Ingersoll-Rand 5R Series Setup guide

16572596
Edition 3
May 2014
Save These Instructions
Air Drill
5 and 5R Series
Maintenance Information

2 16572596_ed3
Product Safety Information
WARNING
WARNING
Failure to observe the following warnings, and to avoid these potentially hazardous situations, could result in death or serious
injury.
Read and understand this and all other supplied manuals before installing, operating, repairing, maintaining, changing accessories
on, or working near this product.
Always wear eye protection when operating or performing maintenance on this tool. The grade of protection required should be
assessed for each use and may include impact-resistant glasses with side shields, goggles, or a full face shield over those glasses.
Always turn o the air supply, bleed the air pressure and disconnect the air supply hose when not in use, before installing, removing
or adjusting any accessory on this tool, or before performing any maintenance on this tool or any accessory.
Note: When reading the instructions, refer to exploded diagrams in parts Information Manuals when applicable (see under Related Documentation
for form numbers).
•
•
•
•
Each time a Series 5 or 5R Drill is disassembled for maintenance and
repair or replacement of parts, lubricate the tool as follows:
1. Inject a few drops of Ingersoll Rand No. 10 Oil into each vane
slot in the Rotor bore before inserting the Vanes.
2. Work enough Ingersoll Rand No. 23 Grease into the Front Rotor
Bearing (32) and Spindle Bearing (46) to coat the balls and races;
apply a heavy coat of the grease into the Rear Rotor Bearing (4)
before installing the motor in the Motor Housing.
3. Apply a coat of Ingersoll Rand No. 23 Grease to the Planet Gears
(40 and 47). The planet gear shafts, the bearing surfaces on the
Spindle (42) and Gear Head (39) and the teeth on the Ring
Gear (36).
NOTICE
Do not pack the gear chamber with grease; excessive grease will
cause a loss of power and overheating.
General Instructions
1. Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
2. Whenever grasping a tool or 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 and housings.
3. Do not remove any part which is a press t in or on a
subassembly unless the removal of that part is necessary for
repairs or replacement.
4. Do not disassemble the tool unless you have a complete set of
new gaskets and O-rings for replacement.
Disassembly of the Gearing
1. Lightly clamp the Motor Housing (1) in a vise with the spindle
end up.
NOTICE
Take care not to distort the motor bore.
2. Remove the Spindle Bearing Locknut (48) from the Housing and
withdraw the gearing. Except for the moderate press t of the
Spindle Bearing (46) on the Spindle (42), all gearing parts are free
tting and will easily slide apart.
Disassembly of the Motor
NOTICE
All motor parts are free tting except for the Rear and Plate (26)
which is retained by the End Plate Retainer (27).
1. Withdraw the motor assembly from the Housing.
2. Remove Rear End Plate Gasket (35) from the Housing.
3. Remove End Plate Retainer and Rear End Plate.
4. Remove Bearing Retaining Washer (33), Front Rotor Bearing (32),
Front Rotor Bearing Housing (31), Cylinder Dowel (34),
Cylinder (28), Rotor (25) and Vanes (29).
Disassembly of the Throttle Mechanism
1. Using a small punch, remove the Throttle Retaining Pin (19) from
the Motor Housing and withdraw the throttle mechanism.
2. Remove the Throttle Valve Face (7) from the Throttle Valve (6).
3. Remove the Throttle Valve from the Throttle Bushing (8) and
remove the Throttle Bushing Seals (9). For Reversible Models,
remove the Throttle Valve Seat (11), Reverse Valve Bushing (17)
and Reverse Valve Seal Rings (16).)
NOTICE
If it is necessary to remove the Trigger (11A), a new Trigger must
be installed.
Assembly
General Instructions
1. Always press on the inner ring of a ball-type bearing when
installing the bearing on a shaft.
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 with
threaded parts and housings.
4. Always clean every part and wipe every part with a thin lm of oil
before installation.
5. Apply a lm of o-ring lubricant to all O-rings before nal
assembly.
6. Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a suitable cleaning solution and
dry with a clean cloth. Sealed or shielded bearings should
never be cleaned. Work grease thoroughly into every open
bearing before installation.
7. Unless otherwise noted, press on the stamped end of a needle
bearing when installing the needle bearing in a recess. Use a
bearing inserting tool similar to the one shown in Dwg. TPD786.
Disassembly
Lubrication

16572596_ed3 3
Needle Bearing inserting Tool
Pilot to t I.D. of Bearing.
Length of Pilot to be
approximately 1/8” less than
length of Bearing
Shoulder to
Regulate Depth
15°
(Dwg. TPD786)
Assembly of the Throttle Mechanism
NOTICE
If it becomes necessary to remove the Trigger (11A), a new
Trigger must be installed. The orientation of the Valve and
Trigger is important for maintaining optimum performance.
1. Install the Throttle Bushing Seat (10) in the Housing (1).
2. Install the Throttle Valve Face (7) in the groove in the Throttle
Valve (6) and apply a thin coat of O-ring lubricant.
3. For Reversible Models, install the Reverse Valve Detent Ball (13)
and Reverse Valve Detent Spring (14) in the Reverse Valve (12)
and secure with the Reverse Valve Detent Adjusting Screw (15).
4. Examine the Throttle Valve to identify a ground arc on the Valve
shaft near the Throttle Valve Face. Two unground at faces
connect with the arc.
5. Slide the Throttle Valve, barbed end rst, into the round end of
the Throttle Bushing Assembly (8) or Reverse Valve Assembly (12)
and locate the drilled hole in the outside diameter of the Bushing.
6. View the Throttle Valve stem through the drilled hole. Rotate
the Throttle Valve until the ground arc lls the view through the
drilled hole. Maintain this relative positioning and stand the
partially assembled throttle on the workbench with the Throttle
Valve Face down.
7. Align the at on the top of the Trigger with the at on the top of
the Bushing, keeping the alignment as in Step 5 above, and press
the Trigger onto the exposed barbed end of the Valve. Recheck
the alignment of the Valve, Trigger and Bushing. When the parts
are properly positioned, the at on the Bushing and the at on
the top of the Trigger should align when the ground arc is seen
through the port in the side of the Bushing. See Dwg. TPD782.
Throttle Valve Stem
Air Port
View the ground portion of the
Throttle Valve Stem through here
Throttle
Bushing
Trigger
Cross section through Throttle Valve
Bushing and Throttle Valve showing
relative positon of Air Port and Valve Stem.
(Dwg. TPD782)
8. When inserting the assembled Throttle into the Motor Housing,
align the at on the Trigger with the at on the Bushing and
insert the assembly into the throttle hole with the ats closest to
the body of the Housing.
9. Retain the throttle mechanism in the Housing using the Throttle
Retaining Pin (19).
Assembly of the Motor
1. Slip the Rear End Plate (26) on the rear hub of the Rotor (25) and
install the End Plate Retainer (27) in the groove.
2. Hold the Rotor vertically and clamp the short hub in leather-
covered or copper-covered vise jaws. Insert a Vane (29) in each slot.
NOTICE
When assembling the motor, be sure to properly install the
Cylinder. The motor will not operate properly if the Cylinder
is inverted. If the air ports through the cylinder wall are in the
bottom right quadrant, you are facing the front of the Cylinder.
3. Place the Cylinder (28), front end up, over the Rotor and onto
the Rear End Plate. To determine which end of the Cylinder is the
front end, hold the Cylinder horizontally. facing one end. Position
the external groove for the Dowel (34) at the top as shown in the
illustration.
4. Slip the Front End Plate (30) over the rotor shaft. Press the Front
Rotor Bearing (32) into the Bearing Housing (31) with the sealed
face of the Bearing ush with one face of the Housing. Slide the
Bearing and Housing, sealed side rst, followed by the Retaining
Washer (33), onto the shaft.
5. Enter the Rear End Plate Gasket (35) into the Motor Housing
(1), positioning the Gasket smoothly on the backbore so that
the dowel notch in the Gasket aligns with the dowel hole in the
Housing.
6. Obtain a sti steel rod 3/32”(2.3 mm) diameter and
approximately 10”(254 mm) long to use as an assembly dowel.
7. Align the dowel groove in the Rear End Plate, Cylinder and Front
End Plate with the dowel hole through the Rotor Bearing Housing
and insert the rod.
8. Enter the end of the assembly dowel in the dowel hole and slide
the motor assembly into the Housing. This is a sliding t and if
proper alignment is maintained, the assembly will enter under
only slight nger pressure.
NOTICE
Do not drive or otherwise force the motor into position.
9. Replace the assembly dowel with the Cylinder Dowel.
NOTICE
Make sure the Cylinder Dowel is entered into and remains
in the dowel hole in the Housing. When in proper position,
approximately 3/32” (2.3 mm) of the Dowel protrudes from
the face of the Bearing Housing. If it is not in the hole, it will
protrude approximately 7/32” (5.5 mm).
Assembly of the Gearing
1. Work the Slinger Ring (43), large end rst, over the spindle shaft
and against the gear frame race. Follow with the Seal (44) and the
Grease Shield (45).
2. Install the Spindle Bearing (46) over the spindle shaft. Firmly
support the Spindle (42) and press, do not drive, the Bearing into
position using an arbor that will contact only the inner ring of the
Bearing.
3. Slide the Ring Gear (36) into the Motor Housing making sure
the Cylinder Dowel (34) enters one of the notches in the end of
the Gear. Check this engagement by trying to rotate the Gear by
hand.
4. For H, J or N ratio, slide the Rotor Pinion Spacer (37) followed by
the Rotor Pinion (38) onto the spline shaft on the Rotor (25).
5. For N ratio, slide a Gear Head Planet Gear (40) (13 teeth) onto
each of the three gear shafts on the Gear Head (39). Enter the

4 16572596_ed3
assembly into the Ring Gear (36) and slide it into engagement with the Rotor Pinion. Slip the Gear Head Spacer (41) over the spline on the
Gear Head.
NOTICE
For N ratio, a Gear Head Planet Gear (40) has 13 teeth and a Spindle Planet Gear (47) has 14 teeth. Do not mix, mismatch or switch
locations with these small gears when reassembling a Tool.
6. Slide a Spindle Planet Gear onto each of the three gear shafts on the Spindle (42) and slide the assembly into the Ring Gear and into
engagement with the Rotor Pinion or Gear Head.
7. Clean the threads on the Spindle Bearing Locknut (48) and Motor Housing to remove all grease and oil.
8. Apply lm of Vibra-Tite®** VC3 to the threads of Motor Housing.
9. With the Locknut hand tight, connect the air hose to the Inlet (22) and operate the Drill to check for smooth operation.
10. Clamp the Tool in a vise, taking care not to damage the Housing and tighten the Locknut a minimum torque of 25 ft-lb (33 Nm).
11. Install Drill Chuck Spacer (49) on the Spindle.
12. Thread Drill Chuck onto Spindle and tighten.
13. For reversible models, install the Chuck Screw (56) and tighten it securely.
** Registered trademark of ND industries
Troubleshooting Guide
Trouble Probable Cause Solution
Loss of Power Low air pressure. Check air supply at the Inlet. For top performance, the air
pressure must be 90 psig (6.2 bar/620 kPa) at the inlet.
Plugged Air Strainer Screen or Inlet
Screen.
Clean the Air Strainer or screen in a clean, suitable,
cleaning solution. If the Screen cannot be cleaned,
replace it.
Clogged Muer or Exhaust Silencer. Clean the Muer Element in a clean, suitable cleaning
solution. If it cannot be cleaned, replace it.
Worn or broken Vanes. Replace the complete set of Vanes.
Damaged Rear End Plate Gasket. Install a new Rear End Plate Gasket.
Worn or broken Cylinder. Replace the Cylinder if it is cracked or if the bore appears
wavy or scored.
Improper lubrication or dirt build-up. Clean the Motor Unit parts and lubricate as instructed.
Leaky Throttle Valve Worn Throttle Valve and/or Throttle Valve
Seat.
Install a new Throttle Valve and/or a Throttle Valve Seat.
Dirt accumulation on Throttle Valve and/or
Throttle Valve Seat.
Pour about 3 cc of a clean, suitable cleaning solution
in the air inlet and operate the tool Valve for about 30
seconds.
Immediately pour 3cc of light oil in the air inlet and
operate the tool for 30 seconds to lubricate all the
cleaned parts.
Gear Case gets hot Excessive grease. Clean and inspect the Gear Case and gearing parts and
lubricate as instructed.
Worn or damaged parts. Clean and inspect the Gear Case and gearing.
Replace worn or broken components.
Related Documentation
For additional information refer to:
Product Safety Information Manual 04580353.
Product Information Manual 16572208.
Parts Information Manual 16572836.
Manuals can be downloaded from ingersollrandproducts.com

Notes:

Notes:

Notes:

ingersollrandproducts.com
© 2014 Ingersoll Rand