Ingersoll-Rand QP Series Setup guide

16572679
Edition 2
May 2014
Save These Instructions
Air Drill
QP Series
Maintenance Information

2 16572679_ed2
Product Safety Information
WARNING
Failure to observe the following warnings, and to avoid these potentially hazardous situations, could result in death or serious
injury.
Read and understand this and all other supplied manuals before installing, operating, repairing, maintaining, changing accessories
on, or working near this product.
Always wear eye protection when operating or performing maintenance on this tool. The grade of protection required should be
assessed for each use and may include impact-resistant glasses with side shields, goggles, or a full face shield over those glasses.
Always turn o the air supply, bleed the air pressure and disconnect the air supply hose when not in use, before installing, removing
or adjusting any accessory on this tool, or before performing any maintenance on this tool or any accessory.
Note: When reading the instructions, refer to exploded diagrams in parts Information Manuals when applicable (see under Related Documentation
for form numbers).
Lubrication
•
•
•
•
Each time a Series QP Drill is disassembled for maintenance and
repair or replacement of parts, lubricate the tool as follows:
Coat all exposed gears with Ingersoll Rand No. 67 Grease
and work some of the Grease into the gearing of the Spindle
Assembly (29).
1.
Use Ingersoll Rand No. 10 Oil to lubricate the motor.
Inject approximately 1 to 2 cc of oil into the air inlet before
attaching the air hose to the tool.
2.
Speed Adjustment
Series QP Drills are furnished with the ability to precisely control,
within certain ranges, the optimum drilling speed for exotic
materials. Setting the speed requires a tachometer and a jeweler’s
screwdriver. Therefore, the adjustment, although simple, should
only be attempted by a competent technician using the proper
equipment.
A small, round opening is located adjacent to the Inlet Bushing
Assembly (4) in the molded exhaust vent. A tiny screw at the bottom
of that hole controls the location of the exhaust control plate. Take
an initial reading of the tool speed by applying a tachometer to the
end of the Chuck without a drill bit and with the trigger completely
depressed. If the tachometer has a concave tip, close the chuck
completely; if the tip is convex, open the chuck completely.
After determining the actual velocity, shut o the air supply and
insert a small jeweler’s screwdriver into the slot of the exhaust control
plate screw and rotate the screw approximately fteen degrees.
Restore the air supply and check the velocity again. The control plate
provides unrestricted exhaust for 90 degrees, completely restricted
exhaust for 90 degrees and variable, adjustable exhaust for 180
degrees. Determine which direction you need to rotate the screw
to obtain the desired speed and then move the screw accordingly.
Best results are achieved by using gradual increments and frequent
tachometer readings. Be sure to turn o the air supply when making
adjustments to the screw.
Disassembly
General Instructions
Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
Whenever grasping a tool or part in a vise, always use leather-
covered or copper-covered vice jaws to protect the surface of
the part and help prevent distortion. This is particularly true of
threaded members and housings.
Do not remove any part which is a press t in or on a
subassembly unless the removal of that part is necessary for
repairs or replacement.
Do not disassemble the tool unless you have a complete set of
gaskets and O-rings for replacement.
Disassembly of the Tool
Each Series QP Drill is made up using three modules or units which
include a housing and throttle unit, a motor unit and a combined
gearing and spindle unit. The tool can be disassembled for repairs to
each individual unit without disturbing the other units. To separate
the modules, proceed as follows:
Remove the Chuck (35) using the following technique:
Insert the short leg of a 1/4”hex wrench into the jaws of the
Chuck and tighten the Chuck.
Using a brass hammer, sharply rap the long leg of the wrench
in a counterclockwise direction to loosen the Chuck.
Unscrew and remove the Chuck from the spindle.
2. To separate the Gear Case (30) from the Housing (1), proceed as
follows:
Install a standard 1-1/16” open end wrench on the ats of the
Gear Case.
Grasp the handle portion of the Motor Housing and rotate
1.
2.
3.
4.
1.
a.
b.
c.
a.
b.
the Housing counterclockwise to begin unscrewing it from
the Gear Case.
When the Housing begins to turn freely, remove the wrench
from the Gear Case and with the spindle upward, nish
unscrewing the Housing from the Gear Case.
Set the assembled Gear Case on the workbench.
3. Remove the Motor Clamp Washer (21) and the Motor Seal (20)
from the assembled motor in the Housing.
4. Grasp the shaft of the Rotor (15) and pull the assembled motor
out of the Motor Housing.
5. To remove the throttle unit, grasp the hex of the Inlet Bushing
Assembly (4) in vise jaws with the Motor Housing upward.
6. Using the Inlet Retainer Removal Tool (37), depress the two tabs
on the Inlet Bushing Retainer (7), located 180 degrees apart,
while pulling the Housing o the Inlet Bushing Assembly.
7. If the Inlet Bushing Seal (8F) remained in the Housing when
the Inlet Bushing Assembly was removed, remove it from the
Housing.
Disassembly of the Gearing
For Series QP05, QP09, QP15, QP20 and QP38, using snap
ring pliers, remove the Gear Retainer (22) from inside the Gear
Case (30) and remove the Gear Head Spacer (23).
For Series QP38, lightly rap the motor end of the Gear Case on
a wooden work bench top to remove the Planet Gear Head Drive
Plate (24), Planet Gear Head Assembly (25) and the Planet Gear
Head Spacer (28).
For Series QP05 and QP09, lightly rap the motor end of the Gear
Case on a wooden work bench top to remove the three Planet
Gears (26), the Planet Gear Head Assembly (25) and the Planet
Gear Head Spacer (28).
c.
d.
1.
2.

16572679_ed2 3
For Series QP15 and QP20, lightly rap the motor end of the Gear
Case on a wooden work bench top to remove the three Planet
Gears (26), the Rotor Pinion (27), the Planet Gear Head
Assembly (25) and the Planet Gear Head Spacer (28).
NOTICE
If the Spindle Assembly is being removed or replaced, the
Spindle Bearing and Spindle Cap Bearing may be damaged
during the removal process. We recommend that new
replacement bearings be available for installation when the tool
is reassembled.
3. Stand the Gear Case on the table of an arbor press with the
threaded end of the Spindle Assembly (29) upward. Using a rod
slightly smaller than the spindle shaft, press the Spindle Assembly
out of the Spindle Cap Bearing (34) and Spindle Bearing (31).
4. Insert a long, small drift through the central opening of the
Spindle Bearing and push the Bearing Spacer (32) o to one side.
Using a hammer with the drift, tap the inner ring of the Spindle
Cap Bearing. Repeat the process at several points until the
Bearing is free from the Gear Case. Remove the Bearing Spacer
from the Gear Case.
5. Using snap ring pliers, remove the two Bearing Stops (33).
6. Stand the Gear Case on the table of an arbor press with the
threaded end upward, and press the Spindle Bearing out of the
Gear Case.
Disassembly of the Motor
Using snap ring pliers, remove the Rear End Plate Assembly
Retainer (12) and slide the Rear End Plate Assembly (11) o the
rear hub of the Rotor.
Use a piece of leather or other protective material to grasp the
splined shaft of the Rotor and pull the assembled Rotor out of the
1.
2.
Cylinder (13).
Remove the Vanes (16) from the Rotor.
Support the Front End Plate Assembly (17), as near the rotor body
as possible, on the table of an arbor press and press the Rotor
from the Front Rotor Bearing (19). Remove the Bearing from the
Front End Plate.
Disassembly of the Throttle Mechanism
Grasp the hex of the Inlet Bushing Assembly (4) in leather-covered
or copper-covered vise jaws with the end having the Inlet Bushing
Screen (5) downward.
Remove the Inlet Bushing Seal (8F) from the Inlet Bushing
Assembly.
Using snap ring pliers, remove the Valve Seat Retainer (8E) and the
Valve Seat Support (8D) from the Bushing.
Using a hooked tool without sharp edges or points, remove the
Throttle Valve Seat (8C) from inside the Bushing.
Remove the Throttle Valve (8A) and Throttle Valve Spring (8B) from
the Bushing.
If the Inlet Bushing Screen is dirty, ush it clean using a clean,
suitable, cleaning solution in a well ventilated area. Remove
the Screen only if it is damaged or as a last resort and have
a replacement Screen on hand whenever removal becomes
necessary. Use the eraser end of a pencil to push it out the inlet
end of the Bushing.
If the Inlet Bushing Bezel (6) needs replacement, slightly spread
the Inlet Bushing Retainer (7) and push it o the side of the
Bushing. Slide the Bezel o the Bushing.
To remove the Trigger Assembly (3A), insert a long probe with a
small hook into the opening for the Inlet Bushing Assembly in the
Motor Housing (1) and hooking the Trigger Retainer (3B), pull the
Retainer out of the Housing. Pull the Trigger out of the Housing.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
Assembly
General Instructions
Always press on the inner ring of a ball-type bearing when
installing the bearing on a shaft.
Always press on the outer ring of a ball-type bearing when
pressing the bearing into a bearing recess.
Whenever grasping a tool or part in a vise, always use leather-
covered or copper-covered vise jaws to protect the surface of
the part and help prevent distortion. This is particularly true of
threaded members and housings.
Except for bearings, always clean every part and wipe every part
with a thin lm of oil before installation.
Apply o-ring lubricant to all O-rings before nal assembly.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a clean, suitable cleaning solution
and dry with a clean cloth. Sealed or shielded bearings should
never be cleaned. Work grease into every open bearing before
installation.
Assembly of the Throttle Mechanism
If the Trigger Assembly (3A) was removed, insert the shaft of the
Trigger into the Motor Housing (1) and push it all the way into the
trigger recess in the Housing until it stops.
Using long reach needle nose pliers to hold the Trigger
Retainer (3B), insert the Retainer into the inlet bushing opening
and install the straight leg of the Retainer in the hole through the
shaft of the Trigger.
Install the Inlet Bushing Bezel (6), convex end leading, onto the
Inlet Bushing Assembly (4). Bring the convex end into contact
with the hex at the inlet end of the Bushing.
Spread the opening slightly on the Inlet Bushing Retainer (7) and
install it around the Inlet Bushing with the tab end nearest to the
bushing hex and against the Bezel.
Grasp the hex of the Inlet Bushing in leather-covered or copper-
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
covered vise jaws with the throttle valve opening upward.
Insert the Throttle Valve Spring (8B), large end leading, followed
by the Throttle Valve (8A), long stem end trailing, into the valve
opening.
Place the Throttle Valve Seat (8C) followed by the Valve Seat
Support (8D) in the opening against the Valve.
Using snap ring pliers while compressing the Throttle Valve
Spring and moving the Seat and Support inward, capture the
components by installing the Valve Seat Retainer (8E) in the
Bushing internal groove.
Moisten the Inlet Bushing Seal (8F) with o-ring lubricant and
install it on the exterior of the Inlet Bushing.
Remove the assembled Bushing from the vise jaws. If the Inlet
Bushing Screen was removed, use a at faced dowel slightly less
than 1/2” in diameter to push the new Screen into the opening at
the hex end of the Bushing.
Assembly of the Motor
Place the Front End Plate (17) on the splined shaft of the
Rotor (15) with the bearing recess away from the rotor body.
Place the Front Rotor Bearing (19) onto the shaft and using a
sleeve or piece of tubing that contacts the inner race of the
Bearing, press the Bearing onto the shaft until the Front End Plate
nearly contacts the rotor body.
NOTICE
In the following step, the measurement must be made at the end
corner of the large rotor body.
3. The clearance between the Front End Plate and Rotor is critical.
While pressing down with your nger on the outer edge of the
Front End Plate on the bearing side, insert a 0.004” (0.1 mm) feeler
gauge between the face of the rotor body and the face of the End
Plate at a point that is 180 degrees from where the pressure is
6.
7.
8.
9.
10.
1.
2.

4 16572679_ed2
applied. Refer to Dwg. TPA1740. To increase the gap, support the
End Plate and lightly tap the rotor shaft with a plastic hammer; to
decrease the gap, press the Bearing farther onto the rotor shaft.
Measurement of Front End Plate Clearance
Pressure
Feeler
Gauge
(Dwg. TPA1740)
4. Wipe each Vane (16) with a light lm of Ingersoll Rand No. 10 Oil
and place a Vane in each slot in the Rotor.
5. One end of the Cylinder Assembly (13) has a notch that breaks
the outer wall and end face of the Cylinder. With that end trailing,
install the Cylinder Assembly over the Rotor and Vanes against
the Front End Plate. Make certain the Cylinder Alignment Pin (14)
enters the hole in the Front End Plate.
6. Install the Rear End Plate Assembly (11), at face leading, on the
rear hub of the Rotor. Make certain the Cylinder Alignment Pin
enters the hole in the Rear End Plate.
7. Using snap ring pliers, install the Rear End Plate Assembly
Retainer (12) in the annular groove on the rear rotor hub to
secure the assembly in position.
8. Set the assembled motor aside.
Assembly of the Gearing
Work some Ingersoll Rand No. 67 Grease into the gearing of the
Spindle Assembly (29).
Insert the threaded end of the Spindle Assembly into the
threaded end of the Gear Case (30) while meshing the teeth of the
gears with the spline inside the Gear Case.
Support the gear end of the Spindle Assembly on the table of
an arbor press while leaving clearance for the Gear Case. Using a
piece of tubing that will clear the shaft and contact the inner ring
of the Spindle Bearing (31), press the Bearing onto the shaft of the
Spindle Assembly until it contacts the gear hub.
Using snap ring pliers, install one of the Bearing Stops (33) in the
internal groove nearest the Bearing.
Apply some Ingersoll Rand No. 67 Grease to the Bearing
Spacer (32) and slide it onto the shaft of the Spindle Assembly
with the smaller end trailing.
Using snap ring pliers, install the second Bearing Stop in the
internal gear case groove nearest the threaded spindle end.
Stand the assembled Gear Case on the table of an arbor press
with the output Spindle upward. Install the Spindle Cap
Bearing (34) over the output shaft, and using a piece of tubing
1.
2.
3.
4.
5.
6.
7.
that contacts the outer ring of the Bearing, press the Bearing into
the Gear Case against the Bearing Stop.
For Series QP05, QP09, QP15, QP20 and QP38, insert the Planet
Gear Head Spacer (28) and Planet Gear Head Assembly (25), spline
hub leading, into the open end of the Gear Case.
For Series QP05, QP09, QP15 and QP20, apply Ingersoll Rand
No. the three Planet Gears (26) and install them on the shafts of
the Planet Gear Head Assembly.
For Series QP15 and QP20, apply Ingersoll Rand No. 67 Grease
to the Gear Head Pinion (27) and while meshing the gear teeth,
insert it in the opening between the three Planet Gears.
For Series QP38, install the Planet Gear Head Drive Plate (24) on
the shafts of the Planet Gear Head Assembly.
For Series QP05, QP09, QP15, QP20 and QP38, place the Gear
Head Spacer (23) in the Gear Case and secure the assembly by
using snap ring pliers to install the Gear Retainer (22) in the
annular groove inside the Gear Case.
Assembly of the Tool
Grasp the hex of the Inlet Bushing Assembly (4) in vise jaws with
the Throttle Valve (8A) upward. Pull the stem of the Valve fully
outward to enable proper engagement with the trigger stem.
Hold the Motor Housing (1) above the Bushing and align the two
cut out slots in the inlet end of the Motor Housing with the tabs
on the Inlet Bushing Retainer (7).
Lower the Housing onto the Bushing until the bottom of the
Housing contacts the retainer tabs. If necessary, squeeze the
Retainer to start the tabs into the Housing. Push down on the
Housing until the tabs engage the two slots in the Housing.
Visually inspect the Housing to make certain that both tabs
entered the slots in the Housing.
Remove the Housing from the vise jaws.
Grasp the spline of the Rotor (15) and align the assembled motor
so that the End Plate Alignment Dowel (18) is positioned at twelve
o’clock in the Housing. It must be aligned with the notch through
the threads in the Motor Housing. Insert the assembled motor
in the Housing. When the motor is seated properly, the groove
below the housing threads for the Motor Seal (20) will be clearly
visible.
Moisten the Motor Seal with o-ring lubricant and carefully work
it into the Housing against the Front End Plate (17). Use a hex
wrench, ball point pen or other non-damaging tool to make
certain it is completely seated under the housing threads against
the End Plate.
Align the tab on the Motor Clamp Washer (21) with the notch
in the Housing and the hole in the Washer with the Alignment
Dowel in the End Plate and insert the Washer into the Housing.
Make certain the Dowel enters the hole in the Washer and the
Washer is at against the Motor Seal. Failure to have the Washer
at, will cause the motor to lock up.
While engaging the spline of the rotor shaft with the gearing in
the assembled Gear Case (30), thread the two assemblies together
hand tight.
To tighten the Gear Case on the Housing, proceed as follows:
Install a standard 1-1/16” open end wrench on the ats of the
Gear Case.
Grasp the handle portion of the Motor Housing and rotate the
Housing clockwise to tighten it on the Gear Case.
Tighten the joint between 15 and 20 ft-lbs. (20.3 and
27.1 Nm) torque.
10. Remove the tool from the vise jaws and thread the Chuck (35)
onto the Spindle (29).
11. Check the free speed of the tool using a tachometer and follow
the instructions in the SPEED ADJUSTMENT section of this
manual.
8.
9.
10.
11.
12.
1.
2.
3.
4.
5.
6.
7.
8.
9.
a.
b.
c.

16572679_ed2 5
Troubleshooting Guide
Trouble Probable Cause Solution
Loss of Power Low air pressure Check air supply. For top performance, the air pressure
must be 90 psig (6.2 bar/620 kPa) at the inlet.
Plugged Inlet Bushing Screen Clean the Inlet Bushing Screen using a clean, suitable
cleaning solution. If the Screen cannot be cleaned,
replace it.
Worn or broken Vanes Replace a complete set of Vanes.
Worn or broken Cylinder Replace the Cylinder if it is cracked or if the bore
appears wavy or scored.
Exhaust control restricted Make certain the exhaust control plate in the Housing is
in the fully open position.
Motor won’t run Motor Clamp Washer binding Remove the Gear Case make certain the Washer is at
and the Motor Seal is properly positioned.
Gears binding Clean and inspect all gearing. Replace any worn or
damaged gearing.
Leaky Throttle Valve Worn Throttle Valve and/or
Throttle Valve Seat
Install a new Inlet Parts Kit (Part No. TRD-K303).
Dirt accumulation on Throttle Valve and/or
Throttle Valve Seat
Remove the throttle unit from the Housing and
disassemble, clean and reassemble the unit as
instructed in the maintenance instructions.
CAUTION
Never ush the throttle unit with leaning solution
while it is in the Housing. Internal components will
be damaged.
Gear Case gets hot Excessive grease Clean and inspect Gear Case and gearing parts and
lubricate as instructed.
Worn or damaged parts Clean and inspect the gear Case and Gearing. Replace
worn or broken components.
Related Documentation
For additional information refer to:
Product Safety Information Manual 04580353.
Product Information Manual 16572034.
Parts Information Manual 16572745.
Manuals can be downloaded from ingersollrandproducts.com

Notes

Notes

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