Ingersoll-Rand 100P4 Setup guide

16575425
Edition 1
December 2010
Save These Instructions
Air Pulse Tools
100P4 and 140P6 Models
Maintenance Information

2 16575425_ed1
WARNING
Always wear eye protection when operating or performing maintenance on this tool.
Always turn o the air supply and disconnect the air supply hose before installing, removing or adjusting any accessory on this tool or
before performing any maintenance on this tool.
Note: When reading the instructions, refer to exploded diagrams in parts Information Manuals when applicable (see under Related Documentation
for form numbers).
Disassembly
Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
When 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.
1.
2.
Do not remove any part which is a press t in or on an assembly
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 replacements.
Use impulse Tool Rebuild Tools listed in Table 2 .
3.
4.
5.
Changing The Mechanism Fluid
To change the Mechanism Fluid in the Impulse Mechanism, proceed
as follows:
Using a hex wrench, remove the four mechanism Cover Bolts (71)
and Spring Washers (70). Lift the Mechanism Cover (68) o of the
Motor Housing (1). Remove the mechanism Cover Gasket (43).
Lift the assembled mechanism o the Rotor (39).
Using a 2 mm hex wrench, rotate the Torque Adjustment
Screw clockwise until the Screw stops. Rotate the Screw
counterclockwise until it stops or makes six complete revolutions.
Remove the Oil Plug (61) and Oil Plug Seal (60).
With the oil plug opening downward over a container, rotate
the Drive Shaft to purge the uid from the mechanism. As an
alternate method, using the Syringe from the Fluid Replacement
Kit (Part No. EQ106S-K400), purge the uid from the rst cavity.
Then rotate the Drive Shaft to expose the second cavity and
purge the uid using the syringe.
Using the syringe and uid from the Fluid Replacement Kit (Part
No. EQ106S-K400), ll the mechanism with the uid furnished in
the Kit. (Refer to Dwg. TPD1265)
NOTICE
DO NOT SUBSTITUTE ANY OTHER FLUID. Failure to use the uid
provided could damage the tool, increase maintenance and
decrease performance. Use only clean uid in these tools.
(Dwg. TPD1265)
7. Submerge the ll opening in the remainder of the uid, and using
a wrench, rotate the Drive Shaft to purge any remaining air from
the system.
8. Thread the Oil Plug (61) with the Oil Plug Seal (60) into the
mechanism until it is snug.
9. Using a 2 mm hex wrench, turn the Torque Adjustment Screw
clockwise until it stops. This is the maximum torque position.
1.
2.
3.
4.
5.
6.
10. Wipe the outside of the mechanism dry and clean and remove
the Oil Chamber Plug. Using the syringe, withdraw 1.2 cc of uid
for models 100P4 and 130P4 and 1.3 cc for model 140P6.
11. Install the Oil Plug and tighten it between 20 and 25 in-lb (2.3 and
2.8 Nm) torque.
12. Position a new Mechanism Cover Gasket (43) on the Motor
Housing and install the assembled mechanism on the rotor
shaft (39).
13. Place the mechanism Cover (68) Bushing (67) and Washer (66)
over the Drive Shaft against the Housing and Gasket. Install the
four Mechanism Cover Cap Screws and Lock Washers. Tighten
each Screw between 45 and 50 in-lb (5.1 and 5.6 Nm) torque.
Disassembly of the Impulse Mechanism
Remove the Mechanism Cover Bolts (71) and Spring Washers (70)
and lift the Mechanism Cover (68) o the Motor Housing (1).
Pull the mechanism assembly out of the Cover.
With the oil plug opening downward over a container, rotate the
drive shaft to purge the oil from the mechanism. As an alternate
method, using the syringe from the Fluid Replacement Kit (Part
No. EQ106S-K400), purge the uid from the rst cavity. Then
rotate the Drive Shaft to expose the second cavity and purge the
uid using the syringe.
Grasp the ats of the Liner Case (64) in vise jaws with the output
end of the Drive Shaft downward.
Insert the pins of the Housing Cap Spanner Plug from the Tool
Kit into the holes in the Housing Cap (44). Using a wrench on
the plug, unscrew and remove the Liner Cap from the Housing
Assembly. (Refer to Dwg. TPD1267)
SPANNER PLUG
HOUSING CAP COUNTERCLOCKWISE TO LOOSEN
(Dwg. TPD1267)
1.
2.
3.
4.
5.

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6. Stand the Disassembly Arbor from the Tool Kit, large end
downward, on a workbench or the table of an arbor press. Insert
the output end of the Drive Shaft into the central opening and
either tap the Housing downward o the components or use the
Pressing Sleeve in the Tool Kit to press the Housing downward o
the components. (Refer to Dwg. TPD1268)
PRESSING
SLEEVE
HOUSING
TAP EDGE LIGHTLY
WITH BRASS HAMMER
OR USE PRESSING
SLEEVE FROM TOOL
KIT
DISASSEMBLY ARBOR
FROM TOOL KIT
(Dwg. TPD1268)
7. Disassemble the components of the mechanism in the sequence
shown in manual 16574782.
Disassembly of the Motor
Grasp the Motor Housing (1) in vise jaws with the Motor Housing
Cover (31) up.
Remove the Motor Housing Cover Bolts (28). Remove the Motor
Housing Cover and Motor Housing Cover Gasket (32) from the
Motor Housing.
Secure the Motor Housing in vise jaws with the motor bore in a
horizontal position and handle pointing down. Using a plastic
hammer, lightly tap the Housing surrounding the motor bore to
loosen the motor. Tap Front End Plate and take the assembled
motor out of the Motor Housing.
Remove the Front End Plate (41), Front End Plate Bearing (42),
Cylinder Assembly (37) and Vanes (40) from the Rotor.
On the table of an arbor press, support the Rear End Plate (36)
with blocks as close to the Rotor as possible and press the Rotor
out of the Rear End Plate and Rear Rotor Bearing (35).
To remove the Rear Rotor Bearing from the Rear End Plate, use a
small drift or pin punch through the central opening of the Rear
End Plate to tap the Bearing out of the End Plate. (Refer to
Dwg. TPD1271)
NOTICE
Do not enlarge or damage the shaft hole in the End Plate.
1.
2.
3.
4.
5.
6.
(Dwg. TPD1271)
Disassembly of Throttle and Exhaust Element
Remove Rubber Grip (11).
Using a pin punch, tap the Throttle Retaining Pin (12) out of the
Handle. The Throttle Retaining Pin is protected by an embossed
circular pad of metal. Insert the pin punch into the middle of the
pad to locate the Pin. (Refer to Dwg. TPD1272)
(Dwg. TPD1272-1)
3. Grasp the Trigger (24) and pull the assembled throttle out of the
Motor Housing.
4. Using a pin punch and without damaging the Trigger, remove the
Trigger Pin (23). Slide the Trigger o of the shaft of the Throttle
Rod (14).
5. Grasp the Reverse Lever (25) and pull the Reverse Valve (27) from
the front of the Throttle Bushing Assembly.
6. Remove the Throttle Rod Assembly from the rear of the Throttle
Bushing.
7. Remove Throttle Rod O-ring (13) from the Throttle Rod.
8. If it is necessary to replace the Reverse Lever or Reverse Valve,
use a pin punch to tap out the Reverse Lever Pin (26) out of the
Reverse Lever. Separate the Reverse Lever from the Reverse Valve.
9. Unscrew and remove the Hose Joint (5).
10. This will allow the Exhaust Cover (8) and Exhaust Elements (9, 9A,
9B) to be removed from the Hose Joint.
11. Remove the O-ring (10) from the Motor Housing.
1.
2.
Assembly
General Instructions
When 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.
Always press on the inner ring of a ball-type bearing when
installing the bearing on a shaft.
1.
2.
Always press on the outer ring of a ball-type bearing when
pressing the bearing into a bearing recess.
Except for bearings and mechanism parts, always clean every part
and wipe every part with a thin lm of oil before installation.
Wipe a thin lm of mechanism uid on all internal mechanism
components before installing them in the mechanism.
Apply a lm of O-ring lubricant to every O-ring before installation.
3.
4.
5.
6.

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Assembly of the Motor, Throttle and Exhaust Element
Install the Exhaust Element (9, 9A) over the Exhaust Element (9B)
and insert both inside the Exhaust Cover (8). Install the Exhaust
Cover containing both Elements on the Hose Joint until it seats.
Install the O-ring (10) in the Motor Housing (1).
Thread the Hose Joint with the Exhaust components into the
Motor Housing and tighten to 18-26 ft-lb (25-35 Nm) torque.
Install the Throttle Rod Seal (13) in the groove on the large hub of
the Throttle Rod (14).
Put the Reverse Lever (25) on the Reverse Valve (27) and secure it
with the Reverse Lever Pin (26).
Start the Reverse Valve into the Throttle Bushing (19). Install
the Reverse Lever Detent Spring (21) in the hole in the Bushing.
Set the Reverse Lever Detent Ball (22) on the Spring and while
holding it in place, align the Ball with the detent hole in the
Bushing. Push the Valve into the Bushing until the Reverse Lever
Detent Ball seats in the detent hole.
Insert the Throttle Rod, shaft end rst, through the rear of the
Throttle bushing and through the Reverse Valve so that the hub of
the Throttle Rod seats against the end of the Throttle Bushing.
Install the Trigger (24) on the Throttle Rod and secure it with the
Trigger Pin (23).
Install the Throttle Retaining Pin (12) in the Housing, making sure
that it captures the Throttle Bushing Assembly.
Using an arbor press and the End Plate Jig that contacts the outer
ring of the bearings, press the Front End Plate Bearing (42) into
the Front End Plate (41) and the Rear End Plate Bearing (35) into
the Rear End Plate (36). (Refer to Dwg. TPD1274)
END PLATE
TUBING
BEARING
(Dwg. TPD1274)
11. Stand the Rotor (39) on the table of an arbor press. It should be
upright on a at metal plate having a clearance hole for the shaft.
The shaft with the hex must be upward.
12. Place a 0.001”(0.025 mm) shim on the upward surface of the large
portion of the rotor body. Using a piece of tubing that contacts
the inner ring of the bearing, press the Rear Rotor Bearing and
Rear End Plate onto the shaft of the Rotor until the End Plate
contacts the shim. Remove the shim. (Refer to Dwg. TP2202)
BALL BEARING
ROTOR
END PLATE JIG
SHIM SPACE
(0.02~0.03mm)
REAR END PLATE
(Dwg. TP2202)
13. Coat each Vane (40) with a thin lm of oil and insert a Vane into
each of the rotor vane slots with the straight edge of the Vane
outward.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
14. Install the Cylinder (37) over the Vanes and Rotor with the end of
the Cylinder having the Rear End Plate Alignment Pin (38). Make
certain the Pin enters the hole in the face of the Front End Plate.
(Refer to Dwg. TP2203).
ROTOR PIN
PIN
VANE
CYLINDER
BALL BEARING
BALL
BEARING
FRONT
END PLATE
REAR END PLATE
(Dwg. TP2203)
15. Place the Front End Plate and Bearing against the face of the
Cylinder, Bearing end trailing.
16. Install the Motor Housing Cover O-rings (33) in the grooves in the
rear of the Motor Housing.
17. Insert the assembly into the rear of the Motor Housing. It may be
necessary to tap the assembly into position with a brass or plastic
hammer.
18. Install the Motor Housing Cover Gasket (32) and Motor Housing
Cover (31) on the rear of the Motor Housing. Secure it with the
motor Housing Cover Bolts (28). Tighten to 40-50 in-lb (5.1-
5.6 Nm) torque.
MOTOR
ASSEMBLY
(Dwg. TP2204)
Assembly of the Impulse Mechanism
Insert the Relief Valve (49, 50, 51, 52, 53) into the Liner (48) as
shown in manual 16574782.
Place a Blade (54) into one of the slots of the Drive Shaft (56) with
the assembly holes inward.
From the opposite side of the Shaft, set a Blade Spring (55, 55A, or
55B) in the hole of a blade.
Compress the Springs with the Blades until both Blades are ush
with the Drive Shaft and install the assembly in the Liner with the
output end of the Drive Shaft protruding out the end of the Liner
containing Adjust Bolt. Make certain the ends of the Blades are
ush with the ends of the Liner. (Refer to Dwg. TPD1284).
(Dwg. TPD1284)
1.
2.
3.
4.

16575425_ed1 5
5A. For 100P or 130P:
Install the Drive Shaft Seal (57) rst and then Seal Back-up Ring (58)
on the Drive Shaft against the hub. (Refer to Dwg. TPD1285)
SEAL BACK- UP RING
DRIVE SHAFT SEAL
(Dwg. TPD1285)
5B. For 140P:
Install Drive Shaft Seal (57), Back-Up Ring (58) and Washer (63C) in
order, to Front Liner Cover. Afterward, set the Retaining
Ring (63B) in the groove.
6. Align the pin holes in the face of the Rear Liner Cover (45) with
the two Liner Pins (47) at the rear of the Liner and place the Cover
against the Liner. A groove will be formed on Liner Cover. Do not
attempt to put the Seal in the groove at this time.
7. Install O-ring (52) and Back-Up Ring (53) to the Adjust Bolt (51).
8. Align the pin holes in the Front Liner Cover (59) with the Pins in
the front face of the Liner and place the Cover against the face of
the Liner. Stand the assembly on the workbench with the output
end of the Drive Shaft upward. (Refer to Dwg. TPD1288)
LINER SEALS
(Dwg. TPD1288)
9. Apply a thin lm of grease to the Liner O-rings (63).
10. Lubricate the Liner Cover O-ring (46) and install it in the groove
on the Liner Upper Plate (45).
11. Lubricate the Front Liner Seal (63) and put it on the Front Liner
Cover after orienting the Housing to the proper position, install
the Housing over the Liner.
12. Grasp the ats of the Housing (64) in vise jaws with the output
spindle downward. (Refer to Dwg. TPD1289)
GREASE
(Dwg. TPD1289)
13. Install Liner Upper Plate (45) and use a hex socket to push it
below the threads at the rear of the Housing. (Refer to
Dwg. TPD1290)
PUSH DOWN
(Dwg. TPD1290)
14.
Install the Liner Cap (44) and using the Housing Cap Spanner Plug
furnished in the Tool Kit, tighten the Cap 100P - 200 Nm (148 ft-lb),
130P - 220 Nm (163 ft-lb) and 140P - 240 Nm (177 ft-lb). (Refer to
Dwg. TP2205)
LINER
CAP
HOUSING CAP
SPANNER PLUG
LINER
CASE
(Dwg. TP2205)
15. Make certain the Drive Shaft rotates freely and then ll the
mechanism with uid and reassemble the tool as instructed in
the section, CHANGING THE MECHANISM FLUID.

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Table 2 - Impulse Tool Rebuild Tools
Tool Name Part Number Tool Kit Number Model Used On
Housing Cap Spanner Plug 100P4-A-HCT 100P4-99 and 130P4-99 100P4 and 130P4
Housing Cap Spanner Plug 140P6-A-HCT 140P6-99 140P6
Disassembly Arbor 100P4-B-HA 100P4-99 and 130P4-99 100P4 and 130P4
Disassembly Arbor 140P6-B-HA 140P6-99 140P6
Pressing Sleeve 100P4-C-HA 100P4-99 100P4
Pressing Sleeve 130P4-C-HA 130P4-99 130P4
Pressing Sleeve 140P6-C-HA 140P6-99 140P6
End Plate Jig 100P4-H-HA 100P4-99 100P4
End Plate Jig 130P4-H-HA 130P4-99 130P4
End Plate Jig 140P6-H-HA 140P6-99 140P6
Related Documentation
For additional information refer to:
Product Safety Information Manual 04584983.
Product Information Manual 80167547.
Maintenance Information Manual 16574782.
Manuals can be downloaded from www.ingersollrandproducts.com.

Notes:

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