the base with a C–clamp.  
2. Remove the four Housing Cover Cap Screws (2).  
3. Being careful not to damage the Cylinder Seals (8A), pull  
the Motor Housing Cover and the Motor Housing (11) off  
the Gear Box (18).  
4. Grasp the Cylinder (8) with both hands and carefully work  
the motor from the Gear Box.  
5. While holding the Cylinder with one hand, drive against  
the splined end of the Rotor (12) with a soft hammer until  
the Front Rotor Bearing (13) comes free from the rotor  
shaft.  
NOTICE  
Press against the inner ring of the Bearing when  
pressing the Front Rotor Bearing on the rotor shaft.  
9. Align the dowel hole in both End Plates and Cylinder, and  
insert the Cylinder Dowel (9) so that it protrudes from the  
Rear End Plate.  
10. Place the Housing Cover Gasket (4) in the recess in the  
Housing Cover so that the dowel notch in the Gasket is  
aligned with the dowel hole in the Cover.  
11. Set the motor assembly in the Cover so that the Cylinder  
Dowel enters the dowel hole.  
12. Slide the Motor Housing (11) over the Cylinder and  
against the Motor Housing Cover.  
13. Place the Gear Box Gasket (17) on the face of the Front  
End Plate.  
6. Withdraw the Front Rotor Bearing, Front Rotor Bearing  
Spacer Assembly (14) and Front End Plate (7).  
7. Withdraw the Cylinder (8), turn it end–for–end, and slide  
it back over the Rotor.  
14. Pick up the entire assembly and being careful not to  
damage the Cylinder Seals, work it into the pilot recess in  
the gear box.  
15. Install the Housing Cover Cap Screws and, with the  
Motor running at a slow speed using air pressure of 30 to  
40 psig (2.07 to 2.76 bar/207 to 276 kPa), alternately  
tighten the Screws to 28 to 31 ft–lb. (38.0 to 42.0 Nm)  
torque.  
8. Install the Front End Plate, Front Rotor Bearing Spacer  
Assembly and Front Rotor Bearing.  
(Dwg. TPB490)  
Form P6401 Edition 6  
3
 
Reversible Motor Applicatons Air Flow Information  
NOTICE  
When these motors are used on applications requiring a reversible motor, a 4–way throttle valve or two 3–way throttle  
valves must be used in the air supply line in accordance with the following schematic diagram (TPB491).  
When the application requires a non–reversible motor, a 2–way inline valve can be used in the air supply line. In either  
case, the inlet and outlet of the valve must be equal in size, and preferably one size larger, than the inlet of the motor.  
(Dwg. TPB491)  
4
Form P6401-Edition 6  
 
Notes  
Form P6401 Edition 6  
5
 
92N and 92R Series Exploded Diagram  
(Dwg. TPA551-1)  
6
Form P6401-Edition 6  
 
92N and 92R Series Parts List  
Sl. No.  
Description  
Motor Housing Cover  
for Series 92N  
Part Number Sl. No.  
Description  
for Model 92NA008 or  
92RA008  
Part Number  
48NA-755-008  
48NA-755-011  
48NA-755-014  
48NA-755-017  
48NA-755-022  
1
92N-102  
92R-102  
for Series 92R  
for Model 92NA011 or  
92NA011  
2
*
Short Housing Cover Cap Screw  
(4 for 92N; 2 for 92R)  
Long Housing Cover Cap Screw  
(2 for 92R)  
12BMP-634  
for Model 92NA014 or  
92RA014  
107-25  
for Model 92NA017 or  
92RA017  
3
Copper Seal Washer (4)  
Motor Housing Cover Gasket  
Rear Rotor Bearing  
Rear Rotor Bearing Retainer  
End Plate (2)  
D02-504  
92R-283  
92RMG10-22  
R380Q-6  
4
5
6
7
8
for Model 92NA022 or  
92RA022  
for Series 92NB or 92RB  
First Stage Intermediate Gear  
Rear Bearing  
92RMG10-11  
22  
23  
24  
Cylinder Assembly  
R1AP-97  
R38P-97  
for Series 92N  
92RMG10-A3  
92R-A3  
First Stage Intermediate Gear  
Front Bearing  
for Series 92R  
8A Cylinder Seal (2)  
Cylinder Dowel  
92RMG10-103  
92R-98  
Motor Shaft Rear Bearing or  
Intermediate Gear Pinion Rear  
Bearing  
9
10 Vane Packet (set of 5 Vanes)  
11 Motor Housing  
R5H-42-5  
92N-40  
48NA-510  
25  
26  
Second Stage Intermediate  
12 Rotor  
92N-53  
Gear (for Series 92NB or 92RB) 48NA-756-022  
Second Stage Intermediate  
13 Front Rotor Bearing  
14 Front Rotor Bearing Spacer  
Assembly  
T02-33  
Gear Key or Motor Shaft Gear  
92N-A65  
48N-758  
AF160-294  
92R-283  
Key (2)  
R4H-410  
15  
16  
Front Rotor Seal  
27  
Intermediate Gear Pinion  
for Model 92NB029 or  
92RB029  
Bearing Spacer Seal  
17 Gear Case Gasket  
Gear Box Assembly  
48NB-760-029  
48NB-760-036  
48NB-760-045  
48NB-760-078  
for Model 92NB036 or  
92RB036  
for Model 92NA005 or  
92RA005  
92NA-A750-005  
92NA-A750-008  
92NA-A750-011  
92NA-A750-014  
92NA-A750-017  
92NA-A750-022  
92NB-A750-029  
92NB-A750-036  
92NB-A750-045  
for Model 92NB045 or  
92RB045  
for Model 92NA008 or  
92RA008  
for Model 92NB078 or  
92RB078  
for Model 92NA011 or  
92RA011  
28  
29  
30  
31  
Intermediate Gear Pinion  
Roller Bearing (for Series  
92NB or 92RB)  
for Model 92NA014 or  
92RA014  
48NB-765  
48NB-764  
C6H20A-518  
for Model 92NA017 or  
92RA017  
Intermediate Gear Pinion  
Front Bearing (for Series  
92NB or 92RB)  
for Model 92NA022 or  
92RA022  
Third Stage Intermediate Gear  
Bearing (for Series 92NB or  
92RB)(2)  
for Model 92NB029 or  
92RA029  
for Model 92NB036 or  
92RA036  
Third Stage Intermediate Gear  
for Model 92NB029 or  
92RB029  
for Model 92NB045 or  
92RA045  
48NB-761-029  
48NB-761-036  
48NB-761-045  
48NB-761-078  
for Model 92NB036 or  
92RB036  
for Model 92NB078 or  
92RA078  
92NB-A750-078  
92NA-750  
for Model 92NB045 or  
92RB045  
18  
19  
Gear Box  
Gear Box Frame (for Series  
92NB or 92RB)  
for Model 92NB078 or  
92RB078  
48NB-763  
48NA-752  
20  
21  
Gear Box Gasket  
First Stage Intermediate Gear  
for Model 92NA005 or  
92RA005  
48NA-755-005  
Form P6401 Edition 6  
7
 
92N and 92R Series Parts List (Continued)  
Sl. No.  
Description  
Motor Shaft Thrust Bearing  
Race  
Part Number Sl. No.  
Description  
92RB045  
Part Number  
32  
48NB-762-029  
for Model 92NB078 or  
92RB078  
for Series 92NB or 92RB  
Motor Shaft Thrust Bearing  
for Series 92NB or 92RB  
Motor Shaft Gear  
for Model 92NA005 or  
92RA005  
48NB-767  
37  
48NB-762-078  
33  
34  
Motor Shaft Key  
48NB-769  
for Series 92NA or 92RA  
for Series 92NB or 92RB  
Gear Box Cover Assembly  
for Series 92NA or 92RA  
for Series 92NB or 92RB  
Motor Shaft Seal  
107-54  
R5H51-768  
38  
48NA-756-005  
48NA-A751  
48NB-A751  
for Model 92NA008 or  
92RA008  
48NA-756-008  
48NA-756-011  
48NA-756-014  
48NA-756-017  
48NA-756-022  
39  
for Model 92NA011 or  
92RA011  
for Series 92NA or 92RA  
for Series 92NB or 92RB  
Vent Plug  
48NA-759  
48NB-759  
48NA-368  
for Model 92NA014 or  
92RA014  
40  
41  
Gear Box Cover Cap Screw (11)  
for Series 92NA or 92RA  
for Series 92NB or 92RB  
1/4 Lock Washer (11)  
Oil Plug (12 for Series 92NB or  
92RB; 11 for others)  
for Model 92NA017 or  
92RA017  
R0H-354-4  
48NB-354  
8U-58  
for Model 92NA022 or  
92RA022  
42  
43  
35  
36  
Motor Shaft Front Bearing  
for Series 92NA or 92RA  
for Series 92NB or 92RB  
Motor Shaft  
R2-227  
C6H20A-518  
48NB-766  
*
*
Nameplate  
Nameplate Screw (3)  
92N-301  
20BM-302  
for Series 92NA or 92RA  
for Model 92NB029,  
92RB029, 92NB036,  
92RB036, 92NB045, or  
48NA-757-4  
*
Not illustrated  
To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one  
(pair or set) of each part indicated by a bullet (•) for every four motors in service.  
8
Form P6401-Edition 6  
 
Maintenance Section  
Disassembly  
General Instructions  
1. Do not disassemble the motor any further than necessary  
to replace or repair damaged parts.  
2. Do not disassemble the motor unless you have a  
complete set of new gaskets and O–rings for  
replacement.  
of the Intermediate Gear. If the Bearings are frozen on  
the hubs, use a bearing puller to remove them.  
6. Push the assembled Motor Shaft out of the Gear Box  
Cover Assembly.  
7. Pull the Motor Shaft Rear Bearing (24) off the rear hub of  
the Motor Shaft.  
3. When grasping a motor or part in a vise,always use  
leather–covered or copper–covered vise jaws to protect  
the surface of the part or motor and help prevent  
distortion. This is particularly true of threaded members  
and housings.  
4. 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.  
5. Do not press any needle bearing from a part unless you  
have a new needle bearing on hand for installation.  
Needle bearings are always damaged during the removal  
process.  
8. Pull the Motor Shaft Front Bearing (35) off the front hub of  
the Motor Shaft.  
9. Using a gear puller, pull the Motor Shaft Gear (34) off the  
rear of the Motor Shaft. Remove the two Shaft Keys (26).  
10. Using a hooked tool, pull the Motor Shaft Seal (39) out of  
the Gear Box Cover.  
Disassembly of Series 92NB and 92RB Gearing  
1. Unscrew and remove the eleven Gear Box Cover Cap  
Screws (41) and Lock Washers (42).  
2. Remove the Motor Shaft Key (37) and lay the assembled  
gear box on a workbench with the Motor Shaft (36)  
upward.  
Disassembly of the Motor  
3. Grasp the Gear Box Frame (19) and carefully separate  
the assembled Frame and Gear Box Cover Assembly  
(38) from the Gear Box (18) and set it aside. If the First  
Stage Intermediate Gear (21) remains with the Gear Box  
Frame, make certain it does not drop onto any hard  
surfaces or other gearing.  
1. Remove the Vent Plug (40) and positioning the Drain  
Plug (43) over a container, remove the Drain Plug and  
drain the lubricant from the Gear Box (18). Clamp the  
mounting foot of the Gear Box to the work bench.  
2. Remove the Housing Cover Cap Screws (2) and  
Washers (3).  
4. Remove the Gear Box Gasket (20).  
3. Grasp the Motor Housing (11) and Motor Housing Cover  
(1) and separate the motor parts from the Gear Box.  
4. Separate the Motor Housing Cover from the Motor  
Housing and being careful not to damage the Cylinder  
Seals (8A), grasp the spline end of the Rotor (12) and pull  
the assembled motor out of the Motor Housing.  
5. Pull the Front Rotor Bearing (13), Front Rotor Bearing  
Spacer Assembly (14) and Front End Plate (7) off the hub  
of the Rotor.  
6. Peel the Gear Case Gasket (17) from the End Plate. If  
portions of the Gasket remain adhered to the End Plate,  
use a scrapper made from a non–damaging material  
such as nylon, to scrap the Gasket and adhesive from the  
End Plate.  
7. Pull the Cylinder (8) and Cylinder Dowel (9) off the Rotor  
and remove the Vanes (10) from the vane slots in the  
Rotor.  
8. Remove the two Cylinder Seals (8A) from the grooves in  
the large flanges of the Cylinder.  
9. Using snap ring pliers, remove the Rear Rotor Bearing  
Retainer (6) and pull the Rear Rotor Bearing (5) and End  
Plate off the rear hub of the Rotor.  
10. Peel the Motor Housing Cover Gasket (7) from the End  
Plate. If portions of the Gasket remain adhered to the  
End Plate, use a scrapper made from a non–damaging  
material such as nylon, to scrap the Gasket and adhesive  
from the End Plate.  
5. Lift the First Stage Intermediate Gear out of the Gear  
Box. Pull the First Stage Intermediate Gear Rear Bearing  
(22) and First Stage Intermediate Gear Front Bearing (23)  
off the hubs of the Intermediate Gear. If the Bearings are  
frozen on the hubs, use a bearing puller to remove them.  
6. Carefully separate the Gear Box Cover Assembly from  
the Gear Box Frame and remove the Gear Case Gasket.  
Be careful not to allow the Motor Shaft Thrust Bearing  
Race (32) or the Motor Shaft Thrust Bearing (33) to slide  
off the Motor Shaft and become damaged.  
7. Remove the Third Stage Intermediate Gear (31) and the  
two Third Stage Intermediate Gear Bearings (30) from  
either the Gear Box Frame or the Gear Box Cover  
Assembly. Pull the two Bearings from the shafts of the  
Gear. If the Bearings are frozen on the shafts, use a  
bearing puller to remove them.  
8. Pull the Intermediate Gear Pinion Rear Bearing (24) off  
the rear hub of the Intermediate Gear Pinion (27).  
9. Using a gear puller, pull the Second Stage Intermediate  
Gear (25) from the rear hub of the Intermediate Gear  
Pinion. Remove the two Shaft Keys (26).  
10. Push the Intermediate Gear Pinion out the motor shaft  
end of the Gear Box Frame.  
11. Pull the Intermediate Gear Pinion Front Bearing (29) off  
the Pinion and if the Intermediate Gear Pinion Roller  
Bearing (28) must be replaced, pull it from the Pinion.  
12. If the Motor Shaft Thrust Bearing and Bearing Race have  
not been removed, remove them from the Shaft.  
13. Push the assembled Motor Shaft out of the Gear Box  
Cover Assembly.  
14. Pull the Motor Shaft Front Bearing (35) off the front hub of  
the Motor Shaft.  
15. Using a hooked tool, pull the Motor Shaft Seal (39) out of  
the Gear Box Cover.  
Disassembly of Series 92NA and 92RA Gearing  
1. Unscrew and remove the eleven Gear Box Cover Cap  
Screws (41) and Lock Washers (42).  
2. Remove the Motor Shaft Key (37) and lay the assembled  
gear box on a workbench with the Motor Shaft (36)  
upward.  
3. Carefully separate the Gear Box Cover Assembly (38)  
from the Gear Box (18) and set it aside. If the  
Intermediate Gear (21) remains with the Gear Box Cover,  
make certain it does not drop onto any hard surfaces or  
other gearing.  
4. Remove the Gear Box Gasket (20).  
5. Lift the Intermediate Gear out of the Gear Box. Pull the  
First Stage Intermediate Gear Rear Bearing (22) and First  
Stage Intermediate Gear Front Bearing (23) off the hubs  
Form P6401 Edition 6  
9
 
Assembly  
General Instructions  
1. Always press on the inner ring of a ball–type bearing  
when installing the bearing on a shaft.  
8. Using a piece of tubing that contacts the inner ring of the  
Motor Shaft Front Bearing (35), press the Bearing onto  
the output end of the Motor Shaft (36).  
2. Always press on the outer ring of a ball–type bearing  
when pressing the bearing into a bearing recess.  
3. Whenever grasping a tool or part in a vise, always use  
leather–covered or copper–covered vise jaws. Take extra  
care not to damage threads or distort housings.  
4. Except for bearings, clean every part and wipe every part  
with a thin film of oil before installation.  
5. Check every bearing for roughness. If an open bearing  
must be cleaned, wash it thoroughly clean suitable  
solution and dry with a clean cloth. Sealed or shielded  
bearings should not be cleaned. Work grease into every  
bearing before installation.  
6. Apply a film of O–ring lubricant to every O–ring before  
installation.  
7. Unless otherwise noted, always press on the stamped  
end of a needle bearing when installing a needle bearing  
into a recess. Use a bearing inserting tool similar to the  
one shown in Dwg. TPD786.  
9. Install the Motor Shaft Thrust Bearing (33) followed by the  
Motor Shaft Thrust Bearing Race (32) onto the opposite  
end of the Motor Shaft and insert the assembled Shaft,  
Bearing Race leading, into the Pinion Roller Bearing.  
10. Place one of the Gear Box Gaskets (20) onto the Gear  
Box Frame making certain the Gasket fits over the  
alignment pin in the Frame and fits well around the large,  
raised alignment hub.  
11. Using a dowel, push the Motor Shaft Seal (39), small  
opening leading, into the recess in the Gear Box Cover  
Assembly (38).  
12. Position the Cover over the Box Frame and install the  
Seal on the Motor Shaft by bringing the Cover down  
against the Gasket. Make certain the alignment pin and  
hub on the Frame enter the hole and recess in the Cover.  
13. Turn the assembly over so that the output end of the  
Motor Shaft is downward.  
14. Using a piece of tubing that contacts the inner ring of the  
First Stage Intermediate Gear Front Bearing (23), press  
the Bearing onto the shaft adjacent to the small spline of  
the First Stage Intermediate Gear (21).  
NEEDLE BEARING INSERTING TOOL  
15. Using a piece of tubing that contacts the inner ring of the  
First Stage Intermediate Gear Rear Bearing (22), press  
the Bearing onto the shaft adjacent to the large spline of  
the First Stage Intermediate Gear (21).  
16. Position the Bearing nearest the smaller spline on the  
shaft of the First Stage Intermediate Gear above the  
bearing recess in the Gear Box Frame. Engage the  
smaller spline of the Gear with the spline of the Second  
Stage Intermediate Gear while pushing the Bearing into  
the recess.  
17. Using a piece of tubing that contacts the inner ring of the  
Intermediate Gear Pinion Rear Bearing (24), press a  
Bearing onto the shaft of the Intermediate Gear Pinion.  
18. Place the remaining Gear Box Gasket onto the Gear Box  
Frame making certain the Gasket fits over the alignment  
pin in the Frame and fits well around the large, raised  
alignment hub.  
SHOULDER TO  
REGULATE DEPTH  
PILOT TO FIT I.D. OF BEARING.  
LENGTH OF PILOT TO BE  
APPROXIMATELY 1/8” LESS  
THAN LENGTH OF BEARING  
19. Position the Gear Box (18) over the assembly and bring  
the Gear Box down against the Gasket while making sure  
the Bearings enter the bearing recesses in the Gear Box.  
Make certain the alignment pin and hub on the Frame  
enter the hole and recess in the Gear Box.  
20. While keeping the assembly together, turn it over and  
insert the eleven Gear Box Cover Cap Screws (41) with  
their Lock Washers (42) through the holes of the Cover  
and Frame and into the Gear Box. Tighten the Screws  
evenly, a little at a time, using an alternating pattern. Use  
the Screws to draw the assembly together without  
distortion and without binding.  
(Dwg. TPD786)  
Assembly of Series 92NB and 92RB Gearing  
1. Using a bearing inserting tool, press the Intermediate  
Gear Pinion Roller Bearing (28) into the Intermediate  
Gear Pinion (27).  
2. Using a piece of tubing that contacts the outer ring of the  
Intermediate Gear Pinion Bearing (29), press the Bearing  
into the large bearing recess in the spindle side of the  
Gear Box Frame (19).  
3. Insert the shaft of the Intermediate Gear Pinion through  
the Bearing and Frame, and rest the assembly on the  
table of an arbor press with the pinion shaft upward and  
the gear end face of the pinion supported.  
4. Insert the two Second Stage Intermediate Gear Keys (26)  
into the slots in the shaft and press the Second Stage  
Intermediate Gear (25) onto the pinion shaft capturing the  
Gear Box Frame within the assembly.  
5. Using a piece of tubing that contacts the inner ring of the  
Third Stage Intermediate Gear Bearing (30), press a  
Bearing onto each shaft of the Third Stage Intermediate  
Gear (31).  
6. Place the assembled Gear Box Frame on a workbench  
with the roller bearing end of the Pinion upward.  
7. Position the Bearing nearest the large spline on the shaft  
of Third Stage Intermediate Gear above the bearing  
recess in the Gear Box Frame. Engage the large spline of  
the Gear with the spline of the Pinion while pushing the  
Bearing into the recess.  
Assembly of Series 92NA and 92RA Gearing  
1. Insert the two Motor Shaft Gear Keys (26) into the slots in  
the Motor Shaft (36) and press the Motor Shaft Gear (34)  
onto the Motor Shaft.  
2. Using a dowel, push the Motor Shaft Seal (39), small  
opening leading, into the recess in the Gear Box Cover  
Assembly (38).  
3. Using a piece of tubing that contacts the inner ring of the  
Motor Shaft Front Bearing (35), press the Bearing onto  
the output end of the Motor Shaft.  
4. Using a piece of tubing that contacts the inner ring of the  
Motor Shaft Rear Bearing (24), press a Bearing onto the  
motor end of the Motor Shaft.  
5. Insert the output end of the Motor Shaft through the Motor  
Shaft Seal and push it into the into the gear Box Cover  
Assembly until the Motor Shaft Front Bearing seats in the  
bearing recess.  
10  
Form P6401-Edition 6  
 
6. Using a piece of tubing that contacts the inner ring of the  
First Stage Intermediate Gear Front Bearing (23), press  
the Bearing onto the shaft adjacent to the small spline of  
the First Stage Intermediate Gear (21).  
7. Using a piece of tubing that contacts the inner ring of the  
First Stage Intermediate Gear Rear Bearing (22), press  
the Bearing onto the shaft adjacent to the large spline of  
the First Stage Intermediate Gear (21).  
8. Place the Gear Box Cover Assembly on a workbench  
with the output end of the Motor Shaft downward.  
9. Position the Bearing nearest the smaller spline on the  
shaft of the First Stage Intermediate Gear above the  
bearing recess in the Gear Box Cover. Engage the  
smaller spline of the Gear with the spline of the Motor  
Shaft Gear while pushing the Bearing into the recess.  
10. Place the Gear Box Gasket (20) onto the Gear Box Cover  
making certain the Gasket fits over the alignment pin in  
the Cover and fits well around the large, raised alignment  
hub.  
5. Place a Vane (10) in each vane slot.  
6. Install new Cylinder Seals (8A) in the grooves in the large  
hubs of the Cylinder (8).  
7. For Series 92N Non–reversible Motors, the direction of  
rotation of the Motor depends on the relationship of the  
Cylinder and End Plates. To obtain desired shaft rotation,  
proceed as follows:  
a. Rotate the End Plate until the 17/64” (6.75 mm)  
through hole (dowel hole) is facing you. Note there is a  
similar hole extending lengthwise through the Cylinder,  
and at about 40 to one side of the hole is an air port.  
b. Hold the Cylinder upright, facing the dowel hole and  
with the air port to the right for clockwise shaft rotation, to  
the left for counterclockwise shaft rotation. Then place it  
over the Rotor so that the dowel hole in the Cylinder and  
End Plate are in alignment. For Series 92R Reversible  
Motors, place the Cylinder over the Rotor so that the  
dowel hole in the Cylinder and End Plate are in  
alignment.  
11. Position the Gear Box (18) over the assembly and bring  
the Gear Box down against the Gasket while making sure  
the Bearings enter the bearing recesses in the Gear Box.  
Make certain the alignment pin and hub on the Frame  
enter the hole and recess in the Gear Box.  
12. While keeping the assembly together, turn it over and  
insert the eleven Gear Box Cover Cap Screws (41) with  
their Lock Washers (42) through the holes of the Cover  
into the Gear Box. Tighten the Screws evenly, a little at a  
time, using an alternating pattern. Use the Screws to  
draw the assembly together without distortion and without  
binding.  
8. The Gear Case Gasket has adhesive on one side of the  
Gasket. Place the remaining End Plate flat on a clean  
surface with the face having the channel going from the  
central opening to the outer edge upward. Orient the  
Gasket to the End Plate, making certain the cylinder  
dowel hole openings align, and attach it to the End Plate  
by bringing the gasket adhesive into contact with the face  
of the End Plate. Press it flat onto the face.  
9. Install the End Plate, Gasket side trailing, onto the short  
hub of the Rotor. Rotate it so that the cylinder dowel hole  
is aligned with the corresponding hole in the Cylinder.  
Insert the Cylinder Dowel (9) to maintain the alignment  
with the Dowel protruding through the Rear End Plate.  
10. Slide the Rear Rotor Bearing (5) on the short hub of the  
Rotor and against the End Plate. Using snap ring pliers,  
install the Rear Rotor Bearing Retainer (6) to keep the  
Bearing and End Plate in position.  
11. Position the Motor Housing Cover (1) over the Rear Rotor  
Bearing and End Plate. Make certain the cylinder dowel  
holes and porting are aligned correctly. Remove the  
assembly from the vise jaws.  
12. Carefully slide the Motor Housing (11) over the  
assembled motor and position it against the Motor  
Housing Cover.  
Motor Assembly  
1. The Gear Case Gasket (17) has adhesive on one side of  
the Gasket. Place one End Plate (7) flat on a clean  
surface with the face having the channel going from the  
central opening to the outer edge upward. Orient the  
Gasket to the End Plate, making certain the cylinder  
dowel hole openings align, and attach it to the End Plate  
by bringing the gasket adhesive into contact with the face  
of the End Plate. Press it flat onto the face.  
2. Slip the End Plate, gasket face trailing, onto the spline  
end of the Rotor (12).  
3. Install the Front Rotor Bearing Spacer Assembly (14) and  
the Front Rotor Bearing (13) onto the splined shaft of the  
Rotor and against the End Plate. If the Bearing is a tight  
fit on the shaft, use a piece of tubing that contacts the  
inner ring of the Bearing and clears the rotor shaft to  
press the Bearing onto the shaft.  
13. Position the assembled Gear Box (18) against the face of  
the Motor Housing. Make certain the spline of the Rotor  
engages the teeth of the First Stage Intermediate  
Gear(21) properly.  
14. Install the Housing Cover Cap Screws (2) along with the  
Washers (4). With the motor running at a slow speed  
(30 to 40 psig) (267 to 276 kPa) alternately tighten the  
Screws to 28 to 31ft–lb. (38.0 to 42.0 Nm) torque.  
4. While holding the Rotor in a vertical position, grasp the  
spline in copper–covered vise jaws.  
Form P6401 Edition 6  
11  
 
© 2005 Ingersoll-Rand Company  
 

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