Ingersoll-Rand MULTI-VANE M004 Series User manual
Refer All Communications to the Nearest
Ingersoll--Rand Office or Distributor.
Ingersoll--Rand Company, 2001
Printed in U.S.A.
03535812 Form P6855
Edition 4
April, 2001
OPERATION AND MAINTENANCE MANUAL
for
SERIES M004 MULTI--VANEAIR MOTORS
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ THIS MANUAL BEFORE OPERATING TOOL.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
S
Always operate, inspect and maintain this motor in
accordance with American National Standards
Institute Safety Code for Portable Air Tools
(ANSI B186.1).
S
For safety, top performance and maximum
durability of parts, operate this motor at 90 psig
(6.2 bar/620 kPa) air pressure at the inlet with 5/16”
(8 mm) air supply hose.
S
Always turn off the air supply and disconnect the
air supply hose before installing, removing or
adjusting any accessory on this motor.
S
Keep hands, loose clothing and long hair away from
rotating end of motor.
S
Anticipate and be alert for sudden changes in
motion during start up and operation of any
motor.
S
Motor shaft may continue to rotate briefly after the
throttle is released.
S
Do not lubricate motor with flammable or volatile
liquids such as kerosene, diesel or jet fuel.
S
Do not remove any labels. Replace and damaged
label.
S
Use accessories recommended by Ingersoll--Rand.
S
This motor is not designed for working in explosive
atmospheres.
S
This motor is not insulated against electric shock.
TheuseofotherthangenuineIngersoll--Randreplacementpartsmayresultinsafetyhazards,decreasedtoolperformance
and increased maintenance, and may invalidate all warranties.
Ingersoll--Rand is not responsible for customer modification of tools for applications on which Ingersoll--Rand was not
consulted.
Repairs should be made only by authorized, trained personnel. Consult your nearest Ingersoll--Rand Authorized
Servicenter.
It is the responsibility of the employer to place the information in this manual into the hands of the operator.
All manuals and user guides at all-guides.com
2
WARNING LABEL IDENTIFICATION
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
Always wear eye protection
when operating or perform-
ing maintenance on this
motor.
WARNING WARNING
Always wear hearing
protection when operating
this motor.
Always turn off the air supply
and disconnect the air supply
hose before installing, removing
or adjusting any accessory on
this motor, or before performing
any maintenance on this motor.
WARNING
WARNING
Do not use damaged, frayed
or deteriorated air hoses
and fittings.
WARNING
Operate at 90 psig (6.2 bar/
620 kPa) Maximum air pressure.
90 psig
(6.2bar/620kPa)
PLACING TOOL IN SERVICE
LUBRICATION
Ingersoll--Rand No. 10 Ingersoll--Rand No. 28
We recommend the use of an air line lubricator in the air
supply line. Attach the unit as close to the tool as practical.
Where the lubricator cannot be permanently mounted, we
recommend using an Ingersoll--Rand No.
L18--03--LK00--28 Lubricator.
For permanent installations, we recommend using an
Ingersoll--Rand No. C18--03--FKG0--28
Filter--Lubricator--Regulator unit. These units have 3/8”
pipe tap inlet and outlet and 5/16 pint (148 ml) oil capacity.
Larger capacity units may be used, but do not use a unit
having less than a 3/8” pipe tap inlet and outlet.
After each forty hours of operation, or as experience
indicates,
remove the Gear Case Grease Screw (16) and
inject 1.5 cc of the recommended grease into the opening.
Do not grease excessively. Too much grease in the Gear
Case (15) will cause heating. Grease leakage from the
spindle end is also an indication that an excessive amount
of grease has accumulated within the Gear Case.
Whenever the gear end of the Motor is disassembled,
lubricate the gear train as follows:
For gear ratio 000:1,
work approximately 19 cc of the
recommended grease into and around the Bearings (35) and
on the Spindle (27).
For gear ratios 004:1 and 006:1,
work approximately 19 cc
of the recommended grease into the gearing and around the
Bearings (31 and 35) and on the Spindle (27).
For gear ratios 011:1, 015:1, 023:1 and 033:1,
work
approximately 22 cc of the recommended grease into the
gearingandaroundtheBearings(19,21,29,31and35)andon
the Spindle (27).
Forgearratios050:1,083:1and167:1,
workapproximately
26 cc of the recommended grease into the gearing and around
the Bearings (21, 25, 29, 31 and 35) and on the Spindle (27).
For continuous operation:
Continuous operation of geared motors generates heat which
can cause grease to dry out and cake. The addition of fresh
grease temporarily rectifies this problem. However, a small
amount of oil should be added to the grease to replace the oil
which was lost during continuous operation. The oil creates a
slurry which makes the grease less likely to dry out and cake.
After each eight hours of continuous operation or as
experience indicates,
add ten drops of the recommended oil
to the opening of each grease screw or grease fitting.
All manuals and user guides at all-guides.com
3
PLACING TOOL IN SERVICE
OPERATION
For optimum performance, the air source and supply lines
must be capable of maintaining 90 psig (6.2 bar/620 kPa)
air pressure at the Motor. Hoses that are 5/16” (8 mm)
diameter or larger are necessary for ample air flow to each
Motor.
Reversible Motors require the use of a 4--way valve, or two
3--way valves in the supply line because the reverse air inlet
port becomes an auxiliary port when the Motor operates in
forward rotation. In reverse, the forward inlet becomes the
auxiliary exhaust port.
An example of each method is illustrated in Dwg. TPB854.
Single Four--Way Valve for Controlling Forward and Reverse Operation of Motor
Two Three--Way Valves for Controlling Forward and Reverse Operation of Motor
(Dwg. TPB854)
All manuals and user guides at all-guides.com
4
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7
MODEL IDENTIFICATION
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0
2
3
(
2
3
:
1
)
0
3
3
(
3
3
:
1
)
0
5
0
(
5
0
:
1
)
0
8
3
(
8
3
:
1
)
1
6
7
(
1
6
7
:
1
)
M 004 RV R 023 A R3
All manuals and user guides at all-guides.com
8
MAINTENANCE SECTION
Always use protective eyewear when performing main-
tenance on a motor or when operating a motor.
Always turn off the air supply and disconnect the air
supply line before installing, removing or adjusting
any accessory on this motor or before performing any
maintenance on this motor. Failure to do so could re-
sult in injury.
DISASSEMBLY
General Instructions
1. Do not disassemble the motor any further than neces-
sary to replace or repair damaged parts.
2. Do not disassemble the motor unless you have a com-
plete set of new gaskets and o--rings for replacement.
3. When grasping a tool in a vise, always use leather--
covered or copper--covered vise jaws to protect the
surface of the part or motor and help prevent distor-
tion. 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 neces-
sary for repairs or replacement.
Disassembly of the Motor
1. Clamp a large adjustable wrench in vise jaws with the
adjustable opening upward.
2. Adjust the jaw of the wrench to clear the body of the
Gear Case (14).
3. Roll the motor in the wrench jaw until it stops against
the Gear Case Grease Screw (15) and, using a wrench
on the flats of the Coupling Nut (33) at the flange end
of the Gear Case, loosen the Coupling Nut.
4. Roll the motor in the opposite direction until it stops
against the Gear Case Grease Screw and, using a
wrench on the flats of the Coupling Nut at the flange
end of the Gear Case, loosen the Coupling Nut.
5. Holding the motor horizontally over a workbench,
unscrew the Coupling Nut at the motor end of the
Gear Case and pull the motor from the Gear Case.
Do not lose the Flange Key (42).
6.
For Models with Square Drive Adapter (27A),
using a hex wrench, unscrew and remove the two
Adapter Screws (27B).
7. Unscrew the Coupling Nut and pull the Flange As-
sembly and the Spindle (27) out the of Gear Case.
Once the Spindle is removed from the Gear Case, the
entire gear train must be disassembled to install the
Spindle Planet Gears (28) or the Spindle Planet Gear
Assemblies (30) on the opposite end of the Spindle.
Do not lose the Flange Key.
8.
For Models with Square Drive Adapters,
carefully
grasp the Spindle in copper--covered vise jaws and
using a wrench on the square drive, unscrew and re-
move the Adapter.
9. Push the Spindle out the gear end of the Flange As-
sembly.
10. Remove the Spindle Seal (41) and Flange Seal (40)
from the inside of the Flange (39).
11. Using snap ring pliers, remove the Spindle Retaining
Ring (37) and pull the two Spindle Bearings (35) and
the Spindle Bearing Spacer (36) from the shaft of the
Spindle. Remove the second Spindle Retaining Ring.
12. Remove the Motor Clamp Washer (13) from the Gear
Case.
13.
For Models with 000 ratios,
pull the Spindle Drive
Plate (32) from the Gear Case.
For Models with 006 ratios,
pull the three Spindle
Planet Gear Assemblies (30) from the Gear Case.
For Models with 004 ratios,
pull the Rotor Pinion
(16) and the three Spindle Planet Gear Assemblies
(30) from the Gear Case.
For Models with 011 ratios,
pull the Rotor Pinion
(16), three Gear Head Planet Gears (18), three Planet
Gear Bearings (19), Gear Head (17), Gear Head
Spacer (26), three Spindle Planet Gears (28) and three
Spindle Planet Gear Bearings (29) from the Gear
Case.
For Models with 015 ratios,
pull the Rotor Pinion
(16), three Gear Head Planet Gear Assemblies (20),
Gear Head (17), Gear Head Spacer (26) and three
Spindle Planet Gear Assemblies (30) from the Gear
Head.
For Models with 023 ratios,
pull the three Gear
Head Planet Gear Assemblies (20), Gear Head (17),
Gear Head Spacer (26), four Spindle Planet Gears
(28) and four Spindle Planet Gear Bearings (29) from
the Gear Case.
For Models with 033 ratios,
pull the three Gear
Head Planet Gear Assemblies (20), Gear Head (17),
Gear Head Spacer(26) and three Spindle Planet Gear
Assemblies (30) from the Gear Case.
For Models with 050 ratios,
pull the Rotor Pinion
(16), three Gear Head Planet Gear Assemblies (20),
Gear Head (17), Gear Head Spacer (22), three Inter-
mediate Gear Head Planet Gear Assemblies (24),
Intermediate Gear Head (23), Gear Head Spacer (26),
three Spindle Planet Gears (28) and three Spindle
Planet Gear Bearings (29) from the Gear Case.
For Models with 083 ratios,
pull the three Gear
Head Planet Gear Assemblies (20), Gear Head (17),
Gear Head Spacer (22), three Intermediate Gear Head
Planet Gear Assemblies (24), Intermediate Gear Head
(23), Gear Head Spacer (26), three Spindle Planet
Gears (28) and three Spindle Planet Gear Bearings
(29) from the Gear Case.
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9
MAINTENANCE SECTION
For Models with 167 ratios,
pull the three Gear
Head Planet Gear Assemblies (20), Gear Head (17),
Gear Head Spacer (26), three Intermediate Gear Head
Planet Gear Assemblies (24), the Intermediate Gear
Head (23), Gear Head Spacer (26) and three Spindle
Planet Gear Assemblies (30) from the Gear Case.
14. Using a thin blade screwdriver, pry one of the Cou-
pling Nut Retainers (34) out of the Groove in the
Gear Case and slide the two Coupling Nuts off the
Gear Case.
15. Grasp the shaft of the Rotor (6) in copper--covered
vise jaws and pull the Motor Housing (1) off the as-
sembled motor unit.
16. Pull the Front End Plate Assembly off the Rotor.
17. Remove the two Front End Plate Seals (11) from the
Front End Plate (10).
18. Push the Front Rotor Bearing (12) out of the Front
End Plate.
19. Separate the Cylinder (8), Vanes (7) and Cylinder
Dowel (9) from the Rotor.
20. Remove the Rear End Plate Gasket (4) from inside
the Motor Housing.
21. If the Rear Rotor Bearing (3) or Rear End Plate (5)
must be replaced, use a wrench to remove the Rear
Rotor Bearing Retaining Nut (2).
22. Supporting the End Plate near the rotor body on the
table of an arbor press, press the Rotor from the End
Plate and Bearing.
ASSEMBLY
General Instructions
1. Keep work area and tools neat and clean. Do not
remove protective covering from parts, especially
bearings, until the time of installation.
2. Unless otherwise noted, always press on the stamped
end of a needle bearing when installing needle bear-
inginarecess.
3. Always press on the inner ring of a ball--type bearing
when installing the bearing on a shaft.
4. Always press on the outer ring of a ball--type bearing
when installing the bearing in a bearing recess.
5. Check every bearing for roughness. If an open bear-
ing must be cleaned, wash it thoroughly in clean sol-
vent and dry it with a clean cloth. Work grease thor-
oughly into every open bearing before installation.
Sealed or shielded bearings should ever be cleaned.
6. Except for bearings, always clean every part and wipe
every part with a thin film of oil before installation.
7. When grasping a Motor or one of its parts in a vise,
always use leather or copper vise jaws covers to pro-
tect the surface of the part and reduce the likelihood
of damage. This is particularly important when
clamping threaded members, shafts with splines, etc.
8. Apply O--ring lubricant to each O--ring before assem-
bly and use only new gaskets when reassembling the
Motor.
Assembly of the Motor
1. Place the Rear End Plate (5), porting slots leading,
onto the threaded hub of the Rotor (6). Position the
Rear Bearing (3) on the hub and using a sleeve that
contracts the inner ring of the Bearing, press the
Bearing onto the hub to within 1/32” (1 mm) of the
Rear End Plate.
2. Place the Retaining Nut Washer (2A) over the hub
against the Bearing. Insert a 0.001” feeler gauge or
shim between the face of the Rotor and End Plate.
Thread the Rear Rotor Bearing Retaining Nut (2)
onto the hub of the Rotor and tighten until the feeler
gauge has a slight drag during removal. The Rotor
must spin freely while holding the End Plate.
3. Lightly grasp the threaded hub of the Rotor in cop-
per--covered vise jaws with the splined hub upward.
4. Wipe each vane (7) with a film of light oil and place a
Vane in each slot in the Rotor.
5.
For reversible models,
align the cylinder dowel hole
in the Cylinder (8) with the hole in the Rear End Plate
and install the Cylinder over the Rotor and Vanes
against the End Plate.
Nonreversible Cylinders have a drill point mark at
one end of the three hole string portion of the five
hole pattern. When the mark is near the Rear
End Plate, rotation will be forward; when near the
Front End Plate, rotation will be reverse.
For nonreversible models,
the installation of the
Cylinder (8) determines the rotational direction of the
motor. Looking past the rotor body and vanes, align
the cylinder dowel hole in the Rear End Plate at
twelve o’clock. There are five holes drilled crosswise
into the Cylinder. Align the cylinder dowel hole in
the Cylinder with the hole in the Rear End Plate and
install the Cylinder over the Rotor and Vanes against
the Rear End Plate. If the five holes are at the three
o’clock side of the assembly, the rotational direction
will be forward (right hand). Rotational direction
will be reverse (left hand), if the holes are at the nine
o’clock side of the assembly. To change rotational
direction, remove the Cylinder, turn it end for end
and reposition it in the assembly.
6. Install the two Front End Plate Seals (11) in the annu-
lar grooves in the Front End Plate (10).
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10
MAINTENANCE SECTION
The Bearing in the following step is a light press
and may require the use of an arbor press.
7. Push the Front Rotor Bearing (12) into the recess in
the Front End Plate.
8. Remove the assembled motor from the vise and,
standing the Rotor on the unsplined end, push the
Front End Plate Assembly, bearing end trailing, onto
the splined shaft of the Rotor until the Front End
Plate just contacts the Cylinder.
9. Align the cylinder dowel holes in the Front End Plate,
Cylinder and Rear End Plate and insert an assembly
dowel (3/32” [2.5 mm] diameter by 9” [230 mm]
long) into the aligned dowel holes in the assembly.
10. Inject 2 cc of the recommended grease into the cen-
tral recess at the bottom of the bore in the Motor
Housing (1).
11. Place the Rear End Plate Gasket (4) at the bottom of
the bore in the Motor Housing. Make certain all
holes and porting align.
12.
For nonreversible models,
insert the end of the as-
sembly dowel nearest the Rear End Plate into the
dowel hole at the bottom of the motor bore in the
Housing. Slide the assembled motor along the as-
sembly dowel until the motor stops against the bot-
tom of the motor bore. Carefully with draw the as-
sembly dowel and install the Cylinder Dowel (9) in
its place. Make certain the Dowel is below the face
of the Front End Plate.
For reversible models,
insert the end of the assem-
bly dowel nearest the Rear End Plate into one of the
dowel holes at the bottom of the motor bore in the
Housing. With the inlet hole at twelve o’clock and
the two cylinder dowel holes at eleven and one
o’clock respectively, inserting the assembly dowel in
the one o’clock hole will orient the motor for for-
ward (right hand) rotation while inserting the assem-
bly dowel in the eleven o’clock hole will orient the
motor for reverse (left hand) rotation. Slide the as-
sembled motor along the assembly dowel until the
motor stops against the bottom of the motor bore.
Carefully withdraw the assembly dowel an install the
Cylinder Dowel (9) in its place. Make certain the
Dowel is below the face of the Front End Plate.
13. Install a Coupling Nut Retainer (34) in one of the
grooves encircling the Gear Case (14).
14. Position the nonthreaded ends of the two Coupling
Nuts (33) against each other and slide them onto the
Gear Case from the end without the Retainer.
15. Install the second Retainer in the remaining groove
encircling the Gear Case.
16. Using snap ring pliers, install one of the Spindle Re-
taining Rings (37) in the annular groove on the
Spindle (27) adjacent to the large hub.
17. In the order named, install a Spindle Bearing (35),
Spindle Bearing Spacer (36) and the remaining
Spindle Bearing on the splined shaft against the
Spindle Retaining Ring. Secure the three parts by
installing the remaining Ring in the groove on the
shaft.
18. Lubricate the Spindle Seal (41) with a thin coat of
Ingersoll--Rand No. 28 Grease and insert it, lip end
trailing, into threaded end of the Flange (39).
19. Insert the Flange Seal (40) into the groove inside the
threaded end of the Flange.
20. Being careful not to damage the Spindle seal, install
the Flange Assembly, threaded end first, over the
Spindle.
21.
For Models with Square Drive Adapter,
carefully
grasp the pin end of the Spindle in copper--covered
vise jaws and thread the Adapter (27A) onto the
Spindle. Install the two Adapter Screws (27B).
22. Align a notch in the Flange with a notch in the Gear
Case and maintain the alignment by installing a
Flange Key in the two notches.
23. Thread the Coupling Nut onto the Flange until it is
hand tight.
24. Insert the pin end of the Spindle into the unsplined
end of the Gear Case and push the large spindle hub
against the spline.
25. If the Planet Gear Bearings (21, 25 or 31) are being
replaced in the Planet Gear Assemblies (20, 24 or
30), use a bearing inserting tool as shown in Dwg.
TPC488 to press the Bearings into the Gears.
(Dwg. TPC844)
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11
MAINTENANCE SECTION
26.
For Models with 000 ratios,
insert the Drive Plate
(32) into the splined end of the Gear Case. Make
certain the spindle pins enter the holes in the Drive
Plate.
For Models with 011, 023, 050, and 083 ratios,
push a Spindle Planet Gear Bearing (29) into each
Spindle Planet Gear (28) and using long tweezers,
install a Bearing and Gear on each spindle gear shaft.
Forallothermodels,
using long tweezers, install a
Spindle Planet Gear Assembly (30) on each spindle
gear shaft.
27.
For Models with 004 ratios,
install the Rotor Pinion
(16) in the center of the three Spindle Planet Gear
Assemblies.
For Models with 011 ratios,
install the Gear Head
Spacer (26) against the Spindle Planet Gears. Push a
Planet Gear Bearing (19) into each Gear Head Plan-
et Gear (18). Install the Gear Head (17), assembled
Gear Head Planet Gears with Planet Gear Bearings
and the Rotor Pinion (16) in the Gear Case (14).
For Models with 015 ratios,
install the Gear Head
Spacer (26) against the Spindle Planet Gear Assem-
blies. Install the Gear Head (17), three Gear Head
Planet Gear Assemblies (20) and Rotor Pinion (16) in
the Gear Case (14).
For Models with 023 and 033 ratios,
install the
Gear Head Spacer (26) against the Spindle Planet
Gears or Spindle Planet Gear Assemblies. Install the
Gear Head (17) and three Gear Head Planet Gear As-
semblies (20) in Gear Case (14).
For Models with 050 ratios,
install the Gear Head
Spacer (26) against the Spindle Planet Gears. Install
the Intermediate Gear Head (23), three Intermediate
Gear Head Planet Gear Assemblies (24), Gear Head
Spacer (22), Gear Head (17), three Gear Head Planet
Gears (20) and Rotor Pinion (16) in the Gear Case
(14).
For Models with 083 and 167 ratios,
install the
Gear Head Spacer (26) against the Spindle Planet
Gears or Spindle Planet Gear Assemblies. Install the
Intermediate Gear Head (23), three Intermediate Gear
Head Planet Gear Assemblies (24), Gear Head Spacer
(22), Gear Head (17) and three Gear Head Planet
Gears (20) in the Gear Case (14).
28. Place the Motor Clamp Washer (13), concave end
leading, against the Planet Gears or Drive Plate.
29. Being careful that the Spindle does not move out of
position, engage the gear case gearing with the
splined shaft of the Rotor.
30. Align the Gear Case with the Motor Housing by
installing a Flange Key (42) to enter the notches in
both the Housing and Gear Case. Hand tighten the
Coupling Nut onto the Motor Housing.
31. Thread the Gear Case Screw (15) into the Gear Case,
if it was removed, and hand tighten it with a hex
wrench.
32. Clamp a large adjustable wrench in vise jaws with the
adjustable opening upward.
33. Adjust the jaw of the wrench to clear the body of the
Gear Case.
34. Roll the Motor in the wrench jaw until it stops against
the Gear Case Grease Screw and, using a torque
wrench on the flats of one Coupling Nut, tighten the
Nut between 45 to 50 ft--lb (61 to 68 Nm) torque.
35. Roll the Motor in the opposite direction untill it stops
against the Gear Case Grease Screw and, using a
torque wrench on the flats of the second Coupling
Nut, tighten the Nut between 45 to 50 ft--lb (61 to 68
Nm) torque.
All manuals and user guides at all-guides.com
TROUBLESHOOTING GUIDE
Trouble Probable Cause Solution
Motor will not operate
Gears binding due to improper
installation. Using a hand torque wrench, turn the output shaft.
If the force needed to turn the shaft exceeds
3--7 in--lbs (.339--.791 N m), the gearing is improp-
erly installed. Disassemble and reassemble the
gearing as instructed in the
Maintenance
section.
Low air pressure at Motor. Check air supply. For top performance, the air
pressure must be 90 psig (6.2 bar/620 kPa) at the
inlet.
Worn Vanes. Install a new set of Vanes.
Loss of power. Damaged Rear End Plate Gasket. Install a new Rear End Plate Gasket.
Inadequate Motor lubrication. Check air line lubricator. Refer to page 2 for
lubrication specifications.
Worn or damaged parts. Disassemble the Motor and examine parts. Replace
any worn or damaged parts.
Motor heats up. Inadequate lubrication. Refer to
Lubrication
sectiononpage2.
Gear Case Heats up. Improper lubrication. Refer to
Lubrication
sectiononpage2.
Grease leakage. ToomuchgreaseintheGearCase. Refer to
Lubrication
sectiononpage2.
SAVE THESE INSTRUCTIONS. DO NO DESTROY.
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