Ingersoll-Rand 8655-B, 8657-B, 8658-B, 8656-B, 8659-B User Manual
Tool Products
OPERATOR’S MANUAL
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
LEAD SCREW TAPPER
Models: 8655-B()-(), 8656-B()-(),
8657-B()-(), 8658-B()-()
and 8659-B()-().
SECTION
MANUAL
Released:
M 104
32
5/78
Revised: 8-11-95
Form:
FEATURES:
“NO-HOLE” SENSOR SYSTEM
FIVE (5) ACCESSORY PORTS
PRECISION MOUNTED SPINDLE
1/2”, 7/16”, 3/8”, 5/16” or 1/4” CAPACITIES
LEAD SCREW THREAD SIZES 11 THRU 56 PITCH
METRIC THREAD SIZES AVAILABLE
3/16” (MIN.) TO 2” (MAX.) STROKE ADJUSTMENT
THREE (3) BASIC SECTIONS FOR EASY MAINTENANCE
175, 325, 600, 1300, 2400 R.P.M. FREE SPEEDS AVAILABLE
PRODUCES ACCURATE THREADS IN PRE-DRILLED MATERIAL
INDEX
GENERAL DESCRIPTION AND OPERATION
SET-UP PROCEDURE
AIR AND LUBE REQUIREMENTS
MODEL IDENTIFICATION
MAINTENANCE
DISASSEMBLY AND REASSEMBLY OF TOOL
CROSS SECTION OF TOOL
REMOTE CONTROL CIRCUITING
ACCESSORIES
DIMENSIONAL DATA
TROUBLE SHOOTING
TABLE OF SPEEDS AND LUBRICANTS
For additional Maintenance/Repair information, Form 1631-2 (English) is available at $5.00 each. Send request to The ARO
Corporation, One Aro Center, Bryan, Ohio 43506, Attn: “Sales Training”.
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PAGE
2 and 3
4 and 5
6 and 18
.......
8 thru 17
19
19 thru 26
27
28
7
8
9
IMPORTANT: READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
For parts and
Center, White
ARO Tool Products
Ingersoll-Rand Company
1725 U.S. No. 1 North l P.O. Box 8000 • Southern Pines, NC 28388-8000
01995 THE ARO CORPORATION. PRINTED IN U.S.A.
service
information, contact your local ARO distributor, or the Customer
House, TN at PH: (615) 672-0321, FAX: (615) 672-0801.
Service Dept. of the Ingersoll-Rand Distribution
INGERSOLLRAND®
PROFESSIONALTOOLS
GENERAL DESCRIPTION AND OPERATION
The tapping cycle is started by manually actuating and releasing
“START’ valve at the tool. The start valve must be held long
enough to allow the stop signal valve to close (page 9); about one
(1) second duration for most applications.
NOTE: For very low spindle speeds with medium to fine pitch lead
screw, the signal duration may need to be increased beyond one
second. For very high spindle speeds and short stroke settings,
the signal duration may need to be decreased and positively controlled - consult factory in this case.
The unit will advance the tap to a pre-set depth and automatically
retract to the initial position whereupon the unit will stop with all air
,-ACCESSORY PORT “C”
PORT “D” - CONNECT TO
SENSOR VALVE - PORT “F”-
REMOTE RETRACT PORT “E”
ALL PORTS 1/18” N.P.T.
to the unit shut-off. To aid set-up procedure, ‘RETRACT” and
“STOP” may be manually initiated at the tool by actuating one of
two trip tabs located inside the nameplate cover. Swing cover up
for for access (page 4).
WARNING: Do not use fingers to manually actuate trip tabs - use
a blade type screwdriver or similar tool.
The ARO Lead Screw Tapper may be used in a single unit application or a multiple unit application.
The maximum stroke length of unit is 2”. Maximum stroke length
of unit with dual spindle head is 1-1/4”.
REMOTE START PORT “B”
SECONDARY EXHAUST EXIT
-PORT “A” -TO SUPPLY AIR TO
SENSOR VALVE - PORT “G”
-MANUAL START VALVE
PORT “F” - SENSOR VALVE
-SENSOR VALVE
PRIMARY EXHAUST EXIT
DRIVE GEARING
AUXILIARY GEARING
AIR TUBES
,
The three basic sections of the Lead Screw Tapper are arranged
for efficient maintenance. The following is a brief description of the
sections and their functions.
VALVE SECTION is composed of a two-way and a four-way
spool valve, both being a two position, double pilot pressure operated type.
The tap function is manually actuated by the operator while the
“RETRACT” and “STOP” functions are automatically actuated by
the tool. The start valve must be depressed with a short duration of
dwell when starting a cycle from the automatically stopped position. Hold valve down only so long as necessary to properly start
the advance (1 second). “RETRACT’ and “STOP” trip tabs need
only be depressed briefly to achieve proper response.
Located between and piloting within the “RETRACT” and “STOP”
valves is actuator (40521-1) with the two trip tabs (40523-1) pilot-
ACCESS PORT FOR LEAD NUT
TENSION ADJUSTMENT
ing on the actuator with set screws provided to hold a positive setting between either trip tab and the actuator (page 4). It is the
purpose of the adjustable trip tabs to provide contact with the
bracket on the traversing spindle drive and properly actuate the
“RETRACT” and “STOP” valves to achieve the proper mode. The
“START” and “RETRACT” functions may be manually operated at
the tool or remotely operated through remote inlet ports using recommended tubing, fittings and valves (see page 19 for remote
control hook-up).
Each time the “START” valve is depressed, the unit will start in the
advancing (forward) mode.
To start in the retract mode when the unit has been stopped in
mid-stroke, depress and hold retract tab to the left and press the
“START” valve and release retract tab after retraction com-
mences (see warning note above).
2
GENERAL DESCRIPTION AND OPERATION
32
Also contained in the valve section are five (5) 1/8” NPT ports for
accessory purposes. The ports and their functions are listed as
follows:
PORT “A” - provides constant line pressure. This port is used to
connect air supply to the “no-hole” sensor valve, port “G” (page
20). Do not use this port to supply another unit.
PORT “B” - use for remote start input (page 19).
SPINDLE AND LEAD SCREW SECTION has provisions for primary mounting and houses the spur gear drive train, lead screw
shaft, lead screw assembly, main drive spindle and sleeve and a
“no-hole” sensor valve located in rear housing (45443), see page
20.
The spindle is mounted in a precision sleeve by a pair of ball bear-
ings and a precision roller bearing.
The spindle sleeve is mounted within two precision finished
bronze bushings contained in the spindle housing. The spindle is
connected to the lead screw shaft thru a rigid, no-back-lash coupling. The spindle is free to rotate but axially retained in the sleeve
by the ball bearings. The lead screw shaft is driven thru a sliding
PORT “C” is pressurized during the advance and retract cycles
and is not pressurized when the unit is stopped. This port can be
used to control a valve for coolant, cycle completion, etc. (page
21).
PORT “D” is used to connect port “F” of the “no-hole” sensor
valve to the retract valve in the valve housing (page 20).
PORT “E” - use for remote retract input (page 19).
spline connection with a final gear of the three spur gear system.
Feed is accomplished by connecting the lead screw to the rotating
lead screw shaft by means of another rigid, no-back-lash coupling. The lead nut within the lead screw housing has provisions
for tension adjustment with the lead screw. The tension adjustment provision is accessible from the outside of the lead screw
housing by removing pipe plug (Y227-2-L). The lead screw and
nut assembly is easily accessible from the rear of the tool by removing three (3) screws (Y154-53) and housing (45443) and
may be changed to provide another pitch in 10 minutes or less
(see page 5).
The non-interchangeable spur gear system is easily accessible
for maintenance.
-
-
_
POWER UNIT SECTION is comprised of a reversible motor as- mensurate with the planetary gear reduction of a specific model.
sembly and housing and bolt-on type planetary gearing. The
“2200” series motor develops .60 horsepower at approximately
half of free speed. The torque and free speed developed is com-
MOUNTING the unit is accomplished with 5/16”-18 bolts or cap
screws from the underside of the fixture. Keyways are provided in
the units two mounting feet (page 27) and it is recommended that
The planetary gearing is accessible and completely interchangeable for easy change of tapping speed. A typical change of
speeds may be accomplished in 15 minutes or less (see page 12).
keys be used for alignment of the unit to the fixture. Keys (45060)
- .500” wide x .375” thick x 1.000” long -are available as optional
equipment.
SET-UP PROCEDURE
SET-UP PROCEDURE: The ARO Lead Screw Tapper is adaptable to many applications. Its maximum stroke of 2” can be reduced to a minimum stroke of 3/16” by adjusting the “RETRACT’
and “STOP” trip tabs, located beneath the nameplate door. Any
stroke setting of less than 2” can be positioned at any point within
the 2” length by properly setting the trip tabs.
When shipped from the factory, the spindle is in its full retracted
position with the internal sleeve bracket addressing the “STOP”
trip tab and the inside edge of the trip tab directly under the zero (0)
index line on the gauge plate (step 1). The unit is thus properly calibrated forstroke indication. In this position, the unit should remain
stopped when air is admitted to the main air inlet.
IMPORTANT NOTE: Adjustment of the trip tabs should be made
BEFORE connecting air pressure to the tool or with the air supply
line to the tool shut off and exhausted (drained) of compressed air.
Prior to setting the stop trip tab, the spindle will have to be ad-
vanced at least 1/4” in order to allow moving the stop tab to the left
(trip bracket 41235 must be moved away from trip tab). To accomplish this, rotate chuck until trip bracket has moved sufficiently forward to allow the stop trip tab to be moved to the desired position.
The purpose of setting the stop trip is to prevent excessive “cutting of air” during the advance cycle, decreasing cycle time and
increasing production.
RETRACT TAB-’
ACTUATOR 40521-1
DESIRED TAP PENETRATION
L
STOP TAB
TRIP BRACKET 41235
The following example of set-up (figure 1) is given to explain the
setting of the “RETRACT” and “STOP” trip tabs.
Determine the distance between the tap and the desired tap
1.
penetration into the workpiece (3/4” in illustration). Loosen
set screw in retract trip tab one (1) turn and slide tab so the
inside edge of the tab is aligned with the 3/4” mark on the index scale. Tighten set screw (step 1).
To determine the distance necessary to retract the tap to suf-
2.
ficiently clear the workpiece (9/16” in illustration), subtract a
constant of 1/16” from the 9/16” (9/16” - 1/16” = 1/2”). Subtract the remainder (1/2”) from the previously set desired tap
penetration (3/4”) to yield 1/4” (3/4” - 1/2” = 1/4”). Loosen set
screw one turn in stop trip tab and slide tab so the inside edge
of tab is aligned with the 1/4” mark on the index scale (step 2).
Subtraction of the constant 1/16” is necessary to allow for the
spindle over-running the set stop position by l/l 6”.
Once set, the depth control will consistently repeat within .005”,
assuming stable air pressure is maintained (90 p.s.i.g.) at the air
inlet.
BEFORE STARTING tool, be sure pitch of tap and lead screw
match. Thread pitch is etched on both the lead screw and lead
screw nut.
1/16 CLEARANCE
TOTAL DESIRED RETRACT LENGTH
FIGURE 1
(PUSH LEFT TO RETRACT)
POSITION OF TRIP TABS AFTER UNIT HAS BEEN ADVANCED
AND STOPPED, SHOWING 1/16” OVERRIDE
STEP 2
(PUSH RIGHT TO STOP)
TAB
POSITION OF TRIP TABS AFTER COMPLETE CYCLE AND WITH
1/16” OVERRIDE
FIGURE 2
SET-UP PROCEDURE
The following items must be given proper consideration to correctly apply the ARO Lead Screw Tapper.
1.
Accuracy of positioning the tapdrilled hole with the tapper (X,
Y and Z axis).
2. Speed at which the material should be tapped (S.F.M., see
page 29)
3. Size and diameter variation of the hole to be tapped (% of effective thread height).
4. Length - diameter - pitch ratio of thru or blind hole -chip size
- amount of chips -compaction of chips in hole bottom - chip
load on flutes.
5. Coolant or no coolant used -chip flushing and friction of tap
to material (see page 29).
6. Cutting face angle of tap per material (see page 29).
Under favorable conditions, the rated capacity of a given model
tapper may be exceeded.
Where the position of the tap drilled hole is held reasonably close
with the tapper (X -Y position), the standard tap chuck is recommended for the application.
Where the X - Y position of the tap drilled hole varies too greatly to
maintain proper cutting conditions, a floating Collet holder is recommended. The Collet holder has floating capability of .030” T.I.R.
parallel float to compensate for hole shift. This floating holder will
also compensate for about .004” maximum hole angularity. Floating holder and colltets used with holders are listed under “ACCESSORIES”, page 22.
It is essential, during the operation of the unit, to have the stroke
adjustment cover door (nameplate) closed to prevent contamination entry (cutting oil, chips, etc.) into the spindle sleeve area.
Coolant or cutting oil flow should never be directed to the region of
the cover door.
Lead screw and nut may be changed without disturbing any other
section of the tool. Disconnect tool from air supply or shut off air
supply to tool and exhaust (drain) air line to tool of compressed air
before continuing further. Disconnect tubing from sensor valve
ports. Remove three (3) screws (Y154-53) and washers
(Y14-10), housing (45443) spring (49533) and spacer (44848).
Using a wrench on flats at rear of shaft (40516-1), rotate shaft
clockwise, advancing drive spindle approximately 1/4”, or until trip
bracket (41235) is no longer in contact with trip tab (40523-1).
M104
32
CAUTION: If the tool is mounted in a vertical or near vertical position, block the chuck end of drive spindle to prevent the spindle
from dropping down when lead screw and nut are removed. Remove two (2) set screws (45445) from lead screw (41258-).
NOTE: Small end of tapered hole in shaft (40516-1) is identified
by an “X” stamped on one side of flats at end of shaft. Insert a
punch thru lead screw at side identified with “X” and lightly tap
punch to remove taper pin (45446). After removal of taper pin, pull
on lead screw to remove lead screw and nut assembly (45453-).
REASSEMBLY
Assemble lead screw and nut assembly to shaft (40516-1), aligning holes in lead screw with tapered hole in shaft. Assemble taper
pin (45446) - small end first -thru lead screw and shaft from the
side opposite the “X” identification mark on the shaft and assemble one set screw (45445) into the same hole in lead screw,
tightening the set screw against taper pin, forcing the pin into lock
position. Torque the set screw to 40 in. Ibs. Assemble the other set
screw (45445) in the opposite side of lead screw and torque to 35
in. Ibs.
Remove block from chuck end of spindle if used, and rotate shaft
(40516-1) if necessary to insure lead screw nut is properly positioned into housing (40508-2), slot in lead nut aligned with dowel
pin in housing. Insure lead screw and nut area contains proper
amount of grease (see “Air and Lube Requirements”, page 6) assemble spacer (44848), spring (49533) and housing assembly
(45452) and adjustment nut (45444) and secure with washers
(Y14-10) and screws (Y154-53).
LEAD NUT TENSION ADJUSTMENT
Remove pipe plug located at the side of lead screw housing
(40508-2). Set trip tabs so the unit will cycle with a minimum of 1”
stroke length. Operate the unit and, using an allen type wrench,
slowly tighten adjustment screw until load is noted on motor (motor noise decreases slightly).
Remote control of start and retract functions is achieved by
introducing air pressure into the proper remote control port (see
pages 2 and 19). The unit is equipped with built-in check valves to
assure free flow to the tool but checks the signal from leaving the
tool thru the remote control line.
5
AIR AND LUBE REQUIREMENTS
FOR LUBRICATION OF
GEARING ASSEMBLY
FOR LUBRICATION OF
GEARING ASSEMBLY
LUBRICATION POINTS
(GREASE FITTING LOCATIONS)
Air pressure of 90 p.s.i.g. (6.2 bars) at the air inlet of the tool is required for maximum motor efficiency. An air regulator should be’
installed to maintain this pressure when the tool is in operation.
ARO will not guarantee directional response when the pressure
drops below 60 pounds (operating) at the air inlet of the tool, or an
oiler/filter is not used.
Filtered and oiled air will allow the tool to operate more efficiently
and yield a longer life to operating parts and mechanisms. A line
filter capable of filtering particles larger than 50 microns should be
used with a line oiler.
A Filter/Regulator/Lubricator (F.R.L.) assembly is recommended
for use with this air tool. The capacity of the individual Filter-Regulator-Lubricator is adequate to provide clean (40 micron), oiled
and regulated air for the tool. See page 18 for recommended FR-L systems.
RECOMMENDED HOSE SIZE: See page 18 for recommended
power air inlet systems.
- FOR LUBRICATION OF
LEAD SCREW AND LEAD
SCREW NUT
NOTE: MUST ALWAYS BE 1/2
TO 2/3 FULL OF GREASE
Inject grease (40036-1) - 2 to 3 strokes - thru all grease fittings
after each 40 hours of operation, or as experience indicates. Cavity of housing (45443) and cavity of adjusting nut (45444) should
be kept 1/2 to 2/3 full of grease (40036-1). When assembling lead
screw and lead nut to tool, lubricate internal threads of lead nut
and threads on lead screw liberally with grease (40036-1) and fill
cavities of housing and adjusting nut from 1/2 to 2/3 full.
RECOMMENDED LUBRICANTS:
MOTOR: Spindle oil 29665, 1 qt. (.9 liter) or equivalent type 1 light
oil. Consult manufacturer of air line lubricator used to insure
equivalent oil used is compatible with construction of lubrica-
tor bowl.
LEAD SCREW, GEARS, BEARINGS, ETC.: Grease 400361,1
lb. (.45 kg) container, or equivalent grade containing molyb-
denum disulfides.
“0” RING: Lubricant 36460, 4 oz. (113 g) tube.
PART NUMBER WHERE USED
29665
40036-1 GEARS & BEARINGS
36460 “0” RINGS & LIP SEALS
AIR MOTOR
6
DESCRIPTION
A HIGH QUALITY LIGHT TURBINE OR SPINDLE OIL, RUST INHIBITED, WITH A VISCOSITY OF 100-150 S.U.S. AT
100” F. OIL IS COMPATIBLE WITH POLYCARBONATE TYPE AIR LINE LUBRICATOR BOWLS.
A HlGH QUALlTY “EP” EXTREME PRESSURE MOLYBDENUM GREASE SUlTABLE FOR CLUTCH APPLICATIONS,
NLGI NO. 1, FREE OF CORROSIVE MATTER AND FILLERS, WITH A VISCOSITY OF 500-700 S.U.S. AT 100” F.
A STRINGY LUBRICANT FOR RUBBER SEALS, WITH GOOD ADHESIVE QUALITIES.
MODEL IDENTIFICATION
Model numbers are comprised of the basic model number, thread pitch or lead of the lead screw and American or Metric thread as shown
M104
82
in the following:
Basic Number
Dash Number lndicates Lead or Pitch
The basic difference in the Lead Screw Tapper models is in the combination of gearing assemblies (gear ratio) which determines the
rated free speed (r.p.m.) of the tool as shown in the table below.
MODELS
8656-BXX-A
8657-BXX-A
8658-BXX-A
8659-BXX-A
1/2”
7/16”
3/8”
5/16”
CAPACITY
I
R.P.M.
METRIC
14 mm
12
mm
10mm
8mm
7mm 2.400
I
175
325
600
1,300
40834
40833
40833
GEARING
I
I
I
I 41370
DRIVE
41371
41371
41370
41371
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AIR TUBE
(2 REQ’D)
41219-5
41219-5
41219-5
41219-4
41219-4 I
The complete model number, which includes the numbers indicating the pitch or lead of the lead screw, is shown in the table below.
Where model numbers are omitted from the table, the lead screw is not compatible with the rated free speed of the tool. The complete
lead screw and nut assembly, as furnished with a particular model, is also shown in the table. See page 22 for pans breakdown of lead
screw and nut assembly.
NUT ASSEMBLY
MODELS WITH METRIC THREAD LEAD SCREW
.40
.45
.50
.60
.70
.75
.80
1.00
1.25
1.50
11
12
13
14
16
,I(
20
24
27
28
32
38
40
44
48
56
8655-B6-A
8655-B7-A
8655-B9-A
8655-B10-A
8655-B11-A
8655-B12-A
8655-B13-A
8655-B14-A
8655-B16-A
8655-B18-A
8655-B20-A
8655-B24-A
8655-B27-A
8655-B28-A
8655-B32-A
8655-B36-A
8655-B40-A
8655-B44-A
8655-B48-A
8655-B56-A
‘STALL TORQUE
8656-B4-A
8656-B5-A
8656-B6-A
8856-B7-A
8656-B9-A
8656-B10-A
8656-B11-A
8656-B12-A
8656-B13-A
8656-B14-A
1 8656-B16-A t
8656-B18-A
8656-B20-A
8656-B24-A
8656-B27-A
8656-B28-A
8656-B32-A
8656-B36-A
8656-B40-A
8656-B44-A
8656-B48-A
8656-B56-A
8657-B2-A
8657-B4-A
8657-B5-A
8657-B6-A
8657-B7-A
8657-B8-A
8657-B9-A
8657-B10-A
MODELS WITH AMERICAN THREAD LEAD SCREW
8657-B11-A
8657-B12-A
8657-B13-A
8657-B14-A
8657-B16-A
8657-B18-A
8657-B20-A
8657-B24-A
8657-B27-A
8657-B28-A
1
1 8657-B32-A 1 8658-B32-A 1 8659-B32-A 1 45453-32
8657-B36-A
8657-B40-A
8657-B48-A
8658-B2-A
8658-B3-A
8658-B4-A
8658-B5-A
8658-B6-A
8658-B7-A
8658-B8-A
8658-B9-A
8658-B10-A
8658-B13-A
8658-B14-A
8658-B16-A 1
1
8658-Bl8-A
8658-B20-A
8658-B24-A
8658-B27-A
8658-B28-A
1 8658-B36-A
8658-B40-A
1
1
8658-B48-A
8659-B2-A
8659-B3-A
8659-B4-A
8659-B5-A
8659-B6-A
8659-B7-A
8659-B8-A
1
8659-B24-A
8659-B27-A
1
8659-B28-A
1
8659-B36-A
1 8659-B40-A
8659-B44-A
1
8659-B48-A
1
1
1
1
1
1
45785-45
45785-50
4578560
45785-70
45785-75
45785-80
45785-100
45785-125
45785-150
45453-11
45453-12
45453-13
45453-14
45453-16
45453-18
45453-20
45453-24
45453-27
45453-28
45453-36
45453.40
45453-44
45453-48
I
1
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1
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1
7
MAINTENANCE
Disconnect air supply from the tool or shut off air supply and exhaust (drain) line of compressed air BEFORE performing maintenance or service to tool.
Tool maintenance and repair should be performed by authorized,
trained, competent personnel. Maintenance and repair records
should be maintained on all tools. Insure tool is receiving adequate lubrication, as failure to lubricate can create operating
conditions resulting in excessive wear. Insure that the air supply
lines and connectors are of the proper size to provide a sufficient
quantity of air to the tool.
Air tools are made of precision parts and should be handled with
reasonable care when servicing. Excessive pressure exerted by
a holding device may cause distortion of a part. Apply pressure
evenly when disassembling or assembling parts which have a
press fit. When removing or installing bearings, apply pressure to
the bearing race that will be the press fit to the mating part; if this is
not practiced, Brinelling of the bearing races may occur, making
replacement necessary. It is important that the correct tools and
fixtures are used when servicing this air tool.
DISASSEMBLY AND REASSEMBLY OF TOOL
Disconnect air supply from the tool or shut off the air supply and
exhaust (drain) line of compressed air BEFORE performing maintenance or service to the tool.
Before starting to disassemble or reassemble this tool (any part or
completely), be sure to read “Maintenance Section”.
Disassembly should be done on a clean work bench with a clean
cloth spread to prevent the loss of small parts. After disassembly
is completed, all parts should be thoroughly washed in a clean solvent, blown dry with air and inspected for wear levels, abuse and
contamination. Double sealed or shielded bearings should never
be placed in a solvent unless a good method of relubricating the
bearing is available. Open bearings may be washed but should
not be allowed to spin while being blown dry. When replacement-
parts are necessary, consult the drawing containing the part.
Before reassembling, lubricate parts where required. Use ARO
33153 grease, or equivalent, in bearings. Use ARO 36460 “0”
ring lube for “0” ring assembly. When assembling “0” rings or
parts adjacent to “0” rings, care must be exercised to prevent
damage to the rubber sealing surfaces. A small amount of grease
will usually hold steel balls and other small parts in place while assembling.
When ordering parts, be sure to list part number, part name,
model number and serial number of tool. Use only genuine
ARO replacement parts.
screws (Y154-53). Remove four (4) screws (Y154-54) and
washers (Y14-10). Lift valve section to clear bracket (41235) and
pull forward carefully to disengage air tubes (41219-). If air tubes
remain with valve section, pull carefully to remove.
POWER UNIT SECTION
-
-
To minimize the possibility of parts damage, and for convenience,
the steps for disassembly or reassembly listed on the following
pages are recommended.
Listed below are the three (3) basic sections of the tool and
instructions for removing them.
VALVE SECTION
Remove three (3) screws (Y154-53). housing assembly (45452)
spring (49533) and spacer (44848) from the rear of the tool. Place
a suitable wrench on flats of shaft (40516-1) and rotate shaft
clockwise until bracket (41235) has advanced far enough forward
so it no longer contacts stop trip tab (40523-1). If only the valve
section is being removed from the tool at this time, replace spacer
(44848), spring (49533) and housing (45452) and secure with
Remove four (4) screws (Y154-55) and washers (Y14-10) and
pull motor and gearing section from housing section. If the unit is
equipped with both drive and auxiliary gearing, remove four (4)
screws (Y154-52) and washers (Y14-10) and pull gearing from
motor section. Grasp end of rotor and pull to remove motor as-
sembly from housing.
SPINDLE AND LEAD SCREW SECTION
The lead screw and nut assembly (45453-) can be serviced without removing the tool from the fixture mounting. To remove from or
reassemble to tool, see “Lead Screw and Nut” on page 5.
For complete disassembly of a particular section, refer to the appropriate section contained in the following pages.
For additional maintenance information, the manual “Tips on Air Tools”, form 5946 (English) or form 2158-X
to: The ARO Corporation, One Aro Center, Bryan, Ohio 43506, Attn: “Sales Training”.
8
(Spanish), is available at $5.00 each, send request
TYPICAL CROSS SECTION OF TOOL
M104
32
STOP SIGNAL VALVE
SECTION A-A
OPEN
SPINDLE HAS ADVANCED SUFFICIENTLY TO
ALLOW BRACKET TO MOVE CLEAR OF TRIP
TAB, THUS ALLOWING STOP SIGNAL VALVE
TO CLOSE.
STOP SIGNAL VALVE CLOSED
&
INSTALL WIPER IN THIS POSITION
9
VALVE SECTION
DISASSEMBLY
To remove manifold (42432-1) remove six (6) cap screws
(Y154-57) and four (4) washers (Y14-10). NOTE: Springs
(31125) and balls (44967) are loose parts and may drop out. To
remove valve stem (40522) and spring (31125) remove pipe plug
(Y227-2-L). NOTE: Gaskets (40524 and 45459) should be replaced with new gaskets if manifold is removed from valve housing.
To remove valve pistons and/or components from valve housing
(40511-1); remove screws (Y132-107-C) valve plates
(40525-1) and gaskets (41222-1).
CAUTION: Exercise reasonable care when disassembling or assembling valve parts, so as not to cause damage to outside diameter of bushings, pistons. valves or bore diameters of bushings or
housing.
Remove end pistons (41213) using a number 8-32 machine
screw threaded into threads of piston. Pull out to remove. Tap end
of housing lightly with a soft face hammer until bushing extends
from housing enough to grasp with fingers and remove bushing
with valve stem and other piston. Remove valve stem and piston
from bushing.
Using a non-metallic rod (1/4” max. dia.), press spacer (41234)
and other bushing, valve stem and piston out opposite end of
housing. NOTE: Replace all “0” rings with new “0” rings when
reassembling.
Assemble valve stem (40522) with “0” ring (Y325-7) and spring
(31125) to manifold and secure with pipe plug (Y227-2-L). Assemble balls (44967) and springs (31125) to manifold. Assemble
“0” rings (Y325-14) to manifold.
Assemble “0” rings (Y325-17) to spacer (41234) and assemble
to housing with large hole in spacer facing towards front end of
housing (see cross section below).
Assemble “0” rings (40284 and Y325-17) to bushings (41214-1
and 41215). Assemble “0” rings (Y325-15) to pistons (41213).
Assemble “0” rings (15066) to valve (41217-1).
Assemble valve (41217-1) and pistons (41213) to bushing
(41214-1) and assemble bushing to housing. NOTE: See cross
section view below for correct installed position of bushing, piston
and valve stem.
Assemble valve stem (41216) and pistons (41213) to bushing
(41215) and assemble bushing to housing, NOTE: Align slots in
bushing with exhaust holes in housing as shown in auxiliary view
on page 11. Assemble pistons as shown in cross section view below.
Assemble trip tabs (40523-1), with spacers (41572), to actuator
(see correct assembled position below) and secure with screws
(45457). Assemble retaining rings (Y 145-18) to actuator. Position
actuator in housing and assemble valves (40522) with “0” rings
(Y325-7) to housing and pins of actuator, securing actuator in
housing.
To remove actuator and pin assembly; remove springs (39452)
move actuator to the extreme left and remove valve stem (40522)
from left side of housing. Slide actuator to extreme right and remove othervalve stem (40522) from that end of housing. Actuator
and pin assembly can now be removed from housing. To remove
trip tabs; remove retaining ring (Y145-18) from actuator, loosen
screw (45457) and slide trip tab off actuator.
To remove screen (41266) remove screws (Y8-243-C) and plate
(41246-1).
REASSEMBLY
It is recommended “0” rings be replaced with new “0” rings when
reassembling. Lubricate all “0” rings with 36460 lubricant and
coat pistons and valve stems with 29665 spindle oil when assembling.
WRONG
BOTTOM VIEW OF TRIP TABS SHOWING
CORRECT ASSEMBLED POSITION.
Assemble springs (39452) gaskets (41222-1) spacer (46496)
and valve plates (40525-1) to housing and secure with screws
(Y132-1074). NOTE: Torque screws to 45 - 55 in. Ibs.
When assembling the valve section to tool, be sure bracket
(41235) page 17, is positioned between the two trip tabs and air
tubes are properly aligned. Secure valve section to spindle housing with cap screws (Y 154-54) and washers (Y14-10).
RIGHT
CROSS SECTION THRU VALVES
10
ASSEMBLE PISTONS WITH THREADED
HOLE POSITIONED AS SHOWN
ASSEMBLE WITH
HOLE AS SHOWN
LARGE
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