Ingersoll Rand QP05, QP20, QP38, QP15, QP09 User Manual

16572679

May 2014

Air Drill QP Series

Maintenance Information

Edition 2

Save These Instructions

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Product Safety Information

WARNING

Failure to observe the following warnings, and to avoid these potentially hazardous situations, could result in death or serious

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injury. Read and understand this and all other supplied manuals before installing, operating, repairing, maintaining, changing accessories

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on, or working near this product. Always wear eye protection when operating or performing maintenance on this tool. The grade of protection required should be

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assessed for each use and may include impact-resistant glasses with side shields, goggles, or a full face shield over those glasses. Always turn o the air supply, bleed the air pressure and disconnect the air supply hose when not in use, before installing, removing

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or adjusting any accessory on this tool, or before performing any maintenance on this tool or any accessory.

Note: When reading the instructions, refer to exploded diagrams in parts Information Manuals when applicable (see under Related Documentation

for form numbers).

Lubrication

Use Ingersoll Rand No. 10 Oil to lubricate the motor. Each time a Series QP Drill is disassembled for maintenance and repair or replacement of parts, lubricate the tool as follows:

Coat all exposed gears with Ingersoll Rand No. 67 Grease

and work some of the Grease into the gearing of the Spindle Assembly (29).

2. Inject approximately 1 to 2 cc of oil into the air inlet before attaching the air hose to the tool.

Speed Adjustment

Series QP Drills are furnished with the ability to precisely control, within certain ranges, the optimum drilling speed for exotic materials. Setting the speed requires a tachometer and a jeweler’s screwdriver. Therefore, the adjustment, although simple, should only be attempted by a competent technician using the proper equipment.

A small, round opening is located adjacent to the Inlet Bushing Assembly (4) in the molded exhaust vent. A tiny screw at the bottom of that hole controls the location of the exhaust control plate. Take an initial reading of the tool speed by applying a tachometer to the end of the Chuck without a drill bit and with the trigger completely depressed. If the tachometer has a concave tip, close the chuck completely; if the tip is convex, open the chuck completely.

After determining the actual velocity, shut o the air supply and insert a small jeweler’s screwdriver into the slot of the exhaust control plate screw and rotate the screw approximately fteen degrees. Restore the air supply and check the velocity again. The control plate provides unrestricted exhaust for 90 degrees, completely restricted exhaust for 90 degrees and variable, adjustable exhaust for 180 degrees. Determine which direction you need to rotate the screw to obtain the desired speed and then move the screw accordingly. Best results are achieved by using gradual increments and frequent tachometer readings. Be sure to turn o the air supply when making adjustments to the screw.

Disassembly

General Instructions

Do not disassemble the tool any further than necessary to replace

1. or repair damaged parts. Whenever grasping a tool or part in a vise, always use leather-

2. covered or copper-covered vice jaws to protect the surface of the part and help prevent distortion. This is particularly true of threaded members and housings.

Do not remove any part which is a press t in or on a

3. subassembly unless the removal of that part is necessary for repairs or replacement. Do not disassemble the tool unless you have a complete set of

4. gaskets and O-rings for replacement.

Disassembly of the Tool

Each Series QP Drill is made up using three modules or units which include a housing and throttle unit, a motor unit and a combined gearing and spindle unit. The tool can be disassembled for repairs to each individual unit without disturbing the other units. To separate the modules, proceed as follows:

Remove the Chuck (35) using the following technique:

Insert the short leg of a 1/4” hex wrench into the jaws of the

Chuck and tighten the Chuck. Using a brass hammer, sharply rap the long leg of the wrench

in a counterclockwise direction to loosen the Chuck. Unscrew and remove the Chuck from the spindle.

2. To separate the Gear Case (30) from the Housing (1), proceed as

follows:

Install a standard 1-1/16” open end wrench on the ats of the

Gear Case. Grasp the handle portion of the Motor Housing and rotate

the Housing counterclockwise to begin unscrewing it from the Gear Case. When the Housing begins to turn freely, remove the wrench

from the Gear Case and with the spindle upward, nish unscrewing the Housing from the Gear Case. Set the assembled Gear Case on the workbench.

3. Remove the Motor Clamp Washer (21) and the Motor Seal (20) from the assembled motor in the Housing.

4. Grasp the shaft of the Rotor (15) and pull the assembled motor out of the Motor Housing.

5. To remove the throttle unit, grasp the hex of the Inlet Bushing Assembly (4) in vise jaws with the Motor Housing upward.

6. Using the Inlet Retainer Removal Tool (37), depress the two tabs on the Inlet Bushing Retainer (7), located 180 degrees apart, while pulling the Housing o the Inlet Bushing Assembly.

7. If the Inlet Bushing Seal (8F) remained in the Housing when the Inlet Bushing Assembly was removed, remove it from the Housing.

Disassembly of the Gearing

For Series QP05, QP09, QP15, QP20 and QP38, using snap

ring pliers, remove the Gear Retainer (22) from inside the Gear Case (30) and remove the Gear Head Spacer (23). For Series QP38, lightly rap the motor end of the Gear Case on

a wooden work bench top to remove the Planet Gear Head Drive Plate (24), Planet Gear Head Assembly (25) and the Planet Gear Head Spacer (28).

For Series QP05 and QP09, lightly rap the motor end of the Gear

Case on a wooden work bench top to remove the three Planet Gears (26), the Planet Gear Head Assembly (25) and the Planet Gear Head Spacer (28).

For Series QP15 and QP20, lightly rap the motor end of the Gear

NOTICE

Case on a wooden work bench top to remove the three Planet Gears (26), the Rotor Pinion (27), the Planet Gear Head Assembly (25) and the Planet Gear Head Spacer (28).

If the Spindle Assembly is being removed or replaced, the Spindle Bearing and Spindle Cap Bearing may be damaged during the removal process. We recommend that new replacement bearings be available for installation when the tool is reassembled.

3. Stand the Gear Case on the table of an arbor press with the threaded end of the Spindle Assembly (29) upward. Using a rod slightly smaller than the spindle shaft, press the Spindle Assembly out of the Spindle Cap Bearing (34) and Spindle Bearing (31).

4. Insert a long, small drift through the central opening of the Spindle Bearing and push the Bearing Spacer (32) o to one side. Using a hammer with the drift, tap the inner ring of the Spindle Cap Bearing. Repeat the process at several points until the Bearing is free from the Gear Case. Remove the Bearing Spacer from the Gear Case.

5. Using snap ring pliers, remove the two Bearing Stops (33).

6. Stand the Gear Case on the table of an arbor press with the threaded end upward, and press the Spindle Bearing out of the Gear Case.

Disassembly of the Motor

Using snap ring pliers, remove the Rear End Plate Assembly

Retainer (12) and slide the Rear End Plate Assembly (11) o the rear hub of the Rotor. Use a piece of leather or other protective material to grasp the

splined shaft of the Rotor and pull the assembled Rotor out of the

Cylinder (13). Remove the Vanes (16) from the Rotor.

3. Support the Front End Plate Assembly (17), as near the rotor body

4. as possible, on the table of an arbor press and press the Rotor from the Front Rotor Bearing (19). Remove the Bearing from the Front End Plate.

Disassembly of the Throttle Mechanism

Grasp the hex of the Inlet Bushing Assembly (4) in leather-covered

1. or copper-covered vise jaws with the end having the Inlet Bushing Screen (5) downward. Remove the Inlet Bushing Seal (8F) from the Inlet Bushing

2. Assembly. Using snap ring pliers, remove the Valve Seat Retainer (8E) and the

3. Valve Seat Support (8D) from the Bushing. Using a hooked tool without sharp edges or points, remove the

4. Throttle Valve Seat (8C) from inside the Bushing. Remove the Throttle Valve (8A) and Throttle Valve Spring (8B) from

5. the Bushing. If the Inlet Bushing Screen is dirty, ush it clean using a clean,

6. suitable, cleaning solution in a well ventilated area. Remove the Screen only if it is damaged or as a last resort and have a replacement Screen on hand whenever removal becomes necessary. Use the eraser end of a pencil to push it out the inlet end of the Bushing. If the Inlet Bushing Bezel (6) needs replacement, slightly spread

7. the Inlet Bushing Retainer (7) and push it o the side of the Bushing. Slide the Bezel o the Bushing. To remove the Trigger Assembly (3A), insert a long probe with a

8. small hook into the opening for the Inlet Bushing Assembly in the Motor Housing (1) and hooking the Trigger Retainer (3B), pull the Retainer out of the Housing. Pull the Trigger out of the Housing.

Assembly

General Instructions

Always press on the inner ring of a ball-type bearing when

1. installing the bearing on a shaft. Always press on the outer ring of a ball-type bearing when

2. pressing the bearing into a bearing recess. Whenever grasping a tool or part in a vise, always use leather-

3. covered or copper-covered vise jaws to protect the surface of the part and help prevent distortion. This is particularly true of threaded members and housings. Except for bearings, always clean every part and wipe every part

4. with a thin lm of oil before installation. Apply o-ring lubricant to all O-rings before nal assembly.

5. Check every bearing for roughness. If an open bearing must be

6. cleaned, wash it thoroughly in a clean, suitable cleaning solution and dry with a clean cloth. Sealed or shielded bearings should never be cleaned. Work grease into every open bearing before installation.

Assembly of the Throttle Mechanism

If the Trigger Assembly (3A) was removed, insert the shaft of the

1. Trigger into the Motor Housing (1) and push it all the way into the trigger recess in the Housing until it stops. Using long reach needle nose pliers to hold the Trigger

2. Retainer (3B), insert the Retainer into the inlet bushing opening and install the straight leg of the Retainer in the hole through the shaft of the Trigger. Install the Inlet Bushing Bezel (6), convex end leading, onto the

3. Inlet Bushing Assembly (4). Bring the convex end into contact with the hex at the inlet end of the Bushing. Spread the opening slightly on the Inlet Bushing Retainer (7) and

4. install it around the Inlet Bushing with the tab end nearest to the bushing hex and against the Bezel. Grasp the hex of the Inlet Bushing in leather-covered or copper-

covered vise jaws with the throttle valve opening upward. Insert the Throttle Valve Spring (8B), large end leading, followed

6. by the Throttle Valve (8A), long stem end trailing, into the valve opening. Place the Throttle Valve Seat (8C) followed by the Valve Seat

7. Support (8D) in the opening against the Valve. Using snap ring pliers while compressing the Throttle Valve

8. Spring and moving the Seat and Support inward, capture the components by installing the Valve Seat Retainer (8E) in the Bushing internal groove. Moisten the Inlet Bushing Seal (8F) with o-ring lubricant and

9. install it on the exterior of the Inlet Bushing. Remove the assembled Bushing from the vise jaws. If the Inlet

10. Bushing Screen was removed, use a at faced dowel slightly less than 1/2” in diameter to push the new Screen into the opening at the hex end of the Bushing.

Assembly of the Motor

Place the Front End Plate (17) on the splined shaft of the

1. Rotor (15) with the bearing recess away from the rotor body. Place the Front Rotor Bearing (19) onto the shaft and using a

2. sleeve or piece of tubing that contacts the inner race of the Bearing, press the Bearing onto the shaft until the Front End Plate nearly contacts the rotor body.

In the following step, the measurement must be made at the end corner of the large rotor body.

3. The clearance between the Front End Plate and Rotor is critical.

While pressing down with your nger on the outer edge of the Front End Plate on the bearing side, insert a 0.004” (0.1 mm) feeler gauge between the face of the rotor body and the face of the End Plate at a point that is 180 degrees from where the pressure is

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