Ingersoll-Rand AF1260-XX User Manual

OPERATOR’S MANUAL AF1260-XX

WARNING

WARNING

AF1260 AF1260-01

CAUTION

INCLUDING: SERVICE KITS, TROUBLESHOOTING, PARTS LIST,
DISASSEMBLY & REASSEMBLY.

RELEASED:
REVISED:

(REV. 02)

12” AIR MOTORS

6” STROKE

Also covers 637489 service kits

READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.

It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.

THIS MANUAL COVERS THE FOLLOWING MODELS

MODEL

AF1260 AF1260-01

SERVICE KITS

Use only genuine ARO® replacement parts to assure com-



patible pressure rating and longest service life.
637489 for general repair of all air motors.



GENERAL DESCRIPTION

DO NOT EXCEED MAXIMUM OPERATING

PRESSURE AS INDICATED ON PUMP MODEL PLATE.

REFER TO GENERAL INFORMATION SHEET
FOR ADDITIONAL SAFETY PRECAUTIONS AND IMPOR­TANT INFORMATION.

This manual only covers the air motor section. It is one of



four documents which support an ARO pump. Replace­ment copies of these forms are available upon request.

Pump Model Operator’s Manual.



General Information for Air Operated or Hydraulically



Operated Pumps.

Lower Pump End Operator’s Manual.



Air or Hydraulic Motor Operator’s Manual.



The 12” air motor is a general purpose power unit and



is used with many 2-ball and chop check pumps. It uti­lizes tie rod type construction for easy breakdown and it
connects to the various lower ends via tie rods for easy
operation. Consult pump model operator’s manual for
specic instructions.

MODEL DESCRIPTION CHART

A F 12 X X – XX

Air Motor Diameter

12 - 12”

Stroke Length

6 - 6”

Air Motor Base/Rod Combination

0 - Divorced pump base with quick coupled rod connection
(See Figure 3)

Air Motor Options

01 – Integrated On/O Valve and Regulator

OPERATING AND SAFETY PRECAUTIONS

DO NOT EXCEED MAXIMUM AIR INLET PRESSURE OF



90 P.S.I. (6.2 BAR) OR 75 CYCLES PER MINUTE.

High pressure equipment – Always dis­connect air supply and relieve material pressure be­fore attempting to service.
A ground lug is located on the air motor. This ground



lug allows proper grounding of the pump.

[A] = Aluminum [D] = Acetal
[B] = Buna Nitrile [PP] = Polypropylene
[Br] = Brass [SS] = Stainless Steel
[Bz] = Bronze [Ef] = Epoxy - Fiberglass Filament Reinforced
[C] = Carbon Steel [CK] = Ceramic

DISASSEMBLY OF AIR MOTOR

NOTE: All threads are right hand.

Force the piston assembly up by pushing the (115) rod

1.
toward the top of the air motor.
Remove the (201) muffler/muffler assembly for ease of

2.
disassembly.
Remove the four (138) socket head screws from the (140)

3.
head manifold and the one (138) socket head screw form the
(122) head plate. Remove the (140) head manifold by pull­ing up and outward to remove from tubes (114) and (137).
Remove (141) major gasket from the (140) head mani

4.

Figure 1

MATERIAL CODE

8-16-10
8-10-12

fold.

(continued on page 3)

INGERSOLL RAND COMPANY LTD

209 NORTH MAIN STREET – BRYAN, OHIO 43506

[phone]  FAX [phone]



© 2012 CCN 15331416

PARTS LIST / AF1260-XX

Item Description (Qty) Part No. [Mtl]

101 Base & Bearing (1) 66507-1 [A]
109 Nut
111 O-Ring



112 Cylinder (1) 96941 [Ef]
113 O-Ring



114 Tube (1) 96872 [C]

*115 Rod (1) [SS]

116



*117 Piston (1) [A]

*119 Bushing (1) [C]
*120 Trip Rod Assembly (1) [A]

121 Bolt
122 Head Plate (1) 96863 [A]
123 O-Ring



124 O-Ring



125 Cap (1) 96897 [D]
126 Sleeve (1) 96901 [Br]
127 Ground Lug (1) 96878 [Bz]

128 O-Ring



129 Snap Ring
130 Washer (1) 96894 [C]
131 Pin (1) 96895 [C]
132 Driver (1) 96868 [C]
133 U-Cup



134 Spool (1) 96875 [A]
135 Vent Bushing (1) 96896 [D]

136



137 Tube (1) 96871 [C]
138 Socket Head Screw
140 Head Manifold (1) 96858 [A]
141 Major Gasket (1) 96900 [B]



142 Valve Plate (1) 96884 [CK]
143 D-Valve (1) 96889 [D]
144 Valve Housing (1) 96866 [A]
145 Socket Head Screw
146 Pilot Insert (1) 96882 [D]

147 Pilot Valve Plate (1) 96883 [CK]

148 Pilot Gasket (1) 96899 [B]



149 Vent Plug (1) 96906 [D]

150 Pilot Cover (1) 96865 [A]

152



153 Washer (1) 92216 [Br]
154 Snap Ring (1) Y147-237 [C]
155 Muer (1) 96916 [C]
201 Muer Kit
202 Regulator / Shut-O

*203

 Items included in Service Kit (637489).

For simplification of ordering and stocking, the Universal Ser­vice Kit contains service parts that can be used for every size of
air motor. When repairing the motor, use only the parts that are
needed for that specific motor. Extra service parts from the kit
will remain after repair of the air motor.

(1/2” - 20)

(1/8” X 11 3/4” o.d.)

(1/16” X 3/4” o.d.)

(1/4” X 12” o.d.)

O-Ring

(1/2” - 20 x 10 1/4”)

(3/32” X 1/2” o.d.)

(1/16” X 2” o.d.)

(1/16” X 1 11/16” o.d.)

(3/16” X 1 1/2” o.d.)

(5/32” X 1 3/8” o.d.)

U-Cup

(1.180” o.d.)

(5/16”-18 X 1”)

(5/16”-18 X 4 1/2”)

(8) Y11-8-C [C]
(2) Y325-277 [B]

(4) Y325-24 [B]

Y325-452

(1)

(8) 94046-1 [C]

(1) Y325-109 [B]
(1) Y325-32 [B]

(1) 96917 [B]
(1) Y147-7 [C]

(1) 96908 [B]

(1) 96907 [B]

(9) Y99-52 [C]

(2) Y99-516 [C]

U-Cup (1) Y186-24 [B]

(Optional, See Fig. 4)

(Optional, See Fig. 4)

Piston Assembly

and 120)

Lubriplate FML-2 Grease Packet



(Includes items 115, 117, 119

(1/4 oz.)

(1) 67445-5 [C]
(1) 67442

(1) 67499

(2) 94276

[B]

138

150

148

�

146

�

121

*203

Not User

Serviceable

�

�

122

111

147

126

135

131

�

�

�

�

�

136

134

130

128

125

124

123

154

152

149

144

138

133

132

129

119

120

115

153

145

143

�

�

127

111

116

117

112

�

142

�

141

113

�

137

113

�

�

�

TORQUE SEQUENCE

7

140

113

137

113

155

138

�

�

5

 TORQUE REQUIREMENTS 

NOTE: DO NOT OVERTIGHTEN FASTENERS.

101

2

3

Tighten (109 & 121) to 10-15 ft-lbs (13.6-20.3 Nm)

Tighten (138 & 145) to 50-60 in-lbs (5.6-6.8 Nm)

LUBRICATION / SEALANTS

 NOTE: Lubricate with Grease (ARO p/n 94276).

Page 2 of 4 AF1260-XX (en)

Figure 2

109

4

6

1

8

DISASSEMBLY OF AIR MOTOR (CONT’D)

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

5.
Remove the four (113) O-rings from both tubes (114) and

6.
(137).
Remove the (142) valve plate and the (143) D-valve from

7.
the (144) valve housing.
Remove the four (138) socket head screws to extract the

8.
(150) pilot cover.
Remove the (148) pilot gasket from the (150) pilot cover.

9.
Remove the (147) pilot valve plate and the (146) pilot

10.
insert from the (144) valve housing.
Remove the two (145) socket head screws from the (144)

11.
valve housing.
Remove the (144) valve housing by pulling straight up.

12.
Remove the (124) O-ring, the (135) vent bushing, and the

13.
(136) U-cup from the (144) valve housing.
Remove the (128) O-ring and the (126) sleeve from the

14.
motor assembly by sliding it straight up.
Pull the (134) spool as far from the motor assembly as

15.
possible to expose the under side of the spool itself.
Locate and remove the (129) snap ring from the (134)

16.
spool utilizing snap ring pliers.
Lift to remove the (134) spool and remove the (133)

17.
U-cup from it.
Slide the (131) pin to remove the (132) driver, (130) washer,

18.
and (129) snap ring from the (120) trip rod assembly.
Remove the eight (109) nuts from (121) hex head bolts.

19.
Remove the eight (121) bolts from the (122) head plate

20.
and the (101) base assembly.
Remove (122) head plate from the (112) air cylinder.

21.
Remove the (111) O-ring, the (125) cap, and (123) O-ring

22.
from the (122) head plate.
Pull upward on (112) air cylinder until (203) piston as-

23.
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.
If the (112) air cylinder and (203) piston assembly are

24.
removed as one unit, then remove the (203) piston as­sembly from the (112) air cylinder.
Remove the (116) O-ring from the (117) piston.

25.
Remove the (111) O-ring from (101) base assembly.

26.
Remove (154) snap ring, (153) washer, and (152) U-cup

27.
from the (101) base assembly.

REASSEMBLY OF AIR MOTOR

Apply grease to all O-rings, U-cups, and other rubber

1.
goods before installing.
Install (152) U-cup, (153) washer, and (154) snap ring into

2.
the (101) base assembly.
Install the (111) O-ring in the groove on the (101) base

3.
assembly.
Install the (116) O-ring in the groove on the (117) piston.

4.
Push (115) piston rod thru the (101) base assembly, be-

5.
ing careful not to damage the lips of the (152) U-cup or
the (102) O-ring.
Lubricate the inside diameter of the (112) air cylinder and

6.
slide it down over the (203) piston assembly and onto the
(101) air motor base assembly.
Align notch in (122) head plate with the port in (101) base

7.
assembly and press the (122) head plate down until it is
seated against the (112) air cylinder. The (120) trip rod as­sembly must lead thru the center of the (122) head plate.

Assemble the eight (121) bolts thru the (122) head plate

8.
and the (101) base assembly.
Assemble the eight (109) nuts to (121) hex head bolts

9.
and tighten per specied torque sequence and value.
Pull the (120) trip rod assembly as far out of the air mo-

10.
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.
Slide the (125) cap over the (120) trip rod assembly and

11.
down into the bore found in the (122) head plate.
Slide the (129) snap ring rst and the (130) washer sec-

12.
ondly, onto the (120) trip rod assembly.
Slide the (132) driver onto the (120) trip rod assembly.

13.
Align the hole of the (132) driver with the hole in the
(120) trip rod assembly and insert the (131) pin.
Assemble the (133) U-cup to the (134) spool. Take note

14.
of the (133) U-cup lips should point down towards the
(122) head plate.
Slide the (134) spool onto the (120) trip rod assembly over

15.
the (132) driver and insert the (130) washer behind it. Uti­lizing 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.
Lubricate the inside diameter of the (126) sleeve and

16.
slide it onto the (134) spool and locating it into the (125)
cap.
Install the (128) O-ring onto the top gland of the (126)

17.
sleeve.
Install the (136) U-cup, the (135) vent bushing into the

18.
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.
Install the (144) valve housing to the motor assembly

19.
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.
Install the two (145) socket head screws thru the (144)

20.
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 specied torque value.
Install the (146) pilot insert thru the (144) valve housing

21.
and into the (134) spool. The (134) spool may need to
be turned to orient its’ shallower slot to face the smaller
pocket of the (144) valve housing.
Install the (147) pilot valve plate into the (144) valve

22.
housing covering the (146) pilot insert.
Install the (148) pilot gasket into the (150) pilot cover

23.
and assemble to the (144) valve block using four (138)
socket head screws. Tighten to torque specications.
Install the (143) D-valve thru the (144) valve housing and

24.
into the (134) spool.
Install the (142) major valve plate into the (144) valve

25.
housing covering the (143) D-valve.
Install the four (113) O-rings onto both (114 & 137) tubes.

26.
Loosely install the (137) tube into the bore in the (122)

27.
head plate.
Loosely install the (114) tube into the bore in the (101)

28.
base assembly.

(continued on page 4)

AF1260-XX (en) Page 3 of 4

REASSEMBLY OF AIR MOTOR (CONT’D)

201

Optional

67445-5

t

202

Optional

67442

Self-Relieving

Ball Valve

Regulator / Shut-O

(AF1260-01)

TYPE -0-

Divorced Base, Quick Coupled Rod

65023 BASE and

67489 PISTON ASSEMBLY

Install the (141) manifold gasket into the (140) mani-

29.
fold and telescope onto both (114 & 137) tubes until
the (113) O-rings are seated. Fasten the (140) manifold
to the (144) valve block using four (138) socket head
screws. Install one (139) socket head screw thru the ear
of the (140) manifold into the (122) head plate. Tighten
all ve (138 & 139) fasteners to torque specications.
Install the (201) muer/muer assembly.

30.

TROUBLE SHOOTING

Air leakage out of main exhaust.

Damaged (141) track gasket. Replace (141) track gasket.



Worn (116) piston seal. Replace (116) piston seal.



Continual air leakage out (149) pilot exhaust.

Worn (136) “U” cup. Damaged (148) track gasket. Replace



(136) “U” cup and (148) track gasket.

Air leakage out (149) pilot exhaust only during the down
stroke.

Worn (133) “U” cup. Rolled or damaged (128) “O” ring.



Replace (133) “U” cup and (128) “O” ring.

Air leakage around (115) piston rod.

Worn or damaged (152) “U” cup. Replace (152) “U” cup.



Air Motor Base and Rod Combination

Figure 3

Available Options for AF0860-XX Air Motors

Page 4 of 4 AF1260-XX(en)

Figure 4

PN 97999-1474