Ingersoll-Rand QM5 Series Setup guide

Form 04581369
Edition 2
April 2005
Fixtured In-Line DC Electric
Nutrunner
QM5
Maintenance Information
Save These Instructions

2Form 04581369-Edition 2
General Instructions:
• Refer to “Suggested Tools" in the Parts Information Manual Form
04581328 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. Separate spindle, transducer, gear pack, and motor.
2. Disassemble spindle and gear case.
3. Clean and degrease all parts.
4. Once gear case is clean, apply prescribed amounts of
Ingersoll-Rand #222 Grease as follows:
a. 1 cc into the ring gear.
b. 2.5 cc into the first stage gears in the Gear Head Assembly (24).
c. 2.5 cc into the second stage gears in the Spindle Assembly (18).
5. Wipe clean the Spindle Assemblies with a clean, dry and lint-free rag.
6. Work 2.5 cc of Ingersoll-Rand #222 grease into the inner diameter
of the Coupler (9).
Tool Dismounting Methods
It should be noted that disassembly of the tool into the modules will differ
slightly depending on the method used for mounting. If the tool is
mounted with the plate spacer in place, the tool can be disassembled by
following the first set of instructions (A). The reason for the plate spacer
is to allow the tool to be dismounted and remain fully assembled.
The tool can also be mounted with a bracket or mounting plate that takes
the place of the spacer. If this is the desired mounting method, the
mounting plate used must be the same thickness as the plate spacer
provided or the tool will not fit together properly. In this case the second
set of instructions (B) should be followed.
Disassembly
To aid in the disassembly process, the tool can be broken down into
modules. There are five different modules in the tool; the spindle
assembly, transducer, gear case assembly, motor assembly, and
electronics pod assembly. The following instructions are for breaking the
tool down into each modular assembly.
WARNING
• This procedure is to be performed by an authorized, trained
repair person to ensure proper functioning of the tool.
CAUTION
• When replacing a Gear Case 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.
Disassembly into Smaller Modules
(A)
1. Using an allen wrench remove the M10 Screws (4) that hold the tool
to the mounting plate and slide the tool out.
2. Remove the M3 Screws (5) that hold the Spindle Assembly to the
Transducer Assembly (17).
3. Remove the M6 Screws (19) that hold the gear case assembly to the
Transducer Assembly (17).
4. Remove the M6 Screws (21) that hold the gear case to the Motor
Assembly (27).
(B)
1. Using an allen wrench remove the M10 Screws (4) that hold the tool
to the mounting plate. The spindle assembly will now become
disengaged.
2. Slide off the transducer, gear case, and motor assemblies.
3. Remove the M6 Screws (19) that hold the gear case assembly to the
Transducer Assembly (17).
4. Remove the M6 Screws (21) that hold the gear case to the Motor
Assembly (27).
Attachments
WARNING
• 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.
Spindle - Disassembly
1. Use snap ring pliers to remove Retainer Ring (15).
2. Gently tap the end of the spindle on a hard surface while covering the
opposite end to dislodge the slip fit bearing.
WARNING
The input spindle is spring loaded and will therefore exert a force
once dislodged. Make sure to cover the end to avoid potential
injury.
3. Pull the Input Spindle Assembly (11) out of the Housing (3).
4. If necessary, using a bearing puller tool, pull the rear spindle Bearing
(14) off the Input Spindle Assembly (11). The bearing will most likely
become damaged in this process and should therefore be replaced.
5. Remove the Retaining Ring (13), and Washer (12).
6. Now tilt the spindle housing, causing the Spring (10), Coupler (9),
Spindle lock (if applicable), Spindle (8), and Washers (7) and (6) to
slide out.
7. Using pick or screwdriver end, remove the Seal (1).
8. Press the two Needle Bearings (2) out of the Housing (3) from either
direction.
Gear Case - Disassembly
1. Use snap ring pliers to remove Retainer Ring (26).
2. Carefully slide out all of the internal components: Spacer (23),
Spindle Assembly (18), Spacer (23), Gear Head Assembly (24), and
Spacer (23)
3. For 90 and 55 Nm models: Press the Spindle Assembly (18) out of
the front of the Gear Case (20) through Bearing (22).
Disassembly of Electronics Pod
1. Use an allen wrench to remove M6 Screws (35) from Flange (34).
2. Remove the M3 Screw (30) and slide the Cover (38) off.
3. Remove the two O-Rings (37) and remove the Memory Chip
Assembly (31).
4. Unscrew the Nut (36) and remove the Flange (34).
5. Use a small flathead screwdriver to carefully peel the dried sealant
out of the ground slot.
6. Remove the M3 Screw (30) to free the ground wire.
7. Loosen the nut constraining the grommet in the strain relief and
unscrew the strain relief from the Housing (29).
8. Pry out the Clip (33) and slide out the Communication Board (32).
9. Disconnect the motor temperature sensor connector, motor
communication connector, and the torque transducer connector from
the Communication Board (32).

Form 04581369-Edition 2 3
10. Disengage female socket on the communication board from the male
connector on the motor cable.
11. Slide the Housing (29) off of the transducer and motor cables.
Tool Mounting Methods
It should be noted that assembly of the tool into the modules will differ
slightly depending on the method used for mounting. If the tool will be
mounted with the plate spacer in place, the tool can be assembled by
following the first set of instructions (A). The reason for the plate spacer
is to allow the tool to be mounted fully assembled.
The tool can also be mounted with a bracket or mounting plate that takes
the place of the spacer. If this is the desired mounting method, the
mounting plate used must be the same thickness as the plate spacer
provided or the tool will not fit together properly. In this case the second
set of instructions (B) should be followed.
Assembly
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.
Assembly of Modules
(A)
1. Apply serviceable thread locker to all screws that connect the
assemblies together.
2. Insert the two M3 Screws (5) into the Transducer Assembly (17),
through the plate spacer, and engage the threads in the Housing (3).
3. Insert the M6 Screws (19) through holes in the Transducer Assembly
(17) and engage the M6 threads in the Gear Case (20).
4. Insert the M6 Screws (21) through the holes in the Motor Assembly
(27) and engage the M6 threads in the Gear Case (20).
5. Insert the tool into the mounting plate.
6. Use an allen wrench to insert two M10 Screws (4) through the holes
in the mounting plate, through the holes in the Housing (3), through
the Plate Spacer (16), and engage the threads in the Transducer
Assembly (17).
(B)
1. Apply serviceable thread locker to all screws that connect the
assemblies together.
2. Insert the M6 Screws (19) through holes in the Transducer Assembly
(17) and engage the M6 threads in the Gear Case (20).
3. Insert the M6 Screws (21) through the holes in the Motor Assembly
(27) and engage the M6 threads in the Gear Case (20).
4. Position the connected transducer, gear case and motor assemblies
flush with the backside of the mounting plate and the spindle
assembly flush with the front side of the mounting plate.
5. Line up the screw holes and use an allen wrench to insert the two
M10 Screws (4) through the holes in the Housing (3), through the
holes in the mounting plate and engage the threads in the
Transducer Assembly (17).
WARNING
• This procedure is to be done by an authorized, trained repair
person to ensure proper functioning of the tool.
Spindle Assembly
1. Press Needle Bearing (2) into the top of the Housing (3) slightly
below the shoulder to leave room for Seal (1).
2. Press Seal (1) into the front of the Housing (3) flush with the face of
the housing.
3. Turn the housing over and press the second Needle Bearing (2) into
the housing flush with the inside shoulder.
4. Locked Spindle: Fully Retracted (If spindle will not be locked go to
step # 5). Slide spindle lock onto spindle so that it seats flush against
the splined face.
5. Position Spring (10) inside large hole of spindle.
6. Locked Spindle: Fully Extended (If spindle will not be locked go to
step # 7). Insert spindle lock into the housing so that it rests on the
rear face of the splined drive.
7. Slide Washers (6) and (7) onto Spindle (8) and insert spindle into the
Housing (3).
8. Work 2.5 cc of Ingersoll-Rand grease 222 into the inner diameter of
the Coupler (9).
9. Align the Coupler (9) to slide over the spline of the spindle and slide
into the Housing (3).
10. Slide Washer (12) on the Input Spindle Assembly (11).
11. Use snap ring pliers to install the Retaining Ring (13) on top of the
washer.
12. Using an arbor press, press the inner diameter of the rear Bearing
(14) onto the Input Spindle Assembly (11).
13. Insert pin end of Input Spindle Assembly (11) into the Spring (10).
14. Align the input spindle assembly with the spline of the coupler and
insert input spindle assembly into the Housing (3).
15. Insert Bearing (14) into housing and use snap ring pliers to then
install the Retaining Ring (15) into the back of the housing.
16. Slide Plate Spacer (16) over the back of the housing.
Gear Case Assembly
1. Ensure that all the gears are free of debris.
2. Apply 1 cc of IR #222 grease into the ring gear. Work 2.5 cc into the
first stage gears in the Gear Head Assembly (24) along with the
spaces between. Work 2.5 cc into the second stage gears in the
Spindle Assembly (18) along with spaces between.
35 Nm Model
1. Using snap ring pliers, insert retaining ring into groove in front of gear
case.
2. Insert spacer, spindle assembly, spacer, gear head assembly, and
spacer into gear case.
3. Using snap ring pliers to insert the Retaining Ring (26) into the inner
groove.
55 and 90 Nm Model
1. Insert the Spindle Assembly (18) into the Gear case (20).
2. Insert the Bearing (22), flange side out, into the opposite end of the
Gear Case (20).
3. Press the Spindle Assembly (18) into the bearing to secure it into
place.
4. Insert the Spacer (23) followed by the Gear Head Assembly (24)
followed by another Spacer (23).
5. Use snap ring pliers to insert the Retaining Ring (26) into the inner
groove.
Assembly of Electronics Pod
1. Carefully slide Housing (29) over the motor and transducer cables
until all of the connectors emerge from the opposite end.
2. Insert the green yellow ground wire back into the Housing (29), push
through designated hole, and fasten in place with the M3 Screw (30).
3. Connect the motor temperature sensor connector, motor
communication connector, and the torque transducer connector to
the Communication Board (32).
4. Engage female socket on the communication board to the male
connector on the motor cable.
5. Center wires and carefully slide the communication board into the
Housing (29) along grooves with the connectors facing 180° from
ground connection.
6. Press the Clip (33) into place in the inner grove in the housing to
retain the communication board.
7. Fill ground slot (A) with Lexel clear sealant or equivalent until flush
with outer surface of the slot. Slot must be water tight when the
sealant dries.
8. Screw the strain relief into the back of the housing and tighten the
grommet in place to restrain the transducer and motor cable.
9. Slide the Flange (34) over the housing and retain in place with the
Nut (36).
10. Place the Memory Chip Assembly (31) into the slot in the Housing
(29) with the metal tabs exposed and facing the rear of the housing.
11. Push two O-Rings (37) into groove around the memory chip
assembly to hold it in place.
12. Slide the Cover (38) onto the housing and retain in place with M3
Screw (30).
Refer to Recommended Fixture Plate dimensions table on page 4

4Form 04581369-Edition 2
Mounting Options
(Dwg. 80149735) (Dwg. 80150675)
There are two options for mounting tools.
1) When fixture is between Spindle and Transducer (Y), remove and
discard Spacer Plate (Z).
Note: Fixture Plate (X) must maintain thickness of Spacer Plate (Z).
2) When Fixture Plate (X) is in front of Spindle Flange, Spacer Plate (Z)
thickness may be ignored:
Note: M8 or M10 mounting screws must be lengthened by Fixture Plate
(X) thickness.
Recommended Fixture Plate Dimensions
QM Series Wiring (Cable) Chart
XYXZ
Y
Series
Plate
Thickness
Minimum
Counter-
bore Ø
Bolt
Circle Ø Number of
Bolt Holes
Bolt Hole
ØSupplied
Bolt Size
Through
Hole Ø Through
Hole ID
Chamfer
(mm) (mm) (mm) (mm) (mm)
QM3 10 59 45 2 8.97 - 8.71 M8x1.25x30 31.015 -30.985 0.5 x 45°
QM5 11.2 67 50 2 8.97 - 8.71 M10x1.5x35 32.515 -32.485 1.05 x 45°
QM7 11.2 71 57.16 6 8.97 - 8.71 M8x1.25x30 44.48 - 44.45 1.05 x 45°
QM9 18 90 76.2 6 10.63 - 10.37 M8x1.25x45 63.53 - 63.5 1.55 x 45°
Electronics
Pod N/A N/A 60 2 6.65 - 6.05 M6x1x18 39.0 - 50.0 N/A
Connector Pin Wire color (Cable) Logic Connector Pin
ARedVCC 13
BBlackCOM 14
C Gray Spare 1 12
DPinkSpare2 27
E Brown Spare 4 15
FYellowSine 21
G Orange Cosine 28
HVioletSpare3 7
J Green Ground Sense 20
KBlueRX+ 5
L Blue/White RX- 6
MWhiteTX- 8
N White/Blue TX+ 9
U Red Motor Phase B 23
V Black Motor Phase C 34
W White Motor Phase A 36
X Green/Yellow Ground 25
---- ---- TX Shield 1
---- ---- RX Shield 4
---- ---- Hall Shield 22
---- ---- Motor Shield 16

Form 04581369-Edition 2 5
Notes

6Form 04581369-Edition 2
Notes

Form 04581369-Edition 2 7
Notes

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