Ingersoll-Rand 8506-A, 8515-A, 8509-A, 8521-A User Manual

Tool Products

OPERATOR’S MANUAL

INCLUDING: OPERATION, INSTALLATION & MAINTENANCE

“O” SERIES “QRT” SCREWDRIVERS

SECTION
MANUAL
Released:
Revised:

M30

33

3-l-77

l-27-95

1018-2

Models:

8506-A( ), 8509-A( ),
8515-A( ) and 8521-A( ).

READ THIS MANUAL CAREFULLY BEFORE INSTALLING,

OPERATING OR SERVICING THIS EQUIPMENT.

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

Pneumatic tools should always be installed and used in accor­dance with A.N.S.I. B186.1 “Safety Code For Portable Air Tools.”

Repeated prolonged operator exposure to vibrations which may

0

Operate this tool at 90 p.s.i.g. (8.2 bar) maximum air pressure
at the air inlet of the tool.

l

Disconnect air supply from tool before removing/installing bit
socket or device attached to tool or performing maintenance
procedures.

l

Keep hands, clothing and long hair away from rotating end of
tool.

0

Anticipate and be alert for sudden changes in motion during
start up and operation of any power tool.

a

Never exceed rated r.p.m. of tool.

l

Wear suitable eye and hearing protection while operating tool.

0

Tool shaft can continue to rotate briefly after throttle is re­leased.

l

Do not lubricate tools with flammable orvolatile liquids such as
kerosene, diesel or jet fuel.

0

Do not remove any labels. Replace any damaged label.

l

Use only accessories recommended by ARO.

be generated in the use of certain hand-held tools may produce

Raynaud’s phenomenon, commonly referred to as Whitefinger
disease. The phenomenon produces numbness and burning
sensations in the hand and may cause circulation and nerve dam­age as well as tissue necrosis. Repetitive users of hand-held
tools who experience vibrations should closely monitor duration
of use and their physical condition.

l

The use of other than genuine ARO replacement parts may
result in safety hazards, decreased tool performance and in­creased maintenance and may invalidate all warranties.

l

ARO is not responsible for customer modification of tools for
applications on which ARO was not consulted.

l

Tool maintenance and repair should be performed by autho­rized, trained, competent personnel. Consult your nearest
ARO authorized servicenter.

l

It is the responsibility of the employer to place the information
in this manual into the hands of the operator.

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

I

Wear hearing protection when
operating this tool.

Turn off air supply and disconnect

.

air supply hose before installing,
removing or adjusting any
accessory on this tool, or before
performing any maintenance on
this tool.

Air powered tools can vibrate in
use. Vibration, repetitive motions
or uncomfortable positions may
be harmful to your hands and
arms. Stop using any tool if
discomfort, tingling feeling or
pain occurs. Seek medical advice
before resuming use.

I

A WARNING

Do not carry the tool by the hose.

Do not use damaged, frayed or
deteriorated air hoses and

fittings.

Do not overreach when operating
this tool. Keep body stance
balanced and firm.

Operate at 90 p.s.i.g.
(6.2 bar/620 kPa)
maximum air pressure.

NOTICE

PN 48176-1 LABEL PN 49883 LABEL

(NON-EU MODELS) (-EU MODELS)

This label must appear on the tool at all times. If It is
lost or damaged, a replacement label Is available at
no cost.

WARNING = Hazards or unsafe practices which could result in severe personal injury, death or substantial
property damage.

J

CAUTION = Hazards or unsafe practices which could result in minor personal injury or product or property
damage.

NOTiCE = important installation, operation or maintenance information.

2

ROUTINE LUBRICATION REQUIREMENTS

M30

33

Lack of or an excessive amount of lubrication will affect the perfor­mance and life of this tool. Use only recommended lubricants at
below time intervals:

EVERY 8 HOURS OF TOOL OPERATION - Fill lubricator reser­voir of recommended F.R.L. with spindle oil (29665). If an in line or
air line lubricator is not used, apply several drops of spindle oil
(29665) in air inlet.

EVERY 160 HOURS OF TOOL OPERATION - Lubricate clutch
parts with molybdenum grease (400361). Lubricate gearing.
Pack bearings, coat shafts and lubricate gears with NLGI #1 “EP”
grease (33153). Gearing should contain approximately 1/8 oz.
(3.5 g) of grease per reduction.

AIR SUPPLY REQUIREMENTS

For maximum operating efficiency, the following air supply specifi-

cations should be maintained to this air tool:

l

AIR PRESSURE - 90 p.s.i.g. (6.2 bar)

l

AIR FILTRATION - 50 micron

l

LUBRICATED AIR SUPPLY

l

HOSE SIZE - 5/16” (8 mm) I.D.

An ARO model C28231-810 air line FILTER/REGULATOR/LU-

BRICATOR (F.R.L.) is recommended to maintain the above air

supply specifications.

Tool maintenance and repair shall be performed by authorized,
trained, competent personnel. Tools, hose and fittings shall be re­placed if unsuitable for safe operation and responsibility should
be assigned to be sure that all tools requiring guards or other safe­ty devices shall be kept in legible condition. Maintenance and re­pair records should be maintained on all tools. Frequency of
repair and the nature of the repairs can reveal unsafe application.

Scheduled maintenance by competent authorized personnel
should detect any mistreatment or abuse of the tool and worn
parts. Corrective action should be taken before returning the tool
for use.

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 sol-

vent, blown dry with air and inspected for wear levels, abuse and

contamination. Double sealed or shielded bearings should never

be placed in solvent unless a good method of m-lubricating the
bearing is available. Open bearings may be washed but should
not be allowed to spin while being blown dry.

Upon reassembling, lubricate parts where required. Use 33153
grease, or equivalent, in bearings. Use 36460 lubricant for “O”
ring assembly. When assembling “O” rings or parts adjacent “O”
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 replacement parts are necessary, consult drawing contain-

ing the part for identification.

RECOMMENDED LUBRICANTS

After disassembly is complete, all parts, except sealed or shielded
bearings, should be washed with solvent. To relubricate parts, or
for routine lubrication, use the following recommended lubricants:

Where ARO Description

Air Motor 29665

“O” Rings & Lip Seals 36460

Gears and Bearings 33153

Clutches 40036-1

1 qt Spindle Oil

4 oz. Stringy Lubricant

5 lb. “EP” - NLGI #1 Grease

1 lb. “EP” Molybdenum Disulfide

INSPECTION, MAINTENANCE AND INSTALLATION

Disconnect air supply from the tool or shut off air supply and ex­haust (drain) line of compressed air before performing mainte­nance or service to the tool.

It is important that the tools be serviced and inspected at regular

intervals for maintaining safe, trouble-free operation of the tool.
Be sure the tool is receiving adequate lubrication, as failure to lu-

bricate can create hazardous operating conditions resulting from
excessive wear.

Be sure that the air supply lines and connectors are of proper size

to provide a sufficient quantity of air to the tool.

.

Always use clean, dry air. Dust, corrosive fumes and/or excessive
moisture can damage the motor of an air tool. An air line filter can
greatly increase the life of an air tool. The filter removes rust,
scale, moisture and other debris from the air lines. Low air pres­sure (less than 90 p.s.i.g.) reduces the speed of the air tool. High
air pressure (more than 90 p.s.i.g.) raises performance beyond
the rated capacity of the tool and could cause injury. Shown below
is a typical piping arrangement.

MAIN LINES 3 TIMES
AIR TOOL INLET SIZE

SYSTEM

REGULATOR

BRANCH LINE 2 TIME/

AIR TOOL INLET SIZE

DRAIN REGULARLY

n

3

MODEL IDENTIFICATION

MODELS WITH -EU SUFFIX ARE “EC” COMPLIANT MODELS.

NOTE: GENERAL PURPOSE WRENCH 37167 FURNISHED WITH -A AND -T MODELS.

DISASSEMBLY AND ASSEMBLY OF TOOLS

Disconnect air supply from tool or shut off air supply and exhaust
(drain) line of compressed air before performing maintenance or

service to tool.

Before starting to disassemble or assemble this tool (any part or
completely), be sure to read “Inspection, Maintenance and Instal­lation” section.

To minimize the possibility of parts damage and for convenience
the steps for disassembly or assembly listed on the following gear.

pages are recommended.

The basic sections and instructions for removing them from the
tool are as follows:

Remove clutch housing from tool (left hand threads); grasp clutch
assembly and pull from gearing.

Remove drive section. Hold motor housing in a suitable fixture or

strap wrench and remove gearing using a wrench on flats of ring

Motor may be removed from housing after removal of gearing.

DRIVE SECTION

GEARING SECTION

MOTOR SECTION

TYPICAL CROSS SECTION OF TOOL

4

DRIVE SECTION

ADJUSTABLE CLUTCH

M30

33

CLUTCH ADJUSTMENT

Remove clutch assembly (36310) from tool. Place pin in hole of
jaw (36318) or wrench on square end of spindle (36311) to adjust
nut (36313). To adjust properly, release nut to least tension. Tight­en nut one or two positions -each click = one position. Assemble
clutch to tool and test torque on fastener to be tightened. Repeat
until desired torque is obtained.

DISASSEMBLY

a. Remove clutch housing (left hand threads) and bit holder as-

sembly (36322) from tool. Grasp clutch assembly and pull
from gearing.

b. Remove nut (36313) releasing washer (33609) clutch

spring, pad (36316) pins (36317) and balls (Y16-205).

c. Remove retaining ring (37243) releasing jaw (36318) key

(36319) jaw (40772) and balls (Y 16-203).

BALL (16) Y 16-203

31092,

SPRING

THRUST PLUG 310933

“O” RING Y 325-8

7

BALL Yl6-205

q

ASSEMBLY

NOTE: Lubricate balls, jaw faces, bit holder shaft, pins and thrust
pad with ARO 40036-1 grease when assembling clutch. Clutch
assembly should contain approximately 1/8 oz. (3.5 g) of grease.

a. Assemble jaw (40772) to spindle (36311) aligning face of jaw

with center of bearing groove in spindle. Assemble balls
(Y16-203) into groove and slide jaw ahead to retain balls in
groove.

b.

Assemble key (36319) and jaw (36318) to spindle and secure
with retaining ring (37243). NOTE: Assemble jaw (36318) to
spindle with small hole in face of jaw facing jaw (40772).

c. Assemble balls (Y16-205), pins (36317) thrust pad (36316)

clutch spring, washer (33609) and nut (36313). Adjust to de­sired tension (see “Clutch Adjustment”).

d. Assemble spring (31092) plug (31093) bit holder assembly

(36322) and bit to spindle and assemble to tool. Assemble
clutch housing to tool.

@PIN (6) 36317

(6) 7

\

RETAINING RING 37243

WASHER

NUT 36313

336091

BIT 30320-2

/

GUIDE ADAPTER IS PRESSED

SEE PAGE 14 FOR ADDlTlONAL GUIDE ADAPTERS

PARTS

MARKED

INTO HOUSING

CLUTCH

ASS’Y. NO.

38310-l

38310

3831 o-2

THUS

q

HIGH TORQUE
MED. TORQUE

LOW TORQUE

ARE

INCLUDED

TYPE

IN SERVICE KIT NO. 42114 AND/OR

CLUTCH

SPRING NO. TYPE WIRE WIRE THICKNESS

37872
36315
38512 ROUND

JAW 8 BIT HOLDER

ASS’Y 36322

SPRING IDENTIFICATION

FLAT
FLAT

.093” x .188”
.062” x .156”

.080” DIAMETER

42341, SEE PAGE 12.

5

DRIVE SECTION

TORQMATIC CLUTCH

CLUTCH ADJUSTMENT

Remove clutch assembly from tool. Place wrench on square end
of spindle (38322) to adjust nut (38313). To adjust properly, re­lease nut to least tension. Tighten nut one or two positions -each
click = one position. Assemble clutch to tool and test torque on
fastener to be tightened. Repeat until desired torque is obtained.

DISASSEMBLY

a. Remove clutch housing (left hand threads) and bit holder as-

sembly (38322) from tool. Grasp clutch assembly and pull
from gearing.

b. Remove nut (36313) releasing washer (33809) and clutch

spring.

c. Remove snap ring (31124) releasing retaining ring

(37241-l), retainer (38317) and spring (44888). Driver

(36319) and cams (38320 and 38321) are now free to be re­moved, releasing steel balls (Y16-203) and pins (38325).
Lockout cam (38324) and springs (38313 and 38314) are now
free to be removed.

d. Remove retaining ring (38327) releasing spacer (38316) jaw

(40771) and steel balls (Y16-204).

,

ASSEMBLY

NOTE: Lubricate balls, pins, jaw faces, lockout cam, cams, driver

and bit holder shaft with ARO 40036-l grease when assembling

RETAINING RING 36327

clutch. Clutch assembly should contain approximately 1/8 oz. (3.5
g) of grease.

a.

Place jaw (40771) on bench, cam face down, start spindle into
jaw, assemble one row of steel balls (Y16-204) and slide to
shoulder of spindle. Invert spindle and jaw, assemble balance
of steel balls (Y16-204) and spacer (38318) and secure with
retaining ring (38327).

b. Assemble lockout cam (38324) and springs (38313 and

36314) into end of spindle (38322) in proper sequence.

c. Assemble cam (38321) to spindle, tang end first. Assemble

cam (36320) onto spindle until cam face is flush with groove in
spindle, assemble first row of steel balls (Y16-203) into
groove, slip cam ahead to second groove, assemble steel
balls into second groove and slide cam ahead to secure.

d. Assemble driver (38319) over cam (38320) until face is flush

with holes in spindle, assemble pins (38325) into holes and
slide drive ahead to secure.

e. Assemble spring (44868) over shoulder of cam (38320) as-

semble spring retainer (38317) to spindle and secure with re­tainers (37241-l) and snap ring (31124).

f.

Assemble spring and washer (33609) to spindle and secure

with nut (36313). Adjust to desired tension and assemble with

bit holder assembly (36322) into housing.

SNAP RING

RETAINING RING HALF (2)

RETAINER 38317

31124

BIT 30320-2

RETAINING RING 36326

PIN (3) 36325

PARTS SHOWN BELOW THIS LINE ARE NOT lNCLUDED IN 38311- CLUTCH ASS’Y

HOUSING ASS'Y 38312-2

.

3831 I- TORQMATIC CLUTCH ASS’Y

6

GUIDE ADAPTER IS PRESSED INTO HOUSING

SEE PAGE 14 FOR ADDITIONAL GUIDE ADAPTERS