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other end is rounded. Press the Shaft, bevel leading, into
the gear end of the Spindle until rounded end extends
above the shoulder of the gear 0.551" to 0.554"
(14.0 to 14.1 mm).
15. Grasp the Lower Angle Head (66) in leather-covered or
copper-covered vise jaws with output end upward.
16. Slide the Bevel Gear (67) and Spindle Upper Bearing
Shaft (59) assembly into output end of Lower Angle Head
housing (66). Slide the Bearings (61) onto the Bevel Gear
shaft.
NOTICE
The thread in the following step is a left-hand thread.
Rotate the wrench counterclockwise to tighten the
Bearing Cap (68).
17. Thread the spindle Bearing Cap (68) into the Lower
Angle Head (66) and using a spanner wrench, tighten the
Cap between 5 and 10 ft-lbs. (6.8 and 13.5 Nm) torque.
18. Reposition Lower Angle Head (66) with input end
upward. Slide Lower Housing Pinion (65) into Angle Head
and slide Bearings (61) onto Pinion Shaft.
19. Slide Adapter (64) onto Lower Housing Pinion (65).
20. Take assembled Upper Angle Head (56) and connect
output end with input end of assembled Lower Angle
Head (66). Adapter (64) connects Bevel Gear (60) to
Lower Housing Pinion (65). Thread Lower Housing
Coupling Nut (62) onto assembled Lower Angle Head
(66). Torque between 5 and 10 ft-lbs. (6.8 and 13.5 Nm).
21. Remove the assembly from the vise jaws and slide the
Upper Housing Coupling Nut (51), threaded end trailing,
onto the notched end of Upper Angle Head (56). Move
the Nut far enough onto the housing to install the
Coupling Nut Retainer (50) in the angular groove at the
notched end of the Upper Angle Head (56).
Assembly of the Tool
1. Lightly grasp the flats on the Motor Housing (1) in
leather- covered or copper-covered vise jaws with the
inlet end of the tool upward.
2. Insert a 5/8" dowel through the opening in the Back Cap
(7), and using the dowel as an alignment device, install
the three Muffler Elements (9) in the cavity of the Back
Cap. Make certain the notches in the outer edge of the
Elements fit over the memory chip pocket in the bottom of
the Cap.
3. If the tool is equipped with a Memory Chip (10), install
it (with the leads entering first) in the pocket at the bottom
of the Back Cap.
4. Make certain the tab on the inside edge of the Back Cap
Gasket (8) is aligned with the pocket for the Memory Chip
and install the Gasket, metal face leading, in the recess
of the Back Cap against the face with the cavity
containing the Muffler Elements.
5. Position the gasket end of the alignment dowel against
the inlet hub on the Motor Housing. Align the flats on the
Cap with the flats on the Housing. Orient the Back Cap
and slide the Back Cap Assembly off the alignment dowel
and onto the Motor Housing.
6. The Exhaust Diffuser (16) has one slot that is longer than
the other five slots. The Back Cap has a short, molded
stud projecting from inlet end. Place the Exhaust Diffuser
against the Back Cap with the long slot encircling the
molded stud. Rotate the Diffuser counterclockwise until
the wall of the slot stops against the stud. The exhaust
ports are now in the full open position and will provide
maximum free speed.
7. Being careful not to damage it, insert the Throttle Valve
Seat (13) into the central opening at the inlet end of the
Motor Housing at an angle until it clears the threads in the
Housing. Using a rod with a flat end and no sharp edges,
EN-5
push the Seat to the bottom of the opening until it seats
flush.
8. Using needle nose pliers, insert the Throttle Valve (14),
long stem leading, into the opening against the Seat.
Center the Valve in the Seat.
9. Install the Throttle Valve Spring (15) in the opening so
that it encircles the Valve.
10. If the Inlet Screen (19) required replacement, use a
wooden dowel to carefully push a new one into the Inlet
Bushing (17).
11. If the Inlet Bushing Seal (18) is nicked or damaged,
carefully install a new one over the threads of the Inlet
Bushing.
12. Thread the Inlet Bushing Assembly through the Diffuser
and Back Cap into the Motor Housing. Using a 1-3/16"
wrench on the flats of the Back Cap to keep it from
turning, tighten the Inlet Bushing between 15 and 20 ft
lbs. (20 and 27 Nm) torque.
13. The Throttle Plunger (6) has a lengthwise flat on the
outer edge at one end of the Plunger. Insert the Plunger,
flat end first, into the cross-hole in the Housing. Push on
the end of the Plunger to make certain it springs back
from contact with the stem of the Throttle Valve.
14. Position the Throttle Lever (11) in the slot in the Back Cap
and Motor Housing and using a 1/16" diameter rod, align
the holes through the Back Cap, Motor Housing and
Throttle Lever. While maintaining alignment, install the
Throttle Lever Pin (12) in place of the rod by tapping it
through all three pieces.
15. Remove the assembled Housing from the vise jaws.
16. Lightly grasp the flats of the Motor Housing in
leather-covered or copper-covered vise jaws with the
motor bore upward.
17. Grasp the spline of the Rotor (27) in the assembled motor
and after aligning the End Plate Alignment Pin (30) with
the internal notch in the motor end of the housing bore,
insert the assembled motor into the Motor Housing. Make
certain the motor is far enough into the Housing to have
the undercut below the internal housing thread visible.
18. Lubricate the Motor Seal (32) with O-ring lubricant and
install it around the Front End Plate (29) and into the
undercut in the Housing.
19. Align the tab of the Motor Clamp Washer (33) with the
internal notch in the Housing and install it over the rotor
hub and End Plate Alignment Pin against the Motor Seal.
Make certain the Pin enters the hole in the Washer and
the Washer is flat against the Seal.
20. Apply some Ingersoll Rand No. 67 Grease to the spline
on the rotor shaft.
21. Thread the assembled Gear Case (42) and Spindle
Assembly (41), gear case end leading, into the Motor
Housing and using a 1-1/16" wrench, tighten the joint
between 15 and 20 ft-lbs. (20 and 27 Nm) torque.
22. Install the Housing Grip (46), internal slotted end leading,
over the motor and Housing and engage the slots in the
Grip with the projections on the Housing.
23. Position the Housing Lock Spacer (49) in the Gear Case
with the tabs of the Spacer going into the notch openings.
NOTICE
The thread in the following step has left-hand thread.
Rotate the Nut counterclockwise to tighten it.
24. Orient the assembled Angle head to the desired position
and insert the notched end of the Angle head into the
Gear Case to engage the tabs of the Spacers. Make
certain the external hex of the Bevel Pinion (55) enters
the hex recess of the Spindle Assembly (41). Thread the
Coupling nut (51) onto the Gear Case and tighten it
between 2 and 5ft-lbs. (2.7 and 6.8 Nm) torque.
25. Remove the tool from the vise jaws.
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