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Ingersoll-Rand QA6 series, Maintenance Information, Page: 82 / 94

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16601056_ed1

Assembly Instructions for Second Stage and Assembly (G)

Place Assembly (G) in Second stage. Align Sun’s gears with the second stage’s planet gears. Also the bearing of clutch module must sit 

against the bearing placement face of the gear case of second stage.

1.

Summary of Contents for QA6 series

Page 1: ...16601056 Edition 1 April 2008 Save These Instructions Air Angle Wrench and Nut Runner QA6 and QA8 Series Maintenance Information ...

Page 2: ...ion Part Number Throttle Housing Module QA6 NPT A231 QA6 BSP A231 QA8 NPT A231 QA8 BSP A231 1 Throttle Housing 2 Ball Seat 12 mm 3 Throttle Pin 4 O Ring 3 4 mm 5 Ball 12 mm 6 Ball Spring 7 Muffler Black QA8 311 1 QA8 311 1 QA8 311 2 QA8 311 2 8 Muffler White QA6 311 2 QA6 311 2 9 Diffuser Plate 10 Pin 2 mm 11 Chip Holder Assembly QA4 A528 QA4 A528 QA4 A528 QA4 A528 12 Inlet Bushing Assembly QA6 NP...

Page 3: ...rench torque Wrench Punch Hammer Subassemblies Inlet Bushing Assembly Exploded View O Ring 11 mm Inlet Bushing Screen Dwg RG_45504578 Inlet Bushing Assembly Parts List Item Part Description Part Number 12 Inlet Bushing Assembly QA6 NPT A465 QA6 BSP A465 12A Inlet Bushing Assembly 12B O Ring 11 mm 12C Screen ...

Page 4: ...nstructions Mount screen 12C into inlet bushing 12A screen placement face See section view for the proper placement 2 Coat o ring 12B with o ring lube and mount on inlet bushing 12A O ring groove See section view for the proper placement 1 ...

Page 5: ...sembly Parts List Item Part Description Part Number 13 Lever QA6 A93 13A Lever 13B Pin 3 5 mm Throttle Housing Module Assembly Instructions Coat Ball Seat holding diameter of tool OM127 with O ring Grease 2 Hold Ball Seat 2 on Ball Seat Assembly tool OM127 as shown in picture below 1 ...

Page 6: ...tion view for the proper placement 4 Insert pin 10 into pin hole in throttle housing and press to full depth by manual press or hammer and punch 5 Put chip holder assembly 11 into Chip holder assembly hole in throttle housing 1 so that leads are showing 6 Coat O ring 4 with O ring lube and place over Throttle Pin 3 ...

Page 7: ...ng in throttle housing 1 using needle nose pliers Adjust to get throttle pin into throttle bush Throttle pin must be visible from outside over throttle housing bush area 8 Insert ball 5 in Throttle Housing 1 Make sure ball sits under Throttle Pin 3 ...

Page 8: ...flers to match Throttle Housing Profile For QA8 Place Muffler 7 Qty 2 in the Throttle Housing 1 Align Mufflers to match Throttle Housing profile 10 Place Diffuser Plate 9 on Throttle Housing Align Pin 10 in Throttle Housing with Diffuser Plate Pin Hole 11 Grease Ball Spring 6 Ground Face and Mount on Inlet Bushing Assembly 12 Mounting Face ...

Page 9: ...e Housing Module Exploded View 7 3 4 5 6 1 8 10 2 9 Dwg RG_45500816 Remote Housing Module Parts List Item Part Description Part Number Remote Housing Assembly QA6 R A40 QA8 R A40 1 Remote Start Housing 2 Chip Holder Assembly QA4 A528 QA4 A528 3 Valve Seat Remote housing Tune Up kit QA6 1R K40 QA8 1R K40 4 O Ring 15 6 mm 5 Shut off Valve 131128 131128 6 O Ring 40 mm 7 Remote Motor Housing 8 Remote ...

Page 10: ...t Exploded View 4 5 6 Dwg RG_45513520 Remote Housing Tune Up Kit Parts List Item Part Description Part Description Remote housing Tune Up kit QA6 1R K40 QA8 1R K40 4 O Ring 15 6 mm 5 Shut off Valve 131128 131128 6 O Ring 40 mm Assembly Instructions for Remote Housing Module Place Valve Seat 3 in remote Motor Housing s 7 valve seat groove 1 ...

Page 11: ...ersoll Rand 68 Grease and Mount on the Valve Seat s 3 O ring Groove in above Assembly 3 Place Shut off Valve 5 on Valve Seat s 3 Step Diameter Make Sure That Stem of Shut off Valve Passes Through The Hole In Valve Guide In Remote Motor Housing ...

Page 12: ...Grease and Mount in Remote Start Housing 1 Internal Groove 5 Insert Remote Screw 8 in the Remote Screw Hole of Remote Housing Slide this Assembly onto Remote Motor Housing 7 Tighten this Screw onto Remote Screw s threads in Remote Motor Housing by hand first ...

Page 13: ...ly and tighten screws onto screw s threads in remote motor housing by hand first 7 Tight screw 8 clockwise to 5 nm 3 7 Ft lb and screws 9 clockwise to 6 nm 4 5 Ft lb assembled in step 5 and 6 by using a torque wrench 8 Insert Chip Holder Assembly 2 into the chip holder hole in remote start housing 1 ...

Page 14: ...ssembly QA6 A40 QA8 A40 1 Motor Housing 2 Grip QA6 145 QA6 145 3 Reverse Valve QA6 329 QA6 329 4 O Ring 14 8 mm 5 Spring 3 6 mm 6 Ball 7 Reverse Ring Assembly QA6 A273 QA6 A273 8 Reverse Screw M8 131069 131069 See Subassembly Exploded View and Parts List for Detail Tooling Required Standard tools and Products O ring Lube Ingersoll Rand 68 Loctite 542 Allen Key 4mm ...

Page 15: ...ng Assembly Parts List Item Part Description Part Number 7 Reverse Ring Assembly QA6 A273 7A Reverse Ring 7B O ring 38 mm 2 Assembly Instructions for Reverse Ring Assembly Coat O ring 7b Qty 2 with O ring lube and mount in Reverse Ring 7a grooves one each See section view for the proper placement 1 ...

Page 16: ... Grip 2 on motor housing 1 Make sure to align motor housing pockets with grip pockets Note Do not use oil or other lubricants heat slightly to soften the grip if required 2 Orient Reverse Ring Assembly 7 with indicator hole closer to indicator hole on motor housing 1 1 ...

Page 17: ...t Spring 5 with o ring grease and place onto reverse valve 3 spring hole 5 Coat O ring 4 with o ring lube and place on the groove in reverse valve 3 6 Place above reverse valve assembly onto motor housing Make sure that ball spring in reverse valve sits over ball placed in motor housing See Step 3 above ...

Page 18: ...Part Number Motor Assembly QA6 A53 8 QA6 A53 10 QA6 A53 11 QA8 A53 10 QA8 A53 11 1 Rotor QA6 53 8 QA6 53 10 QA6 53 11 QA8 53 10 QA8 53 11 2 Vane Pack QA6 42 5 QA6 42 5 QA6 42 5 QA8 42 5 QA8 42 5 Motor Kit QA6 1 K53 QA6 1 K53 QA6 1 K53 QA6 1 K53 QA6 1 K53 3 Wave Washer 4 Adjustment Screw M5 5 Rear End Bearing 17x7x5 6 Front End Bearing 22x7x7 7 Rear Endplate Assembly QA6 A12 QA6 A12 QA6 A12 QA6 A12...

Page 19: ...ng QA6 QA8 3 Rotor Spline Adaptor 80187412 11 Teeth Motor spacing QA6 QA8 4 Motor Clamp tool 80187388 Motor spacing QA6 5 Motor Clamp tool 16604845 Motor spacing QA8 6 Motor Press Assembly 80187370 Motor Back Bearing Press QA6 QA8 7 Motor Assembly tool 80187420 Motor Back Bearing Press QA6 QA8 Standard tools and Products Loctite 243 Vice 3mm Hex Key Ingersoll Rand 10 Oil Ingersoll Rand 68 Grease H...

Page 20: ...tem Part Description Part Number 2 Vane Pack QA6 42 5 QA8 42 5 2A Vane 5 5 Motor Kit Exploded View 6 3 5 4 Dwg RG_45513546 Motor Kit Parts List Item Part Description Part Number Motor Kit QA6 1 K53 QA6 1 K53 3 Wave Washer 4 Adjustment Screw M5 5 Rear End Bearing 17x7x5 6 Front End Bearing 22x7x7 ...

Page 21: ...arts List Item Part Description Part Number 7 Rear Endplate Assembly QA6 A12 7A Rear Endplate 7B Roll Pin 19 mm Y178 41 Assembly Instructions for Rear Endplate Assembly Insert Roll Pin 7B in rear endplate 7A hole and press to maintain pin projection of 2 5Mm See views below for the proper placement 1 ...

Page 22: ...m Part Description Part Number 8 Cylinder Assembly QA6 A3 QA8 A3 8A Cylinder 8B Roll Pin Y178 191 Y178 191 Assembly Instructions for Cylinder Assembly Insert Roll Pin 8B into Cylinder 8A Pin Hole and Press Pin on Manual Press to Maintain Pin Projection of 2 5mm See views below for the proper placement 1 ...

Page 23: ... motor module 2 Remove Vanes 2A qty 5 from rotor and using degreaser clean all surfaces of rotor and endplates Make sure not to get degreaser in bearing or it may be damaged 3 Oil all surfaces of new vanes qty 5 with ingersoll rand 10 oil Place them one at a time in rotor 1 slots Make sure to match vane profile radius with rotor profile radius See view below Note Motor will run without lubrication...

Page 24: ...rear endplate with pin hole in cylinder assembly Note Hold assembly in straight upward direction otherwise vanes will walk out 5 Place Front Endplate with Wave Washer and Bearing assembly onto rotor shaft Align roll pin 8b in cylinder assembly with pin hole in front endplate ...

Page 25: ...ed at least 0 025mm below the surface of the end plate and not exceeding 0 2mm The front bearing press fixture 80187420 provides this spacing Disassembly of Motor Module Heat Adjustment Screw 4 screwed in the rear of motor with heat gun Note Adjustment Screw has loctite Heat is used to break that bonding 2 Hold Spline Adaptor in vice Insert rotor splines into adaptor s 80187396 80187404 80187412 d...

Page 26: ...degreaser clean all surfaces of rotor and endplate 6 Remove rear endplate assembly 7 from rotor Note It is not a hard press so gently press out rotor with a pin 7mm from endplate Assembly Instructions for Motor Module Note Replacement of motor parts may change shut off operation of tool We recommend ordering new pushrod 132017 1 Completely clean rotor and cylinder with a degreaser agent it may be ...

Page 27: ...late must be upward Note Fixture provides proper placement of front endplate and bearing Bearing must be pressed a minimum of 0 025mm below front endplate surface after final motor spacing adjustment Heat build up and bearing failure may occur if not properly spaced 5 Place Rotor onto front endplate bore Hold fixture 80187370 in manual press and press rotor in front endplate ...

Page 28: ...tch vane profile radius with profile radius of rotor Note Motor will run without lubrication but oil is used for maximum vane life 7 Slide Cylinder Assembly 8 over rotor and front endplate Align roll pin 8b in cylinder assembly with front endplate pin hole Note Hold Assembly in straight upward direction otherwise vanes will walk out ...

Page 29: ...e of rear endplate assembly must be upward 9 Grease Bearing 5 with Ingersoll Rand 68 Grease and place onto Rotor Shaft and Rear Endplate Assembly counter Bore Press Bearing Using Fixture 80187370 Until Assembly is tight and will not rotate Note Rear Endplate press fixture 80187370 presses the bearing inner race Pressing outer race may damage bearing ...

Page 30: ...Motor Assembly so that the pin 7B in rear endplate assembly locates into pin hole at the bottom of fixture 2 Thread Back Cap onto fixture Tighten it to 40 nm 30 ft lb using a wrench Note Motor clamp tool fixture simulates motor in actual tool assembly Unclamped motors may not be properly spaced and cause motor to overheat or bind 1 ...

Page 31: ...lines 4 Clean Adjustment screw 4 and screw hole in back of rotor with degreaser Coat initial few threads of adjustment screw with Loctite 243 Partially thread adjustment screw into the screw hole of rotor using 3mm hex key 5 Slowly tighten Adjustment Screw Tighten it until Assembly rotates freely Remove Motor module from Motor Clamp Fixture 80187388 16604845 ...

Page 32: ...ould still spin freely This is to ensure proper rotor spacing during normal tool operation First Stage Module Exploded View 4 2 3 5 1 6 Dwg RG_53449310 First Stage Module Parts List Item Part Description Part Number 1st Stage Gear Assembly 132023 132022 132020 132021 1 Front Cap 132004 132004 132004 132004 2 Needle Roller Bearing Kit QA6 1 K24 QA6 1 K24 QA6 1 K24 QA6 1 K24 3 Planet Gear Kit QA6 K1...

Page 33: ... Parts List Item Part Description Part Number 2 Needle Roller Bearing Kit QA6 1 K24 2A Needle Roller Bearing 3 Planet Gear Kit Note If Planet teeth are broken it is recommended to buy this kit for maximum tool life Planet Gear Kit Exploded View 3A Dwg RG_45513827 Planet Gear Kit Parts List Item Part Description Part Number 3 Planet Gear Kit QA6 K10 29 QA6 K10 25 QA8 K10 29 QA8 K10 13 3A Planet Gea...

Page 34: ...ing Unshielded Side of Bearing must face Spindle Assembly 4 The Gear Pins assembled with carrier of spindle assembly 4 must not press further during pressing the bearing Otherwise check pin projection of 10 225 10 075Mm from carrier face as shown in view below 2 Use an External Circlip pliers to place circlip 4b on the groove of carrier of above assembly 1 a b c ...

Page 35: ... Instructions for First Stage Grease Needle Roller Bearings 2a with Ingersoll Rand 90 Grease Place Needle Roller Bearing Qty 3 onto Gear Pins of Carrier 2 Place Planet Gear Qty 3 onto Needle Roller Bearings of above Assembly 1 ...

Page 36: ...e assembly must sits against the placement face of gear case See section view below for the proper placement Note Hold Assembly in straight upward direction otherwise planet gears and needle roller pins will walk out 4 Grease Spindle Assembly s 4 Gears with Ingersoll Rand 90 Grease 5 Note This is an additional Step for 132010 Assembly only Mount Pinion 6 in Planet Gears set in the above Assembly ...

Page 37: ...16601056_ed1 37 6 Place Front Cap 1 inside the gear case of above assembly Back face of bearing cap 1 must sits against the placement face of gear case See section view below the proper placement ...

Page 38: ...132017 132017 7 Bearing 119277 119277 119277 119277 119277 8 Bearing 132059 132059 132059 132059 9 Driver Shaft 132056 132056 132056 132056 QA6 590 10 Spring Guide 132063 132063 132063 132063 11 Circlip 181A13 CXRS106 2 181A13 CXRS106 2 181A13 CXRS106 2 181A13 CXRS106 2 12 Plunger 132061 132061 132061 132061 13 Shutoff Collar 132062 132062 132062 132062 14 Lower Jaw 132057 132057 132057 132057 15 ...

Page 39: ...ick Ingersoll Rand 68 Grease Ingersoll Rand 40036 1 Clutch Grease torx Driver for Clutch Adjustment 125116 Subassemblies Ball Kit Exploded View 5 00 22 21 19 20 6 00 2 83 2 78 Dwg RG_45513850 Ball Kit Parts List Item Part Description Part Number Ball Kit QA6 1 K581 QA6 1 K581 QA6 1 K581 QA6 1 K581 19 Plunger Ball 2 38 mm 6 6 6 6 20 Ball 2 78 mm 21 21 21 21 21 Clutch Ball 6 mm 3 3 3 3 22 Ball 5 mm ...

Page 40: ...Retaining Ring 3 off of Driver Shaft 9 with Pick to Unlock Adjustment Nut 5 See Detail view below 2 Insert The Bit of torx Driver 125116 in the teeth of Adjustment Nut and Nut Lock Washer s 17 Slot Rotate torx Driver in Clockwise Direction to loose Adjustment Nut 1 ...

Page 41: ...6_ed1 41 3 Rotate Adjustment Nut in counter clockwise direction to remove Note 1 Hold clutch module in upward direction as shown in view below otherwise the balls 20 in adjustment nut ball groove will walk out ...

Page 42: ...t Lock Washer 17 Bearing 8 Spring Guide 15 and Clutch Spring 1 5 Remove Retaining Ring 4 from Driver Shaft s Retaining Ring Groove by using a pick Note Retaining Ring deforms permanently after removal destroy it and use a new one ...

Page 43: ...Remove 3 X Clutch Balls 6mm 21 from upper driven jaw s cam profile Note Check that there are 3 balls and keep them for re assembly unless heavily worn 8 Remove 6 X Ball 2 78mm 19 from clutch shaft s plunger holes Note Check that there are 6 balls and keep them for re assembly unless heavily worn ...

Page 44: ...1056_ed1 9 Remove Retaining Ring Qa8 701 from upper driven jaw s 18 retaining ring groove 10 Take off Pin Qa6 15 from upper driven Jaw s Pin Hole by Inserting A Pin of Diameter Less Than 1 3mm through Pin hole ...

Page 45: ... Driven Jaw 18 by Hand 12 Remove Bearing 7 from Upper Driven Jaw 18 Using Manual Press Note Removal Process Can Damage Bearing It Is Recommended to use a New Bearing for Assembly 13 Remove Circlip 11 Qty 2 from Upper Driven Jaw 18 Using Pick ...

Page 46: ... 16601056_ed1 14 Remove Plug from driven jaw by tapping upper driven jaw gently against the work surface 15 Remove 9 X Balls 5mm 22 by rotating and tapping upper driven jaw gently against the work surface ...

Page 47: ...arate Driver Shaft 9 from Upper Driven Jaw 18 Note Check that there are 9 Balls and Keep them for Re assembly Assembly Instructions for Clutch Module Fill Internal Ball Groove and Cam Pockets of Upper Driven Jaw 18 with Ingersoll Rand 40036 1 Grease 1 ...

Page 48: ...48 16601056_ed1 2 Fill Ball Groove and Plunger Hole of Driver Shaft 9 with Ingersoll Rand 40036 1 Grease 3 Insert Upper Driven Jaw 18 onto Driver Shaft 9 ...

Page 49: ...one in the Ball Groove of Driver Shaft 9 and upper driven jaw 18 through plug hole of upper driven jaw 5 Place Plug 16 in plug hole of upper driven jaw 18 The smaller diameter of plug must face ball 22 inserted in step 3 Note Plug must sit below the retaining ring surface of upper driven jaw ...

Page 50: ...p 11 onto upper driven jaw s 18 plug retaining ring groove 7 Grease Ball Pocket of Driver Shaft 9 with Ingersoll Rand 40036 1 Grease 8 Insert 3 X Clutch Ball 6mm 21 In Upper Driven Jaw S 18 Cam Pocket Through Driver Shaft s 9 Ball Hole ...

Page 51: ...d 40036 1 Grease Insert Plunger Into Driver Shaft s 9 Hole through upper driven jaw s hole See section view below for the proper placement Note Make sure that the balls placed in step 3 do not walk out 11 Grease 3 X cross holes of driver shaft with Ingersoll Rand 40036 1 Grease and Insert 2 X Plunger Ball 2 38mm 19 Per Hole See section view below for the proper placement ...

Page 52: ...1 12 Grease I D of shutoff collar 13 with Ingersoll Rand 40036 1 Grease Slip shutoff collar over drive shaft 13 Slip Collar Spring 2 over Drive Shaft Flat face of Collar Spring Must Sit on the Step of Shutoff Collar ...

Page 53: ...16601056_ed1 53 14 Slip Spring Guide 10 over Drive Shaft The Other Flat Face of Collar Spring must sit on the step of Spring Guide ...

Page 54: ...Ring tool 80187362 to place Retaining Ring 4 on Driver Shaft 9 Groove Note 1 Check That Retaining Ring 4 is Correctly Positioned onto Driver Shaft s 9 Groove 2 Make Sure that the Plunger Positioned in Steps 10 and 11 is in its Position ...

Page 55: ...ion 17 Coat both the flat ends of clutch spring 1 with Ingersoll Rand 40036 1 Grease Place clutch spring onto lower jaw 14 18 Grease both faces of spring guide 15 with Ingersoll Rand 40036 1 grease and place over clutch spring 1 19 Grease both faces of Bearing 8 with Ingersoll Rand 40036 1 grease and place over spring guide 15 ...

Page 56: ...asher 17 onto above Assembly Align Key on Lock Nut Washer with Keyway In Driver Shaft See View Below for The Proper Placement 21 Grease Ball Race of Adjustment Nut 5 with Ingersoll Rand 40036 1 Grease and place 22 X Ball 2 78mm 20 in it ...

Page 57: ... as shown in view below otherwise the balls placed in adjustment nut in Step 21 will walk out 2 Also Hold Nut Lock Washer 17 in the assembly with hand otherwise the parts will walk out 23 Insert the Bit of torx Driver 125116 in the teeth of adjustment nut and nut lock washer s 17 slot Rotate torx driver in counter clockwise direction to tighten adjustment nut ...

Page 58: ...ed side of Bearing 7 with Ingersoll Rand 68 Grease 26 Mount Bearing 7 onto upper driven jaw 18 Press bearing inner race during pressing Note Unshielded side of bearing must face downward in picture below Note Assemble Push Rod 6 Sun Pin Qa6 15 and Retaining Ring Qa8 701 During Assembly of Complete tool ...

Page 59: ...e Unshielded Side of Bearing 7 with Ingersoll Rand 68 Grease 2 Mount Bearing 7 onto Driver Shaft 18 Press bearing inner race during pressing Note Unshielded side of bearing must face downward in picture below Note Assemble Push Rod 6 during assembly of complete tool 1 ...

Page 60: ...ed View 4 2 1 3 Clutch Cover Assembly Parts List Item Part Description Part Number Clutch Cover Assembly QA6 A415 QA8 A415 1 Clutch Cover 2 Nameplate QA6 301 QA6 301 3 Information Label QA6 299 QA6 299 4 Warning Label WARNING 27 99 WARNING 27 99 ...

Page 61: ...ing Ring QA8 701 QA8 701 QA8 701 QA8 701 8 Spacer Item Part Description Part Number 2nd Stage Gear Assembly QA8 M37 5P64 QA8 M37 3P68 QA8 M37 3P32 1 QA8 M37 3P32 2 QA8 M37 4P64 1 Sun QA8 17 5P64 QA8 17 3P68 QA6 17 5P08 QA6 17 5P08 QA6 17 5P08 2 Gear Case QA8 22 37 QA8 22 37 QA8 22 37 QA8 22 37 QA8 22 37 3 Spindle Assembly QA8 A8 5P64 GEA240 A216 QA8 3P32 32 216 QA8 3P32 31 216 QA8 4P64 32 216 4 Sn...

Page 62: ... Grease Place bearing in gear case 2 with hand first and then press using manual press to butt against the placement face of gear case Support bearing outer race during pressing See section view below for the proper placement 2 Secure Bearing 5 with Retaining Ring 4 using internal circlip pliers See section and detail views below for the proper placement 1 ...

Page 63: ...d first and then press using manual press to butt against the placement face of bearing Support bearing inner race during pressing See section and detail views below for the proper placement Note Make sure that gearing matches before pressing spindle assembly onto bearing 4 Grease Spindle Assembly s 3 Gears with Ingersoll Rand 90 Grease ...

Page 64: ...5p64 Place Bearing 5 in Gear Case 2 with hand first and then press using manual press to butt against the placement face of gear case Support bearing outer race during pressing See section and detail views below for the proper placement 1 ...

Page 65: ...3 onto bearing in gear case with hand first and then press using manual press to butt against the placement face of bearing Support bearing inner race during pressing See section and detail views below for the placement Note Make sure that gearing matches before pressing spindle assembly onto bearing ...

Page 66: ...A8 M37 4p64 Grease Spacer s 8 face with Grease Grease on spacer s face is used to hold it on spindle s face during placing the assembly in gear case 2 Place Spacer on the placement diameter of spindle assembly 3 and butt against the face of spindle as shown in views below 1 ...

Page 67: ...Spacer In Gear Case 2 Spacer 8 Mounted on Spindle Assembly Must Butt Against The Placement Face of Gear Case See Section View for The Proper Placement Note Make sure that gearing matches 4 Grease Spindle Assembly s 3 gears with Ingersoll Rand 90 grease Note Assemble Sun 1 Pin 6 Retaining Ring 7 during assembly of complete tool ...

Page 68: ...7 1 Gear Case QA8 31 37 QA8 32 37 QA8 32 37 2 Spindle Assembly QA8 A8 4P29 1 QA8 A8 4P29 2 QA8 A8 4P067 3 Bearing R1602 510 R1602 510 R1602 510 4 Spacer QA8 208 5 Spacer QA8 442 6 Coupling Nut QA8 47 QA8 47 7 Flange QA8 48 QA8 48 Not Illustrated Tooling Required Standard tools and Products Manual Press Ingersoll Rand 90 Grease Ingersoll Rand 68 Grease Torque Wrench Spanner Wrench ...

Page 69: ...Third Stage Mount Flange 7 on Gear Case 1 Match gear case s splines with flange s splines Note See tool Assembly section for proper mounting 2 Tighten Coupling Nut 6 Counterclockwise onto Gear Case 1 to 90 Nm 66 Ft lb by using a torque wrench 1 ...

Page 70: ...Bearing 3 with Ingersoll Rand 68 Grease 4 Press Bearing onto bearing diameter of spindle assembly 2 to butt against the bearing placement face Support bearing inner race during pressing See views below for the proper placement ...

Page 71: ... R35S08 A550 QA6 R43S08 A550 GAA6S8 AA16S12 1 Pin 131617 132048 804 716 804 716 2 Spring 124491 124492 5UHD 718 5UHD 718 3 Coupling Nut 15E2 27 15E2 27 15E2 27 DAA4 27 4 Coupling Nut Retainer GEA2 29 GEA2 29 GEA2 29 DAA4 29 5 Angle Head Subassembly Float Spindle Assembly Parts List Item Part Description Part Number Spindle Assembly QA64S6 QA64S8 GE4S8 160E4S8 1 Retainer 5020 716 804 716 804 716 80...

Page 72: ... Tooling Required Standard tools and Products Vice Heavy Duty Retaining Ring Pliers Assembly Instructions for Pin retainer and Spring Insert Pin Retainer 1 in the pin hole of output shaft of angle head subassembly 5 1 ...

Page 73: ...sert Spring 2 in the spring hole of output shaft of above assembly Press with hand to slip it over the groove of pin 1 C shaped profile of spring 2 must sit onto the groove of pin 1 See views below for the proper placement ...

Page 74: ...nd Coupling Nut Retainer 1 Slide Coupling Nut 3 over Angle Head Subassembly Note Coupling Nut must be orientated as shown in view below 2 Place Coupling Nut Retainer 4 on the groove of angle housing of above assembly by using heavy duty retaining ring pliers ...

Page 75: ...Assembly Exploded View 2 1 3 4 Dwg RG_45504628 Valve Assembly Parts List Item Part Description Part Number Valve assembly QA6 A159 QA8 A159 1 Valve Seat QA6 A159 QA8 A159 2 O Ring 15 6 mm 3 O Ring 17 17 mm 4 Shut off Valve 131128 131128 1 Grease O ring 2 with Ingersoll Rand 68 Grease Mount it over the O ring groove of reverse valve assembled in motor housing module ...

Page 76: ...eter of valve seat 3 Place Shut off Valve 4 on the shut off valve groove of valve seat 1 of above assembly Make sure that stem of shut off valve passes through the hole in valve guide in motor housing 4 Grease O ring 3 with Ingersoll Rand 68 Grease Mount It over The O ring Groove External of Valve Seat 1 of above Assembly ...

Page 77: ...embly A 1 Mount Throttle Housing Module onto above Assembly A The o ring mounted in the motor housing module must sit in the groove of throttle housing Thread the assembly clockwise by hand first and then tighten to 40 nm 30 ft lb by using spanner wrench and a torque wrench ...

Page 78: ...housing of above assembly b Align slot in front endplate with alignment hole in motor housing to make sure that the roll pin in rear endplate goes into locking hole in motor housing Note Make sure that the roll pin in the rear endplate of motor module goes into the locking hole in motor housing of assembly b ...

Page 79: ...ge s planet gears Also the pilot diameter of front cap in first stage must pilot onto front endplate in motor module Thread gear case with motor housing of assembly c clockwise by hand first and then tighten to 40 nm 30 ft lb clockwise by using spanner wrench and a torque wrench Note Do not over or under torque motor may not function properly 1 ...

Page 80: ... Nm 52 Ft Lb clockwise by using spanner wrenches and a torque wrench Assembly Instructions for Clutch Cover and Assembly E Slide Clutch Cover Assembly onto Clutch Housing of above assembly E it must sit on pilot diameter of clutch housing and adjust in a way so that the clutch window in clutch cover opens clearing onto the clutch window in clutch housing of above assembly E 1 1 ...

Page 81: ...e selection of Sun for a particular module 1 Place Hex side of Sun in the Upper Driver jaw of Clutch module 2 Insert Pin QA6 15 into Upper Driven Jaw s pin hole to hold Sun in upper driven jaw Pin must sit over the pin s groove in Sun 3 Place Retaining Ring QA8 701 onto retaining ring groove of Upper driven jaw to Pin QA6 15 in place ...

Page 82: ...ons for Second Stage and Assembly G Place Assembly G in Second stage Align Sun s gears with the second stage s planet gears Also the bearing of clutch module must sit against the bearing placement face of the gear case of second stage 1 ...

Page 83: ...16601056_ed1 83 Assembly Instructions for Push Rod Assembly F and H Slide Push Rod 132017 through First Stage s gearing and Rotor s hole of Assembly F 1 ...

Page 84: ...he second stage hand tight turn the tool on and slowly unscrew the second stage from the clutch housing clockwise until tool stops Note If tool does not run when lever is initially pressed pushrod is too short and needs to be replaced Release tool lever to reset air pressure Repress lever and slowly tighten second stage until tool starts to rotate from this point mark the housing to identify numbe...

Page 85: ...splines Tighten Gear case with Coupling Nut mounted onto Angle head or Spindle clockwise by hand first and then to 90 Nm 66 Ft Lb clockwise by using spanner wrench and a torque wrench For Three Stages Models QA8AA 150 QA8AA 200 QA8AA 225 QA8AS 090 QA8AS 115 QA8AS 150 QA8AS 180 Assembly Instructions for Third Stage and Assembly J Align Second stage s spindle gears with Third stage s gears Thread se...

Page 86: ...ssembly Float Spindle Assembly and Assembly L Mount Spacer QA8S 442 on Float Spindle s 160E4S8 Pinion shaft for QA8AS 115 QA8AS 150 and QA8AS 180 models Mount Spacer QA8A 442 on Angle Head s AA16S12 Pinion shaft for QA8AA 200 QA8AA 225 models Mount Spacer QA8 442 on Angle Head s GAA6S8 Pinion shaft for QAAA 150 model or Float Spindle s GE4S8 Pinion shaft for QAAS 090 models 1 ...

Page 87: ...at Spindle Assembly s Pinion gearing with third stage s spindle of Assembly L Also align Housing s external splines with Gear case s internal splines Tighten Gear case with Coupling Nut mounted onto Angle head or Spindle clockwise by hand first and then to 100 Nm 74 Ft Lb clockwise by using spanner wrench and a torque wrench ...

Page 88: ...G_45500832 Remote Housing Kit Parts List Item Part Description Part Number Remote Housing Inlet Kit QA6 RB K465 QA6 RN K465 1 Set Screw M5 2 Tube Fitting 3 Tube Fitting 4 Tube Fitting Tooling Required Standard tools and Products Adjustable Spanner Wrench Hex Keys Set ...

Page 89: ...icture are for forward direction only for reverse direction secondary exhaust becomes the inlet and the inlet becomes the secondary exhaust Note Set screw M4 1 is required if shut off signal is not required 1 Tighten Set Screw M4 1 onto Remote Screw in Remote Backend Housing clockwise using Hex key ...

Page 90: ...from tool In this case skip step 1 1 a Tighten Tube fitting 2 onto Remote Screw in Remote Backend Housing clockwise using Adjustable spanner wrench 2 Tighten Tube Fitting 3 onto Primary exhaust hole threads in Remote Backend Housing clockwise using Adjustable spanner wrench ...

Page 91: ...s in Remote Backend Housing using spanner wrench Related Documentation for additional information refer to Air Angle Wrench Screwdriver or Nut Runner Product Safety Information Manual 04585006 Air Angle Wrench and Nut Runner Product Information Manual 16601064 Air Angle Wrench and Nut Runner Parts Information Manual 16601072 Manuals can be downloaded from www irtools com ...

Page 92: ...Notes ...

Page 93: ...Notes ...

Page 94: ...www irtools com 2008 Ingersoll Rand Company ...

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