Ingersoll-Rand QE2 Series Maintenance Information
16609703
Edition 1
March 2009
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DC Electric Tool
QE2 Series
Maintenance Information
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2 16609703_ed1
General Instructions
Refer to “Suggested Tools Parts List” for quick reference to the
tools recommended for the following disassembly/assembly
instructions.
WARNING
Repairs should be made only by authorized trained personnel.
Consult your nearest Ingersoll Rand Authorized Service
Center.
Disconnect the power cord from the receptacle before
performing any maintenance on this or any other tool.
Always use protective eyewear when performing maintenance
on a tool or while operating a tool.
Use of non-Ingersoll Rand parts or failure to follow
Maintenance Instructions may create a risk of electric shock
or injury.
Note: When reading instructions refer to exploded diagrams in
Parts Information manual when applicable (see under related
documentation for form numbers).
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Lubrication
Whenever this product is disassembled, clean the parts and
re-lubricate them as follows:
1. Clean and degrease all parts except for the 1st stage Gear
Assembly and 2nd stage Spindle Assembly (46).
2. Wipe clean the 1st stage Gear Assembly and 2Assembly and 2 and 2nd stage Spindle
Assembly with a clean, dry and lint-free rag. with a clean, dry and lint-free rag.
3. Once cleaned, apply prescribed amounts of Ingersoll Rand
#67 Grease as follows:
2 to 3 cc to central area between gears of 1st stage Gear
Assembly and 2nd stage Spindle Assembly.
1 to 2 cc to faces of 1st stage Gear Assembly and 2nd stage
Spindle Assembly.
Thin layer on Ring Gear teeth.
Thin layer on faces of Washers and O-Ring.
4. For Models with an Angle Assembly Attachment: Use
Ingersoll Rand #67 Grease to lubricate Angle Head through
Grease Fitting.
5. For Models with an In-Line Attachment: Use Ingersoll Rand
#67 Grease to lubricate the Drive Spindle Bearings (117), the Drive
Spindle (122), the Spring (124, 125) and the Needle Bearing (116).
6. For Models with Pistol Attachment: Use Ingersoll Rand #67
Grease to lubricate Pivot Pin (36). Use Ingersoll Rand #160
O-Ring Lube to lubricate sliding surface of Trigger Lever (32).
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Disassembly
WARNING
This procedure is to be performed by an authorized, trained
repair person. To ensure proper functioning of the tool.
When replacing the Motor Housing Assembly (1), always
ensure that the Main Board Assembly (2), Transducer
Assembly (9), Gear Pack Assembly, Spindle Assembly and
Attachment are all assembled as a set with the new Motor
Housing Assembly.
CAUTION
When replacing an Attachment, always use the Assembly
Attachment designed for that model. Never replace an Angle
Assembly Attachment with an In-Line Attachment.
When replacing a Transducer Assembly, Gear Pack Assembly,
always use the Assembly designed for that model.
General Instructions for Disassembly
1. Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
2. To protect part surfaces and to prevent distortion of Housings
and threaded joints, use care when grasping the tool.
3. Avoid clamping non-metal surfaces, unless directed otherwise.
4. Do not remove any press t part or any part of an assembly
unless its removal is necessary for repair or replacement.
Disassembly of Grips and Plastic Components
1. For Models with Levers, use the appropriate hex. key to loosen
Socket Head Cap Screws (16) from Lever (14) and remove Lever
and Spacer (19) from Motor Housing Assembly (1).
2. For Models with Pistol Attachment,
Use the appropriate hex. key to loosen Socket Head Screw (37).
Remove Housing Clip (33) and Hanger Suspension Clip (35)
from the Pistol Handle Set (38).
Remove the Pistol Handle Set from the Motor Housing
Assembly (1).
3. For Models with Lever and Models with Pistol attachment,
remove the Lever Button Housing Assembly (18) from the Motor
Housing Assembly (1) using designated tool.
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4. For all Models, use the appropriate hex. key to loosen low Head
Cap Screw (15) from Suspension Nut. Slide the Suspension
Nut (7) o of Motor Housing Assembly (1).
5. Slide O-Ring (12), Lens cover (6) and Label (13) o of Motor
Housing Assembly (1).
6.
For Push To Start Models and Models with Lever, use
appropriate hex. key to loosen Low Head Cap Screw (17) from the
Main Cover (5).
Push down reverse button (8) and slide Main Cover (5) o of
Motor Housing Assembly (1).
If applicable, slide Hand Flange (4) and O-Ring (11) o of
Motor Housing Assembly (1).
7. For Models with Pistol Attachment, use appropriate hex. key
loosen the Socket Head Screw (37) from the Pistol Housing
Key (34). Remove the Pistol Housing Key.
Attachments
WARNING
NEVER grasp the tool in a vise, as this will likely result in
damage to the tool causing wire leads to malfunction, which
increases risk of electric shock.
CAUTION
When installing or removing a Coupling Nut, use the
designated tool, a Hook Spanner Wrench or similar wrench to
hold the tool, and use a Spanner Wrench to tighten or loosen
the Coupling Nut.
Disassembly of Internal Components
(Common to all Models)
1. Remove the access cover (3).
2. If required, remove the Reverse Button Housing Assembly (8)
from the Access Cover (3) using Button Housing Socket,
CPS2-38-2T.
3. Through the access hole in housing, disconnect the Motor Phase
connector.
4. Disconnect the Motor temperature-sensor connector from the
Main Board Assembly (2).
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16609703_ed1 3
Motor Phases
Connector
Motor Commutation
Socket
Motor Temperature
Sensor Socket
(Dwg. 45540291a)
5. Disconnect the Torque Transducer connector from the
Main Board Assembly (2).
6. Disconnect the Flex PCB (64) from the Main Board Assembly (2).
Torque
Transducer
Socket
Flex PCB
Socket
(Dwg. 45540291b)
7.
Disconnect the Motor commutation connector from the
Main Board Assembly (2).
8. Remove Retainer (20).
9. If necessary, remove the Main Board Assembly (2) from
Motor Housing Assembly (1).
Output Spindle End - Disassembly
1. Disassemble the grips and plastic components..
2. For In-line and Pistol Models,
Using CPS2-25F-70 Fixture Plug, a Hook Spanner Wrench or
similar wrench to hold the tool, and using Spanner Wrench
CPS2-478 (or other appropriate wrench), unscrew Coupling
Nut (81).
Use caution while removing coupling nut. If spindle assembly
becomes disengaged from main housing keys spindle assembly
can rotate causing damage to the ex circuit. Spindle housing
must be held engaged with motor housing keys during nut
disassembly.
Remove the Spring (83).
3. For Angle and Fixtured Models,
Using CPS2-25F-70 Fixture Plug, a Hook Spanner Wrench or
similar wrench to hold the tool, and using Spanner Wrench
CPS2-478 (or appropriate wrench), unscrew Coupling Nut (92).
Note: Left hand thread.
Remove the Angle Head (91) or In-line Attachment.
Remove the Lock Washer (104) o of Spindle Coupling (103).
Using a CPS2-25F-70 Fixture Plug, a Hook Spanner Wrench or
similar wrench to hold the tool, and using Spanner Wrench CPS2478 (or appropriate wrench), unscrew Spindle Coupling (103) o
Spindle Housing (102).
Note: Left hand thread
Remove Light Ring Lens (106) o of Spindle Housing (102).
Using CPS2-25F-70 Fixture Plug, a Hook Spanner Wrench or
similar wrench to hold the tool, and using Spanner Wrench
CPS2-478 (or appropriate wrench), unscrew Coupling Nut (107)
o Motor Housing Assembly (1). Use caution while removing
coupling nut. If spindle assembly becomes disengaged from
the main housing keys the spindle assembly can rotate causing
damage to the ex circuit.
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Remove Spindle Housing (102) .
If required, remove Flex PCB (105) from the Spindle Housing (102).
If required, Remove Retainer (99) o of Bit Holder Plug
Assembly (98).
If required, Remove Bit Holder (76).
Remove Hall Housing (72) from Spindle Housing (102).
Angle Attachment Disassembly
1. For 3/8” and 1/4” Square Drive Spindles,
Looking down hole of the Spindle’s square socket, locate
Retaining Pin (95) and Retaining Spring (94).
If necessary, use a pointed metal probe to pull retaining
Spring out of Spindle cavity.
If necessary, remove Pin from Spindle.
2. For Quick Change Spindles, remove Bit Retaining Spring (97)
and Bit Retaining Ball (96).
3. Using CPS2-25F-70 Fixture Plug, a Hook Spanner Wrench or
similar wrench to hold the tool, and using Spanner Wrench
CPS2-478 (or other appropriate wrench), unscrew Coupling
Nut (92) and pull the Angle Assembly Attachment (91) out of
Motor Housing Assembly (1).
4. If necessary, remove Coupling Nut Retainer (93) using an
appropriate tool.
In-Line Attachment Disassembly
1. Using CPS2-25F-70 Fixture Plug, a Hook Spanner Wrench or
similar wrench to hold the tool, and using Spanner Wrench
CPS2-478 (or other appropriate wrench), unscrew Coupling
Nut (92) and pull the In-Line Attachment out of Motor Housing
Assembly (1).
2. If desired, remove Coupling Nut Retainer (93) using the
appropriate tool.
Note: In the following step, the Bearing Cap (119) has a lefthand
thread.
3. Using CPS3-532T Hex Socket or an adjustable Pin Wrench,
unscrew Bearing Cap (139).
4. Pull the Drive Spindle Assembly (142) out of Housing (141).
5. Remove the Retaining Ring (138). If necessary, using a bearing
puller tool, press the Rear Spindle Bearing (137) o the Drive
Spindle Assembly.
6.
Tilt Spindle Housing, causing the Spring (144, 145), Square Drive
Spindle (140), and Washer (143) to slide out.
7. Note that the No-Float Models have an extra Spacer (146) inside
the Spindle (140).
Spindle Assembly - Disassembly
(Common for Push to start, Trigger and Pistol Model)
1. Remove the Hall Holder (72) from the Spindle Sub Assembly (74).
2. Remove Retainer (69) from the Bit Holder (76, 80).
3. Slide the Push to Start Assembly (73) and Thrust Washer (71) o of
Bit Holder (76, 80).
Note that the No-Float Models have an additional Spacer (81).
4. Slide the Bit Holder (76, 80) out of the Spindle Assembly from the
front end.
5. Use appropriate hex. Key to loosen the Cap Screws (70) from the
Front Spindle Housing (65).
6. Remove the Front Spindle Housing (65).
7. Remove the Light Ring Lens (67).
8. If necessary, disassemble the Flex PCB (64) from the Spindle Sub
Assembly (74).
9. For Quick change type Bit Holder - Remove the Retainer (63)
from the Bit Holder (76). Remove the Spacer (68) and
Spring (62). Remove the Collar (66) from the Bit Holder (76).
Remove the ball (61) from the Bit Holder (76).
10. For Square type Bit Holder - Remove the Rubber Insert (77)
from the Bit Holder (76) using a pick or other appropriate tool.
Remove the retaining pin (78) from the Bit Holder (76).
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