Ingersoll-Rand 6A Series Setup guide

45612702
Edition 2
May 2014
Save These Instructions
Air Drill
6A Series
Maintenance Information

2 45612702_ed2
Product Safety Information
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).
Lubrication
•
•
•
•
Each time a Series 6A Drill is disassembled for repair or replacement
of parts, lubricate the tool as follows:
1. Moisten all O-rings with O-ring lubricant.
2. Work approximately 1.5 cc of Ingersoll Rand No. 67 Grease into
the Rear Rotor Bearing (18), Front Rotor Bearing (24) and the
Spindle Bearing (41).
3. Work approximately 6 cc to 8 cc of Ingersoll Rand No. 67 Grease
into the D, H, J, JJ, K or L ratio gear train and 10 cc to 12 cc of
Ingersoll Rand No. 67 Grease into the M, R or S ratio gear train.
Grease the Planet Gear Bearings (28, 30, 36 and 38), the gear
teeth inside the Gear Case (39) and the planet gear shafts on the
Spindle (26) and Gear Head (35).
Disassembly
General Instructions
Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
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.
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.
Do not disassemble the Tool unless you have a complete set of
new gaskets and O-rings for replacement.
Disassembly of the Gearing
1. For L, M, R or S ratio, loosen the Pinch Bolt (50) and remove the
Dead Handle Assembly (49) and Handle Adapter (48).
2. Remove the Drill Chuck (47) by inserting the Chuck Key in one
of the holes in the Chuck and tapping the Key sharply with a
hammer.
3. Being careful not to distort the Motor Housing (1), grasp the ats
on the Housing in leather-covered or copper-covered vise jaws
with the Gear Case (40) facing upward.
4. Using a wrench on the ats of the Gear Case, loosen, but do not
remove the Gear Case.
NOTICE
In the following step, be sure to hold the tool over a workbench
so that you will not drop or lose parts.
5. Remove the tool from the vise and, while holding the tool
horizontally, carefully unscrew the Gear Case and pull it away
from the Motor Housing.
6. Using snap ring pliers, remove the Gear Retainer (31).
7. For D ratio, remove the Drive Plate (33).
8. For H, J, JJ, K or M ratio, the Rotor Pinion (32) may come out
with the Gear Case, or it may have remained with the Rotor (20)
when the Gear Case was removed. Remove the Rotor Pinion.
9. For R or S ratio, remove the Gear Head Planet Gear Assembly (36),
Gear Head (35) and Gear Head Spacer (34).
For M ratio, remove the Gear Head Planet Gear (37), Gear Head
Planet Gear Bearing (38), Gear Head (35) and Gear Head Spacer (34).
10. Remove the Spindle Planet Gear Assembly (28) or Spindle Planet
Gear (29).
11. Push the Spindle from the Gear Case.
12. If it is necessary to remove the Spindle Bearing (41) from the front
of the Gear Case, use a pair of internal snap ring pliers to remove
the Spindle Bearing Retainer (43). Remove the Bearing Seal (42).
1.
2.
3.
4.
13. Do not remove the Spindle Bearing from the Gear Case unless
it is absolutely necessary and you have a new bearing for
replacement. If you must remove the bearing from the Gear Case,
position the Gear Case vertically in an arbor press, internally
threaded end facing upward. Using a 3/4” (19 mm) diameter
brass rod against the bearing, press the Spindle Bearing from the
Gear Case.
14. Tap the front end of the Gear Case on a workbench to remove the
Grease Shield (44).
15. Remove the and Seal Support (27) from the Spindle.
16. If the Grease Shield Retainer (45) must be removed, insert a thin
blade screwdriver under the tab, and rotary motion, spiral the
Retainer out of the groove in the Gear Case.
Disassembly of the Motor
1. Grasp the splined end of the Rotor (20) in leather-covered or
copper-covered vise jaws and pull the assembled motor from the
Motor Housing (1).
2. Remove the Rear End Plate Gasket (15) from the Motor Housing.
3. Using a wrench, unscrew and remove the Rear Rotor Bearing
Retaining Nut (16).
4. Remove the Rotor from the vise and remove the Bearing Thrust
Washer (17), Rear End Plate (19), Cylinder (22) and Vanes (21).
5. Check the Front Rotor Bearing (24) for damage or roughness. If
replacement is necessary, support the Front End Plate (23) between
two blocks of wood on the table of an arbor press. Using a at face
punch on the inner ring, tap the Bearing out of the End Plate.
Disassembly of the Pistol Grip Motor Housing
1. Carefully grasp the Motor Housing (1) in leather- covered or
copper-covered vise jaws so that the handle is upward.
2. Unscrew and remove the Inlet Bushing Assembly (8).
3. Remove the Muer Assembly (11) and Muer O-ring (12) from
the Muer Assembly.
4. Withdraw the Air Strainer Screen (9), Throttle Valve Spring (7) and
Throttle Valve (6) from the housing handle.
5. Withdraw the Trigger Assembly (3).
6. Remove the Muer Element (13).
7. For R or S ratios, remove the Muer Element (14).
NOTICE
In the following step, only remove the Throttle Valve Seat (5)
when replacing it or when the Trigger Bushing (2) must be
replaced.
8. To remove the Throttle Valve Seat, insert a wire hook through the
central hole of the Seat and hooking the underside of the Seat,

45612702_ed2 3
pull the Seat out of the Motor Housing.
9. Before removing the Trigger Bushing (2), all Seals and
components must be removed from the Motor Housing.
Grasp the Motor Housing in copper–covered vise jaws with
the Trigger Bushing upward.
a.
CAUTION
In the following step, apply enough heat to warm the Housing,
but do not exceed 200°F. Do not apply heat directly to the
Skinsulate covering. Take all precautions necessary to avoid
being burned during the following procedure.
b. Using a torch, apply heat to the Motor Housing around the
Bushing.
c. Thread a 10-32 tap into the Bushing and pull the Bushing out
of the Housing with the tap.
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
installing the bearing in 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.
Assembly of the Pistol Grip Motor Housing
1. If the Trigger Bushing (2) was removed, proceed as follows:
Put a few drops of Loctite* No. 601 Sealant on the end of a
thin stick and insert the stick into the trigger bushing hole of
the Motor Housing. Work the stick so that the Sealant ows
against the shoulder inside the Housing.
Insert the Trigger Bushing into the Motor Housing (1) to a
depth approximately one-half the length of the Bushing.
Put a few drops of Loctite No. 601 Sealant in the counterbore
surrounding the outside diameter of the Bushing.
Rotate the Bushing approximately 180 degrees to make
certain the Sealant makes complete contact around the
outside of the Bushing.
Push the Bushing into the Housing until it bottoms against the
shoulder inside the Housing.
Allow the Sealant to cure for eight hours at room temperature.
2. Carefully grasp the Motor Housing in leather-covered or copper-
covered vise jaws, inlet end facing upward.
3. If the Throttle Valve Seat (5) was removed, use a at-faced
rod 1/2”(13 mm) in diameter by 3” (76 mm) long to push the Seat
into the Motor Housing until it seats.
4. Press the Trigger (3) onto the grooved end of the Trigger Pin so
that it is at right angles to the hole in the opposite end of the Pin.
5. Insert the Trigger Assembly into the Trigger Bushing so that the
hole in the Trigger Pin aligns dead center with the hole in the
Throttle Valve Seat.
6. For R and S ratios, work the Muer Element (14) into the
exhaust cavity in the handle of the Motor Housing.
7. Fold or roll the Muer Element (13) and work it into the exhaust
cavity in the handle of the Motor Housing.
8. Using needle nose pliers to hold the short stem end of the
Throttle Valve (6), install the Valve inserting the long stem end
through the hole in the Throttle Valve and Trigger Pin.
9. Place the Air Strainer Screen (9), closed end rst, inside the large
end coil of the Throttle Valve Spring (7).
10. Insert the Throttle Valve Spring and Screen, small coil end rst, so
that the Spring encircles the end of the Throttle Valve.
11. Apply a thin coat of O-ring lubricant to the Muer O-ring (12)
and install the O-ring on the hub of the Muer (11).
a.
b.
c.
d.
e.
f.
12. Install the Inlet Bushing Spacer (10) in the large hole in the
Muer Assembly (11).
13. Place the Muer Assembly on the face of the handle so that the
hub with the Muer O-ring extends into the handle.
14. Thread the Air Inlet Bushing (8) into the large hole in the Muer
Assembly. Tighten the Bushing to a minimum of 26 ft-lb (35 Nm)
torque.
Assembly of the Motor
1. If the Rear Rotor Bearing (18) was removed, use a sleeve that
contacts the outer ring of the Rear Rotor Bearing and press the
Rear Rotor Bearing into the Rear End Plate (19).
* Registered trademark of Loctite Corporation.
2. Place the Rear End Plate, bearing end trailing, on the threaded
hub of the Rotor (20). Insert a 0.001” feeler gauge or shim
between the face of the Rotor and End Plate. Place the Bearing
Thrust Washer (17) on the threaded hub of the Rotor. Thread the
Rear Rotor Bearing Retaining Nut (16) onto the hub of the Rotor
and tighten it until the feeler gauge has a slight drag during
removal. Remove the feeler gauge.
NOTICE
The Rotor must spin freely while holding the End Plate.
3. Lightly grasp the threaded hub of the Rotor in leather–covered or
copper–covered vise jaws with the splined hub upward.
4. Wipe each Vane (21) with a lm of light oil and place a Vane in
each slot in the Rotor.
5. Looking down the axis of the Rotor and Cylinder (39), position the
Cylinder over the Rotor with the cylinder dowel hole at twelve
o’clock, the notch in cylinder face at ten o’clock and the two slots
in the side of the Cylinder at two o’clock. Place the Cylinder down
over the Rotor and Vanes and against the Rear End Plate.
6. Push the Front Rotor Bearing (24) into the recess in the Front End
Plate (23).
NOTICE
Before pressing the Bearing onto the rotor shaft in the next step,
align the cylinder dowel hole in the Rear End Plate, Cylinder and
Front End Plate. After pressing the Bearing onto the shaft, lightly
rap the end of the splined hub with a plastic hammer to relax
the load on the Bearing. The Rotor must rotate in the Bearing
without drag.
7. Remove the assembled Rotor from the vise and using a sleeve
that contacts the inner ring of the Front Rotor Bearing, press the
Bearing, at side of the Front End Plate rst, onto the rotor shaft.
8. Position the Rear End Plate Gasket (15) in the bottom of the
motor housing bore so that the dowel hole and air inlet port in
the Gasket align with the dowel hole and air inlet in the housing
bore face.
9. Using an assembly dowel 3/32”in diameter by 10” long
(2.3 mm x 254 mm), align the dowel holes in the Front End Plate,
Cylinder and Rear End Plate. Insert the assembly rod through the
aligned holes so that about 3”(76 mm) of the rod extends beyond
the Rear End Plate. Insert the extension into the dowel hole at the
bottom of the housing bore, and slide the motor into the Motor
Assembly

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Troubleshooting Guide
Trouble Probable Cause Solution
Loss of Power Low air pressure Check air supply. For top performance, the air pressure must
be 90 psig (6.2 bar/620 kPa).
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 a 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 them as instructed.
Leaky Throttle Valve Worn Throttle Valve and/or Throttle Valve Seat Install a new Throttle Valve and/or Throttle Valve Seat.
Dirt accumulation on Throttle Valve and/or
Throttle Valve Seat
Pour about 3 cc of a clean, suitable cleaning solution into the air inlet
and operate the tool for about 30 seconds. Immediately, pour 3 cc
of the recommended oil into 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 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 03539707.
Parts Information Manual 45612694.
Manuals can be downloaded from ingersollrandproducts.com
Housing until it seats.
10. Withdraw the assembly dowel and insert the Cylinder Dowel (25)
until the Cylinder Dowel is slightly below the surface of the Front
End Plate.
Assembly of the Gearing
1. Stand the Gear Case (39), end with the ats upward, on a
workbench.
2. If the Shield Retainer (45) was removed, install it in the second
groove below the front face of the Gear Case.
3. Place the Grease Shield (44) in the Gear Case so that it butts
against the Shield Retainer.
4. Using a sleeve that contacts the outer ring of the Bearing, press
the Spindle Bearing (41) into the Gear Case until it butts against
the Grease Shield. Install the Spindle Bearing Seal (42).
5. Using snap ring pliers, install the Spindle Bearing Retainer (43)
against the Bearing Seal and into the groove in front of the
Spindle Bearing.
6. Turn the Gear Case over so that the internal threaded end faces
upward.
7. Install the Seal Support (27), large end rst, over the hub of the
Spindle (26).
8. Slide the Spindle into the Gear Case, threaded end rst, until the
Seal Support contacts the inner ring of the Spindle Bearing.
9. For D ratio, align the three holes in the Drive Plate (33) with the
spindle pins and install the Drive Plate on the pins of the Spindle.
10. For H Ratio, push the Spindle Planet Gear Bearings (30) into the
Spindle Planet Gears (29). Grease the assembled Spindle Planet
Gears and Bearings and install them on the pins of the Spindle.
11. For J, JJ, K, L, M, R or S ratio, grease the bearings and gears of
the Spindle Planet Gear Assemblies (28) and install them on the
pins of the Spindle.
12. For M, R or S ratio, install the Gear Head Spacer (34) in the Gear
Case against the Spindle Planet Gears.
13. For M, R or S ratio, grease the splined hub of the Gear Head
(35) and insert it into the Gear Case. The splined hub must pass
through the Gear Head Spacer and mesh with the teeth of the
Spindle Planet Gears.
14. For M ratio, push the Gear Head Planet Gear Bearings (38) into
the Gear Head Planet Gears (37). Grease the assembled Gear
Head Planet Gears and Bearings and install them on the pins of
the Gear Head.
15. For R or S ratio, grease the bearings and gears of the Gear Head
Planet Gear Assemblies (36) and install them on the pins of the
Gear Head.
16. For H or J ratio, grease the Rotor Pinion (32) and install it in the
center of the Spindle Planet Gears. Make certain the teeth of the
Pinion and Planet Gears mesh.
For M ratio, grease the Rotor Pinion (32) and install it in the center
of the Gear Head Planet Gears. Make certain the teeth of the
Pinion and Planet Gears mesh.
17. Using snap ring pliers, install the Gear Retainer (31) in the shallow
internal groove in the Gear Case behind the Drive Plate, Spindle
Planet Gears or Gear Head Planet Gears.
18. Thread the assembled Gear Case onto the assembled Motor
Housing until it is hand tight. Make certain the gear teeth on the
Spindle mesh with the gear teeth of the Rotor Pinion, Gear Head
Planet Gears or Spindle Planet Gears.
NOTICE
After hand tightening the Gear Case, run the motor at free speed
on low air pressure while nal tightening the Gear Case. Listen
while tightening to make certain the gears mesh properly.
19. Tighten the Gear Case between 30 and 35 ft–lb (41 and 47 Nm)
torque.
20. For D, H, J, JJ, K or L ratio, install one Drill Chuck Spacer (46)
onto the drill spindle.
For M, R or S ratio, install two Drill Chuck Spacers (46) onto the
drill spindle.
21. Thread the Drill Chuck (47) onto the drill spindle and tighten.
22. For L, M, R or S ratio, install the Dead Handle Adapter (48) and
Dead Handle Assembly (49) onto the front end of the Gear Case.
Tighten the Pinch Bolt (50) between 10 and 20 in. lb
(1.4 and 2.3 Nm) torque.

Notes:

Notes:

Notes:

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