Ingersoll-Rand QE4 Series Setup guide

Form 80151624
Edition 1
October 2005
Pistol DC Electric Nutrunner
QE4 Series
Maintenance Information
Save These Instructions

2Form 80151624-Edition 1
General Instructions:
• Refer to "Suggested Tools" in the Parts Information Manual Form
80151632 for quick reference to the tools recommended for the
following disassembly/assembly instructions. WARNING
• Repairs should be made only by authorized trained personnel.
Consult your nearest Ingersoll-Rand Authorized Service Center.
• 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. Clean and degrease all parts except for the 1st and 2nd Stage
Spindle Assemblies (75 and 77).
2. Wipe clean the 1st and 2nd Stage Spindle Assemblies with a clean,
dry and lint-free rag
3. Once cleaned, apply prescribed amounts of Ingersoll-Rand #67
Grease as follows:
• 2 to 3 cc to central area between gears of Spindle Assemblies
• 1 to 2 cc to faces of Spindle Assemblies
• Thin layer on Ring Gear teeth
4. Apply light coat of grease to Trigger Magnet Post. Use
Ingersoll-Rand #67 Grease.
5. For Trigger Start, Push-To-Start, and Trigger Permit Models: Use
Ingersoll-Rand #67 Grease to lubricate Bearing (43) located inside
Spindle Housing Assembly and the gear teeth drive spindle assembly
(20).
6. For Extended Spindle Models: Use Ingersoll-Rand #67 Grease to
lubricate the Drive Spindle Bearings, the Drive Spindle (68) and the
Disengaging Spring (67).
Disassembly
WARNING
• 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 (34), always
ensure that the Memory Chip (32), Communication Board (38),
Transducer 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 Assembly
Attachment designed for that model. Never replace a Push-To-
Start Assembly Attachment with a Trigger Start or Extended
Spindle Attachment.
• When replacing a Transducer 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.
3. 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.
WARNING
• When grasping tool in vise, support both handle and barrel
simultaneously. Do not clamp down excessively or crush
housing. Use only enough force to arrest rotation.
Disassembly of External Components
1. Unscrew and remove handle cover screw (39) with appropriate hex
key and pull out bottom of handle cover (33). Lower out of pistol
handle opening.
2. Unscrew and remove back cap screws (9) with appropriate hex key
and pull back cap assembly (8) straight back out of housing.
3. Slide Switch Reverse Ring (31) away from the housing, being
cautious not to lose the Ball (45) and Springs (29 and 30).
4. Dislodge O-rings (15).
5. Remove Chip Holder Assembly (32) from Motor Housing Assembly.
Disassembly of Internal Components
1. Remove Retainer (28) used to hold Main Board (38) located in the
handle of the housing.
2. Through the Handle Cover opening, disconnect all connectors.
3. If necessary, remove the Main Board from the pistol housing
assembly. The Main Board must be carefully lifted/bent over the
trigger post. Use a pick or hook tool to aid in this operation.
4. Slide board partially out of housing assembly until trigger screw is
visible through hole in board. Unscrew trigger screw (12), relieving
tension on the board and continue to remove the main board.
WARNING
• Tool board components may be damaged during disassembly if
care is not taken. Board must be bent to clear Trigger Post prior
to dislodging board from Housing.
5. Remove white LED assembly (37) from housing.
6. Slide transducer gear pack assembly (27) out of housing.
7. Remove LED board assembly (35).
8. Unscrew and remove trigger screw (12) and trigger washer (10) and
remove the trigger (16).
For Push-to-Start models: Remove trigger spacer (7) from trigger
post.
9. If necessary, remove trigger spring (11) from trigger body.
Trigger Start, Trigger Permit and Push-to-Start
Attachments
1. While holding tool carefully using a vise, use a spanner wrench to
unscrew nose cap (41).
2. While holding tool carefully using a vise, use a spanner wrench
#GEA40-478 (or other appropriate wrench) to unscrew coupling nut
(40).
For Push-to-Start models: Verify that the Push-to-Start connector
has been removed from its terminal on the main board (38). (See
Disassembly of Internal Components section)
3. Verify that the transducer gear pack assembly connector has been
removed from its terminal on the main board (38). (See Disassembly
of Internal Components section)
For Push-to-Start models: Slide the spindle housing assembly (1)
and transducer gear pack assembly (24, 25, 26 or 27)
simultaneously out of the motor housing assembly (34) while
ensuring clearance for wire assemblies between the spline teeth
of the transducer and the relief notch in the motor housing
assembly.
4. Slide the spindle housing (2) out of the motor housing assembly (34).
5. If necessary, remove coupling nut retainer (42) from spindle housing
(1 or 2).
6. If necessary, press bearing (43) out of spindle housing (2).
7. Remove spring (44).
8. Slide the drive spindle assembly (20) out of the transducer gear case
assembly inside the motor housing assembly.
9. Slide the transducer gear case assembly (24, 25, 26 or 27) out of the
motor housing assembly (34) while ensuring clearance for wire
assemblies between the spline teeth of the transducer and the relief
notch in the motor housing assembly.

Form 80151624-Edition 1 3
10. For 3/8" and 1/4” Square Drive Spindles,
a. Locate Retaining Pin (59 or 61) and Retaining Spring (60 or 62) of
Spindle's square socket.
b. If necessary, use a pointed metal probe to pull Retaining Spring
out of Spindle cavity.
c. Also, if necessary, remove Pin from Square Drive Spindle.
11. For Quick Change Spindles,
a. Remove Retaining Ring (58), using Snap Ring Pliers.
b. Slide Spring (57), Sleeve (56) and Ball (55) off the Spindle (52).
For Extended Spindle Model Attachment
1. Using an adjustable Pin Wrench, unscrew Bearing Cap (72).
NOTICE
• Bearing Cap (72) has a left handed thread.
2. Pull the Drive Spindle Assembly (68) out of Housing Assembly (49).
3. If necessary, using a bearing puller tool, press the Rear Spindle
Bearing (71) off the Drive Spindle Assembly. Then remove the
Retaining Ring (70) and Washer (69).
4. Now tilt Spindle Housing, causing the Disengaging Spring (67),
Coupler (64), Square Drive or Quick Change Spindle (53 or 54 or
52), and Washers (50 and 51) to slide out.
5. Note that the No-Float Models have an extra Spacer (66) inside the
Coupler.
Assembly
Assembly-Motor Housing
General Instructions
1. To protect the part's surfaces and to prevent distortion of Housings
and threaded joints, use care when grasping the tool.
2. Always press on the inner ring of a ball-type bearing when installing
the bearing onto a shaft.
3. Always press on the outer ring of a ball-type bearing when pressing
the bearing into a bearing recess.
4. Refer to the "Lubrication" section of this manual for instructions on
how to properly grease this tool.
WARNING
• The following procedures are to be performed by an authorized,
trained repair person. To ensure proper functioning of the tool.
• When replacing the Motor Housing Assembly (34), always
ensure that the Memory Chip (32), Communication Board (38),
Transducer Gear Pack Assembly, and Attachment are all
assembled as a set with the new Motor Housing Assembly.
CAUTION
• When replacing a Transducer Gear Pack Assembly, always use
the Assembly designed for that model.
Assembly-Transducer Gear Pack
1. Apply Grease (Ingersoll-Rand #67) to ring gear of Transducer
Assembly (73).
2. Place one Spacer (74) into Transducer Assembly against bottom
face.
3. Grease the planet gear teeth of the 2nd Stage Spindle Assembly
(75), and slide into Transducer Assembly.
4. Place second Spacer (76) into Transducer Housing against face of
2nd Stage Spindle Assembly.
5. Grease the planet gear teeth of the 1st Stage Spindle Assembly (77),
and slide into Transducer Assembly, taking care to align gear teeth of
the 1st Stage Spindle Assembly with the planet gears of the 2nd
Stage Spindle Assembly.
6. Place third Spacer (78) against 1st Stage Spindle Assembly.
7. Finally, install Retaining Ring (79) taking care to properly align into
groove of Transducer Assembly.
8. To assure free rotation of assembly, hold Transducer Gear Pack
Assembly steady, and manually rotate the 1st Stage Spindle
Assembly.
Assembly-Trigger Start, Push-to-Start, and
Trigger Permit Attachments
1. Visually check Housing for loose material fragments.
2. For 3/8" and 1/4" Square Drive Spindles, install Socket Retaining
Pin (59 or 61) into small hole on one of the flat sides of square
Spindle.
a. With Socket Retaining Pin (59 or 61) in place, locate the Pin's
groove inside end-hole of square Spindle.
b. Position Socket Retaining Spring (62 or 60) 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 (59 or 61).
c. Holding the Socket Retaining Pin steady, push Spring down hole
of square Spindle until the Socket Retaining Spring's wire
engages Socket Retaining Pin.
d. Socket Retaining Pin is properly installed when Socket Retaining
Spring snaps into place.
3. For Quick Change Spindles,
a. Place Ball (55) into hole in Spindle.
b. Slide Sleeve (56) onto Spindle so that it retains the Ball, and slide
Spring (57) onto Spindle underneath the Sleeve.
4. Place Retaining Ring (58) into groove of Spindle to retain Spring and
Sleeve.
5. Slide Coupling Nut (64) over Attachment.
6. Using an appropriate tool, install Retainer (70) on assembly. Take
care to seat Retainer Ring in groove.
7. Slide Coupling Nut over Retainer (70), and spin by hand to check
freedom of movement.
8. Engage Attachment's Pinion into spline of Spindle Assembly (68),
then engage the spline on the Attachment with the internal spline of
the Motor Housing Assembly.
9. Thread Coupling Nut (64) onto Motor Housing Assembly.
10. While holding the tool using a Hook Spanner or similar wrench, use a
Spanner Wrench to torque Coupling Nut to 15 - 20 lb. ft. (20 - 27 Nm).
Assembly-Extended Spindle Attachment
1. Visually check Housing for loose material fragments.
2. For 3/8" and 1/4" Square Drive Spindles, install Socket Retaining
Pin (59 or 61) into small hole on one of the flat sides of square
Spindle.
a. With Socket Retaining Pin (59 or 61) in place, locate the Pin's
groove inside end-hole of square Spindle.
b. Position Socket Retaining Spring (62 or 60) 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 (59 or 61).
c. Holding the Socket Retaining Pin steady, push Spring down hole
of square Spindle until the Socket Retaining Spring's wire
engages Socket Retaining Pin.
d. Socket Retaining Pin is properly installed when Socket Retaining
Spring snaps into place.
3. For Quick Change Spindles,
a. Place Ball (55) into hole in Spindle.
b. Slide Sleeve (56) onto Spindle so that it retains the Ball, and slide
Spring (57) onto Spindle underneath the Sleeve.
c. Place Retaining Ring (58) into groove of Spindle to retain Spring
and Sleeve.
4. Spin Spindle by hand to check freedom of movement.
5. Lubricate the bearings of the Housing Assembly (49) with
Ingersoll-Rand #67 Grease.
6. Slide Washer (50) and Washer (51) onto applicable output Spindle;
Square Drive Spindle (53 or 54) or Quick Change Spindle (52), and
insert output Spindle into Housing Assembly (49).
7. Align the Coupler (64) to slide over splines of output Spindle.
8. Slide Coupler into position in Housing Assembly (49).
9. For No-Float Models, insert Spacer (66) into the Coupler.
10. Slide Washer (69) on the Drive Spindle Assembly (68).
11. Use snap-ring Pliers to install the Retaining Ring on top of the
Washer.
12. Press on Rear Spindle Bearing (71) to Drive Spindle Assembly (68).
13. Place Disengaging Spring (67) over Drive Spindle Assembly.
14. Align the Drive Spindle Assembly with spline of Coupler and insert
Drive Spindle Assembly into Housing Assembly (49).
15. Apply one drop of Perma-Lok MM-115 to threads of Bearing Cap(72).
16. Carefully grasp the Housing Assembly.
NOTICE
In the following step, the Bearing Cap (72) has a left-handed thread.

4Form 80151624-Edition 1
17. Using the appropriate tool, tighten Bearing Cap to 15-20 lb. ft.
(20 - 27 Nm) of torque.
18. Slide Coupling Nut (64) over Housing Assembly (49).
19. Using an appropriate tool, install Retainer (42) onto spline of Housing
Assembly until seated into groove.
20. Slide Coupling Nut over Retainer (40), and spin by hand to check
freedom of movement.
Installation-Transducer Gear Pack Assembly
1. Orient the Spacer located in the Motor Housing Assembly groove at
the bottom of the spline, so that the opening in the spacer lines up
with the hole in the housing.
2. After guiding Transducer's connector into the hole found at end of
Motor Housing Assembly's inner groove, insert Transducer Gear
Pack Assembly into Motor Housing Assembly.
3. Carefully pull Transducer's connector and wiring through opposite
end of Motor Housing Assembly.
4. Engage external spline teeth of Transducer Gear Pack Assembly into
the internal spline teeth of Motor Housing Assembly. Continue sliding
Transducer Gear Pack Assembly into the Motor Housing while
guiding the wire through the hole.
5. Align and engage the 1st Stage Spindle planet gears with gear teeth
on rotor of the Motor Housing Assembly. Be Certain that the
Transducer wire exits the Transducer directly over the access hole
through with the wire was fed.
6. Continue inserting the Transducer Assembly until it is fully seated.
Installation-Trigger Start, Attachment
1. Insert applicable output spindle assembly (52, 53 or 54) into spacer
(4).
2. Press bearing (43) into spindle housing (2).
3. Press coupling nut retainer (42) onto groove in OD of spindle housing
(2).
4. Insert output spindle assembly into spindle housing (2).
5. Insert spring (44) into hole in end of drive spindle assembly (20).
6. Insert drive spindle assembly (20) into transducer assembly inside
motor housing assembly (34).
7. Guide output spindle assembly and spindle housing assembly over
spring (44).
8. Engage external gear spline on spindle housing (2) with internal
spline in motor housing assembly (34).
9. Align gear teeth of output spindle assembly with matching teeth of
drive spindle assembly (20).
10. Thread coupling nut (40) onto motor housing assembly (34).
11. While holding the tool carefully in a vise, use a spanner wrench to
torque coupling nut to 20-27 Nm.
Installation- Push-to-Start and Trigger Permit
Attachments
1. Press coupling nut retainer (42) onto groove in OD of spindle housing
assembly (1).
2. Insert applicable output spindle assembly (21, 22 or 23) into spindle
housing assembly (1).
3. Insert spring (44) into hole in end of drive spindle assembly (20).
4. Guide output spindle assembly and spindle housing assembly over
spring (44).
5. Align gear teeth of output spindle assembly with matching teeth of
drive spindle assembly (20).
6. Insert transducer assembly onto drive spindle bearing and hold the
group of parts as one unit.
7. Group the transducer wire and spindle housing assembly wire
together making sure the spindle assembly wire is sitting in the
groove on the outside of the transducer body.
8. Insert the two wire assemblies into housing along groove inside
motor assembly housing.
9. Carefully guide the transducer and spindle housing assembly wires
through the housing from the opposite end while inserting all the
parts.
10. Engage external gear spline on spindle housing assembly (1) with
internal spline in motor housing assembly (34).
11. Thread coupling nut (40) onto motor housing assembly (34).
12. While holding the tool carefully in a vise, use a spanner wrench to
torque coupling nut to 20-27 Nm.
Installation-Extended Spindle Attachment
1. Position the Attachment appropriately.
2. Engage the spline on the drive spindle of the Attachment with the
matching internal spline of the Transducer Gear pack Assembly,
engage the spline on the Housing Assembly with the internal spline
of the Motor Housing Assembly and thread the Coupling Nut onto the
Motor Housing.
3. While holding the tool carefully using a vise, use a Spanner wrench
to torque the Coupling Nut to 15 - 20 lb. ft. (20 - 27 Nm).
Assembly-Internal Components
1. Pull the LED Assembly (37) wires first through the small opening at
the top of the front of the Motor Assembly Handle.
2. Install O-Rings (15) around the LED Assembly in housing in Motor
Assembly (34).
3. Place Trigger Spring (11) around the long metal post on the reverse
side of the Trigger Assembly (16) and rotate the Trigger Spring
clockwise and counterclockwise until it is secure.
For Push-to-Start models: Install trigger spacer (7) onto metal post
of trigger assembly.
4. Push Trigger Assembly (16) into housing in the Motor Assembly (34).
5. Put Trigger Washer (10) around Trigger Screw (12) and screw
Trigger Screw into reverse side of Trigger Assembly to secure the
One Finger Trigger in Motor Assembly housing.
6. Insert the LED Board Assembly (35) in the rear of the Motor
Assembly. Gently guide the LED Board Assembly by the cable
assembly.
7. Insert the Main Board (38) into the Motor Assembly by sliding it up
through the bottom opening of the handle of the Motor Assembly,
lifting it gently over the Trigger Post.
8. Using the appropriate tool, push the Retainer (28) into the grove in
the bottom of the Motor Assembly handle.
For the following seven steps (step 9 to step 15), refer to drawing
“GEP15-A2309” and “Tool Board Configuration Chart”.
9. Connect the motor temperature sensor connector to the Main Board.
10. Connect transducer connector to Main Board.
11. Connect green Resolver connector to Main Board.
12. If necessary, connect the Push-to-Start connector to the Main Board.
If not using the Push-to-Start assembly, connect jumper connector to
the Main board.
13. Connect the LED assembly connector to the Main Board.
14. Connect the white LED connector to the Main Board.
15. If Push-to-Start only trigger needs to be disabled by installing jumper
connector to main board.
(Dwg. GEP15-A2309)
2
4
7
6
8
5
3
1

Form 80151624-Edition 1 5
Assembly-External Components
1. Rotate tool so that Handle End faces upwards and insert Spring (29)
into spring track in Switch Reverse Ring (31).
2. Insert Spring (30) followed by Ball (45) into rear of Motor Assembly
and be careful to hold them compressed and in place while slowly
sliding the Switch Reverse Ring over rear of Motor Assembly.
NOTICE
• In Step 2 above, three triangular grooves are cut in the Switch
Reverse Ring. The Spring and Ball will fit inside one of them,
line one of the holes up with the location of the Spring and Ball
when sliding the Switch Reverse Ring over the Motor Assembly.
3. Position the Back Cap Assembly (8) into place, mating it with the
Switch Reverse Ring on the rear of the Motor Assembly.
4. Using the appropriate Allen Wrench, screw the Back Cap Screws (9)
into a secure position through the Back Cap Assembly.
5. Insert Chip Holder Assembly (32) into hole in side of bottom of the
Motor Assembly handle.
6. Using two cable ties (48), dress wires so that they are out of the
trigger post path.
7. Put Handle Cover (33) on back of the Motor Assembly handle by
putting top in first and swinging bottom into position.
NOTICE
• In Step 7 above make sure all wiring is securely inside Motor
Assembly handle and be careful not to crush wiring against the
Main Board.
8. Using appropriate Allen Wrench secure Handle Cover onto Motor
Assembly handle by screwing Handle Cover Screw (39) into position
on the bottom of the Motor Assembly handle.
Tool Board Configuration Chart.
For TRIGGER START (TS), PUSH-TO-START (PTS) and
TRIGGER PERMIT (TP) Models.
Connector Description Model
Configuration Position
Jumper Connector 3 Pin
TS 1
PTS 6
TP not used
Led Board Assembly 8 Pin, White TS, PTS, TP 2
White Led Assembly 2 Pin, Black
Jacketed Cable TS, PTS, TP 3
Motor Commutation
Connector 5 Pin, Green TS, PTS, TP 4
Transducer
Connector 5 Pin, White TS, PTS, TP 5
Push-to-start
Connector 3 Pin, White
TS not used
PTS 1
TP 1
Temperature Sensor
Connector 2 Pin, Grey Wires TS, PTS, TP 7
Motor Phases
Connector 4 Pin, Black TS, PTS, TP 8

6Form 80151624-Edition 1
Notes

Form 80151624-Edition 1 7
Notes

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