135DPV-B Series Variable Speed Drills
Contents
1. 869788 863984 869584 14 only X 869445 PARTS LIST PART NO NAME OF PART QUANITY 202279 Motor Spacer 812165 Cylinder Pin 833859 Governor Weight Pin 842768 Governor Center Bearing 843446 Rear Rotor Bearing 843871 Governor Center Stop Pin 863983 Governor Center 863984 Governor Weight 863986 Rear Bearing Plate 864196 Rotor Collar 865587 Bovernor Body 869445 Front Rotor Bearing 869451 Cyliinder incl 812165 869584 Pinion Spacer 869607 Rotor 6T 869720 Front Bearing Plate 869788 Rotor Blade gt Se Se ck sch Se Se ap SH SH sch gt 203617 6 847806 203617 864584 863994 869582 V gp 1 C gt B47411 O m i Te lt 203616 8 203616 832638 DRILL ASSIST MODELS Bare Handle 869853 Handle Subassembly 861902 869581 PARTS LIST HANDLE SUBASSEMBLY 201905 Trigger Assembly 863995 Indexing Blade 203616 Throttle Link Pin 864185 Indexing Blade Pin 203617 Throttle Valve 864193 Rotational Stop Set Screw 412775 Air Inlet Screen 864505 Governor Spacer 007 832638 Trigger Pin 864506 Governor Spacer 020 833303 Muffler Screen 864584 Auxiliary Spring Cap 842652 Indexing Blade Spring 867916 Inlet Bushing 847033 Retainer Ring 869581 Muffler 847411 O Ring 11 16 x 13 16 869582 Throttle Valve Spring 847806 Auxiliary Governor Spring 869603 135DPV 7B Speed Indicating Ring 863987 Speed Adjusting Cap 869604 135DPV 14B Speed Indi2. Keep body and hands warm and dry cold weather is reported to be a major factor contributing to Raynaud s Syndrome Avoid anything that inhibits blood circulation Smoking Tobacco another contributing factor Cold Temperatures Certain Drugs Tasks should be performed in such a manner that the wrists are maintained in a neutral position which is not flexed hyperextended or turned side to side Avoid OK Avoid Avoid OK Avoid OR Zo l Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation Stressful postures should be avoided select a tool appropriate for the job and work location Avoid highly repetitive movements of hands and wrists and continuous vibration exposure after each period of operation exercise to increase blood circulation Keep tool well maintained and replace worn parts KE Safety Recommendations Work gloves with vibration reducing liners and wrist sup ports are available from some manufacturers of industrial work gloves Tool wraps and grips are also available from a number of different manufacturers These gloves wraps and wrist supports are designed to reduce and moderate the effects of extended vibration exposure and repetitive wrist trauma Since they vary widely in design material thickness vibration reduction and wrist support qualities itis recommended thatthe glove tool wrap or wrist support manufacturer be consulted for items designed for your specifi
3. reflective surfaces process noises and resonant structures can substantially contribute to and increase the noise level in the area Excessive air pressure above 90 PSIG or worn motor components can also increase sound level emitted by tool Proper hearing conservation measures including annual audiograms and training in the use and fit of hearing protection devices may be necessary For additional information on hearing protection refer to Federal Regulations Section 1910 95 Occupational Noise Exposure and American National Standards Institute ANSI 512 6 Hearing Protectors WARNING Wear respirator where necessary Drilling operations may produce hazardous fumes and or dust To avoid adverse health effects utilize adequate ventilation and or wear respirator Respirators should be selected fitted used and maintained in accordance with Occupational Safety and Health Administration and other applicable regulations Read the material safety data sheet of any cutting fluids or materials involved in the drilling process Follow good ma chine shop practices Rotating shafts and moving components can entangle and en trap and can result in serious injuries Never wear long hair loose fitting clothes gloves ties or jew elry when working with or near drill of any type Do not wear loose fitting clothes long hair gloves ties or jewelry Cleco drills are designed to operate on 90 psig 6 2 bar maxim
4. 14 867907 867922 884125 869256 867921 867905 867925 867921 867866 867922 gu 867871 28 Gear Train 202031 202032 202033 202037 202038 202312 832128 842728 843635 867866 867871 867902 867903 867904 867905 867907 867921 867922 867925 869254 869255 869256 869552 869584 884125 PARTS LIST NAME OF PART QTY Bearing Retainer Spindle Bearing Front 28 Spindle Incl 867922 7 Spindle 14 Spindle Incl 832128 Shim 14 2nd Idler Gear Pin 7 2nd Idler Gear Pin Spindle Bearing Rear 28 Idler Gear 18T Incl 867921 28 Gear Case 42T 14 Pinion 15T 14 Idler Gear 15T Incl 867925 14 Idler Gear 15T 14 1st Red Spider 15T Incl 884125 7 amp 14 Gear Case 45T 7 amp 28 1st Idler Gear Bearing 7 amp 28 1st Idler Gear Pin 14 1st Idler Gear Bushing 2 amp 7 Idler Gear 19T Incl 867921 7 Idler Gear 15T 7 1st Red Spider 15T Incl 867922 Chuck Spacer 14 Pinion Spacer 14 1st Idler Gear Pin O 43 WWWWWA 0 The complete gear train can be purchased as a subassembly using the part numbers below 7 861954 14 861956 28 861957 Does not include pi nion spacer 869254 867903 869584 14 Only 867902 14 Only 842768 843871 E 865587 Ur oe x S 812165
5. B series requires a 5 16 hose The drill is started by depressing the trigger and is stopped by releasing the trigger SPEED ADJUSTMENT Adjustment of the speed is done by depressing the indexing blade and rotating the speed adjustment cap to the desired RPM TRIGGER mye E INDEX BLADE ER LUBRICATION An automatic in line filter lubricator is recommended as it increases tool life and keeps the tool in sustained operation The in line lubricator should be regularly checked and filled with a good grade of 10W machine oil Proper adjustment of the in line lubricator is performed by placing a sheetof paper next to the exhaust ports and holding the throttle open approximately 30 seconds The lubricator is properly set when a light stain of oil collects on the paper Excessive amounts of oil should be avoided In the event that it becomes necessary to store the tool for an extended period of time overnight weekend etc it should receive a generous amount of lubrication atthat time and again when returned to service The tool should be stored in a clean and dry environment SPEED ADJUSTING CAP SERVICE INSTRUCTIONS DISASSEMBLY DISASSEMBLY Insert a hex wrench into the drill chuck and tighten the chuck securely Use a suitable hammer to strike the hex wrench sharply in a counter clockwise direction when facing the chuck Remove the drill chuck from the spindle Unscrew left hand threads the bearing reta
6. a solvent and inspected for damage or wear Particular attention should be given to all bearings gears gear pins and rotor blades as failure of these parts could cause damage to more expensive parts Rotor blades should be replaced if they measure less than 5 32 4mm on either end During reassembly of the motor unit care must be exercised in order to preventthe rotor from drifting forward and rubbing the front bearing plate Must be replaced if less than 5 32 4mm on either end To properly set the rotor collar No 864196 assemble the rear rotor bearing into the rear bearing plate Hold the inner race of the bearing forward and measure the depth of the inner race from the face of the bearing plate Select or fit by sanding a rotor collar 0015 larger than this dimension KE SELECT OR SAND ROTOR COLLAR TO THIS MEASUREMENT PLUS 0015 038mm p SE M REAR 4 BEARING PLATE IIS INNER RACE OF BEARING Assemble the collar rotor bearing bearing plate and gov ernor assembly left hand threads to the rotor Check clearance between rear bearing plate and rotor The clear ance should be 001 0254mm after the governor is tightened to the rotor 001 025mm Clearance SASS After final assembly of the motor unit has been completed inspect it to ensure that the rotor does not rub the front bearing plate Assemb
7. amer in drill chuck Always remove chuck key before starting tool Use care when drilling because of the possibility of the cutting tool bending or breaking CAUTION Tools equipped with chuck capacity over 1 4 should have at least one handle offset at a right angle to drill axis to counteract torque developed by tool If tool is equipped with a chuck over 3 8 capacity two handles at right angles to the drill axis Should be used One handle should contain the tool throttle such as pistol grip or offset handle models Always use a dead handle with low RPM high torque tools e e e A WARNING Repetitive work motions and or vibration may cause injury to hands and arms Use minimum hand grip force consistent with proper control and safe operation Keep body and hands warm and dry Avoid anything that inhibits blood circulation Avoid continuous vibration exposure Keep wrists straight Avoid repeated bending of wrists and hands Some individuals may be susceptible to disorders of the hands and arms when performing tasks consisting of highly repetitive motions and or exposure to extended vibration Cumulative trauma disorders such as carpal tunnel syn drome and tendonitis can be caused or aggravated by repetitious forceful exertions of the hands and arms Vibration may contribute to a condition called Raynaud s Syndrome These disorders develop gradually over peri ods of weeks months and years I
8. c application WARNING Proper fit of gloves is important Improperly fitted gloves may restrict blood flow to the fingers and can substantially reduce grip strength Warning Labels The warning labels found on these tools are an essential part of this product Labels should not be removed Labels should be checked periodically for legibility Replace warn ing labels when missing or when the information can no longer be read Replacement labels can be ordered as any Spare part READ OPERATING INSTRUCTIONS 203185 4 203185 203287 This information is a compilation of general safety practices obtained from various sources available at the date of production However our company does not represent that every acceptable safety practice is offered herein or that abnormal or unusual circumstances may not warrant or require additional procedures Your work may require additional specific safety procedures Follow these proce dures as required by your company For more information see the latest edition of ANSI B186 1 Safety Code for Portable Air Tools available from the American National Standards Institute Inc 11 West 42nd Street New York NY 10036 OPERATING INSTRUCTIONS FOR YOUR SAFETY AND THE SAFETY OF OTHERS READ AND UNDERSTAND THE SAFETY RECOMMENDATIONS ON PAGES 2 thru 4 BEFORE OPERATING DRILL OPERATION The 135DPV B series drills are designed to operate on 90 PSIG 6 2 bar air pressure The 135
9. cating Ring 863991 Governor Valve 869611 Handle Incl 863993 863992 Governor Spacer 005 869746 135DPV 28B Speed Indicating Ring 863993 Governor Valve Bushing 863994 Governor Spring Note Denotes parts not included in handle subassembly No 861801 Number of spacers required is variable The complete handle can be purchased as a subassembly using Part No 861801 9 135DPV B DRILL EQUIPMENT MODELS STANDARD EQUIPMENT OPTIONAL EQUIPMENT 135DPV 7B 43 3 8 3 JAW CHUCK 849103 42 1 4 3 JAW CHUCK 849106 CHUCK KEY 849123 CHUCK KEY 849118 CHUCK GUARD 202058 135DPV 14B 51 3 8 SMALL DIAMETER 51 3 8 SMALL DIAMETER 3 JAW CHUCK 849108 3 JAW CHUCK 849108 CHUCK KEY 849120 CHUCK KEY 849120 43 3 8 3 JAW CHUCK 849103 135DPV 28B CHUCK KEY 849123 50 1 2 3 JAW CHUCK 889335 CHUCK KEY 849121 DEAD HANDLE 861006 CHUCK GUARD 202058 TOOLS WITH 1 2 CHUCKS MUST BE EQUIPPED WITH EXTRA CHARGE DEAD HANDLE CHUCK GUARD IS FOR USE WITH 1 4 CAPACITY CHUCKS ONLY gi COOPER Tools CooperTools 670 Industrial Drive Lexington SC 29072 Phone 803 359 1200 Fax 803 359 2013 www cooperindustries com
10. d Hold the body of the rotor in the vise and unscrew the governor assembly left hand threads After removing the rear bear ing plate the rotor collar No 864196 may be removed from the rear rotor shaft Todisassemblethe governor drive the governor center stop pin No 843871 into the 1 0 of the governor body No 865587 Drive the governor weight pins No 833859 out of the body to remove the governor weights No 863984 To disassemble the handle unscrew the inlet bushing This will allow the throttle valve spring and throttle valve to drop out Should the governor valve bushing No 863993 need re placing press it out the front ofthe handle Coat bushing with Locktite 4271 and press in flush with rear of handle NOTE The new bushing must be honed to this dimension 6875 6880 17 4625mm 17 4752mm after being installed 6 10mm 255 A 6 48mm EEE Front Rear lt lt Front fem Rear gt mn DOUBLE REDUCTION MODELS SERVICE INSTRUCTIONS REASSEMBLY REASSEMBLY The tool is reassembled in the reverse order of disassem bly Wash all parts thoroughly in a solvent and inspect for damage or wear before reassembly The rotor and spindle bearings should be replaced if excessive looseness is evident or if they feel rough As the various gears and bearings are being reassembled they should receive a generous amount of NLGI 2 EP grease REASSEMBLY GENERAL All parts should be washed in
11. iner No 202031 or chuck guard from the gear case GEAR TRAIN DISASSEMBLY Unscrew lefthand threads the spindle bearing retainer No 202031 The spindle may now be pressed out of the spindle bearings If replacement of the idler gear pins is necessary the old pins should be pressed out the rear and the replacement pins pressed in as shown in the following diagrams 240 6 10mm 2255 6 48mm ul Se d SINGLE REDUCTION MODEL 360 9 14mm 5 Sail 37 9 53mm EG 240 Unscrew and remove the gear case from the handle Re move the rotational stop set screw No 864193 and un screw the speed adjusting cap No 863987 Note The speed adjusting cap has a triple start thread and should be marked so that the threads can be started correctly when reassembled The auxiliary governor spring No 847806 auxiliary spring cap No 864584 governor spring No 863994 and governor valve No 863991 can now be removed from the handle The governor spacers should be removed either from the inside of the governor valve or the backofthe governor center bearing atthistime to avoid them being lost or misplaced during repair of the tool The motor and governor assembly can now be removed from the handle by bumping the handle on the workbench Hold the front bearing plate in a vise and use a soft hammer to drive the rotor shaft out of the front rotor bearing This will permit the cylinder and rotor blades to be remove
12. le the motor unit with governor assembly and gear case to the handle When inserting the motor into handle do not damage governor Slide the governor valve No 863991 into the governor valve bushing No 863993 as far as it will go Screw No 4 40 x2 screw into the governor center No 863983 and pull towards the rear until stopped by the governor center stop pin No 843871 Measure the depth of the governor valve No 863991 from the rear end of the governor bushing No 863993 and add governor shims between the governor center bearing No 842768 and the governor valve until the valve and the bushing are flush within or 003 Assemble the governor spring auxiliary spring cap auxiliary governor spring and the speed adjust ing cap to the handle Run the tool and adjust the speed to 350 R P M for the 135DPV 7B 800 R P M forthe 135DPV 14B or 1500 R P M for the 135DPV 28B Mark the speed adjusting cap at the nearest notch to the desired speed remove and press on the speed indicating ring with the desired speed in line with the mark Place a few drops of 10W machine oil in the air inlet before attaching the air hose This will ensure immediate lubrication of all parts as soon as the air is applied 202037 202031 j 202038 14 843635 7 amp 14 Gear Trains 202031 202312 202033 Y 869552 202032 842728 7 832128 14 869255 7 867904
13. p Operation amp Service Manual COOPER Tools 823040 2 01 135DPV B Series Variable Speed Drills Drill Chuck 3 8 24B 1 4 HD Capacity 3 8 24B 3 8 HD Capacity 50 3 8 24B 1 2 Capacity Series 51 3 8 24B 3 8 Capacity 40 No Chuck 3 8 24B Handle PV Pistol Variable Speed eneration B Second Gear Train Designation 7 14 28 NORTH AMERICA EUROPE CooperTools Cooper Power Tools GmbH amp Co P O Box 1410 Postfach 30 Lexington SC 29071 D 73461 Westhausen Safety Recommendations For your safety and the safety of others read and under stand the safety recommendations and operating instruc tions before operating a drill Always wear protective equipment WARNING Impact resistant eye protection must be worn while operating or working near this tool For additional information on eye protection and face protection refer to Federal OSHA Regulations 29 Code of Federal Regulations Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI 787 1 Occupational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 11 West 42nd Street New York NY 10036 CAUTION Personal hearing protection is recommended when operating or working near this tool Hearing protection is recommended in high noise areas 85 dBA or greater The operation of other tools and equipment in the area
14. t is presently unknown to what extent exposure to vibrations or repetitive motions may contribute to the disorders Hereditary factors vasculatory or circulatory problems exposure to cold and dampness diet smoking and work practices are thought to contribute to the conditions Any tool operator should be aware ofthe following warning signs and symptoms so that a problem can be addressed before it becomes a debilitat ing injury Any user suffering prolonged symptoms of tingling numbness blanching of fingers clumsiness or weakened grip nocturnal pain in the hand or any other disorder of the shoulders arms wrists or fingers is advised to consult a physician If itis determined that the symptoms are job related or aggravated by movements and postures dictated by the job design it may be necessary for the employer to take steps to prevent further occurrences These steps might include but are not limited to reposi tioning the workpiece or redesigning the workstation reas signing workers to other jobs rotating jobs changing work pace and or changing the type of tool used so as to minimize stress on the operator Some tasks may require more than one type of tool to obtain the optimum operator tool task relationship The following suggestions will help reduce or moderate the effects of repetitive work motions and or extended vibration exposure Use a minimum hand grip force consistent with proper control and safe operation
15. um air pressure If the tool is properly sized and applied higher air pressure is unnecessary Excessive air pressure increases the loads and stresses on the tool parts and may result in breakage Installation of a filter regulator lubricator in the air Supply line ahead of the tool is recommended Before the tool is connected to the air supply check the throttle for proper operation i e throttle moves freely and returns to closed position Being careful not to endanger adjacent personnel clear the air hose of accumulated dust and moisture Before removing a tool from service or changing a drill bit tap reamer or any accessory make sure the air line is shut off and drained of air This will prevent the tool from operating if the throttle is accidently engaged Sudden and high reaction torque may CAUTION be experienced with any drill if drill motor stalls by excessive load being applied to drill bit or drill bit snags on material being drilled on break through when the drill bit passes through the material being drilled User must be prepared to resist torque 4 Safety Recommendations CAUTION Drill bits are sharp Handle them carefully to avoid injury Cutting tool maximum speed rating must equal or exceed rated speed of tool Drill bits or accessories not centered properly in the chuck can cause excessive wobble or vibration Use appropriately sized chuck key to securely tighten drill bit tap or re
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