Ingersoll-Rand AF1060-XX manual Disassembly of AIR Motor CONT’D, Reassembly of AIR Motor

DISASSEMBLY OF AIR MOTOR (CONT’D)

5.Remove tubes (114) and (137) by pulling upward.

6.Remove the four (113) O-rings from both tubes (114) and

7.Remove the (142) valve plate and the (143) D-valve from the (144) valve housing.

8.Remove the four (138) socket head screws to extract the

(150)pilot cover.

9.Remove the (148) pilot gasket from the (150) pilot cover.

10.Remove the (147) pilot valve plate and the (146) pilot insert from the (144) valve housing.

11.Remove the two (145) socket head screws from the (144) valve housing.

12.Remove the (144) valve housing by pulling straight up.

13.Remove the (124) O-ring, the (135) vent bushing, and the

(136)U-cup from the (144) valve housing.

14.Remove the (128) O-ring and the (126) sleeve from the motor assembly by sliding it straight up.

15.Pull the (134) spool as far from the motor assembly as possible to expose the under side of the spool itself.

16.Locate and remove the (129) snap ring from the (134) spool utilizing snap ring pliers.

17.Lift to remove the (134) spool and remove the (133) U-cup from it.

18.Slide the (131) pin to remove the (132) driver, (130) wash- er, and (129) snap ring from the (120) trip rod assembly.

19.Remove the eight (109) nuts from (121) hex head bolts.

20.Remove the eight (121) bolts from the (122) head plate and the (101) base assembly.

21.Remove (122) head plate from the (112) air cylinder.

22.Remove the (111) O-ring, the (125) cap, and (123) O-ring from the (122) head plate.

23.Pull upward on (112) air cylinder until (203) piston as- sembly separates from the (101) base assembly. If, in this step, the (203) piston assembly is not pulled from the

(101)base assembly, then remove it after removing the

(112)air cylinder.

24.If the (112) air cylinder and (203) piston assembly are removed as one unit, then remove the (203) piston as- sembly from the (112) air cylinder.

25.Remove the (116) O-ring from the (117) piston.

26.Remove the (111) O-ring from (101) base assembly.

27.Remove (154) snap ring, (153) washer, and (152) U-cup from the (101) base assembly.

REASSEMBLY OF AIR MOTOR

1.Apply grease to all O-rings, U-cups, and other rubber goods before installing.

2.Install (152) U-cup, (153) washer, and (154) sanp ring into the (101) base assembly.

3.Install the (111) O-ring in the groove on the (101) base assembly.

4.Install the (116) O-ring in the groove on the (117) piston.

5.Push (115) piston rod thru the (101) base assembly, be- ing careful not to damage the lips of the (152) U-cup.

6.Lubricate the inside diameter of the (112) air cylinder and slide it down over the (203) piston assembly and onto the (101) air motor base assembly.

7.Align notch in (122) head plate with the port in (101) base assembly and press the (122) head plate down until it is seated against the (112) air cylinder. The (120) trip rod as- sembly must lead thru the center of the (122) head plate.

8.Assemble the eight (121) bolts thru the (122) head plate and the (101) base assembly.

9.Assemble the eight (109) nuts to (121) hex head bolts and tighten per specified torque sequence and value.

10.Pull the (120) trip rod assembly as far out of the air mo- tor assembly as possible, slide the (123) O-ring over the

(120)trip rod assembly and down into the gland found in the (122) head plate.

11.Slide the (125) cap over the (120) trip rod assembly and down into the bore found in the (122) head plate.

12.Slide the (129) snap ring first and the (130) washer sec- ondly, onto the (120) trip rod assembly.

13.Slide the (132) driver onto the (120) trip rod assembly. Align the hole of the (132) driver with the hole in the

(120)trip rod assembly and insert the (131) pin.

14.Assemble the (133) U-cup to the (134) spool. Take note of the (133) U-cup lips should point down towards the

(122)head plate.

15.Slide the (134) spool onto the (120) trip rod assembly over the (132) driver and insert the (130) washer behind it. Uti- lizing snap ring pliers, assemble the (129) snap ring to the internal groove found in the (134) spool. Be certain that the (129) snap ring is fully engaged into the groove. Slide the (134) spool downward into the bore of the (122) head plate nesting on top of the (125) cap.

16.Lubricate the inside diameter of the (126) sleeve and slide it onto the (134) spool and locating it into the (125) cap. Take note that large taper on (126) Sleeve is to locate into

(125)Cap.

17.Install the (128) O-ring onto the top gland of the (126) sleeve.

18.Install the (136) U-cup, the (135) vent bushing into the center bottom bore of the (144) valve housing. Take note that the (136) U-cup lips must be facing up towards the top of the (144) valve housing. Install the (124) O-ring into the bottom recess gland of the (144) valve housing.

19.Install the (144) valve housing to the motor assembly by sliding the center bore onto the (134) spool and the

(126)sleeve. Take caution not to dislodge any of the O-rings (124 & 128). Take note to align the large valve pocket on the side of the (144) valve housing towards the notch in the (122) head plate.

20.Install the two (145) socket head screws thru the (144) valve housing and thread into the (122) head plate. The

(144)valve housing may need to be rotated slightly to align the tapped holes. Tighten the (145) socket head screws per specified torque value.

21.Install the (146) pilot insert, with pocket facing outward, thru the (144) valve housing and into the (134) spool. The (134) spool may need to be turned to orient its’ shal- lower slot to face the smaller pocket of the (144) valve housing.

22.Install the (147) pilot valve plate, with identification dimple facing outward, into the (144) valve housing cov- ering the (146) pilot insert.

23.Install the (148) pilot gasket into the (150) pilot cover and assemble to the (144) valve block using four (138) socket head screws. Tighten to torque specifications.

24.Install the (143) D-valve, with pocket facing outward, thru the (144) valve housing and into the (134) spool.

25.Install the (142) major valve plate, with identification dimple facing outward, into the (144) valve housing cov- ering the (143) D-valve.

26.Install the four (113) O-rings onto both (114 & 137) tubes.

27.Loosely install the (137) tube into the bore in the (122) head plate.

(continued on page 4)

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