Page 1
SECTION M107
R
OPERATOR’S MANUAL
INCLUDING:ĂOPERATION,ĂINSTALLATIONĂ&ĂMAINTENANCE
SERIES 34 ELECTRA–FEED DRILL
MANUAL 15
Released: 6-1-93
Revised: 11-20-99
49999-447
Models FE034A–( )–A( )
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.
OPERATING AND SAFETY PRECAUTIONS
• Keep hands and clothing away from rotating end of tool and all
moving parts of the tool.
• Wear suitable eye protection while operating tool or when
near tool when it is being operated.
• Disconnect air and electrical supply from tool before remov-
ing/installing bits or performing other maintenance or service
procedures.
ROUTINE LUBRICATION REQUIREMENTS
When this tool was built, an “O” ring lubricant was applied to all appropriate dynamic seals to insure continued operation. Drive train
components and bearings were also supplied / filled with grease
to insure appropriate life of components. As long as all exterior
seals and wipers are maintained in good working order and all
covers and breather vents are kept in place, it is reasonable to expect that external debris will not enter the tool. It is also reasonable to expect that lubricants applied to the tool interior will require
replenishment for at least 5000 hours of normal operation.
Adding spindle oil to the power air inlet of this tool is not
necessary.
MOUNTING
Mounting clamps 49690 and 46982–1 are available for mounting
of this tool. These items are shown on page 11. Both mounts allow
the clamp to grip the outer sleeve of the tool and feature keyways
for alignment.
AIR SUPPLY REQUIREMENTS
For maximum operating efficiency, the following air supply specifications should be maintained to this air tool:
• AIR PRESSURE – 90 PSIG (6 bar)
• AIR FILTRATION – 50 micron
• HOSE SIZE – 5/16” (8 mm) I.D.
An ARO R model P29231–110 air line FIL TER/REGULATOR p l u s
100067 gauge is recommended to maintain the above air supply
specifications.
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 Used ARO Part # Description
‘‘O” Rings, Lip Seals
and Air Cylinder
Sliding Splines and
Bearings
36460 4 oz. Stringy Lubricant
33153 5 lb. ‘‘EP” – NLGI #1
Grease
For parts and service information, contact your local ARO distributor, or the Customer Service Dept. of the Ingersoll–Rand Distribution
Center, White House, TN at PH: (615) 672–0321, FAX: (615) 672–0801.
ARO Tool Products
Ingersoll–Rand Company
1725 U.S. No. 1 North D P.O. Box 8000 D Southern Pines, NC 28388–8000
E1999 INGERSOLL–RAND COMPANYD PRINTED IN U.S.A.
Page 2
MODEL IDENTIFICATION
FE 03 4 A–
XX X –A
ELECTRIC SELF–FEED TOOL
HORSEPOWER
03 = .33
4.0” MAX. STROKE LENGTH FREE SPEED
MODEL
NUMBER
FE034A–17B–A( ) 1684 49763–1 22 47 49685–1 .468:1
FE034A–19B–A( ) 1918 49763–2 24 45 49685–1 .533:1
FE034A–22B–A( ) 2178 49763–3 26 43 49685–1 .605:1
FE034A–24B–A( ) 2398 49763–4 28 42 49685–1 .666:1
FE034A–27B–A( ) 2700 49763–5 30 40 49685–1 .750:1
FE034A–30B–A( ) 3031 49763–6 32 38 49685–1 .842:1
FE034A–34B–A( ) 3398 49763–7 34 36 49685–1 .944:1
FE034A–38B–A( ) 3808 49763–7 36 34 49685–1 1.058:1
FE034A–43B–A( ) 4274 49763–6 38 32 49685–1 1.187:1
FE034A–48B–A( ) 4800 49763–5 40 30 49685–1 1.333:1
FE034A–54B–A( ) 5400 49763–4 42 28 49685–1 1.500:1
FE034A–59B–A( ) 5954 49763–3 43 26 49785–1 1.654:1
FE034A–67B–A( ) 6750 49763–2 45 24 49685–1 1.875:1
FE034A–77B–A( ) 7690 49763–1 47 22 49685–1 2.136:1
FE034A–08C–A( ) 842 49763–1 22 47 49685–2 .468:1
FE034A–10C–A( ) 959 49763–2 24 45 49685–2 .533:1
FE034A–11C–A( ) 1089 49763–3 26 43 49685–2 .605:1
FE034A–12C–A( ) 1199 49763–4 28 42 49685–2 .666:1
FE034A–14C–A( ) 1350 49763–5 30 40 49685–2 .750:1
FE034A–15C–A( ) 1516 49763–6 32 38 49685–2 .842:1
FE034A–17C–A( ) 1699 49763–7 34 36 49685–2 .944:1
FE034A–19C–A( ) 1904 49763–7 36 34 49685–2 1.058:1
FE034A–22C–A( ) 2137 49763–6 38 32 49685–2 1.187:1
FE034A–24C–A( ) 2400 49763–5 40 30 49685–2 1.333:1
FE034A–27C–A( ) 2700 49763–4 42 28 49685–2 1.500:1
FE034A–30C–A( ) 2977 49763–3 43 26 49685–2 1.654:1
FE034A–34C–A( ) 3375 49763–2 45 24 49685–2 1.875:1
FE034A–38C–A( ) 3845 49763–1 47 22 49685–2 2.136:1
SPINDLE
R.P.M.
PULLEY
SET
# OF TEETH
(ITEM 7)
# OF TEETH
(ITEM 12)
MOTOR
(ITEM 11)
CONTROL CODE
A – VALVE IN HEAD
MOTOR CODE
TOOL GENERATION
TOTAL
REDUCTION
MODELS WITH –EU SUFFIX ARE ‘‘EC” COMPLIANT MODELS.
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Page 3
INSTALLATION
The ARO model FE034A–( ) is NOT supplied with the required
motor starter . The motor starter must conform to the local/national
regulations governing the use of this type of electrical equipment
and must provide motor overload protection. The recommended
overload setting is given on the wiring diagram. The power supply,
motor starter and the motor nameplate ratings must be equivalent.
MOTOR: The electric motor develops a minimum of .33 horsepower. The voltage requirements are shown below i n the Electrical Connection Diagram.
M107
15
Connect the motor starter to the motor as shown in the wiring diagram. The minimum wire size should be AWG No. 14, or equivalent, (4107 circular mil) and conform to local/national regulations
governing the use of this type of electrical equipment.
Once the motor is connected, turn on the power supply. If the
spindle fails to rotate or rotates in the wrong direction, de–ener-
gize the motor starter immediately. Turn off the power supply and
recheck the wiring.
SET–UP PROCEDURE
ELECTRICAL CONNECTION DIAGRAM
3 PHASE, 60 Hz
654
8
9
321
LINE A
GROUND
*(60 Hz 1.6 – 2.0 amp.)
TO REVERSE ROTATION: INTERCHANGE ANY TWO LEADS.
WARNING: BE SURE THE ELECTRICAL POWER SUPPLY IS
OFF BEFORE MAKING ANY ELECTRICAL WIRING CONNECTIONS.
WARNING: FAILURE TO PROPERLY GROUND THE MOTOR
MAY CAUSE SERIOUS INJURY TO PERSONNEL.
DO NOT BLOCK THE AIR FLOW TO OR FROM THE MOTOR
COOLING FAN. DO NOT DAMAGE THE MOTOR FAN COVER.
KEEP SMALL OBJECTS CLEAR OF THE OPENINGS IN THE
FAN COVER.
LINE B
SUPPLY 230 V
* RECOMMENDED OVERLOAD SETTING.
7
LINE C
654
8
9
321
LINE A
GROUND
*(60 Hz .8 – 1.0 amp.)
LINE B
SUPPLY 460 V
7
LINE C
WARNING: Keep clear of rotating end of unit with hands and/or
clothing.
• Shut off air supply to tool.
• Loosen screw (41), releasing cover (33).
• Determine the TOTAL STROKE LENGTH the drill must travel
to perform the drilling operation.
• Loosen cap screw (28) securing yoke assembly (27) to quill
(55) and position yoke assembly on quill approximately 5/8”
(16 mm) greater distance between control valve (39) and yoke
assembly than the distance of the Total Stroke Length.
• Tighten cap screw (28), securing yoke assembly (27) to quill
(55).
• Loosen nut (29), securing cap screw (30) and turn cap screw
(30) so the distance between the head of the cap screw (30)
and control valve (39) equals the total stroke length.
• Tighten nut (29), securing cap screw (30).
• Replace cover (33), securing with screw (41).
• Attach air supply to tool.
FEED RATE CONTROL VALVES
• Turn valve (103), marked ‘‘R” at side of control assembly (93),
approximately 1–1/2 turns counter–clockwise (open) from the
closed position.
• Turn the other valve (103), marked ‘‘F” at side of control as-
sembly (93), clockwise until closed (do not tighten too snugly).
• Start the unit and slowly turn valve (103) marked ‘‘F” counter–
clockwise (open) until the desired forward rate of feed is
reached.
• A final adjustment of the rate of return (retract) can be made
with the valve (103) marked ‘‘R”.
DISASSEMBLY/ASSEMBLY INSTRUCTIONS
• Disconnect air and electrical supply ‘‘BEFORE” performing
maintenance or service to tool.
• Never apply excessive pressure by a holding device which
may cause distortion of a part.
• Apply pressure evenly to parts which have a press fit.
• Apply even pressure to the bearing race that will be press
fitted to the mating part.
• Use correct tools and fixtures when servicing this tool.
• Don’t damage ‘‘O” rings when servicing this tool.
• Use only genuine ARO replacement parts for this tool. When
ordering, specify part number, description, tool model number
and serial number.
BELT AND PULLEY SECTION DISASSEMBLY
_ Remove four screws (1), releasing cover (2).
_ Loosen cap screw (13), loosening tensioner assembly.
_ Remove belt (3).
_ Remove cap screws (4) and washers (5), releasing pulleys (7
and 12) and keys (6).
_ To remove motor (11), remove four cap screws (9).
_ Remove cap screw (13), releasing tensioner assembly.
_ To disassemble, remove retaining ring (14), releasing spring
washer (15), bearings (16) and tension wheel (17).
BELT AND PULLEY SECTION ASSEMBLY
_ Apply thread adhesive (Loctite 242) to threads of tension
wheel pin (18) and assemble to bracket (19).
_ Assemble bearing (16), tension wheel (17) and bearing (16) to
tension wheel pin (18), securing with spring washer (15) and
retaining ring (14).
_ Assemble tensioner assembly to housing (10), securing with
cap screw (13). Do not tighten cap screw.
_ Assemble motor (11) to housing (10), securing with four cap
screws (9).
_ Assemble keys (6) and pulleys (7 and 12) to spindle (23) and
motor spindle.
_ Apply thread adhesive (Loctite 290) to threads of cap screws
(4) and assemble screws and washers (5) to spindles, securing pulleys. NOTE: Tighten screws (4) to 50 – 60 in. lbs.
_ Assemble belt (3) over pulleys (7 and 12) and inside belt ten-
sioner.
_ Hold tensioner assembly firmly against belt (3) and secure by
tightening cap screw (13).
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Page 4
DISASSEMBLY/ASSEMBLY INSTRUCTIONS
_ Assemble cover (2) to housing, securing with four screws (1).
PULLEY SPINDLE SECTION DISASSEMBLY
_ Follow instructions for disassembly of BELT AND PULLEY
SECTION and remove belt (3) and pulley (12).
_ Remove four cap screws (20) and separate drive housing (10)
from frame assembly (35). NOTE: Housings will have to be
pulled apart approximately 1 1” (279 mm) to completely sepa-
rate pulley spindle (23) from frame assembly (35).
_ Using a spanner type wrench, unthread and remove lock
screw (25).
_ Pull spindle (23) and components from housing (10).
_ NOTE: Bearings (21) are press fit on spindle (23). Do not re-
move unless it should become necessary to replace, as Brinelling of the bearing races may occur, making replacement
necessary.
PULLEY SPINDLE SECTION ASSEMBLY
_ Assemble felt seal (24) to lock screw (25).
_ Assemble bearing (21) to ‘‘pulley” end of spindle (23), press-
ing on inner race of bearing.
_ Assemble spindle (23) and bearing into housing (10), press-
ing on outer race of bearing.
_ Assemble bearing spacer (22) and bearing (21) onto spindle,
pressing on inner race of bearing.
_ Assemble lock screw (25) to housing (10), securing spindle
and components.
_ Apply approximately 1/4 oz. (7 g) of ARO 33153 grease to in-
ternal splines of spindle (23) and assemble housing (10) and
components to frame assembly (35), securing with four cap
screws (20).
_ Refer to ‘‘BELT AND PULLEY SECTION” to complete the as-
sembly procedure.
_ Refer to ‘‘Pulley Spindle Section” to assemble housing (10) to
frame assembly (35).
_ Grease wiper (67) with ARO 36460 lube and assemble to
groove in front bushing of outer sleeve assembly (64), with lips
of wiper facing towards sleeve (64).
_ Grease wipers (54) with ARO 36460 lube and assemble to
grooves in quill (55), with lips of wipers facing away from each
other.
_ Assemble spring washer (53) and plate (52) to quill (55), se-
curing with plate nut (51).
_ Assemble square seal (50) to quill (55).
_ Assemble bearing (56) to spindle (58), pressing on inner race
of bearing.
_ Assemble spindle (58) and spacer (57) into quill (55).
_ Pack bearings (59) with ARO 33153 grease and assemble
onto spindle (58) and into quill (55). NOTE: Assemble bearings with open faces together (shielded sides facing out).
_ Assemble wiper (61) to groove in bearing stop (60), assem-
bling with lip of wiper toward the ‘‘chuck” end of the tool.
_ Assemble bearing stop (60) into quill (55).
_ Assemble spindle nut (62) to spindle and tighten securely.
_ Lubricate i.d. of piston cylinder (63) and o.d. of quill (55) with
ARO 36460 lube and assemble into outer sleeve (64). Handle
piston cylinder with care so as not to damage or distort the i.d.
_ Assemble locknut (68) to quill (55) and tighten securely.
_ Grease ‘‘O” rings (48 and 49) with ARO 36460 lube and as-
semble to grooves in frame assembly (35).
_ Assemble outer sleeve assembly (64) and components to
frame assembly (35), assembling quill (55) thru yoke assembly (27). Tighten outer sleeve securely. NOTE: Use caution
when inserting quill (55) thru frame assembly so as not to
damage wiper (26).
_ Tighten upper cap screw (28), securing yoke assembly.
VALVE HOUSING SECTION DISASSEMBLY
PISTON SECTION DISASSEMBLY
_ Loosen upper cap screw (28) on yoke assembly (27) to allow
for removal of quill (55).
_ Using a strap type wrench, unthread and remove outer sleeve
assembly (64) and components from the tool. NOTE: Remove
sleeve (64) with care. Pull sleeve straight away from the tool
so as not to bend the piston cylinder (63), damaging the inside
diameter.
_ Remove spindle nut (62) and locknut (68).
_ Remove spindle (58), bearing stop (60), bearings (59), spacer
(57) and bearing (56) from quill (55).
_ Remove quill (55) and piston cylinder (63) from sleeve. NOTE:
Handle the piston cylinder carefully to prevent damaging or
distorting the inside diameter.
_ Remove piston cylinder (63) from quill (55).
_ Remove seal (50) and unthread and remove plate nut (51), re-
leasing plate (52) and spring washer (53).
_ Do not remove wiper (26) from groove in frame assembly (35),
unless damage is evident. To remove wiper (26), refer to
‘‘Pulley Spindle Section” to separate drive housing (10) from
frame assembly (35).
_ Remove two cap screws (32), releasing stabilizer rod (31) and
yoke assembly (27) from tool. Wiper (26) can now be removed.
PISTON SECTION ASSEMBLY
_ Grease wiper (26) with ARO 36460 lube and assemble to
groove in frame assembly (35). NOTE: Assemble wiper with
lips towards ‘‘chuck” end of tool.
_ Assemble yoke assembly (27) to stabilizer rod (31) and as-
semble stabilizer rod to frame assembly (35), securing with
two cap screws (32).
_ Control valves (37 and 39), manifold assembly (77) and con-
trol assembly (93) can be serviced without disrupting any other section of the tool.
_ Remove set screws (36 and 40), releasing control valves (37
and 39).
_ To service bushing assembly (45), pin (44), stem (43) or
spring (42), remove outer sleeve (64) and components as described in ‘‘PISTON SECTION”.
_ Remove three cap screws (47), releasing magnet (46).
_ Remove bushing assembly (45), pin (44), stem (43) and
spring (42).
_ See pages 8 and 9 for disassembly and assembly of manifold
assembly (77) and control assembly (93).
VALVE HOUSING SECTION ASSEMBLY
_ Lubricate all ‘‘O” rings with ARO 36460 lube when assem-
bling.
_ Assemble control valves (37 and 39) to frame assembly (35),
securing with set screws (36 and 40). Set screws must be air
tight.
_ Assemble spring (42) to stem (43) and assemble into frame
assembly.
_ Assemble pin (44) into bushing assembly (45) and assemble
into frame assembly.
_ Assemble magnet (46) to frame assembly (tangs on magnet
facing away from frame) and secure with three cap screws
(47). TIGHTEN TO 45–50 IN/LBS.
_ Assemble outer sleeve (64) and components to tool as de-
scribed in ‘‘PISTON SECTION”.
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Page 5
PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING
M107
15
1 Button Head Screw (4 req’d) 49688. . . . . . . . . . .
2 Drive Housing Cover 49682. . . . . . . . . . . . . . . . .
3 Timing Belt 46923. . . . . . . . . . . . . . . . . . . . . . . . . .
4 Cap Screw (2 req’d) (1/4” – 20 x 5/8”) Y99–458. . .
5 Washer (2 req’d) 46922. . . . . . . . . . . . . . . . . . . . .
6 Key (2 req’d) 49673. . . . . . . . . . . . . . . . . . . . . . . .
7 Pulley (available only as a set, see chart) 49763–( )
8 Retaining Ring (.579” i.d.) Y145–22. . . . . . . . . . . . .
9 Cap Screw (4 req’d) (1/4” – 20 x 3/4”) Y99–41. . .
10 Drive Housing 49665. . . . . . . . . . . . . . . . . . . . . . .
11 Electric Motor (.33 h.p., 230/460 V ,
3 phase, 60 Hz)
3600 r.p.m. 49685–1. . . . . . . . . . . . . . . . . . . . . . . . .
1800 r.p.m. 49685–2. . . . . . . . . . . . . . . . . . . . . . . . .
12 Pulley (available only as a set, see chart) 49763–( )
13 Cap Screw (1/4” – 20 x 3/4”) Y99–41. . . . . . . . . . .
14 Retaining Ring (.225” i.d.) Y145–7. . . . . . . . . . . . .
15 Spring W asher 49696. . . . . . . . . . . . . . . . . . . . . . .
16 Ball Bearing (2 req’d) 49695. . . . . . . . . . . . . . . . .
17 Tension Wheel 49669. . . . . . . . . . . . . . . . . . . . . . .
18 Tension Wheel Pin 49670. . . . . . . . . . . . . . . . . . .
19 Tensioner Bracket 49671. . . . . . . . . . . . . . . . . . . .
Tensioner Assembly (includes items 14
thru 19) 49668. . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 Cap Screw (4 req’d) (1/4” – 20 x 2–1/2”) Y99–48.
21 Bearing (2 req’d) 49780. . . . . . . . . . . . . . . . . . . . .
22 Bearing Spacer 49667. . . . . . . . . . . . . . . . . . . . . .
23 Pulley Spindle 49643. . . . . . . . . . . . . . . . . . . . . . .
24 Seal 44899. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 Lock Screw 46931. . . . . . . . . . . . . . . . . . . . . . . . .
26 Wiper 49654. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 Yoke Assembly (includes items 28, 29
and 30) 49662. . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 Cap Screw (2 req’d) (1/4” – 20 x 3/4”) Y99–41. . .
29 Nut (1/4” – 20) Y12–4–C. . . . . . . . . . . . . . . . . . . . . . .
30 Cap Screw (1/4” – 20 x 1”)Y6–45. . . . . . . . . . . . .
31 Stabilizer Rod 49653. . . . . . . . . . . . . . . . . . . . . . .
32 Cap Screw (2 req’d) (#10 – 24 x 3/4”) Y154-54-C. . .
33 Yoke Guard 49687. . . . . . . . . . . . . . . . . . . . . . . . .
34 Check Guard 49686. . . . . . . . . . . . . . . . . . . . . . . .
35 Frame Assembly (includes items 36 thru 40) 49646
36 Set Screw 49597. . . . . . . . . . . . . . . . . . . . . . . . . . .
37 Control Valve 49648. . . . . . . . . . . . . . . . . . . . . . . .
38 Stop Pin 49649. . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 Control Valve 49648. . . . . . . . . . . . . . . . . . . . . . . .
40 Set Screw 49597. . . . . . . . . . . . . . . . . . . . . . . . . . .
41 Button Head Screw (5 req’d) 49688. . . . . . . . . . .
42 Spring 49655. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 Stem 49661. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 Pin 49656. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 Bushing Assembly (includes Y325–8
‘‘O” ring [1/16” x 5/16” o.d.]) 49658. . . . . . . . . . .
46 Piston Stop 49641. . . . . . . . . . . . . . . . . . . . . . . . .
47 Cap Screw (3 req’d) (#10 – 24 x 1/2”) Y154-52-C. . .
48 ‘‘O” Ring (3/32” x 2–5/8” o.d.) Y325-143. . . . . . . . . .
49 ‘‘O” Ring (1/16” x 2–1/2” o.d.) Y325–36. . . . . . . . . .
50 Square Seal 49642. . . . . . . . . . . . . . . . . . . . . . . . .
51 Plate Nut 49639. . . . . . . . . . . . . . . . . . . . . . . . . . .
52 Plate 49638. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53 Spring W asher 49789. . . . . . . . . . . . . . . . . . . . . . .
54 Wiper (2 req’d) 49633. . . . . . . . . . . . . . . . . . . . . . .
55 Quill 49630. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56 Bearing 49780. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57 Bearing Spacer 49632. . . . . . . . . . . . . . . . . . . . . .
58 Taper Spindle 49631. . . . . . . . . . . . . . . . . . . . . . .
59 Bearing (2 req’d) 49779. . . . . . . . . . . . . . . . . . . . .
60 Bearing Stop 46973–1. . . . . . . . . . . . . . . . . . . . . . . .
61 Wiper 47504. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62 Spindle Nut 46975–1. . . . . . . . . . . . . . . . . . . . . . . . .
63 Piston Cylinder 49637. . . . . . . . . . . . . . . . . . . . . .
64 Outer Sleeve Assembly 04596045. . . . . . . . . . . . . . .
67 Wiper 49635. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68 Locknut 46971. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69 Frame Gasket 49679. . . . . . . . . . . . . . . . . . . . . . .
70 Frame Plate 49680. . . . . . . . . . . . . . . . . . . . . . . . .
71 Middle Gasket 49681. . . . . . . . . . . . . . . . . . . . . . .
72 Middle Plate 49704. . . . . . . . . . . . . . . . . . . . . . . . .
73 Manifold Gasket 49776. . . . . . . . . . . . . . . . . . . . .
74 Valve Body Gasket 49705. . . . . . . . . . . . . . . . . . .
75 Cap Screw (3 req’d) (#10 – 24 x 2”) Y154-60-C. . . . .
76 Cap Screw (5 req’d) (#10 – 24 x 1–1/4”) Y154-57-C.
77 Manifold Assembly (includes items 78
thru 92) 49775. . . . . . . . . . . . . . . . . . . . . . . . . . . .
78 Cap (2 req’d) 46696. . . . . . . . . . . . . . . . . . . . . . . .
79 ‘‘O” Ring (2 req’d) (1/16” x 1/2” o.d.) Y325–12. . . . .
80 Spring 40433. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81 Rubber Ball 49847. . . . . . . . . . . . . . . . . . . . . . . . .
82 ‘‘O” Ring (1/16” x 1/4” o.d.) Y325–6. . . . . . . . . . . .
83 Actuator 49773. . . . . . . . . . . . . . . . . . . . . . . . . . . .
84 ‘‘O” Ring (1/16” x 11/32” o.d.) Y325–9. . . . . . . . . .
85 ‘‘O” Ring (1/16” x 9/32” o.d.) Y325–7. . . . . . . . . . .
86 Needle Valve 48441–1. . . . . . . . . . . . . . . . . . . . . . . .
87 Button Head Screw 49688. . . . . . . . . . . . . . . . . . .
88 Retainer 49788. . . . . . . . . . . . . . . . . . . . . . . . . . . .
89 Plug (5 req’d) 59632–1. . . . . . . . . . . . . . . . . . . . . . . .
90 Manifold 49678. . . . . . . . . . . . . . . . . . . . . . . . . . . .
91 Rubber Ball (2) 44967. . . . . . . . . . . . . . . . . . . . . .
92 Seat 49774. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93 Control Assembly (includes items 94 thru
112) 49674. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94 Retaining Ring (2 req’d) (.859” i.d.) Y147–77. . . . .
95 End Cap (2 req’d) 116212. . . . . . . . . . . . . . . . . . . .
96 ‘‘O” Ring (2 req’d) (1/16” x 3/4” o.d.) Y325–16. . . . .
97 ‘‘O” Ring (2 req’d) 116485. . . . . . . . . . . . . . . . . . . .
98 Spool 116207–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99 Face Plate 49677. . . . . . . . . . . . . . . . . . . . . . . . . .
100 Control Valve (2 req’d) 49648. . . . . . . . . . . . . . . .
101 Push Button (2 req’d) 49676. . . . . . . . . . . . . . . . .
102 ‘‘O” Ring (2 req’d) (1/16” x 9/32” o.d.) Y325–7. . . .
103 Needle Valve (2 req’d) 48441–1. . . . . . . . . . . . . . . .
104 Breather Vent (2 req’d) 20311–1. . . . . . . . . . . . . . . .
105 Adapter 49689. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106 Valve Body 49675. . . . . . . . . . . . . . . . . . . . . . . . . .
107 Spring (2 req’d) 48304–1. . . . . . . . . . . . . . . . . . . . . .
108 Rubber Ball (2 req’d) 49784. . . . . . . . . . . . . . . . .
109 Seat (2 req’d) 49777. . . . . . . . . . . . . . . . . . . . . . . .
110 Rubber Ball (2 req’d) 44967. . . . . . . . . . . . . . . . .
111 Seat (2 req’d) 49774. . . . . . . . . . . . . . . . . . . . . . . .
112 Button Head Screw (3 req’d) 49688. . . . . . . . . . .
113 Seat 04596037. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114 Warning Label (2 req’d)(not shown) 49530. . . . .
115 Date Code Plate (not shown) 49683. . . . . . . . . .
1 16 Logo Plate (not shown) 49684. . . . . . . . . . . . . . .
117 Tack (4 req’d)(not shown) 49791. . . . . . . . . . . . .
1 18 Wrench (not shown) 30131–2. . . . . . . . . . . . . . . . . .
5
Page 6
76
75
54
53
52
51
50
45 43
49 48
93
f 74
42
44 L 47 46
40
39
35
38
31
41
77
73
72
71
70
69
26 25
37
36
21
24
29
30
28
68 67
33
64 63
32
62
61 60
27
34
59
6
Page 7
M107
15
23
22
21
11
10
9
8
19 13
7
65
17
18
15
1416
4
4
3
2
ASSEMBLE WITH LOCTITE 290 AND TIGHTEN TO 50 – 60 IN. LBS.
ASSEMBLE WITH LOCTITE 242.
INCLUDED IN 49595 SERVICE KIT.
INCLUDED IN 49594 SERVICE KIT.
f INCLUDED IN 49596 SERVICE KIT.
L TIGHTEN TO 45–50 IN/LBS.
58
#33 JACOBS TAPER
57
1220
56 55
6
5
1
1/4–20 TH’D. x 3/4” LONG
7
Page 8
49775 MANIFOLD ASSEMBLY
INCLUDED IN 49595 SERVICE KIT.
* NOT INCLUDED IN ASSEMBLY
75*
90
113
78
79
84
83
88
85
82
86
87
89
91
MANIFOLD DISASSEMBLY
_ Spring (80), ball (81) and needle valve (86) can be serviced
without removing the manifold from the tool.
_ Unthread and remove cap (78), releasing spring (80) and ball
(81).
_ Remove screw (87), releasing retainer (88).
_ Unthread and remove needle valve (86).
_ To further disassemble, remove three cap screws (75), releas-
ing manifold from the tool.
_ Remove cap (78), releasing actuator (83).
80 78
81 79
91
92
MANIFOLD ASSEMBLY
_ Lubricate all ‘‘O” rings with ARO 36460 lube when assem-
bling.
_ Assemble ‘‘O” rings (82 and 84) to actuator (83) and assemble
actuator into manifold, with the small diameter going into the
manifold first.
_ Assemble ‘‘O” rings (79) to caps (78) and assemble one cap to
manifold, securing actuator.
_ Assemble ball (81) and spring (80), securing with cap (78).
_ Assemble ‘‘O” ring (85) to groove in needle valve (86) and
thread needle valve into manifold.
_ Assemble retainer (88) to manifold, securing with screw (87).
_ Assemble manifold assembly to tool, securing with three cap
screws (75).
#3–56 MOUNTING HOLES
FOR OPTIONAL SOLENOID VALVES.
PORT ``A" INPUT / START (#10-32 THD.).
PORT ``B" INPUT / EMERGENCY RETRACT (#10-32 THD).
PORT ``C" OUTPUT / ``TOOL IS FORWARD" SIGNAL ``ON" AT FORWARD POINT OF PRESET STROKE (#10-32 THD).
PORT ``D" OUTPUT / ``TOOL IS RETRACTED" SIGNAL ``ON" WHEN TOOL IS FULLY RETRACTED (#10-32 THD).
PORT ``E" OUTPUT / AUX. AIR SUPPLY FURNISHES POWER AIR TO SOLENOID VALVE OPTION. SUPPLY IS ``ON" WHEN MAIN AIR INLET IS ``ON" (#10-32 THD).
PORT ``F" OUTPUT / AUX. AIR SUPPLY FURNISHES POWER AIR TO SOLENOID VALVE OPTION. SUPPLY IS ``ON" WHEN MAIN AIR INLET IS ``ON" (#10-32 THD).
DWELL TIME CONTROL ADJUSTMENT KNOB ADJUSTS ``HESITATION" AT RETRACT POINT. TURN IN TO INCREASE TIME, TURN OUT TO DECREASE TIME.
PORT ‘‘A”
DWELL
PORT ‘‘C”
PORT ‘‘D”
#5–40 MOUNTING HOLES
FOR OPTIONAL 49785
PRESSURE SWITCH.
#3–56 MOUNTING HOLES
FOR OPTIONAL SOLENOID VALVES.
8
PORT ‘‘E”PORT ‘‘F”
PORT ‘‘B”
Page 9
49674 CONTROL ASSEMBLY
M107
15
76*
104 105
f 96
95
99
94
112
100
101
103
f 102
110
111
CONTROL DISASSEMBLY
_ Control valves (100) and needle valves (103) can be serviced
without removing the control assembly from the tool.
_ Remove three screws (112), releasing face plate (99).
_ Pull control valves (100) from valve body (106).
_ Unthread and remove needle valves (103).
_ To further disassemble, remove five cap screws (76), releas-
ing control assembly from the tool.
_ Remove retaining rings (94) and end caps (95) and push
spool (98) out of valve body (106).
CONTROL ASSEMBLY
_ Lubricate all ‘‘O” rings with ARO 36460 lube when assem-
bling.
1/8–27 NPT
106
98
97 f
97 f
96
f
94
95
107
108
f INCLUDED IN 49596 SERVICE KIT.
* NOT INCLUDED IN ASSEMBLY
109
_ Assemble ‘‘O” rings (96) to grooves in end caps (95).
_ Assemble one end cap (95) to valve body (106), securing with
retaining ring (94).
_ Assemble ‘‘O” rings (97) to grooves in spool (98) and as-
semble spool into valve body (106).
_ Assemble end cap (95) to valve body, securing with retaining
ring (94).
_ Assemble ‘‘O” rings (102) to grooves in needle valves (103)
and thread needle valves into valve body (106).
_ Grease ‘‘O” rings on control valves (100) and assemble into
valve body (106).
_ Assemble face plate (99) to valve body, securing with three
screws (112).
_ Assemble control assembly to tool, securing with five cap
screws (76).
EXHAUST, FEED CYLINDER
MAIN AIR INLET (1/8–27 N.P.T.)
TURN ‘‘IN” TO DECREASE FEED RATE.
TURN ‘‘OUT” TO INCREASE FEED RATE.
FORWARD / START
PUSHBUTTON
RETRACT / EMERGENCY
RETRACT PUSHBUTTON
RETRACT FEED RATE
ADJUSTMENT KNOB
FORWARD FEED RATE
ADJUSTMENT KNOB
9
Page 10
HYDRAULIC CHECK SET–UP
HYDRAULIC
CHECK
38922
38922–1
38922–2
‘‘W”
‘‘Y”
STROKE
LENGTH
1”
2”
3”
SET–UP PROCEDURE
• Assemble hydraulic check to yoke assembly (27).
• Measure the distance from the drill point to the work piece –
distance ‘‘Y”.
• Distance ‘‘X” between the hydraulic check plunger and stop
pin (38) must be less than distance ‘‘Y” to prevent damage to
the drill point when it approaches the work piece.
• Loosen cap screw (28) and position the hydraulic check to ob-
tain the correct setting for distance ‘‘X”.
• Tighten cap screw (28) securely before operating unit.
• Increase the air flow thru the feed control valve (103) marked
‘‘F” by opening two full turns from the closed position. This will
allow the drill to advance rapidly until the plunger of the hydraulic check contacts the stop pin (38).
• The hydraulic check feed rate adjustment is located at the
nameplate end. Rotate the extended end until the slot at the
end of the spindle is aligned with the number 15 on the name
‘‘F” FEED CONTROL VALVE (103)
‘‘X”
CAP SCREW (28)
HYDRAULIC CHECK
FEED RATE ADJUSTMENT
plate.
• Start the drill unit and the drill will advance at a rapid rate until
the plunger of the hydraulic check contacts the stop pin (38).
• Slowly rotate the extended spindle of the hydraulic check
counter–clockwise toward the number zero on the nameplate
until the drill advances at the desired rate of feed.
TO CONTROL BREAKTHROUGH
• Position the hydraulic check so the distance between the
plunger and the stop pin (38)(distance ‘‘X”) is less than the distance from the drill point to the opposite side of the work piece
(distance ‘‘W”).
• Set–up of the self–feed drill unit will be the same as explained
in ‘‘Set–Up Procedure”, page 3.
10
Page 11
49690 CLAMP ASSEMBLY
ACCESSORIES
1.88
(48 mm)
3 (76 mm)
M107
15
$.01
$.015
1.500
(38 mm)
9/32" DIA. THRU C'BORE 7/16"
DIA. x DEPTH SHOWN (4 HOLES)
45060 KEY (4 REQ'D)
Y194-95 SCREW (4 REQ'D)
49691 CLAMP
$.01
4.78 (121 mm)
2.750 (70 mm)
$.005
.218 (6 mm)
$.005
$.0010
2.9815 (76 mm)
.500 (13 mm)
$.01
2.25 (57 mm)
$.005
4.360 (111
mm)
Y99-53 CAP SCREW (4 REQ'D)
+.000
-.001
3/16 (5 mm)
46982–1 MOUNT ASSEMBLY
46979-1 MOUNT
Y99-678 CAP SCREW
Y99-63 CAP SCREW (2 REQ'D)
4-7/8
(124 mm)
$.010
1.875
(48 mm)
$.010
3.750
(95 mm)
2.985 (76 mm)
3-9/32
(83 mm)
1/2 (13 mm)
$.005
3.000
(76 mm)
(58 mm)
+.002
-.000
$.001
2.750
(70 mm)
2.265
5-9/16 (141 mm)
+.005
-.000
.187 (5 mm)
$.005
4.750 (121 mm)
+.0015
-.0002
.5000 (13 mm)
#10 - 24 THREAD
11
Page 12
CROSS SECTION
12
PN 49999–447
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