Ingersoll Rand Outboard Motor AF0860 XX User Manual

OPERATOR’S MANUAL  
AF0860-XX  
RELEASED:  
REVISED:  
(REV. 02)  
8-16-10  
8-10-12  
INCLUDING: SERVICE KITS, TROUBLESHOOTING, PARTS LIST,  
DISASSEMBLY & REASSEMBLY.  
8” 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  
AF0860  
AF0860-01  
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  
WARNING  
PRESSURE AS INDICATED ON PUMP MODEL PLATE.  
WARNING  
REFER TO GENERAL INFORMATION SHEET  
FOR ADDITIONAL SAFETY PRECAUTIONS AND IMPOR-  
TANT INFORMATION.  
This manual only covers the air motor section. It is one of  
four documents which support an ARO pump. Replace-  
ment copies of these forms are available upon request.  
AF0860  
AF0860-01  
Pump Model Operator’s Manual.  
Figure 1  
General Information for Air Operated or Hydraulically  
Operated Pumps.  
OPERATING AND SAFETY PRECAUTIONS  
Lower Pump End Operator’s Manual.  
Air or Hydraulic Motor Operator’s Manual.  
DO NOT EXCEED MAXIMUM AIR INLET PRESSURE OF  
120 P.S.I. (8.3 BAR) OR 75 CYCLES PER MINUTE.  
The 8” air motor is a general purpose power unit and is  
used with many 2-ball, 4-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  
specific instructions.  
CAUTION  
High pressure equipment – Always dis-  
connect air supply and relieve material pressure be-  
fore attempting to service.  
A ground lug is located on the air motor. This ground  
lug allows proper grounding of the pump.  
MODEL DESCRIPTION CHART  
MATERIAL CODE  
A F 08 X X – XX  
[A]  
[B]  
[Br]  
[Bz]  
[C]  
=
=
=
=
=
Aluminum  
Buna Nitrile  
Brass  
Bronze  
Carbon Steel  
[D]  
=
=
=
=
=
Acetal  
Polypropylene  
Stainless Steel  
Epoxy - Fiberglass Filament Reinforced  
Ceramic  
[PP]  
[SS]  
[Ef]  
[CK]  
Air Motor Diameter  
08 - 8”  
Stroke Length  
6 - 6”  
DISASSEMBLY OF AIR MOTOR  
Air Motor Base/Rod Combination  
0 - Divorced pump base with quick coupled rod connection.  
(See Figure 3)  
NOTE: All threads are right hand.  
1. Force the piston assembly up by pushing the (115) rod  
toward the top of the air motor.  
2. Remove the (155) muffler/(201) muffler assembly for  
ease of disassembly.  
Air Motor Options  
01 – Integrated On/Off Valve and Regulator  
3. Remove the four (138) socket head screws from the (140)  
head manifold and the one (138) socket head screw form the  
(122) head plate. Remove the (140) head manifold by pull-  
ing up and outward to remove from tubes (114) and (137).  
(continued on page 3)  
INGERSOLL RAND COMPANY LTD  
209 NORTH MAIN STREET – BRYAN, OHIO 43506  
© 2012  
CCN 15331390  
(800) 495-0276 FAX (800) 892-6276  
 
8. Assemble the six (121) bolts thru the (122) head plate  
and the (101) base assembly.  
DISASSEMBLY OF AIR MOTOR (CONT’D)  
4. Remove (141) major gasket from the (140) head manifold.  
5. Remove tubes (114) and (137) by pulling upward.  
6. Remove the four (113) O-rings from both tubes (114) and  
(137).  
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) washer,  
and (129) snap ring from the (120) trip rod assembly.  
19. Remove the six (109) nuts from (121) hex head bolts.  
20. Remove the six (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.  
9. Assemble the six (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’ shallower  
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.  
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) snap 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 or  
the (102) O-ring.  
6. Lubricate the inside diameter of the (112) air cylinder and  
slide it down over the (117) piston/assembly and onto the  
(101) air motor base assembly (see figure 2 on page 2).  
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.  
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)  
AF0860-XX (en)  
Page 3 of 4  
 
REASSEMBLY OF AIR MOTOR (CONT’D)  
AIR MOTOR BASE AND ROD COMBINATION  
28. Loosely install the (114) tube into the bore in the (101)  
base assembly.  
29. Install the (141) manifold gasket into the (140) mani-  
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 five (138 & 139) fasteners to torque specifications.  
30. Install the (155) muffler/(201) muffler assembly.  
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) “Ucup and (148) track gasket.  
TYPE -0-  
Divorced Base, Quick Coupled Rod  
65023 BASE and  
Air leakage out (149) pilot exhaust only during the down  
stroke.  
67489 PISTON ASSEMBLY  
Worn (133) “U” cup. Rolled or damaged (128) “O” ring. Re-  
place (133) “Ucup and (128) “Oring.  
Figure 3  
Air leakage around (115) piston rod.  
Worn or damaged (152) “Ucup. Replace (152) “UCup.  
Available Options for AF0860-XX Air Motors  
201  
202  
Optional  
67442  
Optional  
67445-3  
t
Self-Relieving  
Ball Valve  
Regulator / Shut-O  
(AF0860-01)  
Figure 4  
PN 97999-1472  
AF0860-XX (en)  
Page 4 of 4  
 

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