Ingersoll-Rand 100SQ1 Setup guide

47109517
Edition 2
October 2013
Save These Instructions
Air Impulse Wrench (Twin Blade)
Model 100SQ1 and 100SQ1–EU
Maintenance Information

2 47109517_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).
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 (57) against the
Retaining Sleeve Spring (56). While the Spring is compressed, use
another pointed probe or thin blade screwdriver to remove the
RetainingRing (58). Lift the Spring Seat, Spring and Bit Retaining
Sleeve (55) o the Drive Shaft (43) and remove the Bit Retaining
Ball (54).
2. Using snap ring pliers, remove the Retaining Sleeve Spring Stop
(50) from the Drive Shaft.
3. Using copper–covered vise jaws, carefully grasp the ats of the
Mechanism Cover (52) with the output end of the Drive Shaft
downward.
4. 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. TPD1292)
(Dwg. TPD1292)
5. Lift the assembled motor o the Mechanism Cover and pull the
mechanism assembly out of the Cover.
6. Using a 1.5 mm hex wrench, rotate the Torque Adjustment
Bolt (33) clockwise until the Bolt stops. Rotate the Bolt
counterclockwise until it stops in new style Liner Housings. Do
not rotate the Bolt more than 3–1/2 turns counterclockwise in old
style Liner Housings or the Bolt will fall out of the Housing.
7. Using the special Tee Wrench furnished in the Tool Kit (Part No.
100PQ–99), remove the Oil Plug (31) and Oil Plug Seal (32).
8. With the oil plug opening downward over a container, rotate the
Drive Shaft to purge the uid from the mechanism.
9. 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. TPD1293)
10. 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.
11. Thread the Oil Plug with the Oil Plug Seal into the mechanism
until it is snug.
12. Using a 1.5 mm hex wrench, turn the Torque Adjustment Screw
clockwise until it stops. This is the maximum torque position.
13. Wipe the outside of the mechanism dry and clean and remove
the Oil Chamber Plug. Using the syringe, withdraw .25 cc of uid.
14. Install the Oil Chamber Plug and tighten it between 20 and 25
in–lb (2.3 and 2.8 Nm) torque.
15. Insert the mechanism assembly, output end leading, into the
Mechanism Cover clamped in the vise jaws.
16. 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. TPD1294)
(Dwg. TPD1294)

47109517_ed2 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 (57) against the
Retaining Sleeve Spring (56). While the Spring is compressed, use
another pointed probe or thin blade screwdriver to remove the
Retaining Ring (58). Lift the Spring Seat, Spring and Bit Retaining
Sleeve (55) o the Drive Shaft (43) and remove the Bit Retaining
Ball (54).
2. Using snap ring pliers, remove the Retaining Sleeve Spring Stop
(50) from the Drive Shaft.
3. Using copper–covered vise jaws, carefully grasp the ats of the
Mechanism Cover (52) with the output end of the Drive Shaft
downward.
4. 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)
5. Lift the assembled motor o the Mechanism Cover and pull the
mechanism assembly out of the Cover. Remove the Mechanism
Cover Spacer (51).
6. Using a 1.5 mm hex wrench, rotate the Torque Adjustment
Bolt (33) clockwise until the Screw stops. Rotate the Bolt
counterclockwise until it stops in new style Liner Housings. Do
not rotate the Bolt more than 3–1/2 turns counterclockwise in old
style Liner Housings or the Bolt will fall out of the Housing.
7. Using the special Tee Wrench furnished in the Tool Kit (Part No.
100PQ–99), remove the Oil Plug (31) and Oil Plug Seal (32).
8. With the oil plug opening downward over a container, rotate the
Drive Shaft to purge the uid from the mechanism.
9. Grasp the ats of the Liner Housing (30) in vise jaws with the
output end of the Drive Shaft downward.
10. Insert the pins of the spanner plug from the No. 100PQ–99 Tool
Kit into the two holes in the Housing Cap (36). Using a wrench on
the plug, unscrew and remove the Housing Cap from the Housing
Assembly.
(Refer to Dwg. TPD1267)
Spanner
Plug
Counterclockwise
to Loosen
(Dwg. TPD1267)
11. 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. TPD1296)
12. Disassemble the components of the mechanism in the sequence
shown in Drawing TPA1360–1 on Page X.
Disassembly of the Motor
1. Grasp the Motor Housing (1) in vise jaws with the shaft of the
Rotor (23) upward.
2. Insert the pins of the end plate spacer spanner into the holes in
the Front End Plate Spacer (29). 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. TPD1297) Remove the Dust Washer (28).
End Plate
Spacer Sapnner Clockwise to Loosen
(Dwg. TPD1297)
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. TPD1298).
(Dwg. TPD1298)

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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. If the Reverse Valve Bushing Seal (10) was removed from the
reverse valve bushing, install a new Seal inside the bushing.
2. Install a new Reverse Valve Seal (9) on the Reverse Valve (8).
3. Being careful not the cut or nick the Seals, insert the Reverse
Valve, large hub trailing, into the Motor Housing (1) from the lever
side of the Housing. Make certain the hole for the Reverse Lever
Retaining Pin (4) and the valve porting are properly aligned.
4. Position the Throttle Lever (11) on the Housing and secure it by
pressing the Lever Retaining Pin (12) through the Housing and
Lever.
5. Install the Throttle Rod Seal (6) in the groove on the large hub of
the Throttle Rod (5).
6. Install the Reverse Lever Seal (3) on the hub of the
Reverse Lever (2).
7. Insert the Throttle Rod Assembly, small end leading, into the
Reverse Valve Assembly followed by the Throttle Rod Spring (7)
and assembled Reverse Lever.
8. Align the hole in the Reverse Lever with the hole in the Reverse
Valve and install the Reverse Lever Retaining Pin in the aligned
holes.
9. Place the Exhaust Deector Seal (14) on the inlet and of the
Motor Housing followed by the Exhaust Deector.
10. Thread the Inlet Bushing (15) into the small hub the Housing and,
after rotating the Deector to the desired position, tighten the
Inlet Bushing between 30 and 35 ft–lb (40 and 47 Nm) torque.
11. Using an arbor press and a piece of tubing that contacts the outer
ring of the bearings, press the Front End Plate Bearing (27) into
the Front End Plate (25) and the Rear End Plate Bearing (19) into
the Rear End Plate (18).
(Refer to Dwg. TPD1274).
Bearing
Tubing
End Plate
(Dwg. TPD1274)
12. 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.
13. 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.
14. Coat each Vane (24) 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.
15. Install the Cylinder (20) 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.
16. 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.
17. Place the Rear End Plate Spacer (17) against the Rear End Plate
making certain that the Rear End Plate Dowel enters the hole in
the Spacer and the external slots align.
4. Remove the motor from the vise jaws and remove the Front End
Plate (25), Front Rotor Bearing (27), Cylinder Assembly (20) and
Vanes (24) from the Rotor.
5. Remove the Rear End Plate Spacer (17) from the Motor Housing
or the Rear End Plate (18).
6. On the table of an arbor press, support the Rear End Plate with
blocks as close to the Rotor as possible and press the Rotor out of
the Rear End Plate and Rear Rotor Bearing (19).
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)
8. Using an adjustable wrench, unscrew and remove the Inlet
Bushing (15). Remove the Exhaust Deector (13) and Exhaust
Deector Seal (14).
9. Using a pin punch and without damaging the Reverse Lever (2),
remove the Reverse Lever Retaining Pin (4) and separate the
Lever from the Reverse Valve Assembly (8). Remove the Reverse
Valve Seal (9) from the Lever.
(Dwg. TPD1271)
10. Remove the Throttle Rod Assembly (5) and Throttle Rod Spring (7)
from the Reverse Valve Assembly (8).
11. Using a pin punch, tap the Lever Retaining Pin (12) out of the
Throttle Lever (11) and Housing and remove the Lever.
12. Push the Reverse Valve Assembly out the lever side of the
Housing.
Assembly

47109517_ed2 5
18. Insert the assembled motor, Rear End Plate leading, into the
Motor Housing making sure the End Plate Alignment Pin (26)
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)
19. Grasp the handle of the Motor Housing in vise jaws with the
rotor shaft upward. Thread the Front End Plate Spacer (29) 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. TPD1304).
NOTICE
This is a left–hand thread; rotate the wrench counterclockwise
to tighten.
Refer to Dwg. TPD1304.
Counterclockwise
to Tighten
Spanner
(Dwg. TPD1304)
20. 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.
21. When the motor rotates freely, install the Dust Washer (28) on the
rotor shaft and slide it downward against the Front Rotor Bearing.
Assembly of the Impulse Mechanism
1. Install the Rear Liner Cover O–ring (38) in the annular groove
around the Rear Liner Cover (37).
2. Insert the Relief Valve (42) into the Liner (39).
3. Place a Blade Spring (46) into each hole in one of the slots of the
Drive Shaft (43).
4. Place the Blade (44) against the Springs so that each Spring
encircles a Blade Spring Pin (45).
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 (40) 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 (47) over the Drive Shaft
against the spindle end of the Liner making sure that the two
Liner Front Pins (41) enter the holes in the Cover and the Relief
Valve aligns with the opening in the Cover.
8. Install the Drive Shaft Seal (48) followed by the Seal Back–up Ring
(49) 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 (30)
making certain that the Relief Valve is in alignment with the
opening for the Torque Adjustment Bolt (33).
10. Install the Adjustment Bolt Seal (34) followed by the Seal Washer
(34A) and Seal Back–up Ring (35) on the Torque Adjustment Bolt
and thread the assembled Bolt into the Liner Housing.
11. Install the Adjustment Bolt Stop Ring (35A) in the groove of the
Liner Housing to keep the Bolt Assembly from backing out.
12. Install the Oil Plug (31) and Oil Plug Seal (32) in the liner housing
hole 180 degrees from the Torque Adjustment Bolt.
13. Grasp the ats of the Housing in vise jaws with the output spindle
downward. Remove the Rear Liner Cover Assembly and put
grease in the central opening of the Cover.
(Refer to Dwg. TPD1289)
Grease
(Dwg. TPD1289)

6 47109517_ed2
14. Reinstall the Cover Assembly and use a hex wrench to push it
below the threads at the rear of the Housing.
(Refer to Dwg. TPD1290.)
(Dwg. TPD1290)
15. Install the Housing Cap (36) and using the spanner plug furnished
in the Tool Kit, tighten the Cap between 58 and 65 ft–lb (78 and
88 Nm) torque.
(Refer to Dwg. TPD1291).
Spanner Plug Clockwise to Tighten
(Dwg. TPD1291)
16. Make certain the Drive Shaft rotates freely. Install the Mechanism
Cover Spacer (51) and then ll the mechanism with uid and
reassemble the tool as instructed in the section,
CHANGING THE MECHANISM FLUID.
Related Documentation
For additional information refer to:
Product Safety Information Manual 04584983.
Product Information Manual 47133053.
Parts Information Manual 47135488.
Manuals can be downloaded from ingersollrandproducts.com

Notes:

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