Service Manual for QE6 Series Angle Wrench
Contents
1. Power Cord Assembly 90 Deg 3 Meter Power Cord Assembly 90 Deg 10 Power Cord Extension Assembly 10 Meter Power Cord Extension Assembly 20 Meter Power Cord Extension Assembly 40 Meter Angle Head Sleeve for 1 2506 for Models 4506 4508 for Model 5508 Model 6508 Suspension Bail Spanner Wrench u tere en DEA120 K48 DAM120 K48 GEA40 K364 GEM120 K48 GEA40 CORD 3M GEA40 CORD 10M GEA40 CORD 3M 90 GEA40 CORD 10M 90 GEA40 EXT 10M GEA40 EXT 20M GEA40 EXT 40M GEA40 170 GEA40 171 GEA40 172 GEA40 173 7L 365 GEA40 478 T To be used with QE6 Series non flanged Motor Housing Assembly s Dwg TP2103 C QE6 TOOL ASSEMBLIES Angles I R 67 GU b Product Identification Code ch ment 2 S ms e 6 CD Sions f 4 o E D lt Dwg TP2104 In Lines a Tz Solutions EXE CE EE Float i e Float travel Product Identification Code Long Dwg TP21052. pug Sunesg wee VT N men Cy ue x CE gt ojpuidg 81 8 81 8 81 8 81 8 8 1 A quiossy 5 os as eras OS 0PYED een eisernen weeds ee sehr sidad sr cy aie 01 0 OI NTAF DIET QST 1899 Ly 005 W LM9 00S W LMI 00 0 v vd SWIMS QST Suuvog 9r RM Mg s dEq 99gece mm jue ee Were ee os peoumar 1 91 61 9 0 91 98915 281 quiossy Sp doses ai en en rs ande Bro Surg Surureroy 90 0PVHD 90t 0pVdD 907 07 9 o eee 1899 sury LEW LI OPVAD LEW CC Ov VHD LEW 87 0PVAD nen K quiessy xoeq 0 96LV 0r VHD 0 96 v 0rVHD 06 9 4 OS OSLV OPWED A quiessy J99MPSUBIL Ir J9quinw Joquinw JAP A 30701 s9a0 0 0 9 0 0 0 s9a0 CH 0 v9a0 H 250 ISIHO CH 2050 6 uoneonnuepr PPO 2050 5970 CH 2080 4 140g ajgpa yddo A
3. Table 2 Item Tool Used Description Where Used 1 Spanner Wrench I R Part GEA40 478 Coupling Nut 2 Pin Spanner Wrench 3 mm or 1 8 pin Motor Housing Assembly Cable 3 Torque Wrench 1 2 Sq Drive 50 ft Ib capacity General use 4 Adjustable Pin Wrench In Lines Bearing Caps 5 Adjustable Wrench Coupling Nut with flats 6 5 64 Hex Key Cap Screws Low Socket Head 7 9 64 Hex Key Screws Regular Head 8 nternal Snap Ring Pliers General use m o E 10 MAINTENANCE General Instructions e Refer to Table 2 Suggested Tools Parts List for quick reference to the tools recommended for the following disassembly assembly instructions AWARNING Repairs should be made only by authorized trained personnel Consult your nearest Ingersoll Rand Authorized Service Center e 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 Coupling Nut 75 76 85 or 86 2 Unthread Coupling Nut from Motor Housing and remove Ang
4. 001 pos LOUS J9A9T 8c 6UECV OPVHD Henne preog uoneomnunuo ZI eg e i ern ee ds kowo 24 en sense Sz Kernen parda Sundal oi en ee a nenn ea ee S ern eisen ve UIT Sia O ee cr teren PAM fea oh e MT adole did een een erg Bee Sande ac ern ee eat fundis en on Roux oz ee pi ae a ea ee ra 61 ee d een Beisein ES Bear iss raras a Sumo i O P wr o o EN Joquinw Way Jed ISTI 4 S1949 pue sdri A quiassy 910 doqumN asn UYM A s43431 ANY BA WES DNISNOH 930 o F O o o z tc lt o 2 lt gt l m lt oc LLI o 2 a 1 2 lt oc F Ingersoll Rand 170 Dwg TP2023 amp quiassoqns fo sp y SIETOM SIM SA eee Surg Sururiog vc 18 0rINHGI ISEM ES 0SC OPVHD 0SC OPVHD 0ST 0r VID 71 2 u Beni Sunds CC 8rCOPVHD 8 0 E 295 SVID IS
5. EDRN M MISI ERIS YSONAGSNVUL 950 160241 WN 89 19 440 531 19 0355 ONISNOH YOLOW Q39NV 14 HLIM 350 2 3198V1 SLIM ONILNNOW 140 HLIM 350 N ND M IN N N Y L N N 198 LNANHOVLLV ANIT NI 930 ajpunds sumyuo9 COPY LL O86 888107I sos g 4 seg pm noys Inn Surdno3 9 98 0S8HOZl 90518 101 LCOPVHD Inn 5 98 8S9H0Zl t e e e 30519 101 6 0 e e joedg pL 98 999J0Zl t e n ne 90519 101 Ies zevsg dot e nnne dej3uueog c 98 8SPHOZl sosr y opuidg way zu cn 908Tr 101 e e M e 6 Sun 3uumpw IL oppuidg oauqporenbg 9 901 1071 o e e nnn roysem OL 90I FHOZL c rysem co o e e Kiquiassy appuidg anq 69 SOT PIOTI ctt e nnn oysem 79 969 94061 7777777777777 80518 90518 80519 905191017 08 V 8HOClL CU 770077007007 80518 90SI8 3 80819 90816 08ev 9HOZI 80619 90519 20 er Sunds Surseguss q 89 tutt NT 80617 90617 10 mes 186 98
6. 27 0 11 617 3828 Fax 27 0 11 864 5609 UK Ingersoll Rand amp 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 0104
7. ensure that the Memory Chip 12 Communication Board Gear Pack Assembly and Attachment are all assembled as a set with the new Motor Housing Assembly Disassembly of External Components 1 Dislodge O rings 20 and remove Memory Chip 11 from assembly 2 Remove Trigger mechanism 09 from Motor Housing assembly 3 Remove Spring 10 from Trigger mechanism MAINTENANCE Continued 4 Slide Reverse Ring 22 away from Housing being careful not to lose Detent Ball 07 or Springs 08 and 21 5 Remove Retaining Ring 19 from behind Label Cover Lens 18 6 Inasliding motion pull Warning Label 17 and Label Cover Lens 18 off end of Motor Housing Assembly 7 Slide Housing Cover 15 off Motor Housing Assembly 8 Remove O ring 14 located at front of Housing Cover Communication Board Close Up Motor 10 4 Morgue Trans Torque and Motor Connector s Dwg TP2102a_C E d m Motor Temper LEDs and Temperature Connector s Dwg TP2102b C Disassembly of Internal Components 1 Remove Retainer 13 used to retain Communication Board 12 located at rear end of Motor Housing Assembly in Connector cavity 2 Inlarge cavity area s of Motor Housing disconnect the Motor Phase connector Refer to TP2102b 3 Disconnect the Motor temperature sensor connector from the Communication Board Refer to TP2102b 4 Disconnect the Motor Commutat
8. in place locate the Pin s groove inside large end hole of square Spindle Position Socket Retaining Spring inside large hole of square Spindle such that the free ends of the Socket Retaining Spring are faced away from the hole and the closed side of the spring will straddle the Socket Retaining Pin 83 Holding the Socket Retaining Pin steady push Spring down hole of square Spindle until the Socket Retaining Spring s wire engages Socket Retaining Pin Socket Retaining Pin is properly installed when Socket Retaining Spring snaps into place Spin square Spindle by hand to check freedom of movement Slide Teflon Spacer 84 over input shaft of Angle Assembly Attachment Slide Coupling Nut 85 or 86 over Angle Assembly Attachment Using an appropriate tool install Retainer 87 on assembly Take care to seat Retainer Ring in groove Spin Coupling by hand to check freedom of movement For Models with Gear Case Sleeves Slide Gear Case Sleeve 5 over Gear Case of Motor Housing Assem bly Slightly lubricating inside of sleeve with dish soap will help ease the installation process Position the Angle Assembly Attachment to desired orientation Engage Angle Assembly Attachment s Pinion into spline of Spindle Assembly 50 then engage the spline on the Angle Assembly Attachment with the Gear Case of the Motor Housing Assembly 17 15 Thread Coupling Nut 85 or 86 onto Gear Case of Motor Housing Assembly 16 While holding the
9. 1 Looking down hole of the Spindle s square socket locate Retaining Pin 83 and Retaining Spring 82 2 If necessary using a pointed metal probe to pull retain ing Spring out of Spindle cavity 3 Also if necessary remove Pin from Spindle 4 Using Spanner Wrench GEA40 478 or other appropriate wrench grasp the Spanner holes or flats of the Coupling Nut 85 or 86 5 Holding firmly onto tool with the Spanner Holes in the Gear Case unscrew Coupling Nut and pull the Angle Assembly Attachment 81 out of Motor Housing Assembly 01 02 03 or 04 6 Ifneeded pull Teflon Spacer 84 off Angle Assembly Attachment 7 If necessary remove Coupling Nut Retainer 87 using an appropriate tool 8 Remove Coupling Nut In Line Attachments 1 Looking down hole of Spindle s square socket locate Retaining Pin 66 and Retaining Spring 65 2 If necessary using a pointed metal probe to pull retain ing Spring out of Spindle cavity 3 Also if necessary remove Pin from Square Drive Spin dle 64 4 Using Spanner Wrench GEA40 478 or other appro priate wrench grasp the Spanner holes or flats of the Coupling Nut 85 or 86 5 Holding firmly onto tool with the Spanner Holes in the Gear Case unscrew Coupling Nut and pull the In Line Attachment 81 out of Motor Housing Assembly 01 03 or 04 6 If needed pull Teflon Spacer 74 off Attachment 7 If desired remove Coupling Nut Retainer 77 using the appropri
10. 3 Tools Pvt Limited Phone 248 293 5700 Hindley Green 37 A Site 4 Sahibabad Fax 248 293 5800 Wigan WN2 4EZ UK Industrial Area Phone 44 0 1942 257 171 Ghaziabad 201 010 India Fax 44 0 1942 503 450 Tel 91 120 2895116 126 Fax 91 120 2895127 OFFICE LOCATIONS Asia Pacific Operations 86 20 8776 4754 or 86 20 8776 4755Czech Republic Ingersoll Rand Ltd Ingersoll Rand Productivity Solutions 42 Benoi Road Ostrovskeho 34 151 28 Prague Jurong Singapore 629903 Czech Republic Phone 65 861 1555 Phone 420 2 57 109 756 7 Fax 65 861 0317 Fax 420 2 57 109 758 Australia France Ingersoll Rand Ltd Ingersoll Rand Productivity Solutions Landmark Corporate Center A S Division Level 2 Zone du Ch ne Sorcier 454 472 Nepean Highway B P 62 Frankston Vic 3199 Les Clayes sous Bois Cedex 78346 Australia Phone 33 0 1 30 07 69 00 Phone 61 3 8781 1600 Fax 33 0 1 30 07 69 82 Fax 61 3 8781 1611 Germany Canada Ingersoll Rand European Sales Ltd National Sales Office c o Intersoll Rand GmbH Regional Warehouse Postfach 10 09 54 Toronto Ontario 45409 M lheim Ruhr Germany 51 Worcester Road Phone 49 0 208 9994 0 Rexdale Ontario M9W 4K2 Fax 49 0 208 9994 444 Phone 416 213 4500 e mail Assembly Solutions geu irco com Fax 416 213 4510 India Order Desk Ingersoll Rand Wadco Tools Pvt Limited Faster 37 A Site 4 Sahibabad Industrial Area China Ghaziabad 201 010 India Ingersoll Rand Productivity Solutions T
11. bearing QE6Z 050 GEA40 M53 7 GEF40 M53 7 when pressing the bearing into a bearing recess QE6S 035 GEA40 M53 11 GEF40 M53 11 4 Refer to the 2 of pn 2 for QE6A 050 GEA40 M53 11 GEF40 M53 11 instruction on how to properly grease this tool QE6Z 035 GEA40 M53 11 GEF40 M53 11 WARNING Non Flanged Assembly This procedure is to be done by an authorized trained repair person To ensure proper functioning of 2 tool When replacing the Motor Housing Assembly always ensure that the Memory Chip Communication Board Gear Pack and Attachment are all assembled as a set with the 7 new Motor Housing Assembly _ QE6 Series Motor Housing Assembly consists of the Dwg TP2099 following Flanged Gear Assembly 1 One 1 Motor Assembly 2 One 1 Gear Case 7 3 One 1 Pinion 4 gt Note These Motor Housing Assembly models vary in their N maximum torque and Gear Case configurations flanged and non flanged Refer to Table 3 to order the correct sub assembly for your particular model The following two diagrams TP2099 amp TP2100 depict two gt of four possible arrangements listed in Table 3 Drawing 4 X TP2099 illustrates one of
12. using a Spanner wrench on the Spanner holes of the Gear Case torque Coupling Nut to between 45 to 50 ft 61 to 68 Nm NOTICE 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 18 MAINTENANCE Concluded QE6 Series Wiring Cable Chart Connector Pin Wire Color Cable Logic Connector Pin A Red VCC 13 B Black COM 14 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 K Blue 5 L Blue White RX 6 M White TX 8 N White Blue TX 9 U Red Motor Phase B 23 Black Motor Phase C 34 W White Motor Phase A 36 X Green Yellow Ground 25 TX Shield 1 a RX Shield 4 22 Hall Shield 22 Motor Shield 16 SERVICE NOTES 20 SERVICE NOTES 21 SERVICE NOTES 22 SERVICE CENTERS Centres d entretien Ingersoll Rand Niederlassungen Centri di Assistenza Centros de Servicio Service Centra Servicentre Servicecenter Servicesenter Huoltokeskus Centros de Assist ncia T cnica K vtoa Eguvro tnons Ingersoll Rand UK India 1872 Enterprise Drive Ingersoll Rand amp Co Ltd Ingersoll Rand Wadco Rochester MI 48309 Swan Lane Gate
13. 01 7777777777777 80518 90618 80519 9051920 K quressy 19 I8e vHOCl J 7070777777077 77700 07000000000 ttn 805 7 90617107 85840 777 JUDYS 8 9 9 55 271 80518774900 er 5 19 95899 777 9 P PS 9 90518 980 mee 9IL V08 80518 80519 80517107 85940 JUDYS 0 DS Z T 80519 7980 912 0808 90518 90519 9051 IOF 95940 t JUDYS 9 DS 6 90519 7940 Uc 1950061 99 85740 77 8 p X DS 42 1 80517 940 1 Sn 80518 80519 80STp IOF 95740 777 p X DS 8 90517 7980 8SLL Op 90518 20519 9051747 jreunpeny quessy Sundg 1990048 9 papeo Sunds arenbs oppuids m 19QUINN 3 uondridosoq way uorndrid35so q JAP A 3511 sjuouoduro ourT ug 97510 140g asn uauM A eremi AMA ANIT NI 930 QE6 ANGLE ASSEMBLY ATTACHMENT USE WITH 7 MOUNTING OFF 61 68Nm TABLE 2 EN QV N N N 22 USE WITH FLANGED MOTOR HOUSING ASSEMB
14. Assembly against Spacer 44 Grease both sides of the spacer and place Spacer 49 on top of the Gear Head Assembly located inside Ring Gear Grease the planet gear teeth of the Spindle Assembly as described in the lubrication section Align Pinion of Gear Head Assembly with Planet Gear teeth of Spindle Assembly 50 and the Planet gear teeth of the Spindle Assembly with those of the Ring Gear 42 and install Spindle Assembly against Spacer 49 To assure free rotation of assembly while holding Ring Gear steady manually rotate the Spindle Assembly MAINTENANCE Continued Gear Pack Installation Insert the Gear pack into the Gear Case of the Motor Housing Assembly Engage Rotor Pinion with the Gear Head Assembly of the Gear Pack Assembly and gently guide teeth of Ring Gear onto teeth of Transducer Force rubber Grease Seal 51 into Gear Case of the Motor Housing so that it rests flat on top of Ring Gear Drop Wave Spring 52 on top of Grease Seal Lay Retaining Washer 53 on top of Wave Spring Using Snap Ring Pliers install Retaining Ring 54 into Gear Case of the Motor Housing Assembly on top of retaining Washer until Retaining Ring rests inside groove Attachments Angle Assembly Attachment 10 11 12 13 14 Visually check Housing for loose material fragments Install Socket Retaining Pin 83 into small hole on the one of the flat sides of square Spindle With Socket Retaining Pin 83
15. FE Form P7645 Edition 1 January 2004 CCN 04579694 Service Manual for QE6 Series 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 GE Assaniiy Dwg TP2101a GG Dwg TP2101b Refer All Communications to the Nearest Ingersoll Rand Office or Distributor O Ingersoll Rand Company 2004 Printed in U S A am Assemhly Solutions 330 2 e s43431 ANY SdI 5D ATE DNISNOH 930 N 4 89 de 19005 MA LC I ISSET OPVID dur PZ I ISELC OVVHD 1045 8c X 1586 0 duc WY 4 IS 8L7 0PVAD Zundg 01 897 IHELCOVVHD louo seq 0 TISEI 0rV99 oppueH ec I THELT OVVAD 67 X TH865L 0r VHD 19497 UN 40 19QUINN uondid50soq JOSSIDIV RNC See Es 2 7 ae RO NAA SE el llar es aer TSELCOPVHO
16. LIES 61 68 0 Ingersoll Rand 67 Dwg TP2098 i When Ordering use applicable Part Number Model Identification QE6 A2S06 QE6 A4806 QE6 A4S08 QE6 A5S08 Item Part Description Part Number Part Number Part Number Part Number e 81 Angle Assembly Attachment GAA2S6 456 458 GAASS8 82 Socket Retaining Spring 401 718 401 718 SUHD 718 SUHD 718 83 Socket Retaining 5020 716 5020 716 804 716 804 716 84 Space tamed irre GEA40 591 GEA40 591 GEA40 591 GEA40 591 85 Coupling Nut Long with holes GEA40 27 GEA40 27 GEA40 27 GEA40 27 86 Coupling Nut Short with flats DAA4 27 DAA4 27 DAA4 27 DAA4 27 87 ER DAA4 29 DAA4 29 DAA4 29 DAA4 29 e Item 81 includes items 82 and 83 QE6 ACCESSORIES OPTIONAL PARTS 3 When Ordering use applicable Part Number Item QE6 Accessories Parts List Part Description Part Number 100 101 102 103 104 105 106 107 108 109 110 111 112 113 Reaction Bar Mounting Plate Swivel Hange Mounting Plate Assembly Flanged Power Cord Assembly 3 Power Cord Assembly 10
17. and Temperature Connector s Dwg TP2102a_C 5 15 Comma 2 7 es T 7 Torque and Motor Connector s Dwg TP2102b_C Transducer Installation Insert Transducer Assembly 41 into Gear Case of the Motor Housing Assembly wire end first guiding Transducer s connector into the cavity found at end of Motor Housing Assembly s long outer groove Carefully pull Transducer s connector and wiring through cavity of Motor Housing Assembly Engage Transducer s gear teeth to those of the front of Gear Case of the Motor Housing Assembly and continue inserting Transducer assembly further into the Motor Housing while guiding the wire through the cavity Align and engage Transducer s gear teeth with second set of gear teeth located inside the Gear Case 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 Continue inserting the Transducer Assembly until it is fully seated Snap Transducer s connector into Communication Board 12 socket marked Torque Refer to TP2102a MAINTENANCE Continued External Components Slide O ring 14 into groove located at front end of Motor Housing Assembly Slide on Housing Cover 15 ensuring that Transducer and Motor wires are not disturbed Slide Warning Label into Label Cover Lens Note Warning Label 17 and Label Cover Lens 18 slot a
18. ate tool 12 Note In the following step the Bearing Cap 73 has a left hand thread 8 Using an adjustable Pin Wrench unscrew Bearing Cap 73 9 Pull the Drive Spindle Assembly 69 out of Housing Assembly 61 10 If necessary using a bearing puller tool press the Rear Spindle Bearing 72 off the Drive Spindle Assembly 69 Then remove the Retaining Ring 71 and Washer 70 11 Now tilt Spindle Housing causing the Disengaging Spring 68 Coupler 67 Square Drive Spindle 64 and Washers 62 and 63 to slide out Motor Housing Disassembly AWARNING 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 Using appropriate tool remove Retaining Ring 54 Retainer Washer 53 Wave Spring 52 and Grease Seal 51 2 Remove Gear Pack from Motor Housing Assembly 3 Remove Retaining Ring 43 from Ring Gear 42 4 From either end slide internal components out of Ring Gear 5 Separate Spindle Assembly 50 from the Gear Head Assembly 45 6 Separate the Planet Gears 47 Needle Bearings 46 Spacers 44 and 49 and when applicable Sun Gear 48 AWARNING 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 11 always
19. d by an authorized trained repair person To ensure proper functioning of the tool 16 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 ACAUTION 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 Pack Assembly always use the Assembly designed for that model Gear Box Assembly 10 11 12 Grease and install one Needle Bearing 46 into each of the three Planet Gears 47 Slide one Gear Bearing unit onto each of the three Planet Pins of the Gear Head Assembly 45 For Models with Sun Gears engage the teeth of the Sun gear 48 with those of the planets and press Sun Gear into Gear Head Assembly Apply Grease Ingersoll Rand 67 to inside of Ring Gear 42 Install Retaining Ring 43 taking care to align properly into groove of Ring Gear Install metal Spacer 44 inside Ring Gear locating Spacer against Retaining Ring 43 Apply grease to the teeth of the Planet gears and sun gear of the Gear Head Assembly as described in the lubrication section Aligning Planet gear teeth of the Gear Head assembly with gear teeth of Ring Gear gently guide Gear Head Assembly 45 into open end of Ring Gear locating Gear Head
20. el 91 120 2895116 126 Room 1616 South Tower Fax 91 120 2895127 Guangzhou World Trade Center Complex 371 Huanshi East Road Italy Guangzhou 510095 Productivity Solutions China Ingersoll Rand Italia S r l Strada Provinciale Cassanese 108 20060 Vignate Milano Italy Phone 39 02 95056 261 Fax 39 02 95360 159 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
21. engaging Spring 68 over Drive Spindle Assembly 15 Align the Drive Spindle Assembly with spline of Coupler and insert Drive Spindle assembly into Hous ing assembly 61 16 Apply one drop of Perma Lok MM 115 to threads of Bearing Cap 73 17 Carefully grasp the Housing Assembly Note In the following step the Bearing Cap 73 has a left hand thread 18 Using the appropriate tool tighten Bearing Cap 73 to between 45 to 50 ft 61 to 68 Nm of torque Slide Teflon Spacer 74 over In Line Attachment s input spindle Slide Coupling Nut 75 or 76 over Housing Assembly 61 Using an appropriate tool install Retainer 77 onto spline of Housing Assembly until seated into groove Spin Coupling by hand to check freedom of movement 19 20 21 22 MAINTENANCE Continued In Line Attachment Installation 1 For Models with Gear Case Sleeves From threaded end of Motor Housing slide rubber Gear case Sleeve 5 over Housing Slightly lubricating Grip will help ease the installation process 2 Assure presence of Teflon Spacer on Pinion of Attachment Position the In Line Attachment appropriately 4 Engage the spline on the input spindle of the In Line Attachment with the matching internal spline of the Spindle Assembly 50 then engage the spline on the Housing assembly with the Gear Case of the Motor Housing Assembly and thread the Coupling Nut onto the Motor Housing 5 While holding the tool
22. ent with an In Line Attachment When replacing a 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 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 Grips For Models with Levers 1 Using an appropriate tool eg a driver or socket loosen Cap Screws 30 from lever 28 or 29 and remove lever from Handle Grip 23 26 2 Slide Handle Grip off Motor House Assembly For Models with Gear Case Sleeves 1 Note remove all attachments first If desired separate Gear Case Sleeve 5 from Motor Housing Assembly MAINTENANCE Continued Attachments AWARNING Do not separate Gear Case from Motor Housing as this will likely destroy the Transducer wire 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 CAUTION When installing or removing a Coupling Nut ALWAYS hold the tool by the Spanner holes or flats as provided on the Assembly Housing Angle Assembly Attachments
23. ion connector from the Communication Board Refer to TP2102a 5 Disconnect the Torque Transducer connector from the Communication Board Refer to TP2102a 6 Disengage female socket located on front end of Com munication Board from male connector located at cen ter of LED Board 06 by gently sliding board from Motor Housing Assembly 7 Remove LED Board from Motor Housing Assembly Refer to TP2102b 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 out of the Motor Housing Assembly feeding the Transducer wire through the cavity in the Motor Housing Assembly from step 1 4 Carefully push Transducer s connector through the cavity and remove Transducer assembly from Motor Housing Assembly MAINTENANCE Continued ASSEMBLY Motor Housing Assembly Prens Non Flanged Flanged Motor Housing Assembly QE6S 020 QE6S 030 General Instructions QE6S 050 1 protect the part s surfaces and to prevent distortion QE6A 030 GEA40 M53 7 GEF40 M53 7 of Housings and threaded joints use care when grasp QE6A 040 ing the tool QE6A 080 2 Always press on the inner ring of a ball type bearing QE6Z 020 when installing the bearing onto a shaft QE6Z 030 3 Always press on the outer ring of a ball type
24. le Assembly Attachment 3 Slide Gear Case out of Motor Housing Assembly and disassemble Gear Case 4 Clean and degrease all parts except for the First Stage Needle Bearings 46 and the Second Stage Spindle Assembly 50 5 Wipe clean the First Stage Needle Bearings 46 and the Second Stage Spindle Assembly 50 with a clean dry and lint free rag 6 Once cleaned apply prescribed amounts of Ingersoll Rand 170 Grease as follows e 2to3 cc to central area between gears of Spindle Assembly 50 e lto2cc to face of Gear Head and Spindle Assembly e 4105 to Planet Gears Pins and Bearings e Thin layer on Ring Gear teeth 42 For Models with an Angle Assembly Attachment 7 Using Ingersoll Rand 67 Grease lubricate Angle Head through Grease Fitting For Models with an In Line Attachment 8 Using Ingersoll Rand 67 Grease lubricate the Square Drive Spindle Bearings 72 the Drive Spindle 64 and the Disengaging Spring 68 AWARNING e 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 11 Communication Board 12 Gear Pack Assembly and Attachment are all assembled as a set with the new Motor Housing Assembly CAUTION When replacing an Attachment always use the Angle Assembly Attachment designed for that model Never replace an Angle Assembly Attachm
25. nd tab alignment features Slide Label Cover Lens and Warning label over Motor Housing Assembly grip area Install Retaining Ring 19 into groove behind Label Cover Lens Place Spring 21 into Reverse Ring 22 Install and depress Ball 07 and Spring 08 and slide Reverse Ring onto Motor Housing Assembly When replacing the Motor Housing Assembly always ensure that the Memory Chip Communication Board Gear Pack and Attachment are all assembled as a set with the new Motor Housing Assembly 9 10 11 12 13 14 15 16 17 Install Memory chip 11 into grip with terminal aligned with O ring groove Slide two O rings 20 into groove to retain Memory chip Install Spring 10 on rearward post of Trigger and install Trigger into Motor Housing Assembly For models with Extended Levers 29 install additional spring on Trigger s 09 auxiliary post Slide Handle Grip 23 26 onto Motor Housing Assembly Apply a medium strength thread locker to Low Head Socket Cap Screw 27 Install Low Head Socket Cap Screw through hole in Handle Grip into Motor Housing Assembly Torque Low Head Socket Cap Screw to 10 to 15 in 1 1 to 1 7 Nm For models with Levers a Place Lever 28 or 29 in position against Handle Grip and install lever Socket Cap Screws 30 b Torque Socket Cap Screws 30 to 5 to 10 16 in 0 5 to 1 1 Nm AWARNING The following procedures are to be performe
26. the non flanged arrangements ZZ listed in Table 3 drawing TP2100 depicts a typical Dwg TP2100 flanged arrangement Either assembly flanged or nonflanged is available with any one of two possible Pinion types as shown Internal Components 1 Insert the LED Board 6 through one of the Motor Housing Assembly s three large cavities and lay the three ledges of the LED Board 06 against the three edges of the Motor Housing Assembly Refer to TP2102a making sure that the motor commutation wires properly pass through the cutout in the LED board 14 MAINTENANCE Continued 2 Using two of the three internal axial grooves of Motor Housing Assembly slide Communication Board 12 into Motor Housing Assembly 3 Press connector located on front end of Communica tion 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 TP2102a 5 Route Motor Temperature Sensor Connector cable to opposite side of Communication Board snap Motor Temperature Sensor connector into the Motor Temperature Sensor socket 6 Through large cavities of Motor Housing Assembly connect Motor Phase Female Connector to Male Connector of Motor 7 Install Retainer 13 behind Communication Board in connector cavity in the end of the Motor Housing Assembly Communication Board Close Up ee Motor Tempera LEDs
27. tool using a Spanner wrench on the Spanner holes of the Gear Case torque Coupling Nut to between 45 to 50 ft 61 to 68 Nm In Line Attachment Assembly 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 Spindle 3 Position Spring inside large hole of square 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 66 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 Spin Spindle by hand to check freedom of movement 7 Lubricate the bearings of the Housing Assembly 61 with Ingersoll Rand 67 Grease 8 Slide Washer 62 and Washer 63 onto Square Drive Spindle 64 and insert Square Drive Spindle 64 into Housing Assembly 61 9 Align the Coupler 67 to slide over splines of Square Drive Spindle 64 10 Slide Coupler into position in Housing Assembly 61 11 Slide Washer 70 on the Drive Spindle Assembly 69 12 Use snap ring Pliers to install the Retaining Ring 71 on top of the Washer 13 Press on Rear Spindle Bearing 72 to Drive Spindle Assembly 69 14 Place Dis
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