Ingersoll-Rand QE8 Series Service Manual

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Page 1

Form P7775

Edition 1 April, 2004 CCN 04580973

Service Manual for

QE8 Series High Torque

Angle Wrench and In-Line DC Electric Tools

NOTICE

For routine Maintenance, Operation and Instruction information regarding this product, see Publication manual P7609, located at www.irtools.com/techdocuments, or contact the nearest Ingersoll-Rand Office or Distributor.

Refer All Communications to the Nearest Ingersoll-Rand Office or Distributor.

Printed in U.S.A

(Dwg. TP2160a)

(Dwg. TP2160b)

Page 2

QE8 HIGH TORQUE MOTOR HOUSING ASSEMBLY, GRIPS AND LEVERS

(Dwg. TP2155)

OFF 1.1-1.7 Nm

OFF .05-1.1 Nm

5/64"

Page 3

QE8 HIGH TORQUE MOTOR HOUSING ASSEMBLY, GRIPS AND LEVERS

QE6 MOTOR HOUSING ASSEMBLY, GRIPS AND LEV

When Ordering, use applicable Part Number

QE8 High Torque Motor Housing Assembly, Grips, and Levers Parts List

Item Part Description Part Number Item Part Description Part Number

1 Motor Housing Assembly 9 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-2309-104

FOR MODELS: 10 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-136-211

QE8Z{ }070{ } { } . . . . . . . . . . . . . . . . . . . . . . . . . . GEA120-D53-491 11 Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA120-136

QE8Z{ }090{ } { } . . . . . . . . . . . . . . . . . . . . . . . . . GEA120-D53-491 12 Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-99

FOR MODELS: 13 Label-Cover Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-600

QE8A{ }225{ } { }. . . . . . . . . . . . . . . . . . . . . . . . . GEA240-D53-491 14 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-208

QE8S{ }150{ } { } . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-D53-491 15 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-801

QE8Z{ }150{ } { } . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-D53-491 16 Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-329-52

FOR MODELS: 17 Reverse Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-329

QE8A{ }400{ } { }. . . . . . . . . . . . . . . . . . . . . . . . . # GEA400-D53-491 18 Handle Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-135

QE8S{ }230{ } { } . . . . . . . . . . . . . . . . . . . . . . . . . . # GEA400-D53-491 19 Handle Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-135SL

2 LED Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-98 20 Handle Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-135EL

3 Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV1-255 21 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-137

4 Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-329-51 22 Socket Cap Screw (Low Head) . . . . . . . . . . . . . . . . . . . . . GEA40-135-68

5 Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-273 23 Socket Head Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-273EL-68

6 Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-273-51 24 Lever, Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-273SL

7 Memory chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRP-A528 25 Lever, Extended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-273EL

8 Communication Board . . . . . . . . . . . . . . . . . . . . . . . . . . GEA40-A2309

# Also includes GEF400-491-104

Page 4

QE8 HIGH TORQUE GEARING COMPONENTS

(Dwg. TP2160_B)

Ingersoll-rand #67

OFF 68-81 Nm

Page 5

QE8 HIGH TORQUE GEARING COMPONENTS

When Ordering, use applicable Part Number

QE8 HIGH TORQUE GEARING PARTS LIST (Continued)

QE6 MOTOR HOUSING ASSEMBLY, GRIPS AND LEV

QE8 High Torque Gearing Parts List

ANGLE

--- --- --- QE8A{ }225{ }{ }

IN LINE

--- --- --- QE8S{ }150{ }{ }

OFFSET

QE8Z{ }070{ }{ } QE8Z{ }090{ }{ } QE8Z{ }150{ }{ } ---

Item Part Description Part Number Part Number Part Number Part Number

31 O-ring (I.D. 1.563 X .139) . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

32 Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA120-A756-90 GEA120-A756-90 GEA240-A756-160 GEA240-A756-160

33 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEA120-945 DEA120-945 GEA240-945 GEA240-945

* Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEP120-M37 GEP150-M37 GEP240-M37 GEA240-M37

34 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEA120-29 DEA120-29 GEA240-208 GEA240-208

35 Pinion Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . DEA120-17 DEA120-17 DEA120-17 DEA120-17

36 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W64-118 W64-118 W64-118 W64-118

37 Spindle Assembly (1st Stage) . . . . . . . . . . . . . . . . . . . DEA120-A216 DEA150-A216 DEA55-A216 DEA55-A216

Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Planet Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Planet Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Planet Gear (1st) . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- GEA240-80 GEA240-80

39 Spindle Assembly (2nd Stage) . . . . . . . . . . . . . . . . . . . DEA120-A8 DEA150-A8 GEA240-A216 GEA240-A216

Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Planet Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Planet Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Planet Gear (2nd) . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

40 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- GEA240-80 GEA240-80

41 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- GEA240-606 GEA240-606

43 Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEA120-406 DEA200-406 GEA240-406 GEA240-406

Page 6

QE8 HIGH TORQUE GEARING COMPONENTS (Continued)

When Ordering, use applicable Part Number

QE8 High Torque Gearing Parts List

ANGLE

--- --- --- QE8A{ }225{ }{ }

IN LINE

--- --- --- QE8S{ }150{ }{ }

OFFSET

QE8Z{ }070{ }{ } QE8Z{ }090{ }{ } QE8Z{ }160{ }{ } ---

Item Part Description Part Number Part Number Part Number Part Number

Spindle Assembly (3rd Stage) . . . . . . . . . . . . . . . . . . . --- ---

GEA240-A8 GEA240-A8

Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- --- --- ---

Planet Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- --- --- ---

Needle Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- --- --- ---

Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- --- --- ---

Planet Gear (3rd) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--- --- --- ---

Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEF120-29 DEF120-29 GEF240-29 GEF240-29

Coupling Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEF120-43 GEF120-43

GEA240-43 GEA240-43

Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEP120-B37 GEP120-B37 GEP240-B37 GEA240-B37

Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- --- ---

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R38P-606 R38P-606 --- ---

Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W64-118 W64-118 --- ---

REFER ALSO TO THESE MANUALS

P7781 P7781 P7781

---

Page 7

QE8 HIGH TORQUE GEARING COMPONENTS (Continued)

When Ordering, use applicable Part Number

QE6 MOTOR HOUSING ASSEMBLY, GRIPS AND LEV

QE8 High Torque Gearing Parts List (Continued)

ANGLE

QE8A{ }225F{ } --- QE8A{ }400F{ }

IN LINE

QE8S{ }150F{ } QE8S{ }230F{ } ---

OFFSET

--- --- ---

Item Part Description Part Number Part Number Part Number

31 O-ring (I.D. 1.563 X .139) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- GEF400-491-104 GEF400-491-104

32 Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-A756-160 GEF400-A756-230 GEF400-A756-230

33 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-945 N/A N/A

* Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEF240-M37 GEP400-M37 GEF400-M37

34 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-208 N/A N/A

35 Pinion Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEA120-17 GEF400-17 GEF400-17

36 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W64-118 W64-118 W64-118

37 Spindle Assembly (1st Stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEA55-A216 DEA90-A216 DEA90-A216

Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Planet Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Planet Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Planet Gear (1st) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

38 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-80 GEF400-80 GEF400-80

39 Spindle Assembly (2nd Stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-A216 GEF400-A216 GEF400-A216

Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Planet Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Planet Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Planet Gear (2nd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

40 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-80 GEF400-80 GEF400-80

41 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-606 --- ---

43 Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-406 GEF400-406 GEF400-406

Page 8

QE8 HIGH TORQUE GEARING PARTS LIST (Continued)

When Ordering, use applicable Part Number

QE8 High Torque Gearing Parts List (Continued)

ANGLE

QE8A{ }225F{ } --- QE8A{ }400F{ }

IN LINE

QE8S{ }150F{ } QE8S{ }230F{ } ---

OFFSET

--- --- ---

Item Part Description Part Number Part Number Part Number

45 Spindle Assembly (3rd Stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-A8 GEF400-A8 GEF400-A8

Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Planet Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Needle Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

Planet Gear (3rd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- --- ---

46 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEF240-29 N/A N/A

47 Coupling Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-43 GEF400-43 GEF400-43

48 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEF240-B37 GEP400-B37 GEF400-B37

49 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- GEF400-29 ---

50 Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- GEF400-584 ---

51 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- ---

52 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- ---

Page 9

This Page intentionally left Blank

Page 10

QE8 HIGH TORQUE IN-LINE ATTACHMENT COMPONENTS

(Dwg. TP2293)

OFF 61-68 Nm

Ingersoll-Rand #

Page 11

QE8 HIGH TORQUE IN-LINE ATTACHMENT COMPONENTS

When Ordering, use applicable Part Number

QE8 In-line Spindles Parts List

Item Part Description Part Number Item Part Description Part Number

z In-Line Spindle Assemblies --- 66 Socket Retaining Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804-716

--- QE8S{ }150{ }41S08 (1/2" Sq. Drive & 4" Long Shank) 160E4S8 67 Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ---

--- QE8S{ }150{ }61S08 (1/2" Sq. Drive & 6" Long Shank) 160E6S8 --- for 41S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E4-581

--- QE8S{ }150{ }81S08 (1/2" Sq. Drive & 8" Long Shank) 160E8S8 --- for 61S08, and 81S08 . . . . . . . . . . . . . . . . . . . . . . . . . . 120E6-581

61 Housing Assembly --- 68 Disengaging Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ---

--- for 41S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160E4-A580 --- for 41S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E4-626

--- for 61S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160E6-A580 --- for 61S08, and 81S08 . . . . . . . . . . . . . . . . . . . . . . . . . . 120E6-626

--- for 81S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160E8-A580 69 Drive Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160E4-A584

62 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E4-105 70 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E4-106

63 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E4-106 71 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEA100-20

64 Square Drive Spindle --- 72 Rear Spindle Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-593

--- for 41S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E4S8-586 73 Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8SA32-531

--- for 61S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E6S8-586 74 Coupling Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEA240-27

--- for 81S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120E8S8-586 75 Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160E4-29

65 Socket Retainer Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5UHD-718

FOR MODEL REFER TO THESE MANUALS

QE8Z{ }070{ }{ }, QE8Z{ }090{ }{ } P7778

QE8Z{ }150{ }{ } P7778

QE8S{ }230{ }{ } P7777

Page 12

QE8 ANGLE HEAD ATTACHMENTS

OFF 61-68 Nm

HUSKEY HTS-2

(Dwg. TP2294)

When Ordering, use applicable Part Number

QE8 Angle Head Attachments Parts List

Item Product Identification Code Part Number

81 QE8A{ }225{ }A7S12 AA16S12

82 QE8A{ }400{ }A8S12 AA20S12

Page 13

QE8 HIGH TORQUE ACCESSORIES

When Ordering, use applicable Part Number

QE8 High Torque Accessories Parts List

Item Part Description Part Number

100 †

101 †

102 †

103

104

105

106

107

108

109

110

111

† FOR MODEL QE8{ }150{ }{ } NON-FLANGED MODELS ONLY

Reaction Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Plate Assembly (Flanged) . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEM120-K48

Power Cord Assembly

Power Cord Assembly, 90 Deg.

Power Cord Extension Assembly

Suspension Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(3 Meter)

(10 Meter)

(3 Meter)

(10 Meter)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

(10 Meter)

(20 Meter)

(40 Meter)

. . . . . . . . . . . . . . . . . . . . . .

DEA120-K48

DAM120-K48

GEA40-C0RD-3M

GEA40-C0RD-10M

GEA40-C0RD-3M-90

GEA40-C0RD-10M-90

GEA40-EXT-10M

GEA40-EXT-20M

GEA40-EXT-40M

7L-365

GEA40-478

(Dwg. TP2292)

Page 14

QE8 TOOL ASSEMBLIES

Angles

Ingersoll-Rand #

HUSKEY HTS-2

(Dwg. TP2161b)

In-Lines

Table 1

Suggested Tools Parts List

Item Tool Used Description Where Used?

Spanner Wrench I-R Part #GEA40-478 Coupling Nut

Pin Spanner Wrench 3 mm or 1/8” pin Motor Housing Assembly, Cable

Torque Wrench 1/2” Sq. Drive, 50 ft-lb capacity General use

Adjustable Pin Wrench ----- In-Lines, Bearing Caps

Adjustable Wrench ----- Coupling Nut (with flats)

5/64” Hex Key ----- Cap Screws (Low Socket Head)

9/64” Hex Key ----- Cap Screws (Regular Head)

Internal Snap Ring Pliers ----- General use

Pick -----

O-Rings (behind Reverse Ring), Smalley Ring, etc.

(Dwg. TP2161a)

Page 15

MAINTENANCE

General Instructions:

• Refer to Table 1 “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.

LUBRICATION

Whenever this product is disassembled, clean the parts and re-lubricate them as follows:

1. Using appropriate tool, loosen the Attachment Coupling Nut (74).

2. Unthread Coupling Nut from Gear Case Assembly and remove Attachment.

3. Using appropriate tool, loosen the Gear Case Coupling Nut (47).

4. Unthread Coupling Nut and remove Gear Case Assembly.

5. Disassemble Gear Case.

6. Clean and degrease all parts except for the bearings, 1

Stage Spindle Assembly (37), 2

Assembly (39) and the 3 (45).

7. Wipe clean the Spindle Assemblies with a clean, dry and lint-free rag.

8. Once cleaned, apply prescribed amounts of Ingersoll-Rand #67 Grease as follows:

Stage Spindle

stage Spindle Assembly

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 Memory Chip (7), Communication Board (8), Gear Case Assembly, and Attachment are all assembled as a set with the new Motor Housing Assembly.

CAUTION

• When replacing an Attachment, always use the Angle Head Attachment designed for that model. Never replace an Angle Head Attachment with an In-Line Attachment.

• When replacing a Gear Case 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 fit part or any part of an assembly unless its removal is necessary for repair or replacement.

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 the risk of electric shock.

• 3 - 4 cc to central area between gears of each Spindle Assembly (37, 39 & 45).

• Thin layer on Ring Gear teeth (43)

9. For Models with an Angle Head Attachment:

Using HUSKY HTS-2 Grease, lubricate Angle Head (81 or 82) through Grease Fitting.

10. For Models with an In-Line Attachment:

Using Ingersoll-Rand #67 Grease, lubricate the Square Drive Spindle Bearings, the Drive Spindle (64) and the Disengaging Spring (68).

CAUTION

• When installing or removing a Coupling Nut, ALWAYS hold the tool by the Spanner holes or flats as provided on the Assembly Housing.

Page 16

MAINTENANCE (Continued)

Attachment Removal

FOR MODELS:

QE8A{ }225{ }{ } QE8A{ }400{ }{ } QE8S{ }150{ }{ }

1. Using Spanner Wrench #GEA40-478 (or other appropriate wrench), grasp the Spanner holes of the Coupling Nut (74).

2. Holding firmly onto tool with the wrench flats (or Spanner holes) of the Gear Case (48), unscrew Coupling Nut and pull the Attachment out of the Gear Case.

FOR ALL OTHER MODELS:

1. Remove screws around the flange of the Attachment while supporting both ends of the tool.

2. Pull Attachment from the Mounting plate and Gear Case or Offset Gear Case.

3. Pull remainder of the Tool from mounting plate.

Angle Head Attachments - Disassembly

DISASSEMBLY OF ANGLE HEAD ATTACHMENTS IS NOT RECOMMENDED.

Spindle Bearing (72) off the Drive Spindle Assembly (69). Then remove the Retaining Ring (71), and Washer (70).

9. Now tilt Spindle Housing, causing the Disengaging Spring (68), Coupler (67), Square Drive Spindle (64), and Washers (62) and (63) to slide out.

FOR ALL OTHER SPINDLES:

REFER TO THE APPROPRIATE MAINTENANCE MANUAL LISTED IN THE QE8 HIGH TORQUE IN-LINE SPINDLE PARTS LIST.

Motor Housing Disassembly

Gear Case Removal

FOR ALL MODELS:

1. Carefully engage spanner holes on the Gear Case Coupling Nut (47) with the appropriate tool and loosen the Coupling Nut while gripping the wrench flats of the Gear Case (48) with the appropriate wrench.

2. Unthread the Coupling Nut and pull the Gear Case Assembly off the Motor Housing Assembly.

FOR MODELS WITH OFFSET GEAR CASES:

QE8Z{ }070{ }{ } QE8Z{ }090{ }{ } QE8Z{ }150{ }{ }

In-Line Attachments - Disassembly

FOR 160E4S8, 160E6S8 & 160E8S8 IN-LINE ATTACHMENTS.

1. Looking down the hole of the Square Drive Spindle's (64) square socket, locate Retaining Pin (66) and Retaining Spring (65).

2. If necessary, use a pointed metal probe to pull retaining Spring out of Spindle cavity.

3. Also if necessary, remove Pin from Square Drive Spindle (64).

4. Using Spanner Wrench #GEA40-478 (or other appropriate wrench), grasp the Spanner holes (or flats) of the Coupling Nut (74).

5. If desired, remove Coupling Nut Retainer (75) using the appropriate tool.

Note: In the following step, the Bearing Cap (73) has a

left-hand thread.

6. Using an adjustable Pin Wrench, unscrew Bearing Cap (73).

7. Pull the Drive Spindle Assembly (69) out of Housing Assembly (61).

8. If necessary, using a bearing puller tool, press the Rear

1. Remove the screws around the flange of the Offset Gearing that attach it to the Gear Case assembly with the appropriate wrench while gripping the wrench flats of the Tool Gear Case with the appropriate wrench.

2. Pull Offset Gearing from the Gear Case.

Page 17

MAINTENANCE (Continued)

Gear Case - Disassembly

FOR GEP120-M37 AND GEP150-M37

1. Remove the Pinion Coupler Assembly (35) from the Motor Housing Assembly.

2. If the Coupling Nut requires replacement, spread the ends of the Retaining Ring (46) and remove it from the Gear Case Assembly. Slide Coupling Nut off the Gear Case Assembly.

3. Work a pointed tool under the Ring Gear Retainer (34) and spiral it out of the Gear Case (48).

4. Tilt the Gear Case Assembly so that the Ring Gear (43)

and 1

Stage Spindle Assembly (37) slide out of the

Gear Case Assembly.

5. With the motor end of the Gear Case Assembly standing on the table of an Arbor press, carefully press

the 2

Stage Spindle Assembly (39) out of the Bearing (51) while lightly supporting the Spindle Assembly from beneath to avoid breakage.

6. Using internal snap ring pliers, remove the Retaining Ring (52) from the threaded end of the Gear Case (48).

7. Remove Bearing (51) from the Gear Case.

FOR GEF400-M37 AND GEP400-M37

1. Remove the Pinion Coupler Assembly (35) from the Motor Housing Assembly.

2. If the Coupling Nut requires replacement, slide the Coupling Nut off the Motor Housing Assembly.

3. From the output end of the Gear Case Assembly, push

the 3

Stage Spindle Assembly (45) until the Ring

Gear, 1

dle Assembly (39) and 3

Stage Spindle Assembly (37), 2nd Stage Spin-

Stage Spindle Assembly

(45) slide out of the Gear Case (48) all together.

4. Using internal snap ring pliers, remove the Retaining Ring (36) from the Ring Gear.

5. Tilt the ring gear and slide the 1

Assembly (37) and 2

Stage Spindle Assembly (39)

Stage Spindle

out of the Ring Gear.

6. From the output end of the Ring Gear, carefully pull

the 3

Stage Spindle Assembly (45) out of the ring gear. It may be necessary to push it from the opposite side.

7. If necessary, remove the O-ring (31), from the Motor Housing Assembly.

FOR GEA240-M37, GEF240-M37 AND GEP240-M37

1. Remove the Pinion Coupler Assembly (35) from the Motor Housing Assembly

2. Work a pointed tool under the Ring Gear Retainer (34) and spiral it out of the Gear Case (48).

3. Tilt the Gear Case Assembly so that the Ring Gear

(43), 1

dle Assembly (39) and 3

Stage Spindle Assembly (37), 2nd Stage Spin-

stage Spindle Assembly

(45) slide out of the Gear Case (48) all together.

4. Using internal snap ring pliers, remove the Retaining Ring (36) from the Ring Gear.

5. Tilt the ring gear and slide the 1

Assembly (37) and 2

Stage Spindle Assembly (39)

Stage Spindle

out of the Ring Gear.

6. With the output end of the Ring Gear resting on the

table of an arbor press, carefully press the 3

Stage Spindle Assembly (45) from the Spindle Bearing (41) and out of the Ring Gear.

7. From the output end of the Ring Gear, push the Spindle bearing (41) out of the Ring Gear.

8. If the Coupling Nut requires replacement, spread the ends of the Retaining Ring (46) and remove it from the Gear Case Assembly.

FOR OFFSET GEARING DISASSEMBLY:

REFER TO THE APPROPRIATE MAINTENANCE MANUAL LISTED IN THE QE8 HIGH TORQUE GEARING PARTS LIST.

WARNING

• This procedure is to be done by an authorized, trained repair person. To ensure proper functioning of the tool:

When replacing the Motor Housing Assembly (1), always ensure that the Memory Chip (7), Communication Board (8), Gear Case Assembly, and Attachment are all assembled as a set with the new Motor Housing Assembly.

Grips

1. For models with levers, use the appropriate hex key to

loosen Cap Screws (23) from lever (24 or 25) and remove lever from Handle Grip (19 or 20).

2. Use the appropriate hex key to loosen the Cap Screw

(22) from Handle Grip (18, 19, 20 or 21).

3. Slide Handle Grip off of Motor House Assembly (1).

Page 18

MAINTENANCE (Continued)

Disassembly of External Components

1. Dislodge O-rings (15) and remove Memory Chip (7) from assembly.

2. Remove Trigger mechanism (5) from Motor Housing Assembly.

3. Remove Spring (6) from Trigger mechanism.

4. Slide Reverse Ring (17) away from Motor Housing Assembly, being careful not to lose the Detent Ball (3) or Springs (4) and (16).

5. Remove Retaining Ring (14) from behind Label Cover Lens (13).

6. In a sliding motion, pull Warning Label (12) and Label Cover Lens (13) off end of Motor Housing Assembly.

7. Slide Housing Cover (11) off Motor Housing Assembly.

8. Remove O-ring (10) located at front of Housing Cover.

Communication Board

Torque and Motor Connector(s)

(Dwg. TP2162a)

LEDs and Temperature Connector(s)

(Dwg. TP2162b)

Disassembly of Internal Components

1. Remove Retainer (9) used to retain Communication Board (8), located at rear end of Motor Housing Assembly in Connector cavity.

2. In large cavity area(s) of Motor Housing, disconnect the Motor Phase connector.

(Refer to TP2162b)

3. Disconnect the Motor temperature-sensor connector from the Communication Board.

(Refer to TP2162b)

4. Disconnect the Motor Commutation connector from the Communication Board.

(Refer to TP2162a).

Page 19

MAINTENANCE (Continued)

5. Disconnect the Torque Transducer connector from the Communication Board.

(Refer to TP2162a)

6. Disengage female socket located on front end of Communication Board, from male connector located at center of LED Board (2) by gently sliding board from Motor Housing Assembly.

7. Remove LED Board from Motor Housing Assembly.

(Refer to TP2162b)

Transducer Removal

1. Locate the cavity found at end of long axial groove running along the outer surface of the Motor Housing Assembly.

2. Make sure the Transducer connector is disconnected from the Communication Board.

3. Gently pull Transducer (32) out of the Motor Housing Assembly, while feeding the Transducer wire and connector through the cavity in the Motor Housing Assembly.

4. Carefully push Transducer's connector through the cavity of the Motor Housing Assembly.

ASSEMBLY

three tabs of the LED Board against the three ledges of the Motor Housing Assembly (Refer to TP2162a) making sure that the motor commutation wires properly pass through the cutout in the LED board.

2. Using two of the three internal axial grooves located in the connector end of the Motor Housing Assembly, slide Communication Board (8) into Motor Housing Assembly.

3. Press connector located on front end of Communication Board into socket located at center of LED Board.

4. Route Motor Commutation wiring to same side of Communication Board; snap connector into socket marked Motor.

(Refer to TP2162a)

5. Route Motor Temperature Sensor Connector cable to opposite side of Communication Board; snap Motor Temperature-Sensor connector into the Motor Temperature-Sensor socket.

(Refer to TP2162b)

6. Through large cavities of Motor Housing Assembly, connect Motor Phase Female Connector to Male Connector of Motor.

7. Install Retainer (9) behind Communication Board in connector cavity in the end of the Motor Housing Assembly.

Communication Board (Close-Up)

Motor Housing Assembly

General Instructions

1. To protect the part's surfaces and to prevent distortion of Housings and threaded joints, use care when grasping the tool.

2. Always press on the inner ring of a ball-type bearing when installing the bearing onto a shaft.

3. Always press on the outer ring of a ball-type bearing when pressing the bearing into a bearing recess.

4. Refer to the "Lubrication" section of this manual for instruction on how to properly grease this tool.

• This procedure is to be done by an authorized, trained

repair person. To ensure proper functioning of the tool:

LEDs and Temperature Connector(s)

(Dwg. TP2162a)

Internal Components

1. Insert the LED Board (2) through one of the Motor Housing Assembly's three large cavities and lay the

Page 20

MAINTENANCE (Continued)

Torque and Motor Connector(s)

Transducer Installation

1. Insert Transducer Assembly (32) into the Motor Housing Assembly, wire end first, guiding Transducer's connector out through the cavity found at end of Motor Housing Assembly's long outer groove.

2. Carefully pull Transducer's connector and wiring through cavity of Motor Housing Assembly.

3. Align and engage Transducer's gear teeth with the gear teeth located inside the end of the Motor Housing Assembly. Be certain that the Transducer wire exits the Transducer directly over the access cavity through which the wire was fed.

4. Continue inserting the Transducer assembly until it is fully seated.

5. Snap Transducer's connector into Communication Board (8) socket marked Torque.

External Components

(Dwg. TP2162b)

(Refer to TP2162a)

7. Install and depress Ball (3) and Spring (4) and then slide Reverse Ring onto Motor Housing Assembly.

8. Install Memory chip (7) into Housing with terminals aligned with O-ring groove.

9. Slide two O-rings (15) into groove to retain Memory chip.

10. Install Spring (6) on post in middle of Trigger (5) and install Trigger into Motor Housing Assembly.

11. For models with Extended Lever (25), install an additional spring on Trigger's auxiliary post.

12. Slide Handle Grip (18, 19, 20, or 21) onto Motor Housing Assembly.

13. Apply a medium strength thread locker to Low Head Socket Cap Screw (22).

14. Install Low Head Socket Cap Screw into Motor Housing Assembly.

15. Torque Socket Cap Screw to 10 to 15 lb

(1.1 to 1.7 Nm).

• in

16. For models with Levers: a. Place Lever (24 or 25) in position against Handle

Grip and install lever Socket Cap Screws (23).

b. Torque Socket Cap Screw (23) to 5 to 10 lb

(0.5 to 1.1 Nm).

• in

WARNING

• This procedure is to be performed by an authorized, trained repair person. To ensure proper functioning of the tool:

• In the course of disassembling or assembling this product, beware of any attempt to separate the gear case from or tighten the gear case to the motor housing assembly. Destruction of the transducer wire will result.

1. Slide O-ring (10) into groove located at front end of Motor Housing Assembly.

2. Slide on Housing Cover (11), ensuring that Transducer and Motor wires are not disturbed.

3. Slide Warning Label (12) into Label Cover Lens (13). Note Warning Label and Label Cover Lens slot and tab alignment features.

4. Slide Label Cover Lens and Warning Label over Motor Housing Assembly grip area. Orient tabs of Label Cover Lens with mating slots in Motor Housing Assembly, and slide together.

5. Install Retaining Ring (14) into groove behind Label Cover Lens.

6. Place Spring (16) into Reverse Ring (17).

CAUTION

• When replacing an Attachment, always use the Angle Head Attachment designed for that model. Never replace an Angle Head Attachment with an In-Line Attachment.

• When replacing a Gear Case Assembly, always use the Assembly designed for that model.

Page 21

MAINTENANCE (Continued)

Gear Case - Assembly

FOR GEP120-M37 AND GEP150-M37

1. Ensure that all the gears are free of debris.

2. Apply 2-3 cc of IR #67 grease to the central area between the gears and the surface of the gear teeth of

the 1

Stage Spindle Assembly (37) and the 2nd Stage

Spindle Assembly (39).

3. Insert Bearing (51) into threaded end of Gear Case (48) and push it in until it seats against the shoulder in the Gear Case.

4. Assembly the Retaining Ring (52) into the groove directly in front of the Bearing with internal snap ring pliers.

5. Support the Gear Case Assembly, threaded end down, on the inner race of Bearing (51).

6. Position the 2

Stage Spindle Assembly (39) on the inner race of the Bearing (51) inside the Gear Case with the splined end of the Spindle Assembly facing the Bearing.

7. With an appropriate tool, press the 2

Stage Spindle Assembly into Bearing (51) until the Spindle Assembly seats against the inner race of the Bearing.

8. Coat the inside and outside surfaces of the Ring Gear (43) with IR #67 grease.

9. Insert the Ring Gear into the Gear Case with the end of the Ring Gear having an internal groove towards the motor.

10. Align the Ring Gear teeth with those of the planets in

the 2

Stage Spindle Assembly and slide the Ring Gear into the Gear Case until it stops against the shoulder inside the Gear Case.

11. Install the Retainer (34) into the groove inside the motor end of the Gear Case to secure the Ring Gear.

12. Insert the 1

Stage Spindle Assembly (37) into the

Gear Case and engage the teeth of the gear on the Gear

Head Assembly with the planet gears of the 2

Stage Spindle Assembly while aligning the planet gears of the Gear Head Assembly with the Ring Gear.

13. Install Retaining Ring (36) into groove in the end of the Ring gear.

14. Slide the Coupling Nut (47) on the input end of the Gear Case (48). Using the proper tool, slide the Retaining Ring (46) over the end and into the groove of the Gear Case.

FOR GEA240-M37, GEF240-M37 AND GEP240-M37

Assembly (45).

3. Coat the inside and outside surfaces of the Ring Gear (43) with IR #67 grease.

4. Insert the Spindle Bearing (41) into the fine pitch end of the Ring Gear (43) with the flanged side of the bearing facing out until the bearing rests in the interior bore deep inside the ring gear. This may require moderate pressure.

5. Engage the planets of the 3

Stage Spindle (45), squared end out, with the Ring Gear and insert it until it contacts the installed Spindle Bearing (41)

6. Position the Assembly of the previous step with the 3 Stage Spindle resting on the table of an arbor press.

7. With an appropriate tool, press the inner race of the

Spindle Bearing (41) onto the 3

Stage Spindle Assembly until the Spindle Assembly seats against the inner race of the Bearing.

8. Apply a coating of Ingersoll Rand #67 grease to the Spacer (40) and install the spacer on top of the Spindle Bearing (41).

9. Install the 2

Stage Spindle (39). Be sure to engage all

gears properly prior to applying any force.

10. Apply a coating of Ingersoll Rand #67 grease to the

Spacer (38) and install the spacer on top of the 2

Stage Spindle (39).

11. Install the 1

Stage Spindle (37). Be sure to engage all

gears properly prior to applying any force.

12. Install the Retainer (36) into the groove inside the motor end of the Ring Gear.

13. Install the Ring Gear containing the Spindles, output end first, into the Gear Case (48) .

14. Install Retaining Ring (34) into the internal groove in the end of the Gear Case.

15. Slide the Coupling Nut (47) onto the input end of the Gear Case (48). Using the proper tool, slide the Retaining Ring (46) over the end and into the external groove of the Gear Case.

FOR GEF400-M37, AND GEP400-M37

1. Ensure that all the gears are free of debris.

2. Apply 3 - 4 cc of IR #67 grease to the central area between the gears and the surface of the gear teeth of

the 1

Stage Spindle Assembly (37), the 2nd Stage

Spindle Assembly (39) and the 3

Stage spindle

Assembly (45).

3. Coat the inside and outside surfaces of the Ring Gear (43) with IR #67 grease.

1. Ensure that all the gears are free of debris.

2. Apply 3 - 4 cc of IR #67 grease to the central area between the gears and the surface of the gear teeth of

the 1

Stage Spindle Assembly (37), the 2nd Stage

Spindle Assembly (39) and the 3

Stage spindle

Page 22

MAINTENANCE (Continued)

4. Engage the planets of the 3rd Stage Spindle (45) with the large outer diameter end of the Ring Gear and insert it until its spindle bearing seats in the Ring Gear bearing bore.

5. Apply a coating of Ingersoll Rand #67 grease to the

Spacer (40) and install the spacer on top of the 3

Stage Spindle (45) from the small outer diameter end of the Ring Gear.`

6. Install the 2

Stage Spindle (39). Be sure to engage

all gears properly prior to applying any force.

7. Apply a coating of Ingersoll Rand #67 grease to the

Spacer (38) and install the spacer on top of the 2

Stage Spindle (39).

8. Install the 1

Stage Spindle (37) Be sure to engage all

gears properly prior to applying any force.

9. Install the Retainer (36) into the groove inside the motor end of the Ring Gear.

10. Install the Ring Gear containing the Spindles, output end first, into the Gear Case (48) .

11. Assembly O-ring (31) into the proper internal groove in the output end of the Motor Housing Assembly.

12. Slide the Coupling nut (47), threaded side first over the Motor Housing Assembly.

13. FOR GEP400-M37 ONLY: a. Assemble Retaining ring (49) to groove in Spindle

(50)

b. Insert Spline of Spindle (50) into 3

Stage Spindle

(45)

FOR MODELS WITH OFFSET GEAR CASES:

QE8Z{ }070{ }{ } QE8Z{ }090{ }{ } QE8Z{ }150{ }{ }

1. Insert Gear Case into the Offset Gearcase Input Flange.

2. Align the flange holes of the Offset Gear Case flange and Tool Gear Case and thread the Cap Screws into the Tool Gear Case flange.

3. Torque Cap Screws as follows:

QE8Z{ }070{ }{ }, QE8Z{ }090{ }{ } and QE8Z{ }150{ }{ }

18.4 - 25.4 ft • lbs (25 - 34.5 Nm)

FOR OFFSET GEARING ASSEMBLY:

REFER TO THE APPROPRIATE MAINTENANCE MANUAL LISTED IN THE QE8 HIGH TORQUE GEARING PARTS LIST.

Gear Case Assembly Installation

ALL MODELS

1. Install the Pinion Coupler Assembly (35) on the pinion of the motor.

2. Rotate the Gear Case Assembly to the desired orientation relative to the Motor Housing Assembly (1).

3. Insert the Motor Housing Assembly (1) into the Gear Case (48).

4. Align and engage the gear of the Pinion Coupler

Assembly (35) with the Planets of the 1

Stage Gear Head Assembly (37) while engaging the Ring Gear (43) with the Transducer (32) teeth. It may be

necessary to rotate the 3

Stage Spindle Assembly

(39) to aid in assembly.

5. Thread Coupling Nut (47) to the appropriate threads and while using the appropriate tool and the spanner holes on the gearcase torque the Coupling Nut (47) to 50 - 60 ft • lbs

(68 - 81 Nm).

Page 23

MAINTENANCE (Continued)

Attachments

In-Line Attachment - Assembly

FOR 160E4S8, 160E6S8 & 160E8S8 IN-LINE ATTACHMENTS

1. Install Socket Retaining Pin (66) into small hole provided in one of the flat walls of the square Spindle.

2. With Pin in place, locate Pin's groove inside large end-hole of Square Drive Spindle (64).

3. Position Spring (65) inside large hole of Square Drive Spindle such that the free ends of the Socket Retaining Spring are faced away from the hole and the closed side of the Spring straddles the Socket Retaining Pin.

4. Holding the Socket Retaining Pin steady, push Spring down hole of square Spindle until the Socket Retaining Spring's wire engages Socket Retaining Pin.

5. Socket Retaining Pin is properly installed when Socket Retaining Spring snaps into place.

6. Lubricate the bearings of the Housing Assembly (61) with Ingersoll-Rand # 67 Grease.

7. Slide Washer (62) and Washer (63) onto Square Drive Spindle and insert Square Drive Spindle (64) into Housing Assembly (61).

8. Align the Coupler (67) to slide over spline of Square Drive Spindle.

9. Slide Coupler into position in Housing Assembly (61).

10. Slide Washer (70) on the Drive Spindle Assembly (69).

11. Use snap-ring Pliers to install the Retaining Ring (71) on top of the Washer.

12. Press on Rear Spindle Bearing (72) to Drive Spindle Assembly (69).

13. Place Disengaging Spring (68) over Drive Spindle Assembly.

14. Align the Drive Spindle Assembly with spline of Coupler and insert Drive Spindle Assembly into Housing Assembly (61).

15. Apply one drop of Perma-Lok MM-115 to threads of Bearing Cap (73).

16. Carefully grasp the Housing Assembly.

Note: In the following step, the Bearing Cap (73) has a

left-hand thread.

17. Using the appropriate tool, tighten Bearing Cap (73) to between 45 - 50 lb

• ft (61 - 68 Nm) of torque.

18. Slide Coupling Nut (74) over Housing Assembly (61).

19. Using an appropriate tool, install Retainer (75) onto spline of Housing Assembly until seated into groove.

20. Spin Coupling by hand to check freedom of movement.

FOR ALL OTHER SPINDLE ASSEMBLIES:

REFER TO THE APPROPRIATE MAINTENANCE MANUAL LISTED IN THE QE8 HIGH TORQUE INLINE SPINDLE PARTS LIST.

Attachment - Installation

FOR MODELS:

QE8A{ }225{ }{ } QE8A{ }400{ }{ } QE8S{ }150{ }{ }

1. Position the Attachment appropriately.

2. Engage the spline on the input spindle of the Attachment with the matching internal spline of the

Stage Spindle Assembly (45), and then engage the spline on the Attachment Housing with that of the Gear Case (48).

3. Thread the Coupling Nut (74) onto the Gear Case.

4. While holding the tool using an appropriate wrench on the wrench flats (or spanner holes) of the Gear Case, torque Coupling Nut to between 45 - 50 lb

(61 - 68 Nm).

• ft

FOR ALL OTHER MODELS:

1. Insert Gear Case or Offset Gear Case into the Tool mounting plate.

2. Insert Attachment to the Opposite side of the Mounting Plate and properly engage the drive spindle with the Gear Case or Offset Gear Case Output Spindle.

3. Align the mounting holes of the Attachment to the Mounting plate and to the Gear Case or Offset Gear Case and insert the Cap Screws through the holes in the flange of the Attachment and mounting plate.

4. Torque Cap Screws to the Gear Case or Offset Gear Case as follows:

ALL MODELS:

18.4 - 25.4 ft • lbs (25 - 34.5 Nm)

Page 24

MAINTENANCE (Concluded)

QE8 Series Wiring (Cable) Chart

Connector Pin Wire Color (Cable) Logic Connector Pin

ARedVCC13

B Black COM 14

C Gray Spare 1 12

D Pink Spare 2 27

E Brown Spare 4 15

F Yellow Sine 21

G Orange Cosine 28

H Violet Spare 3 7

J Green Ground Sense 20

KBlueRX+ 5

L Blue/White RX- 6

MWhiteTX- 8

N White/Blue TX+ 9

U Red Motor Phase B 23

V Black Motor Phase C 34

W White Motor Phase A 36

X Green/Yellow Ground 25

--- --- TX Shield 1

--- --- RX Shield 4

--- --- Hall Shield 22

--- --- Motor Shield 16

SAVE THESE INSTRUCTIONS. DO NOT DESTROY.

When the life of the tool has expired, it is recommended that the tool be disassembled,

degreased and the parts be separated by material so that they can be recycled.

NOTICE

Page 25

SERVICE NOTES

Page 26

SERVICE NOTES

Page 27

SERVICE CENTERS

Centres d’entretien • Ingersoll-Rand Niederlassungen • Centri di Assistenza •

Centros de Servicio • Service Centra • Servicentre • Servicecenter • Servicesenter •

Huoltokeskus • Centros de Assistência Técnica • Κέντοα Εξυποέτησης

Ingersoll-Rand

1872 Enterprise Drive Rochester, MI 48309 Phone: (248) 293-5700 Fax: (248) 293-5800

Asia Pacific Operations

Ingersoll-Rand Ltd. 42 Benoi Road Jurong, Singapore 629903 Phone: 65-861-1555 Fax: 65-861-0317

Australia

Ingersoll-Rand Ltd. Landmark Corporate Center Level 2 454-472 Nepean Highway Frankston, Vic 3199 Australia Phone: 61 3 8781 1600 Fax: 61 3 8781 1611

Canada

National Sales Office Regional Warehouse Toronto, Ontario 51 Worcester Road Rexdale, Ontario M9W 4K2 Phone: (416) 213-4500 Fax: (416) 213-4510

Order Desk

Fax: (416) 213-4506

China

Ingersoll-Rand Productivity Solutions Room 1616, South Tower, Guangzhou World Trade Center Complex, 371 Huanshi East Road Guangzhou, 510095 China [86] 20 8776 4754 or 86 20 8776 4755

Ingersoll-Rand & Co. Ltd. Swan Lane (Gate 3) Hindley Green Wigan WN2 4EZ UK Phone: +44 (0) 1942 257 171 Fax: +44 (0) 1942 503 450

OFFICE LOCATIONS

Czech Republic

Ingersoll-Rand Productivity Solutions Ostrovskeho 34 151 28 Prague Czech Republic Phone: +420 2 57 109 756/7 Fax: +420 2 57 109 758

France

Ingersoll-Rand Productivity Solutions A.S. Division Zone du Chêne Sorcier B.P. 62 Les Clayes sous Bois Cedex 78346 Phone: +33 (0) 1 30 07 69 00 Fax: +33 (0) 1 30 07 69 82

Germany

Ingersoll-Rand European Sales Ltd. c/o Intersoll-Rand GmbH Postfach 10 09 54 45409 Mülheim / Ruhr Germany Phone: +49 (0) 208 9994 0 Fax: +49 (0) 208 9994 444 e-mail: [email protected]

India

Ingersoll Rand Wadco Tools Pvt. Limited 37-A, Site-4, Sahibabad Industrial Area Ghaziabad-201 010 India Tel : +91-120-2895116-126 Fax: +91-120-2895127

Italy

Productivity Solutions Ingersoll-Rand Italia S.r.l. Strada Provinciale Cassanese 108 20060 Vignate (Milano), Italy Phone: +39 02-95056-261 Fax: +39 02-95360-159

India

Ingersoll Rand Wadco Tools Pvt. Limited 37-A, Site-4, Sahibabad Industrial Area Ghaziabad-201 010 India Tel : +91-120-2895116-126 Fax: +91-120-2895127

Page 28

OFFICE LOCATIONS (CONTINUED)

Japan

IR Japan, Ltd. LS Bldg. 2F, 1-1-17 Kami-Ohsaki, Shinagawa-ku Tokyo, 141-0021 Japan [81] 3-5420-3397

Latin America Operations

Ingersoll-Rand 730 N.W. 107 Avenue Suite 300, Miami, FL, USA 33172-3107 Phone: (305) 559-0500 Fax: (305) 222-0864

Europe, Middle East and Africa

Ingersoll-Rand Douai Operations 111, Avenue Roger Salengro 59450 Sin Le Noble, France Phone: (33) 3-27-93-08-08 Fax: (33) 3-27-93-08-00

Poland

Nowiniarska 1 ap. 1 00-235 Warsaw Poland Phone: +48 (0) 22 635 7245 Fax: +48 (0) 22 635 7332

Russia

Ingersoll-Rand Company Mjasnitskaya Street, 32, bld. 1 101990 Moscow Russia Phone: +7 (8) 095 933 03 24 Fax: +7 (8) 095 785 21 26

Scandinavia

Ingersoll-Rand Drammensveien 126 A 0277 Oslo Norway Phone: +47 (0) 22 55 15 26 Fax: +47 (0) 22 43 65 81

Spain

Ingersoll-Rand Productivity Solutions Tierra de Barros, 2 28820 - Coslada Madrid (Spain) Phone: +34 (0) 91 6277405 / 6277400 Fax: +34 (0) 91 6277406

South Africa

Ingersoll-Rand Company SA (PTY) Ltd. Productivity Solutions P.O. Box 123720 Alrode 1451 South Africa Phone: +27 (0) 11-617-3828 Fax: +27 (0) 11-864-5609

Ingersoll-Rand & Co. Ltd. Swan Lane (Gate 3) Hindley Green Wigan WN2 4EZ UK Phone: +44 (0) 1942 257 171 Fax: +44 (0) 1942 503 450

USA

Ingersoll-Rand Productivity Solutions P.O. Box 970 1467 Route 31 South Annandale, NJ 08801 Phone: (908) 238-7000 Fax: (908) 238-7048

0404