Ingersoll-Rand QS110P4 Setup guide

47156310
Edition 2
December 2012
Save These Instructions
Air Pulse Tools
Models QS110P4, QS120P4, QS140P4 & QS150P6
Maintenance Information

2 47156310_ed2
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).
Changing the Pulse Mechanism Fluid
To change the Mechanism Fluid in the Impulse Mechanism, proceed
as follows:
1. Use jig P to remove Hammer Case (99) from motor case assembly.
2. Using an adjustable wrench, unscrew the Motor Case Assembly
(1) from the Hammer Case (99). This is a left-handed thread, rotate
the Motor Case (1) clockwise to remove it.
(Refer to Dwg. TPD1264)
CLOCKWISE TO LOOSEN
(Dwg. TPD1264)
3. Lift the assembled motor off the Hammer Case and pull the
mechanism assembly out of the Cover.
4. With the assembled mechanism off of the Rotor, use Straight Slot
Screwdriver to unscrew and remove one of the Oil Plug (91) and
O-Ring (92) from the front end of the Mechanism.
5. Using the 1.5 mm hex wrench furnished with the tool, rotate the
Torque Adjustment Screw counterclockwise until it stops. This
screw adjusts the check valve.
6. With the oil plug opening downward over a container, rotate the
Main Shaft (80) to purge the fluid from the mechanism.
7. Using the syringe and fluid from the Fluid Replacement
Kit (Part No. EQ106S-K400), fill the mechanism with the fluid
furnished with the Kit until the fluid overflows the fill hole.
(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)
8. Submerge the mechanism in a reservoir containing mechanism
fluid, and using a wrench, rotate the Drive Shaft clockwise and
counterclockwise to purge any remaining air from the system.
9. Remove the mechanism from the fluid and rotate the Adjustment
Screw clockwise until it stops.
10. Thread the Oil Plug (91) with the O-Ring (92) into the mechanism
until it is snug.
11. Wipe the outside of the mechanism dry and clean and remove
the Oil Plug (91).
12. Install the Oil Chamber Plug and tighten it between 20 and
25 in-lb (2.3 and 2.8 Nm) torque.
13. Insert the mechanism assembly (with output end leading) into
the Mechanism Cover clamped in the vise jaws.
14. 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. Use Jig P to assemble. Rotate counterclockwise
to tighten.
JIG P
16. Test the tool for torque at maximum, minimum and mid-range
torque settings. If the tool does not perform satisfactorily, repeat
the refill procedure and pay particular attention to removing
unwanted air from the fluid system. Refer to the section TORQUE
ADJUSTMENT, in Manual 47156203, for specific adjustment
procedures.
Disassembly
General Instructions
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.
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.
1.
2.
3.
Removal of Hammer Case
CLOCKWISE TO LOOSEN
(Dwg. TPD1264)
1. Use jig P to remove Hammer Case (99) from motor case assembly.
2. Using an adjustable wrench, unscrew the Motor Housing Assembly
from the Hammer Case. This is a left-handed thread, rotate the
Motor Housing clockwise to remove it. (Refer to Dwg. TPD1264.)

47156310_ed2 3
Disassembly of the Impulse Mechanism
1. Lift the assembled motor off the Hammer Case and pull the
mechanism assembly out of the Cover.
91 92 86
66
2. With the assembled mechanism off of the Rotor, use Oil Plug
Wrench to unscrew and remove the Oil Plug (91) and
O-ring (92) from the front end of the Mechanism.
5. Using the 1.5 mm hex wrench furnished with the tool, rotate the
Torque Adjustment Screw (86) counterclockwise until it stops.
6. With the oil plug opening downward over a container, rotate the
Drive Shaft to purge the fluid from the mechanism.
7. Insert the Jig A into the Liner Cap (66). Using a wrench on the Jig
A, unscrew and remove the Liner Cap (66) from the Liner Case.
(Refer to Dwg. TPD1267.)
NOTE: An adhesive agent is used on Models QS140P4 and QS150P6.
Jig A
COUNTERCLOCKWISE TO LOOSEN
(Dwg. TPD1267)
8. Stand the Jig B, with large end downward, on a workbench or
on the table of an arbor press. Insert the output end of the Drive
Shaft into the central opening and either tap/press the Liner Case
downward off the components. (Refer to Dwg. TPD1268.)
HOUSING
Jig B
(Dwg. TPD1268)
9. Disassemble the components of the mechanism in the sequence
shown in Manual 47155908.
Disassembly of Main Shaft and Blades
81
80
82
67
1. Remove the Liner Upper Plate (67).
2. Match the positions of the Blades (81) to the circle center part.
3. While holding the Blades at that position, Push the Main Shaft
(80) out.
4. Remove the main shaft (80), Blades (81) and Spring (82).
Disassembly of Relief Valve
86
84
75
1. Rotate the adjust Bolt (86) clock wise to maximum.
2. Remove the Liner Lower Plate (84).
3. Remove the Relief Valve (75) by pushing the Relief Valve to the
Upper Plate side with a Pin.
NOTICE
In the following step do not push the relief valve to Lower Plate
side, which can make O-ring get jammed.
Disassembly of Liner Lower Plate
86
89
91 92 90
84 94 83
1. Remove the adjust Bolt (86).
2. Loosen Oil plug (91) 2 pcs with a slotted head screwdriver.
3. Remove the Oil Plug (91) from the underside by pushing it with a
Pin.
4. Remove the Liner Lower Plate (A) (83) and Lower Plate (B) (84) .
Note: Can be easily removed by rotating the Liner Lower Plates.
5. Remove the Ball (90) and Spring (89) with a Pin.
NOTICE
Ball and Spring should be retained carefully for future use.
6. Remove the O-ring (92) and Back Up Ring (94) from the adjust
bolt hole with Pin.
Disassembly of Sensor
67 70
71
1. Install the Gimlet with diameter less than 1 mm to the Gimlet
hole of the Liner Upper Plate (67).
2. Remove the Sensor (70) by pushing it with the Gimlet. Remove
O-ring (71).
Disassembly of the Motor Case Cover
Removal of Motor Case Cover Assembly
42 57 56 54 53
1. Loosen the Bolt (56) 4 pcs to remove the Motor Case Cover (42).
2. Remove the Upper Plate Spacer (53) and O-ring (54).

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Disassembly of Motor Case Cover Assembly
52
48
1. Remove the Valve Plug (52) after Warming up the Valve Plug with
a Dryer.
2. Install the M4 Bolt to the thread hole of the shut off Valve Bush (48).
3. Remove the shut off Valve Bush (48) by pulling shut off Valve Bush
out.
4. Disassemble the shut off Valve Bush (48) parts.
Disassembly of the Motor
39
38
Jig W
1
1. Use Jig W to disassemble the Motor Assembly. Place the Motor
Case (1) and female hexagon part of the Rotor (38) to projecting
part of the Jig W.
2. Remove the Motor Assembly by pushing the motor case (1)
vertically downward.
3. Remove vanes (39) from Rotor (38).
4. Remove the Rotor (38) by hitting Jig placed on the Rotor by
hammer.
5. Remove the Upper Plate Assembly from Rotor (38).
Disassembly of Trigger and Throttle Assembly
31
1
19
12
1726 21
24
25272928
5
2
1. Using a Pin Punch, tap the Pin (31) out of the Motor Case (1). The
ends of the pin are covered with cement.
2. Grasp the Throttle Knob (28) and pull the assembled throttle and
reverse valve out of the Motor Case.
3. Using a pin punch and without damaging the Throttle Knob,
remove the Pin (29).
4. Grasp the Reverse Lever (26) and pull the Reverse Valve (21) from
the front of the Throttle Bushing Assembly. The Reverse Lever
Ball (25) and Reverse Lever Spring (24) will fall out of the Reverse
Valve. Take care not to lose them.
5. Remove the Throttle Rod Assembly from the rear of the Throttle
Bushing (12).
6. Remove the Throttle Rod Seal (19) from the Throttle Rod (17).
7. If it is necessary to replace the Reverse Lever or Reverse Valve,
use a pin punch to tap out the Pin (27) out of the Reverse Lever.
Separate the Reverse Lever from the Reverse Valve.
8. Using an adjustable wrench, unscrew and remove the Hose Joint
Assembly (2) and Exhaust Cover (5).
9. To disassemble the shut-off mechanism, grasp the Cover
Assembly in copper-covered vise jaws with the Control Shaft
Assembly upward.
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.
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.
Remove burrs if any on Motor Case Cover, Blades slot parts with
Scrappers.
1.
2.
3.
4.
5.
6.
7.
Assembly of Motor Case Cover
1
42
43
4351
50 49
46
44
52
45
47
48
1. Place O-Ring (49), Back up Ring (43), Ball (47), Spring (46), Shut off
Valve (45) and Buffer Plate (44) in the Shut Off Valve Bush (48).
NOTICE
Apply a little amount of grease before installing the Back Up
Ring to prevent misalignment.
2. Install O-Ring (51) to the side hole in the Shut Off Valve Bush (48).
3. Slightly Apply grease to O-ring. Install the Shut Off Valve housing
(48) to Motor Case Cover (42) adjusting the positions of the side
holes.
NOTICE
Install M4 bolt to the thread hole and pull the part out if there is
misalignment of the position.
4. Place the O-ring (50) in the Shut Off Valve housing (48).
5. Tighten the Valve Plug (52) to the side hole of the Motor Case
Cover (42).

47156310_ed2 5
Assembly of Impulse Unit
7374
75
6872 71
69 67
70
66
76 78 77
79
65 80 81 64
82
92 84 94 93 8391
85
90 89 88 87 86
1. Check whether the relief valve move smoothly and install the
O-ring (76) to the Relief Valve (75).
2. Install the greased O-ring (71) to the Sensor (70) using Jig E.
3. Apply grease to the Sensor inserting hole of the Liner Upper Plate
(67) and then install the Sensor (70) by pushing it all the way to
Bottom.
4. Install the Spring (89) and the Ball (90) to the Liner Lower Plate (B)
(83) in the order.
5. Install the Back Up Ring (88) and O-ring (87) to the Liner Lower
Plate (B) (84) in the order.
6. Apply impulse unit oil to the O-ring.
7. Install the Adjust Bolt (86) to the Relief Valve (75) and insert it by
pushing while rotating it counter-clock wise direction.
8. Remove the Relief Valve (75). If Relief Valve does not comes off,
Use adjustment bolt with hexagon wrench to remove the Relief
Valve by rotating it in Clock wise direction.
9. Apply impulse unit oil and assemble Backup Ring (94) and O-ring
(93) in order in the Liner Lower Plate (B) (84) As shown in the
figure above.
10. Assemble Liner lower Plate (A) (83) and (B) (84).
11. Apply Impulse unit oil to the Main Shaft (80) and install the Main
Shaft (80) to Liner Lower Plate Assembly by rotating the shaft.
NOTICE
Be Careful not to damage the O-Ring in the Liner Lower Plate.
12. Assemble Blades (81) and Spring (82) to Main Shaft (80) and keep
them intact in their position.
13. Insert the Main Shaft (80) aligning the Blades (81) with the circle
center of the liner (72).
14. Align the Adjustment Bolt (86) with the Relief Valve (75) inserting
part by rotating the Liner Lower Plate.
15. Apply impulse unit oil to the O-ring (76) and insert the Relief
Valve (75) by rotating it.
NOTICE
Be Careful not to damage the O-Ring
16. Tighten the Adjust Bolt (86) while holding the Relief Valve (75).
to the Liner.
17. Align the Slotted hole of the Relief Valve (75) with the Pin hole of
the Liner and insert the pin (79). Loosen the adjustment bolt 180°
to 360° from the minimum position.
18. Insert the Ball (78) and Spring (77) to the Relief Valve (75) in Order.
19. Align the hole of the Liner Upper Plate (67) with hole of the Liner
(72) and assemble the Liner Upper Plate (67).
20. Install O-ring (65) to the Liner Case (64), Apply impulse unit oil to
O-ring (65) and assemble the Unit with the Liner Upper Plate (72).
21. Insert the above assembled parts to the Liner Case (64). Lightly hold
the unit with hands when the parts inside goes over the O-ring.
22. Apply impulse unit oil to the end section of the Liner Upper Plate
(67).
23. Use Jig H to fix Liner Case (64) and tighten Liner Case Cap (66) to
specified torque using Jig A.
QS110P4 & QS120P4 QS140P4 & QS150P6
80±8Nm 90±9Nm
NOTICE
Check Main Shaft and Adjust Bolt rotates smoothly. Loosen the
Adjust Bolt.
Assembly of Motor
Rotor Adjustment
33
38
1. Assemble the Upper Plate assembly to the Rotor (38) by hitting
the Upper Plate (33) by about 2 mm. Make sure Rotor (38) rotates
smoothly. Hit the Upper Plate (33) until there is no clearance between
the Upper Plate (33) and the Rotor (38). Adjust the clearance.
Motor Assembly
33
35
36
37 32 1
39
38
1. Install Vanes (39) into the Rotor (38).
2. Apply grease on the Cylinder pin (37) hole and install pin (37) in
the Cylinder (36).
3. Align Cylinder pin (37) with pin hole of the Upper plate (33) and
assemble the Cylinder (36).
4. Assemble the Lower Plate assembly.
5. Apply grease on the pin hole of Upper Plate (33) and install the
Pin (35).
6. Install the O-ring (32) into the Motor Case (1) and slightly apply
grease on the O-ring (32).
7. Aligning the Upper Plate Pin (35) insert the Motor assembly into
the Motor Case (1).
Motor Case Cover Assembly
34
1
38
54
55 56
53
1. Apply grease on the Bearing (34) of the Rotor (38) and mount the
O-ring (54) and upper plate spacer (53) in order.
2. Install the S-Packing (55) and install Motor Case Cover assembly.

6 47156310_ed2
3. Tighten the Bolt (4 pcs) (56), pre-tighten the Bolts in several
batches and check for smooth rotation of motor. Tighten the
Bolts to the specified torque 2.0±0.5Nm.
4. Degrease or wash the female thread part of the Motor Case Cover
and thread part of Valve Plug using Degreasing washing agent.
5. Apply Anaerobic strong sealing agent to whole thread part of
Valve Plug at 2-3 turns.
6. Tighten the Valve Plug to specified torque and wipe out the
overflowed agent from the side of the Motor Case Cover.
(Torque 1.5Nm)
Assembly of Trigger and Throttle Assembly
10
19
12
17
1321
24
2527262928
1. Install O-ring (10) onto the Hose Joint Assembly, followed by the
Exhaust Cover Assembly.
2. Coat the Hose Joint Assembly thread with thread lock and secure
it to the Housing.
3. Install the Throttle Rod Seal in the groove on the large hub of the
Throttle Rod (17).
4. Install O-ring (16) in the groove on the Throttle Rod Bushing (15).
5. Slide the Throttle Rod Bushing, onto the Throttle Rod (17).
6. Secure Throttle rod assembly by installing O-ring (19) in the small
groove on the Throttle Valve Rod (17).
7. Insert the Reverse Valve (21) part way into the Throttle Bushing
(12). Install the Spring (24) and Ball (25), then carefully push the
Reverse Valve the rest of the way into the Throttle Bushing (12).
8. Insure that the Ball (25) is aligned with one of the holes in the side
of the Throttle Bushing.
9. Install the O-ring (13) in the groove on the Throttle Bushing (12).
10. Assemble the Reverse Lever (26) onto the Reverse Valve (21) and
secure with a Roll Pin (27).
11. Insert the Throttle Assembly through the Reverse Valve (21), then
secure with the Throttle Knob (28) and a Roll Pin (29).
12. Insert Throttle Assembly (31) into the Motor Housing, taking care
to align the slots in the Reverse Valve and Throttle Bushing with
the pin hole in the Motor Housing.
13. Secure Throttle Assembly (31) with pin, which should be centered
from side to side.
14. To prevent air leakage, after pin assembly seal each end of the pin
with cement.
Assembly of hammer Case Assembly
59
60
63 40
41
38
61
1
62
99
102 64 100101
96
97
98
1. Insert Rod (59), Spring (60) into Rotor (38). Apply grease to the
bearing (62).
2. Assemble bearing (100) and main shaft bushing (101) to Hammer
Case (99).
3. Apply grease to Bearing of Hammer Case, Bearing Part and to the
hexagon part.
4. Assemble greased Lower Plate Spacer (61) with its Bearing (62)
and washer (63) facing the impulse unit.
5. Aligning the Position of the Washer (63) to the groove of the
Hammer Case (99), Install the Linear Case Assembly to the
Hammer case.
6. Install ST Packing (96, 97, 98).
7. Tighten the Hammer Case (99) to the Motor case (1).
NOTICE
Match the Position of impulse unit and hexagon position of
motor part by rotating the main shaft with ngers In Case there
is a mismatch in the position of impulse unit and hexagon
position of motor part.
7. Fully tighten the hammer case with use of Jig P. Install Jig P on
the Hammer Case by aligning the Socket Plug position with the
bolt on the Hammer Case. (Torque 50±5Nm).

47156310_ed2 7
Troubleshooting
Trouble Probable Cause Solution
The tool rotates under no load.
When under load 0.
The tool does not work (no pulsing). Damaged knock pin of the liner Immediately stop using the tool.
Tool repair and maintenance should
only be carried out by an authorized
Service Center.
Damaged spring for blades
Pulse unit seizure
The oil pulse unit Slips. Oil leaks
Damaged spring for blades
The tool does not stop even after a throttle lever is released. Malfunction of a throttle
The tool does not rotates under no load.
Main shaft rotates if it is turned by ngers. Faulty assembled motor
Immediately stop using the tool.
Tool repair and maintenance should
only be carried out by an authorized
Service Center.
Too low air pressure
Motor part seizure
Dust contamination
Main shaft does not rotates even if it is turned by ngers. Motor part seizure
Damaged vane
Damaged ball bearing
Seized main shaft bushing
Dust contamination
Related Documentation
For additional information refer to:
Product Safety Information Manual 04584983.
Product Information Manual 47156203.
Parts Information Manual 47155908.
Manuals can be downloaded from www.ingersollrandproducts.com.

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