Ingersoll-Rand 100PQ1 Setup guide

47109525
Edition 1
September 2010
Save These Instructions
Air Impulse Wrench (Twin Blade)
Models 100PQ1 and 100PQ1–EU
Maintenance Information

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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 Manual when applicable (see under Related
Documentation for form numbers).
Changing The Mechanism Fluid
To change the Mechanism Fluid in the Impulse Mechanism,
proceed as follows:
1. Use a pointed probe to push the Spring Seat (58) against the
Retaining Sleeve Spring (57). While the Spring is compressed, use
another pointed probe or thin blade screwdriver to remove the
RetainingRing (59). Lift the Spring Seat, Spring and Bit Retaining
Sleeve (56) o the Drive Shaft (44) and remove the Bit Retaining
Ball (55).
2. Using snap ring pliers, remove the Retaining Sleeve Spring Stop
(51) from the Drive Shaft.
3. Remove the Rubber Housing Boot (60).
4. Using copper–covered vise jaws, carefully grasp the ats of the
Mechanism Cover (53) with the output end of the Drive Shaft
downward.
5. Using an adjustable wrench, unscrew the Motor Housing
Assembly (1) from the Mechanism Cover.
This is a left–hand thread, rotate the Motor Housing clockwise to
remove it.
(Refer to Dwg. TPD1264)
(Dwg. TPD1264)
6. Lift the assembled motor o the Mechanism Cover and pull the
mechanism assembly out of the Cover.
7. Using a 1.5 mm hex wrench, rotate theTorque Adjustment
Screw (34) clockwise until the Screw stops. Rotate the Screw
counterclockwise until it stops in new style Liner Housings. Do
not rotate the Screw more than 3–1/2 turns counterclockwise in
old style Liner Housings or the Screw will fall out of the Housing.
8. Using the special Tee Wrench furnished in the Tool Kit (Part No.
100PQ–99), remove the Oil Plug (32) and Oil Plug Seal (33).
9. With the oil plug opening downward over a container, rotate the
Drive Shaft to purge the uid from the mechanism.
10. 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 impulse mechanism uid provided could
damage the tool, increase maintenance and decrease
performance. Use only clean uid in these tools.
(Dwg. TPD1265)
11. 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.
12. Thread the Oil Plug with the Oil Plug Seal into the mechanism
until it is snug.
13. Using a 1.5 mm hex wrench, turn the Torque Adjustment Screw
clockwise until it stops. This is the maximum torque position.
14. Wipe the outside of the mechanism dry and clean and remove
the Oil Chamber Plug. Using the syringe, withdraw .25 cc of uid.
15. Install the Oil Chamber Plug and tighten it between 20 and 25
in–lb (2.3 and 2.8 Nm) torque.
16. Insert the mechanism assembly, output end leading, into the
Mechanism Cover clamped in the vise jaws.
17. Insert the hex end of the rotor shaft into the hex recess at the
rear of the Drive Shaft and thread the assembled Motor Housing
onto the Mechanism Cover. This is a left–hand thread. Rotate the
Housing counterclockwise to tighten it.
(Refer to Dwg. TPD1266)
Counterclockwise To Tighten
(Dwg. TPD1266)

47109525_ed1 3
Disassembly
General Instructions
1. Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
2. 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.
3. 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.
4. Do not disassemble the tool unless you have a complete set of
new gaskets and O–rings for replacement
Disassembly of the Impulse Mechanism
1. Use a pointed probe to push the Spring Seat (58) against the
Retaining Sleeve Spring (57). While the Spring is compressed, use
another pointed probe or thin blade screwdriver to remove the
Retaining Ring (59). Lift the Spring Seat, Spring and Bit Retaining
Sleeve (56) o the Drive Shaft (44) and remove the Bit Retaining
Ball (55).
2. Using snap ring pliers, remove the Retaining Sleeve Spring Stop
(51) from the Drive Shaft.
3. Remove the Rubber Housing Boot (60).
4. Using copper–covered vise jaws, carefully grasp the ats of the
Mechanism Cover (53) with the output end of the Drive Shaft
downward.
5. Using an adjustable wrench, unscrew the Motor Housing
Assembly (1) from the Mechanism Cover.
This is a left–hand thread, rotate the Motor Housing clockwise to
remove it.
(Refer to Dwg. TPD1264.)
6. Lift the assembled motor o the Mechanism Cover and pull the
mechanism assembly out of the Cover. Remove the Bushing
Spacer (52).
7. Using a 1.5 mm hex wrench, rotate theTorque Adjustment
Screw (34) clockwise until the Screw stops. Rotate the Screw
counterclockwise until it stops in new style Liner Housings. Do
not rotate the Screw more than 3–1/2 turns counterclockwise in
old style Liner Housings or the Screw will fall out of the Housing.
8. Using the special Tee Wrench furnished in the Tool Kit (Part No.
100PQ–99), remove the Oil Plug (32) and Oil Plug Seal (33).
9. With the oil plug opening downward over a container, rotate the
Drive Shaft to purge the uid from the mechanism.
10. Grasp the ats of the Housing Assembly (31) in vise jaws with the
output end of the Drive Shaft downward.
Spanner
Plug
Counterclockwise
to Loosen
(Dwg. TPD1267)
11. Insert the pins of the spanner plug from the No. 100PQ–99 Tool
Kit into the two holes in the Housing Cap (37). Using a wrench on
the plug, unscrew and remove the Housing Cap from the Housing
Assembly.
(Refer to Dwg. TPD1267)
12. 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 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)
13. Disassemble the components of the mechanism in the sequence
shown in Drawing TPA1359–3 on Page 17.
Disassembly of the Motor
1. Grasp the Motor Housing (1) in vise jaws with the shaft of the
Rotor (25) upward.
2. Insert the pins of the end plate spacer spanner into the holes in
the Front End Plate Spacer (30). Using a wrench, unscrew and
remove the Spacer. This is a left–hand thread; rotate the wrench
clockwise to remove the Spacer.
(Refer to Dwg. TPD1269).
End Plate
Spacer Sapnner Clockwise to Loosen
(Dwg. TPD1269)
3. Reposition the Motor Housing in the vise jaws so that the vise
jaws grip the end of the rotor shaft and the handle grip of the
Housing is downward.Tap the edges of the Housing surrounding
the motor bore with a plastic hammer to separate the Housing
from the motor.
(Refer to Dwg. TPD1270)
(Dwg. TPD1270)

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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
pressing the bearing into a bearing recess.
3. 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.
4. Except for bearings and mechanism parts, always clean every part
and wipe every part with a thin lm of oil before installation.
5. Wipe a thin lm of mechanism uid on all internal mechanism
components before installing them in the mechanism.
6. Apply a lm of o–ring lubricant to every o–ring before
installation.
Assembly of the Motor
1. Position the Exhaust Deector Assembly (18) in the bottom of the
motor housing handle and install the Deector Retaining Pin (19)
to secure it in position.
NOTICE
It may be necessary to slide the Assembly in or out in order to
align the groove in the Assembly with the pin hole.
2. Install the Throttle Rod Seal (3) in the groove on the large hub of
the Throttle Rod (2).
3. Install the Throttle Valve Seal (5) in the groove on the large hub of
the Throttle Valve (4).
4. Slide the Throttle Valve, Valve Seal end rst, onto the Throttle Rod.
5. Secure the Throttle Valve Assembly by installing theThrottle Valve
Retainer (6) in the small groove on theThrottle Rod.
6. Install the Throttle Bushing Seal (8) on the hub end of the Throttle
Bushing (7).
7. Position theThrottle Lever (12) on the Reverse Valve (9) and
secure it by installing the Reverse Lever Retaining Pin (13).
8. Slide the Throttle Bushing Assembly, seal end leading, onto the
shaft of the Throttle Rod.
9. Slide the Reverse Valve, lever end trailing, onto the shaft of the
Throttle Rod and into theThrottle Bushing until the detent hole
in the Valve reaches the end of the Bushing.
10. Install the ReverseValve Detent Spring (11) followed by the
Reverse Valve Detent Ball (10) in the hole in the ReverseValve.
While compressing the Spring with the Ball, continue sliding the
Valve into the Bushing until the Detent Ball enters one of the
detent pockets inside the Bushing.
11. Position the Trigger (14) on the shaft of theThrottle Rod and
secure it by inserting the Trigger Retaining Pin (15) through the
Trigger and shaft.
12. Insert the assembled Trigger into the Motor Housing. Make
certain the widest end of the Trigger is nearest the motor bore
and the notch across the outside of the Throttle Bushing aligns
with hole in the Motor Housing for the Throttle Retaining Pin
(16). Install the Pin making certain it captures and secures the
assembled Trigger.
4. Remove the motor from the vise jaws and remove the Front End
Plate (27), Front End Plate Bearing (29), Cylinder Assembly (25)
and Vanes (26) from the Rotor.
5. Remove the Rear Motor Seal (17) from the Motor Housing.
6. On the table of an arbor press, support the Rear End Plate (21)
with blocks as close to the Rotor as possible and press the Rotor
out of the Rear End Plate and Rear Rotor Bearing (22).
NOTICE
In the following step, do not enlarge or damage the shaft hole in
the End Plate when removing the Bearing.
7. 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)
(Dwg. TPD1271)
8. Using a pin punch, tap the Throttle Retaining Pin (16) and the
Deector Retaining Pin (19) 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)
9. Grasp the Trigger (14) and pull the assembled throttle out of the
Motor Housing.
10. Using a pin punch and without damaging the Trigger, remove the
Trigger Pin (15).
11. Being careful not to lose the Reverse Valve Detent Ball (10) or
Reverse Valve Detent Spring (11), slide theThrottle Bushing
Assembly (7), Throttle Valve Assembly (4) andThrottle Rod
Assembly (2) o the Reverse Valve (9).
12. Using a pin punch and without damaging the Reverse Lever (12),
remove the Reverse Lever Retaining Pin (13) and separate the
Lever from theValve.
13. Using a thin blade screwdriver, remove theThrottle Valve Retainer
(6) and slide the Throttle Valve Assembly o the shaft of the
Throttle Valve Rod.
14. Grasp the Exhaust Deector Assembly (18) and pull it out of the
Housing.
Assembly

47109525_ed1 5
13. Using an arbor press and a piece of tubing that contacts the outer
ring of the bearings, press the Front End Plate Bearing (29) into
the Front End Plate (27) and the Rear End Plate Bearing (22) into
the Rear End Plate (21).
(Refer to Dwg. TPD1274)
Bearing
Tubing
End Plate
(Dwg. TPD1274)
14. Stand the Rotor (25) 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 downward.
15. 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, End Plate leading, onto the shaft of the Rotor until
the End Plate contacts the shim. Remove the shim.
16. Coat each Vane (26) 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.
17. Install the Cylinder (23) over the Vanes and Rotor with the end of
the Cylinder having the two holes in straight alignment nearest
the end face positioned away from the Rear End Plate. Make
certain the End Plate Dowel (24) enters the hole in the face of the
Rear End Plate and not the porting slot.
18. Place the Front End Plate and Bearing against the face of the
Cylinder, Bearing end trailing. Make certain the End Plate Dowel
in that end of the cylinder enters the hole in the End Plate and
not the porting slot.
19. Insert the Rear Motor Seal (17) in the bottom of the Housing
motor bore.
20. Insert the assembled motor, Rear End Plate leading, into the
Motor Housing making sure the End Plate Alignment Pin (28)
enters the proper notch in the Housing. It may be necessary to
tap the assembly into position with a brass or plastic hammer.
(Refer to Dwg. TPD1279)
(Dwg. TPD1279)
21. Grasp the handle of the Motor Housing in vise jaws with the
rotor shaft upward.Thread the Front End Plate Spacer (30) into
the Housing and using the end plate spacer spanner, tighten
the Spacer to 33 ft–lb (45 Nm) torque.This is a left–hand thread;
rotate the wrench counterclockwise to tighten.
(Refer to Dwg. TPD1280)
22. After installing the Front End Plate Spacer, grasp the shaft of
the Rotor and rotate it by hand. If the Rotor does not turn easily,
disassemble the motor unit and determine where the assembly is
binding. The motor must rotate freely before proceeding further
with the assembly.
Counterclockwise to tighten
Spanner
(Dwg. TPD1280)
Assembly of the Impulse Mechanism
1. Install the Rear Liner Cover O–ring (39) in the annular groove
around the Rear Liner Cover (38).
2. Insert the Relief Valve (43) into the Liner (40).
3. Place a Blade Spring (47) into each hole in one of the slots of the
Drive Shaft (44).
4. Place the Blade (45) against the Springs so that each Spring
encircles a Blade Spring Pin (46).
5. Compress the Springs with the Blade until the Blade is 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 the Relief Valve. (Refer to Dwg. TPD1284)
Make certain the ends of the Blade are ush with the ends of the
Liner.
(Dwg. TPD1284)
6. Place the Rear Liner Cover Assembly against the motor end of
the Liner making sure that the two Liner Rear Pins (41) enter the
holes in the Cover and the rear hub of the Drive Shaft enters the
central opening of the Cover.
7. Install the Front Liner Cover Assembly (48) over the Drive Shaft
against the spindle end of the Liner making sure that the two
Liner Front Pins (42) enter the holes in the Cover and the Relief
Valve aligns with the opening in the Cover.
8. Install the Drive Shaft Seal (49) followed by the Seal Back–up Ring
(50) on the Drive Shaft against the hub.
(Refer to Dwg. TPD1285)
Seal Back-up Ring
Drive Shaft Seal
(Dwg. TPD1285)
9. Install the assembled Liner and Covers in the Liner Housing (31)
making certain that the Relief Valve is in alignment with the
opening for the Torque Adjustment Bolt (34).

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10. Install the Adjustment Bolt Seal (35) followed by the Seal Washer
(35A) and Seal Back–up Ring (36) on the Torque Adjustment Bolt
and thread the assembled Bolt into the Liner Housing.
11. Install the Adjustment Bolt Stop Ring (36A) in the groove of the
Liner Housing to keep the Bolt Assembly from backing out.
12. Install the Oil Plug (32) and Oil Plug Seal (33) in the liner housing
hole 180 degrees from theTorque Adjustment Bolt.
Related Documentation
For additional information refer to:
Product Safety Information Manual 04584983.
Product Information Manual 47133053.
Parts Information Manual 47135678.
Manuals can be downloaded from www.ingersollrandproducts.com

Notes:

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