ARO DR021B User manual

I
INCLUDING:OPERATION.INSTALLATION &MAINTENANCE
OPERATOR'S MANUAL
SECTION M22
MANUAL 70
Released: 5-15-89
I
Tool Products
3
Revised: 11-10-95
- _
20 SERIES RIGHT-ANGLE DRILLS
Form: 3361-2
Models: DR021B-( )-( ),
DR023B-( )-( ) and DR025B-( )-( ).
READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
Pneumatic tools should always be installed and used in accor-
dance with A.N.S.I. 8188.1 “Safety Code For Portable Air Tools.”
l
l
0
a
l
l
a
0
l
0
Operate this tool at 90 p.s.i.g. (8.2 bar) maximum air pressure
at the air inlet of the tool.
Disconnect air supply from tool before removing/installing bit,
socket or device attached to tool or performing maintenance
procedures.
Keep hands, clothing and long hair away from rotating end of
tool.
Anticipate and be alert for sudden changes in motion during
start up and operation of any power tool.
Never exceed rated r.p.m. of tool.
Wear suitable eye and hearing protection while operating tool.
Tool shaft can continue to rotate briefly after throttle is re-
leased.
Donot lubricate tools with flammable orvolatile liquids such as
kerosene, diesel or jet fuel.
Do not remove any labels. Replace any damaged label.
Use only accessories recommended by ARO.
Repeated prolonged operator exposure to vibrations which may
be generated in the use of certain hand-held tools may produce
Raynaud’s phenomenon, commonly referred to as Whitefinger
disease. The phenomenon produces numbness and burning
sensations in the hand and may cause circulation and nerve dam-
age as well as tissue necrosis. Repetitive users of hand-held
tools who experience vibrations should closely monitor duration
of use and their physical condition.
The use of other than genuine ARO replacement parts may
result in safety hazards, decreased tool performance and in-
creased maintenance and may invalidate all warranties.
ARO is not responsible for customer modification of tools for
applications on which ARO was not consulted.
Tool maintenance and repair should be performed by autho-
rized, trained, competent personnel. Consult your nearest
ARO authorized servicenter.
It is the responsibility of the employer to place the information
in this manual into the hands of the operator.
For parts and service information, contact your local ARO distributor, or the Customer Service Dept. of the Ingersoll-Rand Distribution
Center, White House, TN at PH: [phone], FAX: [phone].
ARO Tool Products
Ingersoll-Rand Company
1725 U.S. No. 1 North l PO. Box 8000 l Southern Pines, NC 28388-8000
01995 THE ARO CORPORATION . PRINTED IN U.S.A.

FAILURETO OBSERVETHE FOLLOWINGWARNINGSCOULDRESULTIN INJURY.
Wear eye protection when
operating or performing
maintenance on this tool.
j
Turn off air supply and disconnect
air supply hose before installing,
removing or adjusting any
accessory on this tool, or before
performing any maintenance on
this tool.
Air powered tools can vibrate in
use. Vibration, repetitive motions
or uncomfortable positions may
be harmful to your hands and
arms. Stop using any tool if
discomfort, tingling feeling or
pain occurs. Seek medical advice
before resuming use.
Do not carry the tool by the hose.
Do not overreach when operating
this tool. Keep body stance
balanced and firm.
NOTICE
PN 48176-1 LABEL
(NON-EUMODELS)
PN 49883 LABEL
(-EU MODELS)
This label must appear on the tool at all times. IfIt Is
lost or damaged, a replacement label Is available at
no cost.
Wear hearing protection when
operating this tool.
Do not use damaged, frayed or
deteriorated air hoses and
fittings.
A WARNING
Operate at 90 p.s.i.g.
(6.2 bar/620 kPa)
maximum air pressure.
WARNING = Hazards or unsafe practices which could result in severe personal injury, death or substantial
property damage.
CAUTION = Hazards or unsafe practices which could result in minor personal injury or product or property
damage.
NOTICE = important installation, operation or maintenance information.
2

ROUTINE-LUBRICATION REQUIREMENTS
M22
70
Lackof or an excessive amount of lubrication will affect the perfor-
mance and life of this tool. Use only recommended lubricants at
below time intervals:
EVERY 8 HOURS OF TOOL OPERATION - Fill lubricator reser-
voir of recommended F.R.L.with spindle oil (29665). Ifan in line or
air line lubricator is not used, apply several drops of spindle oil
(29665) in air inlet.
EVERY 160 HOURS OF TOOL OPERATION - Lubricate gear-
ing. Pack bearings, coat shafts and lubricate gears with NLGI #1
“EP” grease (33153). Gearing should contain approximately 1/32
oz. (.9 g) of grease for single reduction and 3/64 oz. (1.3 g) of
grease for double reduction. Right-angle assembly should con-
tain approximately 1/8 oz. (3.5 g) of grease.
AIR SUPPLY REQUIREMENTS
Formaximum operating efficiency, the following air supply specifi-
cations should be maintained to this air tool:
l
AIR PRESSURE - 90 p.s.i.g. (6.2 bar)
l AIR FILTRATION - 50 micron
l LUBRICATED AIR SUPPLY
- HOSE SIZE - 5/16” (8 mm) I.D.
An ARO® model C28231-810 airline FILTER/REGULATOR/LU-
BRICATOR (F.R.L.) is recommended to maintain the above air
supply specifications.
RECOMMENDED LUBRICANTS
After disassembly iscomplete, all parts, except sealed orshielded
bearings, should be washed with solvent. To relubricate parts, or
for routine lubrication, use the following recommended lubricants:
Where ARO
Air Motor 29665 1 qt. Spindle Oil
“0” Rings & Lip Seals 36460 4 oz. Stringy Lubricant
Gears and Bearings 33153 5lb.“EP”- NLGI#1Grease
INSPECTION,MAINTENANCE AND INSTALLATION
Disconnect air supply from the tool or shut off air supply and ex-
haust (drain) line of compressed air before performing mainte-
nance or service to the tool.
It is important that the tools be serviced and inspected at regular
intervals for maintaining safe, trouble-free operation of the tool.
Be sure the tool is receiving adequate lubrication, as failure to lu-
bricate can create hazardous operating conditions resulting from
excessive wear.
Tool maintenance and repair shall be performed by authorized,
trained, competent personnel. Tools, hose and fittings shall be re-
placed if unsuitable for safe operation and responsibility should
be assigned to be sure that all tools requiring guards or other safe-
ty devices shall be kept in legible condition. Maintenance and re-
pair records should be maintained on all tools. Frequency of
repair and the nature of the repairs can reveal unsafe application.
Scheduled maintenance by competent authorized personnel
should detect any mistreatment or abuse of the tool and worn
parts. Corrective action should be taken before returning the tool
for use.
Disassembly should be done on a clean work bench with a clean
cloth spread to prevent the loss of small parts. After disassembly
iscompleted, all parts should be thoroughly washed in aclean sol-
vent, blown dry with air and inspected for wear levels, abuse and
contamination. Double sealed or shielded beatings should never
be placed in solvent unless a good method of m-lubricating the
bearing is available. Open bearings may be washed but should
not be allowed to spin while being blown dry.
Upon reassembling, lubricate parts where required. Use 33153
grease, or equivalent, in bearings. Use 36460 lubricant for“0”
ring assembly. When assembling “0” rings or parts adjacent “0”
rings, care must be exercised to prevent damage to the rubber
sealing surfaces. A small amount of grease will usually hold steel
balls and other small parts in place while assembling.
When replacement parts are necessary, consult drawing contain-
ing the part for identification.
Always use clean, dry air. Dust, corrosive fumes and/or excessive
moisture can damage the motor of an air tool. An air line filter can
greatly increase the life of an air tool. The filter removes rust,
scale, moisture and other debris from the air lines. Low air pres-
sure (less than 90 p.s.i.g.) reduces the speed of the air tool. High
air pressure (more than 90 p.s.i.g.) raises performance beyond
the rated capacity of the tool and could cause injury. Shown below
is a typical piping arrangement.
MAIN LINES 3 TIMES
AIR TOOL INLET SIZE
LUBRICATOR’
BRANCH LINE 2 TIMES
AIR TOOL INLET SIZE
DRAIN REGULARLY
Be sure that the air supply lines and connectors are of proper size
to provide a sufficient quantity of air to the tool.
3

I
MODEL NUMBER GEARING
RED.
DR023B-5( ) DR025B-5( ) 44.49:1
DR021B-7-( ) DR023B-11-( ) DR025B-11-( ) 22.87:1
DR021B-15-() DR023B-21-() DR025B-21-() 11.76:1
DR021B-26-( ) DR023B-37-() 6.67:1
DR021B-50-( ) DR023B-73-( ) DR025B-73-( ) 3.43:1
DR021B-170-() .
MODELS WITH -EU SUFFIX ARE “EC” COMPLIANT MODELS.
* FOR MODELS DR025B-( ): 9/32” - 40 FEMALE THREAD (ITEM 82).
DISASSEMBLY/ASSEMBLY INSTRUCTIONS
Never apply excessive pressure by a holding device which
may cause distortion of a part.
Apply pressure evenly to parts which have a press fit.
Apply even pressure to the bearing race that will be press
fitted to the mating part.
Use correct tools and fixtures when servicing this tool.
Don’t damage “0” rings when servicing this tool.
Use only genuine ARO replacement parts for this tool. When
ordering, specify part number, description, tool model number
and serial number.
RIGHT-ANGLE DISASSEMBLY
(REGULAR DUTY)
Using wrenches on flats of ring gear and lock nut (41) un-
thread and remove right-angle section from tool - LEFT
HAND THREADS.
Remove chuck (66) where applicable.
To disassemble drive assembly, remove lock nut (65) from
housing - LEFT HAND THREADS.
Remove adapter (40) - LEFT HAND THREADS.
Do not disassemble further unless damage is evident. Todis-
assemble, pull pinion (47) from housing.
To remove bearing (46) from pinion, remove snap ring (44)
and spacer (45).
RIGHT-ANGLE ASSEMBLY
(REGULAR DUTY)
Lubricate bearings upon assembly.
Assemble bearing (46) and spacer (45) to pinion (47) secur-
ing with snap ring (44). NOTE: Bearing is to be located .600”
from shoulder on pinion (see illustration, next column).
Assemble bearing (42) to pinion. NOTE: Press on inner race
of bearing.
Assemble pinion and components to housing (48). NOTE:
Press on outer race of bearing.
Assemble lock nut (41) to adapter (40) and assemble adapter
to housing, securing pinion - LEFT HAND THREADS.
Apply approximately 1/8 oz. of grease to right-angle gearing
upon assembly.
Assemble drive assembly (68, 69 or 95) to lock nut (65).
Assemble lock nut and components to housing-LEFT HAND
THREADS.
Assemble coupling (39) to pinion and assemble “0” ring (91)
to adapter (40). NOTE: “0” ring is to be free of oil and grease.
Assemble right-angle housing and components to tool, se-
curing with lock nut (41) - LEFT HAND THREADS.
RIGHT-ANGLE DISASSEMBLY
(LIGHT DUTY)
Using wrenches on flats of ring gear and lock nut (41) un-
thread and remove right-angle section from tool - LEFT
HAND THREADS.
To disassemble right-angle section, grasp right-angle hous-
ing (56 or 78) lightly in a vise. Using a wrench on flats of body
(51) unthread body from housing - LEFT HAND THREADS.
Do not remove pinion (55) from housing unless damage is evi-
dent. To remove pinion, grasp pinion in avise and tap housing
with a soft face hammer.
Pull pinion (55) from body (51).

DISASSEMBLY/ASSEMBLY INSTRUCTIONS
M22
70
Unthread and remove adapter (40) -LEFT HAND THREADS
- releasing bearing (42).
To disassemble drive assembly, unthread lock nut (74) -
LEFT HAND THREADS -and pull drive assembly from hous-
ing (56 or 78). Do not disassemble further unless damage is
evident. NOTE: Drive assembly contains 22 small balls which
will fall out if drive assembly is disassembled.
RIGHT-ANGLE ASSEMBLY
(LIGHT DUTY)
Lubricate bearings upon assembly.
Assemble bearing (71) and gear (70, 75,81,87,89 or 96) to
shaft (72 or 80).
Assemble gear and components to lock nut (74) securing
balls (73) in groove in gear.
Assemble lock nut (74) to housing (56 or 78) - LEFT HAND
THREADS.
Assemble bearing (42) and lock nut (41) to body, securing with
adapter (40) - LEFT HAND THREADS.
Assemble bearing (54) to pinion (55).
Assemble pinion to housing (56 or 78).
Assemble housing (56 or 78) to body (51) to seat needle bear-
ing. Unthread and remove body. NOTE: Bearing is to be lo-
cated .525” from end of housing (56 or 78)(see illustration
below).
Assemble shims (52 and 53) to body.
Assemble housing (56 or 78) to body (51) - LEFT HAND
THREADS.
Assemble coupling (39) to pinion and assemble “0” ring (91)
to adapter. NOTE: “0” ring is to be free of oil and grease. As-
semble right-angle section to tool, securing with lock nut (41)
- LEFT HAND THREADS.
GEARING DISASSEMBLY
Remove right-angle section from tool.
Remove ring gear (24 or 29) using a wrench on flats.
Remove snap ring (28) and washer (27).
Remove spindle(s) and gears from ring gear. NOTE: Keep
gears grouped with mating spindle when disassembling
double reduction gearing.
Do not remove bearing (26) or spacer (25) unless damage is
evident.
To remove bearing (26) and spacer (25) from ring gear, press
on spacer (25) from inside splined end of ring gear.
Do not remove gear (37) from carrier assembly unless dam-
age is evident. Gear (37) is press fit onto carrier assembly.
GEARING ASSEMBLY
Assemble spacer (25) into ring gear.
Press bearing (26) into ring gear. NOTE: Press on outer race
of bearing and press to shoulder of ring gear.
Coat shafts of spindle with ARO 33153 grease.
Assemble gears to shafts of mating spindle,
Assemble carrier assembly to spindle assembly for models
with double reduction gearing.
Lubricate sets of gears liberally with ARO 33153 grease (see
“Routine Lubrication Requirements”, page 3).
Assemble spindle(s) and gearing into ring gear. Rotate
spindle and gears to align gear teeth with splines of ring gear.
Assemble washer (27) to spindle, securing with snap ring
(28).
Thread ring gear (24 or 29) to tool, tightening with wrench on
flats.
Assemble right-angle section to tool.
MOTOR DISASSEMBLY
Remove right-angle section and gearing from tool.
Remove spacer (22) and “0” ring (21).
Tap front edge of housing to remove motor assembly. Locat-
ing pin (23) should also come out.
Tap splined end of rotor (17) with a soft face hammer; motor
will come apart. NOTE: Bearing (20) is light press fit on rotor.
Remove end plate (15) and bearing (14) from rotor.
MOTOR ASSEMBLY
Lubricate bearing (14) with ARO 33153 grease.
Assemble bearing (14) to end plate (15). NOTE: Press on out-
er race of beating.
Assemble end plate (15) to rotor. NOTE: Press on inner race
of bearing.
Coat five rotor blades (16) with ARO 29665 spindle oil and as-
semble to rotor slots - straight side out.
Coat i.d. of cylinder (18) with ARO 29665 spindle oil and as-
semble over rotor. NOTE: Air inlet slots in end of cylinder must
be aligned with two air inlet holes in end plate (15).
Assemble bearing (20) to end plate (19). NOTE: Press on out-
er race of bearing.
Assemble end plate (19) to rotor. NOTE: Press on inner race
of bearing. Be sure rotor turns without binding.
Insert locating pin (23) into .081” diameter blind hole at bottom
of motor cavity in housing.
Align notches of end plates and cylinder and install motor into
housing, aligning notches with locating pin (23).
Grease and assemble “0” ring (21) to end plate (19).
Assemble spacer (22) to motor, with chamfer facing motor.
Assemble gearing and right-angle section to tool.
HOUSING DISASSEMBLY
Clamp air inlet adapter (2) in a smooth face vise.
Unthread housing (9) with a strap type wrench.
Remove spacer (3) washer (4) exhaust cap (5) muffler pad
(6) spring (7) and valve rod (8). CAUTION: Do not remove or
adjust rubberportion ofvalve rod (8) as it ispreset atthe facto-
Remove screen (1) from inlet adapter (2).
Remove throttle pin (11) and spring (10).
Models DR025B-( ) - Do not remove restrictor (83) unless
damage is evident.
HOUSING ASSEMBLY
Lubricate throttle pin (11) with ARO 29665 spindle oil.
Install spring (10) and throttle pin (11) into housing. NOTE:
Align slot in throttle pin with air inlet holes in housing.
Install valve rod assembly (6) into housing. NOTE: Throttle pin
(11) should not pull out when valve rod (8) is seated properly.
Install muffler pad (6) to exhaust cap (5).
Install exhaust cap (5) to housing, aligning lever with throttle
pin (11).
Assemble spring (7) washer (4) and spacer (3) to tool, secur-
ing with inlet adapter (2).
Clean and replace screen (1) in inlet adapter (2).
Models DR025B-( ) - Grease and assemble “0” ring (84) to
restrictor (83) and assemble to housing (9) with opening of re-
strictor positioned towards motor.Secure restrictor withretain-
ing ring (85). -5

LEFT HAND THREADS
78 43 53 54 51 42 41 40
LIGHT DUTY
LEFT HAND THREADS
LEFT HAND THREADS
LIGHT DUTY
71
72
70
74
I
67
DMREi&
;
REGULAR DUTY
LEFT HAND THREADS LEFT HAND THREADS
I
49883 WARNING LABEL (-EU MODELS)
* ITEMS INCLUDED IN SERVICE KIT NO. 484461.
USED ON MODELS DR025B-( ) ONLY.
INCLUDED IN 48219-( ) AND 48328-( ) RIGHT ANGLE
6 ASSEMBLIES (ITEMS 58 AND 79).

M22
v*64 yw
\ 11 70
21* 19 23 r/*65 u
I lo* 2
I
5 3
25 29 30 32 66 32
25 29 33
25 24

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
33
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING
33911
46377
47205
46371
46366-1
48199-1
41654
46354
50
51
53
54
55
56
57
58
59
60
61
63
64
65
66
67
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
88
89
90
91
92
93
94
95
96
97
Screen .............................
Inlet Adapter . .....................
Spacer .............................
Washer .............................
Exhaust Cap .........................
Muffler Pad .........................
Spring ..............................
Valve Rod Assembly .................
Housing Assembly
for models DR021B-( ) and DR023B-( )
for models DR025B-( ) (includes items
83,84 and 85) ......................
Spring ..............................
Throttle Pin .........................
Lever ..............................
Roll Pin .............................
Ball Bearing .........................
Rear End Plate ......................
Blade (5 req’d) ......................
Rotor ...............................
Cylinder ............................
Front End Plate ......................
Ball Bearing.. .......................
MOTORASSEMBLY(includesitems14thru20).
“0” Ring .............................
Spacer .............................
Locating Pin .........................
Ring Gear (single reduction) ...........
Spacer .............................
Ball Bearing.. .......................
Washer .............................
Snap Ring ..........................
Ring Gear (double reduction) ..........
Spindle Assembly 6.67:1 ratio .........
Drive Plate ..........................
PlanetGear(3or6req’d)6.67:1ratio(21teeth).
Spindle Assembly 3.43:1 ratio .........
PlanetGear(3or6 req’d)3.431ratio(15teeth) .
Sun Gear 3.43:1 ratio (21 teeth) .......
Carrier Assembly 3.43:1 ratio ..........
Sun Gear 3.43:1 ratio (21 teeth) .......
Carrier Assembly 6.67:1 ratio ..........
Coupling ............................
Adapter ............................
Lock Nut ............................
Ball Bearing .........................
Grease Fitting .......................
Snap Ring ..........................
Spacer .............................
Needle Bearing ......................
Pinion.. ............................
Right-Angle Housing .................
Needle Bearing ......................
46722
48330-1
46374
46296-1
46326
Y178-28
41643
46245
46301
46338-2
48200-1
47718
Y85-10
48225-1
Y325-116
46305
47719-Z
46322
46496
Y65-13
47694
Y142-2
46323
47741
46709
46875
47742
46904
46561
46493
46560
46336
48184-1
48186-1
48185-1
Y65-8
35967
Y110-5
46742
48202-1
48181-1
48203-1
46750
Sleeve (not shown) ..................
Right-Angle Body. ...................
Right-Angle Shim (.005” thick) (2 req’d) .
Right-Angle Shim (.003” thick) .........
Needle Bearing ......................
Pinion.. ............................
Right-Angle Housing .................
Right-Angle Assembly ...............
Right-Angle Assembly ...............
Spindle .............................
Sleeve .............................
Bevel Gear .........................
Washer .............................
Ball Bearing .........................
Spindle .............................
Lock Nut ............................
Chuck (1/4” capacity) .................
Collet Insert .........................
Spindle Assembly ....................
Spindle Assembly ....................
Gear (1/4” - 28 female thread) .........
Ball Bearing .........................
Shaft ...............................
Ball (22 req’d) .......................
Lock Nut ............................
Gear (9/32” - 40 female thread) ........
Spindle Assembly ....................
Spindle Assembly ....................
Right-Angle Housing (includes item 43) .
Right-Angle Assembly ...............
Shaft ...............................
Gear (9/32” - 40 female thread) ........
Spindle Assembly ....................
Restrictor ...........................
“O” Ring.. ..........................
Retaining Ring ......................
Carrier Assembly 6.67:1 ratio ..........
Gear (#10- 32 female thread) .........
Spindle Assembly ....................
Gear (5/16” - 24 female thread) ........
Spindle Assembly ....................
“0”Ring.. ..........................
Spindle Assembly ....................
Collet Insert .........................
Spindle .............................
Spindle Assembly ....................
Gear (9/32” - 40 female thread) ........
Spindle Assembly ....................
SERVICE KIT includes items 1,6,7, 10,
13, 16,21,27,28,44,45,46, 52, 53, 54,
73,84and 85 .......................
48192-1
48196-1
48197-1
48197-2
46222
48178-1
48206-1
48211-1
48219-( )
48189-1
47600
46735
47694
Y65-13
48191-1
48187-1
31330
48497-169
48213-1
48215-1
48179-1
41643
48183-1
32594
48188-1
48180-1
48207-1
48208-1
48327-1
48328-( )
48319-1
48323-1
48325-1
48322-1
Y325-10
Y147-3
46720
48516-1
48515-1
48683-1
48684-1
Y325-19
48325-2
43497-165
48190-1
48214-1
49604
49605
48446-1

MODELDR021B-170-A
MODELDR023B-21-C

10

M22
70
-11

PN 49999-181