Atlas Copco PFD1500RA-180 Instruction sheet

PFD1500RA-180
Printed Matter No. 9836 6024 01 Positive feed drill
Publication Date 2020-02-11
Valid from Serial No. B2420001 Product Instructions
PFD1500RA-180 (180 r/min) 8440150002
WARNING
Read all safety warnings and instructions
Failure to follow the safety warnings and instructions may result in
electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference

2© Atlas Copco Industrial Technique AB - 9836 6024 01
Table of Contents
Product Information................................................................................................4
General Information ..........................................................................................4
Safety Signal Words ..............................................................................4
Warranty ................................................................................................4
Website..................................................................................................4
ServAid ..................................................................................................5
Safety Data Sheets MSDS/SDS............................................................5
Country of Origin ...................................................................................5
Dimensional Drawings...........................................................................5
Overview...........................................................................................................5
Applications ...........................................................................................5
Main components and functions............................................................6
Technical Product Data .........................................................................7
Accessories ...........................................................................................7
Starting position and drilling depth ........................................................7
Speed ....................................................................................................9
Velocity rapid advance – PFD1500RA-R (only for models with
rapid advance).....................................................................................10
Feed rate .............................................................................................11
Service Overview............................................................................................11
Service Recommendations..................................................................11
Installation .............................................................................................................12
Installation Requirements ...............................................................................12
Air quality.............................................................................................12
Air Lubrication Guide ...........................................................................12
Compressed Air Connection................................................................12
Installation Instructions ...................................................................................12
Installing the rapid advance kit ............................................................12
Changing the spindle...........................................................................17
Installing the scraper kit, for drills with indexer ....................................19
Installing the drill..................................................................................21
Installing the indexer............................................................................23
Installing the ChipLet ...........................................................................25
Changing the air inlet adapter .............................................................27
Installing the scraper kit, for drills without indexer ...............................28
Preparation for the spindles 4141 0253 XX.........................................29
Operation ...............................................................................................................31
Ergonomic guidelines .....................................................................................31
Configuration Instructions ...............................................................................31
Replacing modules ..............................................................................31
Changing the speed ............................................................................32
Changing the feed rate ........................................................................33
Operating Instructions.....................................................................................34

3
© Atlas Copco Industrial Technique AB - 9836 6024 01
Before drilling operation.......................................................................34
Operating the drill ................................................................................35
Service ...................................................................................................................36
Maintenance Instructions................................................................................36
Service Recommendations..................................................................36
Preventive Maintenance ......................................................................36
Lubrication Instructions...................................................................................39
Rust protection and cleaning ...............................................................39
Lubrication guide .................................................................................39
Motor valve ..........................................................................................40
Range gear..........................................................................................40
Indexer 4141 0912 90..........................................................................41
Range gear..........................................................................................42
Split gear .............................................................................................42
Indexer 4141 0306 91..........................................................................43
Head ....................................................................................................44
Motor ...................................................................................................46
Repair Instructions..........................................................................................46
Release the spindle .............................................................................46
Dismantling/Assembling Instructions ..............................................................49
Instructions for vane motor ..................................................................49
Instructions for vane motor ..................................................................51
Assembling Indexer .............................................................................53
Troubleshooting....................................................................................................54
Troubleshooting overview...............................................................................54
Test of overload clutch....................................................................................55
Leak test .........................................................................................................56
Recycling ...............................................................................................................57
Environmental Regulations.............................................................................57

Product Information EN PFD1500RA-180
4© Atlas Copco Industrial Technique AB - 9836 6024 01
Product Information
General Information
WARNING Risk of Property Damage or Severe Injury
Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow
all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.
►Read all Safety Information delivered together with the different parts of the system.
►Read all Product Instructions for installation, operation and maintenance of the different parts of
the system.
►Read all locally legislated safety regulations regarding the system and parts thereof.
►Save all Safety Information and instructions for future reference.
Safety Signal Words
The safety signal words Danger, Warning, Caution, and Notice have the following meanings:
DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or se-
rious injury.
WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if
not avoided, could result in minor or moderate injury.
NOTICE NOTICE is used to address practices not related to personal injury.
Warranty
■Product warranty will expire 12 months after the product is first taken into use, but will in any case ex-
pire at the latest 13 months after delivery.
■Normal wear and tear on parts is not included within the warranty.
■Normal wear and tear is that which requires a part change or other adjustment/overhaul during
standard tools maintenance typical for that period (expressed in time, operation hours or other-
wise).
■The product warranty relies on the correct use, maintenance, and repair of the tool and its component
parts.
■Damage to parts that occurs as a result of inadequate maintenance or performed by parties other
than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the
warranty.
■To avoid damage or destruction of tool parts, service the tool according to the recommended mainte-
nance schedules and follow the correct instructions.
■Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.
Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover
contracts. For further information contact your local Service representative.
For electrical motors:
■Warranty will only apply when the electric motor has not been opened.
Website
Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on
the Atlas Copco website.
Please visit: www.atlascopco.com.

PFD1500RA-180 EN Product Information
© Atlas Copco Industrial Technique AB - 9836 6024 01 5
ServAid
ServAid is a portal that is continuously updated and contains Technical Information, such as:
■Regulatory and Safety Information
■Technical Data
■Installation, Operation and Service Instructions
■Spare Parts Lists
■Accessories
■Dimensional Drawings
Please visit: https://servaid.atlascopco.com.
For further Technical Information, please contact your local Atlas Copco representative.
Safety Data Sheets MSDS/SDS
The Safety Data Sheets describe the chemical products sold by Atlas Copco.
Please consult the Atlas Copco website for more information www.atlascopco.com/sds.
Country of Origin
For the Country of Origin, please refer to the information on the product label.
Dimensional Drawings
Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.
Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.
Overview
Applications
This high-quality, easy-to-handle pneumatic Positive Feed Drill (PFD) can be used for drilling holes in vari-
ous metals and composites.

Product Information EN PFD1500RA-180
6© Atlas Copco Industrial Technique AB - 9836 6024 01
Main components and functions
Pos Part Function
1 Spindle Main rotating part of the drill.
2 Spindle guard Protects the operator from the rotat-
ing spindle. Provides the drill with
coolant to the drill bit.
3 Head Transfers rotational torque and feed
from the motor to the spindle.
4 Feed cassette Defines spindle feed rate. Mea-
sured in inches per revolution (IPR)
or millimeters per revolution (mm/
rev).
5 Air logic Operates the drill.
6 Split gear Defines rotational speed. Measured
in revolutions per minute (RPM).
7 Range gear Defines RPM range.
8 Vane motor Supplies power and rotation to the
spindle.
9 Motor valve Supplies the airflow to the vane mo-
tor and the emergency stop button.

PFD1500RA-180 EN Product Information
© Atlas Copco Industrial Technique AB - 9836 6024 01 7
Pos Part Function
10 Start Starts the motor and activates drill
feed and rotation mechanism. The
motor continues to run after the but-
ton is released. When spindle
reaches the pre-defined drilling
depth, it returns automatically to the
starting position.
11 Rapid advance (optional) Activates rapid spindle feed. The
spindle advances to the work sur-
face faster than the regular feed
rate but does not rotate. Releasing
the button stops the spindle.
12 Retract Returns the spindle to the starting
position at any time during drilling
cycle. The motor switches off auto-
matically after retract.
13 Emergency stop Switches off the motor, and stops
the spindle at any time during
drilling cycle. Once pressed, the
emergency stop button locks in po-
sition. You must manually reset the
emergency stop to restart the drill.
Technical Product Data
Technical Product Data can be found on either ServAid, or the Atlas Copco website.
Please visit: https://servaid.atlascopco.com or www.atlascopco.com.
Accessories
Overview accessories
For detailed information of accessories, refer to ServAid.
Starting position and drilling depth
Using stop rings, you can define the following parameters:
■Starting position of the drill bit
■Drilling depth

Product Information EN PFD1500RA-180
8© Atlas Copco Industrial Technique AB - 9836 6024 01
Pos Part Function
1 Starting position ring Defines the starting position for
drilling. This allows for quick posi-
tioning of the drill bit at the pre-de-
fined safe distance to the surface.
The starting position can be ad-
justed.
2 Depth ring Defines the drilling depth.
3 Depth valve Controls the drilling depth. Once
the depth ring reaches the valve, it
activates the valve, and the spindle
retracts into the starting position.
The motor automatically switches
off after retract.
4 Starting position valve Controls the starting position for
drilling. Once the starting position
ring reaches the valve, it activates
the valve that switches off the mo-
tor.
You can calculate the distance between the depth ring and the drill head (dimension L in the figure below)
for the desired drill depth D according to the following formula:
L (mm) =D (mm) – 31.0 mm
L (in) = D (in) – 1.2 in

PFD1500RA-180 EN Product Information
© Atlas Copco Industrial Technique AB - 9836 6024 01 9
Speed
The combination of range and split gears determines the speed of the drill spindle. Make a selection from
the available combinations of range and split gears in the table below to get the desired RPM.
Range gear
RPM Ordering No. Split gear ratio
38 4141 0043 95 Low
50 4141 0043 95 1:1
67 4141 0043 95 High
100 4141 0043 92 Low
140 4141 0043 92 1:1
180 4141 0043 92 High
200 4141 0043 90 Low
270 4141 0043 90 1:1
360 4141 0043 90 High
400 4141 0043 94 Low
530 4141 0043 94 1:1
700 4141 0043 94 High
670 4141 0043 93 Low
900 4141 0043 93 1:1
1200 4141 0043 93 High
1330 4141 0043 91 Low
1770 4141 0043 91 1:1
2360 4141 0043 91 High
A split gear ratio can be set to high, 1:1 or low depending on the position of the shaft (1) in the relation to
the indent (2), see the figure below. Markings on the split gear housing indicate ratios corresponding to
shaft positions.
Secure that the shaft is in the right position with the fork-shaped tool (4141 1114 00). See the figure be-
low.

Product Information EN PFD1500RA-180
10 © Atlas Copco Industrial Technique AB - 9836 6024 01
Velocity rapid advance – PFD1500RA-R (only for models with rapid
advance)
The rapid advance is depending on the feed rate. High feed rate generates high rapid advance and vice
versa.
Model Spindle (rpm)
Velocity rapid
advance
(mm/s), ±10%
Velocity rapid
advance
(inch/s), ±10%
PFD 1500RA-38-R 38 1.4 0.06
PFD 1500RA-50-R 50 1.9 0.07
PFD 1500RA-67-R 67 2.5 0.10
PFD1500RA-100-R 100 3.7 0.15
PFD1500RA-140-R 140 5.2 0.20
PFD1500RA-180-R 180 6.7 0.26
PFD1500RA-200-R 200 7.4 0.29
PFD1500RA-270-R 270 10.0 0.39
PFD1500RA-360-R 360 13.3 0.52
PFD1500RA-400-R 400 14.8 0.58
PFD1500RA-530-R 530 19.7 0.78
PFD1500RA-670-R 670 24.8 0.98
PFD1500RA-700-R 700 25.9 1.02
PFD1500RA-900-R 900 33.3 1.31

PFD1500RA-180 EN Product Information
© Atlas Copco Industrial Technique AB - 9836 6024 01 11
Model Spindle (rpm)
Velocity rapid
advance
(mm/s), ±10%
Velocity rapid
advance
(inch/s), ±10%
PFD1500RA-1200-R 1200 44.5 1.75
PFD1500RA-1330-R 1330 49.2 1.94
PFD1500RA-1770-R 1770 65.6 2.58
PFD1500RA-2360-R 2360 87.4 3.44
Feed rate
The feed rate of the drill must be balanced with the spindle speed. Make a selection from the available
combinations of feed rate in the table below to get the desired feed rate. Normally a feed cassette can de-
fine two feed rates. By turning it 180 degrees you can change the feed rates, as shown in the figure below.
Feed cassette
IPR mm/rev Ordering No.
0.001 0.023 4141 0034 91
0.002 0.05 4141 0034 92
0.003 0.075 4141 0034 93
0.004 0.10 4141 0034 94
0.006 0.16 4141 0034 95
0.008 0.21 4141 0034 96
0.010 0.27 4141 0034 95
0.013 0.33 4141 0034 94
0.014 0.36 4141 0034 93
0.015 0.38 4141 0034 92
0.016 0.42 4141 0034 91
Service Overview
Service Recommendations
Preventive maintenance is recommended at regular intervals. See the detailed information on preventive
maintenance. If the product is not working properly, take it out of service and inspect it.
If no detailed information about preventive maintenance is included, follow these general guide-
lines:
■Clean appropriate parts accurately
■Replace any defective or worn parts

Installation EN PFD1500RA-180
12 © Atlas Copco Industrial Technique AB - 9836 6024 01
Installation
Installation Requirements
Air quality
Poor air quality may cause damage to the tool and reduce the performance.
■For optimum performance and maximum product life we recommend the use of compressed air with
a maximum dew point of -5°C (23°F). We also recommend to install an Atlas Copco refrigeration type
air dryer.
■Use a separate air filter which removes solid particles larger than 30 microns and more than 90% of
liquid water. Install the filter as close as possible to the tool and prior to any other air preparation units
to avoid pressure drop.
■Lubrication free tools are a better choice from an environmental perspective.
■Lubrication will shorten the life time of the turbine motor and once lubricated, you will need to con-
tinue with the lubrication.
Air Lubrication Guide
Brand Air lubrication
Atlas Copco Optimizer (1 liter) 9090 0000 04
Q8 Chopin 46
Shell Shell Air Tool Oil S2 A 320
Compressed Air Connection
WARNING Risk of severe injury
Air under pressure can cause injury.
►Always shut off the air supply when not in use or before any adjustments.
►Drain the hose of air pressure and disconnect the tool from air supply when not in use or before
any adjustments.
►Always use the correct hose size and air pressure for the tool.
WARNING Compressed Air
High air pressure can cause severe damage and bodily injury.
►Do not exceed maximum air pressure.
►Make sure that there are no damaged or loose hoses or fittings.
For correct air pressure and hose size, see the Technical Product Data on - https://
servaid.atlascopco.com or www.atlascopco.com.
Make sure that the hose and couplings are clean and free from dust before connecting to the tool.
Installation Instructions
Installing the rapid advance kit
WARNING Make sure that the air supply is not connected.

PFD1500RA-180 EN Installation
© Atlas Copco Industrial Technique AB - 9836 6024 01 13
CAUTION Wear gloves to avoid personal injury because of sharp cutting edges. Only experi-
enced maintenance personnel can assemble or disassemble the product.
Required tools
■Vise
■Spanners
■Allen key
■Fork-shaped tool
■Hexagonal tool
■Torx wrench
1. Fasten the drill in a vise with rubber pads, with the front part upwards and the drill handle to the right.
Remove the front part and the drill bit using spanners.
2. Loosen the drill. Turn the drill over and fasten the drill in the vise.
3. Remove the spindle guard.
4. Remove the depth ring from the spindle using a fork-shaped tool.
5. Note the position of the feed cassette. The markings, on the cassette end closest to the spindle, indi-
cate the actual feed rate.
6. Remove the feed cassette using an allen key.
7. Feed the spindle out of the socket by turning a hexagonal tool counterclockwise until the spindle is
removed.
8. Remove the air logic cover and the air logic unit using an allen key.
Do not loose the o-rings on top of the head.
9. Loosen the cylinder using an allen key.
10. Loosen the drill. Turn the drill over and fasten the drill in the vise.
11. Remove the lower part of the head using an allen key.
12. Remove the cylinder from the lower head.
13. Replace the cylinder with the new one (included in the kit) and put it back in position. Fasten the
cylinder using an allen key.
14. Pull out the bevel gear straight up from the head.
15. Pull out the cylinder straight down from the head.
16. Replace the cylinder with the new one (included in the kit). Put it back in position.
17. Replace the bevel gear with the new one (included in the kit and put it back in position.
18. Put the lower head back in original position. Tighten it with screws.
19. Loosen the drill. Turn the drill over and fasten the drill in the vise.
20. Fasten the cylinder with screws using an allen key.
21. Put the air logic unit back in original position. Replace the cover with the new one (included in the kit)
and put it back in position.
22. Install the spindle in the socket from below. Turn a hexagonal tool clockwise several turns to feed the
spindle.
23. Install the depth ring onto the spindle and move it in position. Tighten the ring with the fork-shaped
tool.
24. Put the feed cassette in the original position making sure that the markings on the cassette end clos-
est to the spindle indicate the required feed rate.
25. If you cannot install the cassette easily, turn its splines with the fork-shaped tool to align them.
26. Install the washers and the four screws in the original position. Tighten the screws. Install the lock
and the lock screw. Tighten the screw.
27. Put the spindle guard back in the original position and secure it.
28. Lossen the drill. Turn the drill over and fasten the drill in the vise. Put the drill bit in the spindle. Place
spanners on the spindle socket and the drill bit base to keep them from rotating and tighten the con-
nection. Put the front part over the drill and secure it.

Installation EN PFD1500RA-180
14 © Atlas Copco Industrial Technique AB - 9836 6024 01
29. Loosen the drill. Turn the drill over and fasten it in the vise. Connect the air hose to the nipple. Do a
functional test of the emergency stop button:
1. Push the start button.
2. Push the emergency stop button so that it locks in position. The spindle must stop immediately.
3. Pull the emergency stop button to reset it. The motor must not restart.
4. Disconnect the air hose.

PFD1500RA-180 EN Installation
© Atlas Copco Industrial Technique AB - 9836 6024 01 15

Installation EN PFD1500RA-180
16 © Atlas Copco Industrial Technique AB - 9836 6024 01

PFD1500RA-180 EN Installation
© Atlas Copco Industrial Technique AB - 9836 6024 01 17
Changing the spindle
WARNING Make sure that the air supply is not connected.
CAUTION Wear gloves to avoid personal injury because of sharp cutting edges. Only experi-
enced maintenance personnel can assemble or disassemble the product.
Required tools
■Vise
■Fork-shaped tool
■Hexagonal tool
■Torx wrench
■Allen key
■Spanners
1. Fasten the drill in a vise with rubber pads, with the front part upward and the drill handle to the right.
Remove the front part and the drill bit.
2. Turn the drill over and fasten it in the vise. Remove the spindle guard.
3. Remove the depth ring from the spindle with the fork-shaped tool.
4. Note the position of the feed cassette. The markings, on the cassette end closest to the spindle, indi-
cate the actual feed rate.
5. Remove the feed cassette.
6. Feed the spindle out of the socket by turning a hexagonal tool counterclockwise. Remove the spin-
dle.
7. Perform the steps 4 to 11 in the section “installing the drill”.

Installation EN PFD1500RA-180
18 © Atlas Copco Industrial Technique AB - 9836 6024 01
8. Turn the drill over and fasten it in the vise. Connect the air hose to the nipple. Do a functional test of
the emergency stop button:
1. Push the start button.
2. Push the emergency stop button so that it locks in position. The spindle must stop immediately.
3. Pull the emergency stop button to reset it. The motor must not restart.
4. Disconnect the air hose.

PFD1500RA-180 EN Installation
© Atlas Copco Industrial Technique AB - 9836 6024 01 19
Installing the scraper kit, for drills with indexer
WARNING Make sure that the air supply is not connected.
CAUTION Wear gloves to avoid personal injury because of sharp cutting edges. Only experi-
enced maintenance personnel can assemble or disassemble the product.
Required tools
■Vise
■Spanner
■Allen key
■Mounting tool
Prerequisites
Before installing the scraper kit, make sure that the following components are removed:
■Front part
■Drill bit
■Spindle
■Spindle guard
1. Fasten the drill in a vise.
2. Remove the adapter and the screw.
3. Put the indexer housing in position on the adapter shaft.
4. Apply a few drops of thread locker on the nut threads and fasten the nut on the indexer housing.
Tighten the nut.
5. Put the wave washer in position on the indexer housing. Apply a few drops of thread locker on the
shaft and attach it to the indexer housing.

Installation EN PFD1500RA-180
20 © Atlas Copco Industrial Technique AB - 9836 6024 01
6. Push the button on the index housing so the nut easily moves down to the bottom. Tighten the front
nut on the shaft onto the index housing with a hook wrench.
WARNING Crushing Hazard
Do not operate the tool if the indexer is not properly locked! An unlocked tool may cause the
complete tool to rotate and cause severe property damage and bodily injury.
►Make sure that the lock pin is flush to the nut surface with a tolerance level of less than
0.3mm above the surface.
7. Remove the stop nuts on the spindle.
8. Install a scraper ring on the spindle and fasten it with four screws.
Make sure that the chamfered edge of the scraper ring is pointing towards the drill bit.
9. Install the spindle stop nut on the spindle.
10. Install the spindle in the drill.
11. Install the spindle stop nut on the spindle top.
12. Cut the tube to fit the length of the front part.
The scraper ring on the spindle shall not move outside the tube when drilling.
13. Install the tube and tighten it.
Make sure that the scraper ring runs smoothly to prevent thread damage.
Install the front part.