Quackenbush 230QGDAB Series Installation and operating instructions

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Operation & Service Manual
823213
08/19/2011
230QGDAB Series
Positive Feed Drills
Models:
230QGDAB-B-SU-MS
230QGDABV-B-SU-MS

2
!
Do not wear loose fitting clothes,
long hair, gloves, ties or jewelry.
WARNING
• Quackenbush drills are designed to operate on 90psig (6.2 bar) air
pressure. Excessive air pressure can increase the loads and
stresses on tool parts and drills, and may result in breakage. The
installation of a filter-regulator-lubricator in the air supply line is
highly recommended.
• Before removing a tool from service or changing drill bits, make sure
the air line is shut off and drained of air. This will prevent the tool
from operating if the throttle is accidently engaged.
• Cutting tools used with these Quackenbush drill motors are sharp.
Handle them carefully to avoid injury.
Before mounting any positive feed drill, check the lock screws in the
tooling fixture and drill bushing. Make sure both are in good condition
and securely tightened.
Positive feed drills can exert high torques and high thrust loads. If
failure of the lock screws or drill bushing occurs, the drill may
suddenly spin and back away from the drill fixture.
Warning Labels
The warning labels found on these tools are an essential part of this
product. Labels should not be removed. Labels should be checked
periodically for legibility. Replace warning labels when missing or
when the information can no longer be read. Replacement labels can
be ordered from the manufacturer.
For your safety and the safety of others, read and understand
the safety recommendations and operating instructions.
Always wear protective equipment:
For additional information on eye and face protection, refer to
Federal OSHA Regulations, 29 Code of Federal Regulations, Sec-
tion 1910.133., Eye and Face Protection, and American National
Standards Institute, ANSI Z87.1, Occupational and Educational Eye
and Face Protection. Z87.1 is available from the American National
Standards Institute, Inc., 11 West 42nd Street, New York, NY 10036.
Hearing protection is recommended in high noise areas, 85 dBA or
greater. The operation of other tools and equipment in the area,
reflective surfaces, process noises and resonant structures can
substantially contribute to and increase the noise level in the area.
For additional information on hearing protection, refer to Federal
OSHA Regulations, 29 Code of Federal Regulations, Section 1910.95,
Occupational Noise Exposure, and American National Standards
Institute, ANSI S12.6, Hearing Protectors.
Follow good machine shop
practices. Rotating shafts and
moving components entangle
and entrap, and may result in
serious injuries. Never wear
long hair, loose-fitting clothes,
gloves, ties, or jewelry when
working with or near a drill of
any type.
Safety Recommendations
CAUTION!
CAUTION!
CAUTION!
Personal hearing protection is
recommended when operating
or working near this tool.
WARNING!
Impact resistant eye protection
must be worn while operating
or working near this tool.
Tool Nose
Standard Threaded
Drill Bushing
Lock Screws
Tooling Fixture
•Wear impact resistant eye protection. •Hearing protection is recommended. •Avoid contact with rotating spindle or cutter. •Wear respirator as necessary. •Exposure to repetitive work motion and/or vibration can injure your hands
WARNING
!
and arms.
203246
CAUTION
!
382788
DO NOT ENGAGE RAPID ADVANCE AND GREEN "DRILL" BUTTON AT SAME TIME. To rapid advance the drill, rotate rapid advance lever clockwise. To stop rapid advance, release rapid advance lever. To begin drilling cycle, push the green "DRILL" button. To stop the drill before the completion of the drilling cycle, push the red "STOP" button.
CAUTION
!
203245
Read operating instructions before using tool.
382788
COMPLETE LABEL
KIT - 641028
203245
203246

3
The spindle on right angle positive feed drills retracts at a much faster
rate than it feeds. Care should be taken to avoid entrapment. Nose
pieces usually used with these drills are generally slotted for visibility
and access to chuck, cutter, and retract stop adjustments. A spindle
guard should be used when operating tool. Spindle guards in one
inch increments are available to accommodate any length spindle.
Slotted spindle guards are available for tools with fluid swivels.
Drilling or other use of this tool may produce hazardous fumes and/
or dust. To avoid adverse health effects utilize adequate ventilation
and/or a respirator. Read the material safety data sheet for any
cutting fluids or materials involved in the drilling process.
• Most dusts are combustible. See material safety data sheets for
combustibility of a specific dust.
• Non ferrous metal dusts are particularly hazardous.
Examples: Aluminum, Magnesium, Titanium, Zirconium
(Never collect Magnesium in a dry dust collector)
• Never collect spark generating material in the same dust collector
with combustible material.
Examples: Collecting both steel and Aluminum dust or Steel and
Titanium dust.
• Never use flammable finishing lubricants.
Safety Recommendations
Some individuals are susceptible to disorders of the hands and arms
when exposed to tasks which involve repetitive work motions. Those
individuals predisposed to vasculatory or circulatory problems may
be particularly susceptible. Cumulative trauma disorders such as
carpal tunnel syndrome and tendinitis can be caused or aggravated
by repetitious, forceful exertions of the hands and arms. These
disorders develop gradually over periods of weeks, months, and
years.
• Tasks should be performed in such a manner that the wrists
are maintained in a neutral position, which is not flexed,
hyperextended, or turned side to side.
• Stressful postures should be avoided and can be controlled
through tool selection and work location.
Any tool operator should be aware of the following warning signs and
symptoms so that a problem can be addressed before it becomes a
debilitating injury. Any user suffering prolonged symptoms of tin-
gling, numbness, blanching of fingers, clumsiness or weakened grip,
nocturnal pain in the hand, or any other disorder of the shoulders,
arms, wrists, or fingers is advised to consult a physician. If it is
determined that the symptoms are job related or aggravated by
movements and postures dictated by the job design, it may be
necessary for the employer to take steps to prevent further occur-
rences. These steps might include, but are not limited to, reposition-
ing the workpiece or redesigning the workstation, reassigning work-
ers to other jobs, rotating jobs, changing work pace, and/or changing
the type of tool used to minimize stress on the operator. Some tasks
may require more than one type of tool to obtain the optimum
operator/tool/task relationship.
The following recommendations will help reduce or moderate the
effects of repetitive work motions. The operator of any drill should:
• Use a minimum hand grip force consistent with proper control
and safe operation
• Keep body and hands warm and dry
• Avoid anything that inhibits blood circulation
— Smoking Tobacco
— Cold Temperatures
— Certain Drugs
• Avoid awkward postures
• Keep wrists as straight as possible
• Interrupt work activities, or rotate jobs to provide periods free from
repetitive work motions.
WARNING
!
Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation
Avoid Avoid Avoid OK Avoid OK
WARNING
!
Wear respirator where
necessary.
CAUTION!
Keep fingers and hands away
from this area when handling
or operating tool.
WARNING
!

4
MAJOR TOOL CONTROLS
1 Emergency Stop Button
2 Rapid Advance Lever
3 Exhaust Deflector
4 Drill Button
5 Manual Retract Lever
6 Adjustable Depth Stop
7 Retract Stop Collar
8 Signal Valve
9 Throttle Piston
10 Rear Spindle Guard
11 Variable Speed Control
AIR SUPPLY
AIR PRESSURE, HOSES, AND COUPLINGS:
This tool is designed to operate at 81dbA on 90-110 psig (6.2-
7.6 bars) supply pressure using a 1/2" hose up to 20 ft. in
length. If additional hose is needed, a 5/8" or larger diameter
hose should be connected to the 1/2" in. hose. Quick discon-
nect couplings (if used) should have flow capacity ratings
exceeding 60 SCFM.
LOW PRESSURE:
This drill will shut-off automatically (while drilling or when
retract begins) if the pressure at the tool inlet drops below
65 psig (4.5 bars). Manual restart is required. The drill will not
continue to run when the green drill button is released if the
pressure at the tool inlet is low.
HIGH PRESSURE:
This drill shuts off automatically at the end of the retract cycle.
If the pressure at the tool inlet is over 115 psig (7.9 bars) the
tool may continue to retract, jamming the retract stop collar into
the housing cover causing the tool to either stall or shear the
shear pin.
MAJOR TOOL CONTROLS
10
6
7
8
91
11 2
4
3
5

5
OPERATING INSTRUCTIONS
If the tool has been shipped recently, been in storage, or
repaired, or disassembled; it should be run (without spindle)
through a "tool crib check" of functions.
EMERGENCY STOP—Depressing the red emergency stop
button 1will stop the tool, except when the rapid advance mode
is being utilized. Releasing the rapid advance lever 2will stop
the tool.
RAPID ADVANCE—Depressing the rapid advance lever 2will
advance the cutting tool to the work surface faster than the
regular feed rate and stops advancing forward automatically
until the green drill button 4is depressed. Note: When the rapid
advance lever is depressed, the exhaust deflector 3will move
forward (toward the head) approximately 3/8" and return to its
original position when the lever is released.
DRILLING—Press the green drill button 4firmly and release
it to start the drilling cycle. The cutter will feed to a predeter-
mined depth, dwell, and then retract. The drill motor will shut
off automatically at the end of the retract stroke. The cutter may
be manually retracted at any time by raising the retract lever 5.
IMPORTANT: The spindle retracts at a much faster rate than
it feeds. Care should be taken to avoid entrapment.
Do not hold the drill button down during the end of the retract
stroke—this prevents "motor stop".
DEPTH ADJUSTMENT:
DEPTH COLLAR—Has four (4) holes for adjusting depth in
increments of .005". Going from one hole to the next and using
the same slot in the spindle will either increase (clockwise) or
decrease (counterclockwise) the depth by .005". Using the
same hole and rotating the collar 90° will give an adjustment of
.020" and 360° will give an adjustment of .080". Tighten lock
screw after each depth adjustment. Tip of lock screw must go
into a spindle slot. IMPORTANT NOTE: To insure maximum
repeatability, the work surface, fixtures, and depth stop must
be cleared of any chips or foreign material before beginning the
next hole. Always replace the rear spindle guard after making
a depth adjustment.
TOOL CRIB CHECK
1. With air supply shut off, remove rear spindle guard.
2. Remove depth stop 6(left hand threads).
WARNING: Keep hands and clothing clear of rotating spindle,
turn air supply on and use rapid advance to remove spindle.
3. Shut off air supply pressure.
4. Depress 5/16" diameter steel end of throttle piston 9. The
throttle piston must spring return quickly when released.
5. With air supply on, move rapid advance lever 2all the way.
Motor runs and spindle feed gear (threaded I.D.) must not
rotate. Spindle drive gear (splined l.D.) rotates. Shear pin
is whole and intact.
6. Release rapid advance lever 2and press green drill button
4all the way in. Motor starts. Release drill button 4. Motor
continues to run. Both gears (splined and threaded) rotate.
7. Lift manual retract lever 5and release. An audible "snap"
indicates the retract valve 382333 is shifting as desired.
Spindle feed gear (threaded l.D.) stops rotating.
8. Depress signal valve 8with screwdriver and release.
Motor stops and retract valve 382333 must reset (manual
retract lever 5should drop). Depress red stop button 1
slowly. There should be no venting of air as the stop button
1is depressed.
9. The lift arm assembly 382665 must be intact, undamaged,
and in place in the upper block. The lift arm assembly is
factory adjusted (new tool) for little or no play.
10. Press green drill button 4and release. Motor starts. Press
stop button 1. Motor stops. Do not proceed with test if
steps 1 through 10 indicate malfunction.
11. WARNING: Keep hands and clothing clear of rotating
spindle. Using tool 382593, install spindle (with retract
stop collar 7locked in place). The spindle will retract fully
into the head and the motor will stop automatically. The
retract valve 382333 must reset (manual retract lever 5
should drop) and there should be no venting of air when
the stop button 1is depressed.
12. Screw depth stop 6(left hand threads) onto the rear end
of the spindle and lock in place. Rapid advance until depth
stop 6bears against back of drill head. Rapid advance
clutch will "chatter". Manual retract lever 5must not rise as
clutch "chatters". Release rapid advance lever.
13. Depress green drill button 4and release. Motor starts.
Retract lever 5rises and spindle retracts automatically to
full retract position. Motor will stop automatically.
14. Replace rear spindle guard.

6
INSTALLING A SPINDLE:
Run a "Tool Crib Check" (page 5)
Important: Retract stop collar 2382579 must be in place and
locked on the spindle. Install the spindle in the spindle drive
gear 617200 and use spindle "in & out" tool 382593 to push the
spindle "in". Depress the green drill button to start the motor
and raise the manual retract lever 5. The spindle will retract.
Release the drill button. The spindle will continue to retract until
the retract stop collar 7depresses the signal valve 8and the
tool will automatically shut off. Note: When the retract stop
collar 7is near or touching the signal valve 8; Do not press the
green drill button 4; as this will prevent tool shutoff and jam the
spindle into the head.
CHANGING FEED GEARS—Remove (left hand threads) the
adjustable depth stop 6from the rear of the spindle. Using the
spindle "in & out" tool 382593 to support the front of the spindle,
depress the rapid advance lever 2and feed the spindle forward
until the spindle feeds itself out of the spindle feed gear.
Release the rapid advance lever, shut off the air supply, and
pull the spindle out of the spindle drive gear. Remove the side
hose assembly. Unscrew and remove one (1) 6-32 x 1 (7164"
hex) socket head cap screw 382539 and two (2) 1/4-20 x 2-
1/4 (3/16" hex) socket head cap screws 867839 Note: Clamp-
ing the tool in a vise will make removal of the screws more
convenient. Insert finger in spindle feed gear to prevent the
eighteen (18) 7/32" balls 842160 from being lost when remov-
ing upper block assembly and spindle feed gear. Remove
differential feed gear. Remove gear holder 382557. Refer to
the feed chart on assembly drawing for the appropriate feed
gears. The feed gears are marked with the number of teeth
each one has— example 33T (thirty three teeth). After install-
ing the replacement gears, be sure that gear holder 382557 is
aligned and in place. The right angle head should be securely
clamped in the vise and compressed so that the two (2) cap
screws 867839 and cap screw 382539 can be firmly tightened.
SHEAR PIN MAY SHEAR BECAUSE:
1. Motor doesn't stop at full retract, or the retract valve did not
reset. Retract collar 7jams into housing cover 382582 or
382591. Pin shears.
2. Packed chips or dull cutter may overload the spindle. Feed
rate may be too high. Drilling or reaming may be beyond the
torque capability of this right angle drill. Pin shears.
3. Improper adjustment of lift arm assembly may prevent
automatic retract when the depth stop 6contacts the drill
head. If this occurs possible damage to gears and shearing
of pin will result.
4. Gear teeth have broken, spindle threads have been dam-
aged, or parts inside the drill head have failed.
DOES NOT REQUIRE DISASSEMBLY:
1. Does not require disassembly of drill head, spindle may be
freed in this manner:
A. Turn off air supply.
B. Remove tool from drilling fixture.
C. Rotate spindle with wrench (CCW from rear). . .
opposite drilling direction 2 or 3 turns. This will
require high torque.
D. When spindle is free, replace shear pin. Leave the
pin guard in place. Supply air pressure and rapid
advance the spindle out of the drill head.
E. Correct malfunction and run "Tool Crib Check".
2. Turn off air supply.
A. Remove tool from drilling fixture.
B. Correct torque overload problem.
C. Replace shear pin.
D. Make sure the pin guard is in good condition and
in place.
E. Return tool to service.
3 and 4 require disassembly, cleaning, inspection, and re-
placement of damaged parts inside the drill head. All parts
inside the drill head should be washed and re-greased. When
cause of malfunction is corrected, run "Tool Crib Check" (page
5).
SHEAR PIN INSTALLATION AND REMOVAL
CHANGING RAPID ADVANCE CLUTCH SPRING: Unscrew
and remove the clutch cover 382537. Drive the shear pin out
of the driven gear 629046 and clutch shaft 382525. Remove
clutch assembly from right angle head. Clamp the clutch
assembly in the vise to remove the spring load before driving
the roll pin 415019 out of the lower clutch jaw 382535. Remove
from the vise and slip the clutch shaft 382525 out of the pinion
and clutch hub 382526.
CHANGING THRUST PACKAGE: Remove the upper block
assembly following the instructions for changing feed gears
(place finger into the spindle feed gear to keep the eighteen
(18) balls from falling out). Remove the feed gear and eighteen
(18) balls. Clamp the spring case 382663 and upper block
assembly in the vise to compress the thrust package. Use a
7/32" hex wrench to remove the two (2) 1 0-32 x 1/4" set screws
382637. Remove the assembly from the vise and slip the
spring case and thrust package out of the upper block.

7
REASSEMBLY:
Turn the two (2) set screws 382637 in until the tips are nearly
flush with the bore (must clear spring case). Place one bead of
thread locking liquid on outer thread of each set screw. Using
a vise (or similar device), align the spring case (with Belleville
washers inside) and compress somewhat, until the 5/32" dia.
spotface is in the position shown. Tighten each set screw 1 &
1/2 turns, and remove from vise. Set screws should retain
spring case; but allow spring stack to compress and "spring
back".
Note: Milled slot on top rim of spring case must be visible thru
cast window in the upper block.
Note: Spring washers must be stacked exactly as shown. A
spacer may be included in the spring stack and must be
installed under the bottom washer against the spring case.
Align the bore of the spring washers to clear the 7/8" O.D. of
the spindle.
LUBRICATION:
An automatic in-line filter-lubricator is highly recommended.
This will supply the tool with clean, lubricated air; keep it in
sustained operation; and increase tool life.
The in-line lubricator should be regularly checked and filled
with a good grade of 10W machine oil. In the event an in-line
lubricator is not used, the tool should be disconnected from the
air supply several times daily and several drops of oil poured
into the tool's air inlet bushing.
The right angle drill head should receive a generous amount of
"Lubriplate #907" grease every fifteen (15) to twenty-five (25)
hours of "actual motor running" time through the two (2) flush
type grease fittings in the right angle housing. "Lubriplate
#907" may be purchased in a 5 gallon can using Part No.
107210.
GENERAL MAINTENANCE:
Tool Maintenance and Pressure Test Equipment Kit 381273
is available and can be used for some trouble shooting.
Air control system filter 382505 located in the handle 382480
should be replaced every 2000 drilling cycles or when low air
control system pressure is suspected.
Spindle threads should be blown clean and lubricated every
100 drilling cycles.
DISASSEMBLY—DRILL HEAD:
Remove the side hose assembly. Clamp the drill head in vise
and loosen lockring 619421. Unscrew and remove power unit.
Remove shear pin. Unscrew one (1) 6-32 x 1 (7/64" hex)
socket head cap screw 382539 and two (2) 1/4-20 x 2 1/4
(3/6" hex) socket head screws 867839. Clamp drill head in
upright position in vise. Insert finger in spindle feed gear to
prevent the eighteen (18) 7/32" balls 842160 from being lost
when removing upper block assembly. Remove upper block
assembly. Remove gear holder 382557. Unscrew the two (2)
1/4-20 x 7/8 (3/1 6" hex) socket head cap screws 865123 and
remove the housing cover 382582 or 382591. Gears will come
out with housing cover.
DISASSEMBLY—GEAR TRAIN:
SINGLE REDUCTION—Unscrew and remove the lock ring
619421. Clamp the flats of the internal gear case 382590 in the
vise and unscrew the motor housing 382509. Remove the
spider assembly from the gear case. Remove the rear ball
bearing 613281. Remove the three (3) idler gear pins and
gears. Hold a large hex wrench or similar tool on the side of the
spider and clamp in the vise. Heat the spider and pinion to
approximately 300°F. Insert a suitable pin thru the hole in the
pinion 629045 and unscrew the pinion. Use Tool Maintenance
and Pressure Test Equipment Kit 381273 for easier disassem-
bly.
DOUBLE REDUCTION—Unscrew and remove the lock ring
619421. Clamp the flats of the internal gear case 382590 in the
vise and unscrew the motor housing 382509. Unscrew and
remove the internal gear and housing 617369. Remove the
rear ball bearing 613281 from both spiders. Remove the six (6)
idler gear pins and gears. Hold a large hex wrench or similar
tool on the side of the second reduction spider and clamp in the
vise. Heat the spider and pinion to approximately 300°F. Insert
a suitable pin thru the hole in the pinion 629045 and unscrew
the pinion. Use Tool Maintenance and Pressure Test Equip-
ment Kit 381273 for easier disassembly.
FOR VARIABLE SPEED TOOLS,
SEE PAGES 10 AND 11

8
DISASSEMBLY—MOTOR UNIT:
Clamp the handle in a vise with the motor housing upwards.
Unscrew both the motor housing 382509 and the turnbuckle
collar 382508 in unison from the handle. Tap motor and motor
housing on wooden bench top to remove motor unit. Hold
either the pinion gear 617609 or rotor nut 382522 and unscrew
(left hand threads) the governor assembly. Remove the rear
bearing 864522, bearing plate 867369, cylinder 867377, and
three (3) rotor blades 382520. Note: Check the function of the
rotor blade kickout pins at this time. Blades should stick out
approximately 1/8". If required, the spring cap 382514 must be
drilled and tapped for removal. Clamp the body of the rotor in
the vise and unscrew the pinion 617609 or nut 382522.
Before disassembling the governor, note which "step" the
adjustment ring pin 867187 is "on" in the adjustment ring
867214. Depress the adjustment ring and remove the pin.
Remove the pin retainer 864532 and remove the two (2)
governor weight pins 867184.
DISASSEMBLY—MOTOR BACKHEAD
Important Note: Pressure cap 382507 must not be unscrewed
while the motor backhead is connected to air supply. This
cavity is supplied with high pressure air whenever the backhead
is connected to the air system. Remove pressure cap, spring
864681, ball 812156, and pin 847031. Rapid advance valve
382501 may be removed by unscrewing valve cap 382502 and
removing retainer ring 869460. The rapid advance lever 382503
may be removed by unscrewing (3/16" hex) the flat head cap
screw 382504.
DISASSEMBLY— HANDLE
Unscrew plug 864387 and remove drill button spring 622833.
Depress the drill button 382484 and use a 1/8" diameter rod to
unscrew button guard 382671.
Unscrew inlet bushing 867758 and remove spring 863072 and
throttle valve 202365.
Unscrew end cap 382668 and spring 382489. Push out throttle
piston 382677.
Screw a 1/4-20 cap screw into the metering seat 382491.
Clamp the cap screw in the vise and use a soft faced hammer
to drive the handle off.
Filter 382505 located in 13/32" dia. hole adjacent to the
metering seat should be checked and replaced if necessary.
The emergency stop button 381243 should not be removed
unless the O-ring 844301 needs replacing. Clamp the stop
button in the vise and use a soft faced hammer to drive the
handle off. Tap the bushing 202354 with a 1/4-20 thread.
Screw a 1/4-20 bolt in the vise. Drive the handle off.
Unscrew the check valve seat 382487 and remove O-ring
844302, 3/16" steel ball 842161 and check valve spring
382488. NOTE: Spring is very small.
FOR VARIABLE SPEED TOOLS,
SEE PAGES 10 AND 11
REASSEMBLY— GENERAL
The tool is reassembled in the reverse order of disassembly.
Clean all parts thoroughly in a solvent and inspect for damage
or wear. Check all bearings for wear which can be detected by
excessive end play and/or roughness which would indicate a
brinelled condition. Inspect and replace any O-ring that is
damaged or worn. Rotor blades should be replaced at every
repair cycle or if they measure less than 1/4" (6.35mm) at
either end. All gear teeth, bearings, and pins should receive a
close inspection and be replaced if necessary.
All gears and bearings in the planetary gear train should
receive a generous amount of NLGI 2-EP grease during
reassembly.
All gears and bearings in the right angle drill head should
receive a generous amount of "Lubriplate #907" grease during
reassembly.
Lubricate all O-rings during reassembly with 10W machine oil.
HANDLE REASSEMBLY:
Insert throttle piston 382677 (with O-rings) into throttle piston
cylinder 382676. Replace spring 382489 and end cap 382668.
Rotate the throttle piston 382677, to line up the slot for the
throttle valve 202365. Replace spring 863072, O-ring, and
inlet bushing 867758. If the screen in the inlet bushing is torn
or clogged, replace the inlet bushing.
Insert spring 382489, O-ring 844307, and latch piston 382490,
into handle. Line up the air ports in the metering seat 382491,
and handle 382480, and tap the metering seat into the handle
until the shoulder on the seat is flush with the surface of the
handle. Use a 1/4-20 bolt to tap or press the metering seat.
Install the drill button and shaft assembly 381171, using a
thread retaining compound. Install the drill button spring 622833
and plug 864387 with O-ring.
Press the stop button assembly 381243, into the handle until
the shoulder on the bushing is flush with the handle.

9
When installing the check valve assembly, the spring 382488,
should be installed with the small coil up. Use a slender rod.
Place the 3/16" steel ball 842161, on the small coil and the O-
ring 844302, on the top of the ball. Install the check valve seat
382487, and O-ring 844303, and tighten firmly.
MOTOR BACKHEAD REASSEMBLY:
Install rapid advance valve 382501, muffler plate 382506, and
retainer ring 869460. Put on muffler 869850, exhaust deflector
869844, and valve cap 382502. Fit rapid advance lever 382503,
into detents and tighten flat head screw 382502, tight.
Place 9/32" steel ball 812156 in 25/64" dia. hole and rap with
a soft metal punch to form aluminum seat. Be certain that pin
847031 moves freely in hole. Install pin, ball, spring 864681,
and pressure cap 382507.
FOR VARIABLE SPEED TOOLS,
SEE PAGES 10 AND 11
MOTOR AND GOVERNOR REASSEMBLY:
Assemble governor and pin retainer 864532. Seat the front
rotor bearing 842870, in the front bearing plate 382521, and
support the bearing on its outer race. Measure from the face
of the bearing plate to the bearing inner race. Select or fit by
sanding a rotor collar .002" longer than this measurement.
Install the rotor collar (chamfered side first) and bearing plate
assembly on the rotor. Tighten rotor pinion 617609, or rotor nut
382522, to approximately 35 ft. Ibs. (47.5 Nm). When installing
the rotor blades 382520, be certain that the rotor blade kick-out
pins are working. Assemble the three (3) rotor blades, cylinder
867377, rear bearing plate 867369, rear bearing 864522, and
governor assembly. Be certain pin retainer 864532, is in place.
Tighten (left hand threads) the governor assembly or rear rotor
nut 382523, almost as tight as the pinion gear or front rotor nut.
FOR VARIABLE SPEED TOOLS,
SEE PAGES 10 AND 11
MOTOR HOUSING AND RUNNING MOTOR:
Work the motor unit into the housing and clamp the housing in
the vise with the governor assembly up.
Work the muffler element 382517, into the exhaust deflector
382516. Assemble the O-ring 864589, onto the turnbuckle
collar 382508. Place spring 619394, on motor housing 382509,
and work the exhaust deflector on, compressing the spring.
Screw (left hand threads) the turnbuckle collar on until the
3/32" dia. hole in the front of the exhaust deflector is half
covered.
Screw the motor backhead onto the motor housing (prevent
turnbuckle rotation), clamping the motor unit securely. Use two
(2) 1/4-20 cap screws and wooden hammer handle to tighten
the motor backhead.
Install gasket 382492, and handle 382480, on the backhead,
16 ft. Ibs. (21.7 Nm) minimum. Be sure to include filter 382505.
Temporarily plug the 1/8 NPT port in the motor backhead with
a pipe plug.
Invert unit and clamp in vise on the handle flats with motor gear
up.
NOTE: The exhaust deflector moves forward approximately
3/8" when rapid advance lever is depressed.
Apply 90 PSI air to the inlet bushing. Do not press drill button.
Operate the rapid advance lever and release, several times.
The 9/32" dia. steel ball should seat without leakage, and there
should be little or no slack in the lever. Pin 847031 may require
hand grinding to proper length. Make certain the air supply is
shut off and drained before removing pressure cap 382507. If
the pin is too short, get a new pin and resize. Tighten pressure
cap securely.
It does not matter whether the rotor has been turning or not; but
the following method should get the motor running with the
least chance of rubbing.
Place wrenches on the motor housing hex and the turnbuckle
collar flats rotating them together to loosen the threaded joint
between the turnbuckle collar and the motor backhead 1/4
turn.
Put a few drops of 10W machine oil into the inlet bushing and
apply 90 PSI air pressure to the motor unit. Press the drill
button. The motor should run forward at governed speed. Then
using both wrenches, tighten the motor housing and the
turnbuckle collar in unison to securely clamp the motor unit.
Adjust governed speed when needed by removing the motor
backhead and rotating the governor adjusting ring 867214.
Rotate clockwise to decrease the R.P.M. and counterclock-
wise to increase the R.P.M. setting.

10
Reverse rotation (rapid advance lever depressed) should be
5,700 R.P.M. minimum.
Desired forward rotor speeds (R.P.M.)
Drill Spindle
R.P.M.
75
100
120
150
190
240
310
390
480
585
660
825
960
1165
1,500
VARIABLE SPEED TOOLS
For disassembly of drill head and gear trains, see page 7 & 8.
DISASSEMBLY—VARIABLE SPEED MOTOR AND
GOVERNOR UNIT
Clamp handle in vise with motor housing upwards. Unscrew
both motor housing 382509 and turnbuckle collar 382508 in
unison from handle. Keep governor center 382619, shims, and
bearing 847095 together as a unit. Replace this bearing if it is
damaged.
CAUTION: Do not lose these shims. The same shims must be
used for reassembly.
Tap motor and motor housing on wooden bench top to remove
motor unit. Hold either the pinion gear 617609 or rotor nut
382522 and unscrew (left hand threads) governor assembly.
Remove rear bearing 864522, bearing plate 867369, cylinder
867377 and three (3) rotor blades 382520. Note: Check
function of rotor blade kick-out approximately 1/ 8". If required,
the spring cap 382514 must be drilled and tapped for removal.
Clamp body of the rotor in vise and unscrew pinion 617609 or
nut 382522. To remove governor weights from spider, press
governor weight pins 867184 out.
DISASSEMBLY—VARIABLE SPEED MOTOR BACKHEAD
WARNING: Pressure cap 382507 must not be unscrewed
while the motor backhead is connected to air supply. This
cavity is supplied with high pressure air whenever the backhead
is connected to the air system.
Remove pressure cap, spring 864681, ball 812156, and pin
847031. Rapid advance valve 382501 may be removed by
unscrewing valve cap 382502 and removing retainer ring
869460. The rapid advance lever 382503 may be removed by
unscrewing (3/16" hex) flat head cap screw 382504. Remove
button head screw 844288. That will release the governor
valve 382618. Remove governor spring 382238, shims 202349,
auxiliary spring cap 382264, spring 382271 (inside cap) and
guide stud 382620. Caution: Do not lose those shims. The
same shims must be used for reassembly. Remove set screw
382512 and speed cam. Remove detent pad 382627, set
screw 867502, and spring 512275 for inspection.
DISASSEMBLY—HANDLE Same as on page 8.
REASSEMBLY—GENERAL Same as on page 8.
REASSEMBLY—HANDLE Same as on page 8.
REASSEMBLY—VARIABLE SPEED MOTOR BACKHEAD
Install rapid advance valve and related parts (same as single
speed tool). Lubricate O-ring 844307 on speed cam. As-
semble spring 512275, set screw 867502, and detent pad
382627 onto backhead. Install speed cam and lock set screw
382512. Install governor parts in reverse order of disassembly
and secure with button head screw.
REASSEMBLY—VARIABLE SPEED MOTOR AND
GOVERNOR
Assemble governor weights 867189, pins 867184, and spider
382621. Seat front rotor bearing 842870, in front bearing plate
382521, and support bearing on its outer race. Measure from
face of the bearing plate to bearing inner race. Select or fit by
sanding a rotor collar .002" longer than this measurement.
Install rotor collar (chamfered side first) and bearing plate
assembly on rotor. Tighten rotor pinion 617609, or rotor nut
382522, to approximately 35 ft. Ibs. (47.4 Nm). When installing
the rotor blades 382520, be certain that the rotor blade kickout
pins are working. Assemble the three (3) rotor blades, cylinder
867377, rear bearing plate 867369, rear bearing 864522, and
governor assembly. Tighten (left hand threads) governor
assembly almost as tight as pinion gear or front rotor nut.
VARIABLE SPEED MOTOR HOUSING AND
RUNNING MOTOR
Work the motor unit into the housing and clamp the housing
into a vise with the governor assembly upward. Assemble the
governor center 382619, shims, and bearing 847095, with the
governor weights leaning inward.
Set the speed adjustment to one of these settings:
125 RPM
240 RPM
480 RPM
900 RPM
Rotor Speed
R.P.M.
5,800 -
7,200 -
8,870 -
11,300 -
7,100 -
8,900 -
11,100 -
6,900 -
8,600 -
10,200 -
11,600 -
7,400 -
8,600 -
10.200 -
13,000 Min.
6,200
7,760
9,400
12,100
7,500
9,350
12,200
7,450
9,100
11,100
12,400
7,900
9,130
11,100
(190V)
(375V)
(780V)
(1500V)

11
REASSEMBLY—MOTOR HOUSING AND
RUNNING MOTOR
Same as on page 9 & 10.
DESIRED FORWARD ROTOR SPEED
At the selected speed setting (80, 160, 320, or 650) the rotor
speed should be 8200 - 9700 RPM.
The motor speed should change smoothly as the speed is
adjusted step by step.
Reverse rotation (rapid advance lever depressed) should be
5,700 RPM minimum.
IF SHIMS ARE LOST, OR IF ROTOR SPEED IS IMPROPER
Remove motor unit and clamp in vise with the governor
assembly upward and the governor weights leaning inward.
Add or adjust shims 864732 and 869562 to provide this
clearance:
Reassemble and run motor. If the desired forward rotor speed
is still not acceptable (8200 - 9700 RPM); disassemble motor
backhead and add shims 203349 under governor spring
382238 to increase speed, or remove shims to decrease
speed.
Continue reassembly same as single speed tools
FINAL REDUCTION ASSEMBLY:
Reassemble in the reverse order of disassembly. Grease all
parts with a good grade of NLGI 2-EP grease. Install the
washer and ball bearing 864471 on the front of the output
spider. Clean the threads on the spider and pinion gear
382461. Hold a large hex wrench or similar tool on the side of
the spider and clamp in the vise. Apply a thread locking liquid
to the threads and screw the pinion into the spider (tighten to
approximately 60 ft. Ibs.—81.4Nm). Use Tool Maintenance Kit
for easier assembly.
HEAD REASSEMBLY:
UPPER BLOCK: The retract valve must slide freely
(without O-ring) By its own weight inside the bore. Lubricate
and assemble O-ring 844306, retract valve 382333, spring
382540, and tighten valve cap 382331. Press (press on the
bearings stamped end) the needle bearing 617253, into the
rear of the gear stop 382547. The bearing should be flush with
face. Assemble O-ring 863009, on feed piston 382548 lubri-
cate and fit into bore. Piston should move with finger tip
pressure. Press the gear stop into bore. Apply a drop of thread
locking liquid on the two (2) screws 812667 and tighten them.
Screw the two (2) set screws, 382637 in until they are nearly
flush with the bore (must clear spring case). Place a drop of
thread locking liquid on the outer thread of each screw.
Assemble the thrust package as shown into the spring case.
Clamp the spring case and upper block in the vise, aligning the
spring case and compressing until the 5/32" dia. spotface is in
the position shown. Tighten each set screw 1 & 1/2 turns, and
remove from vise. The set screws should retain spring case;
but allow spring stack to compress and "spring back".
Note: Milled slot on top rim of spring case must be visible
through cast window in the upper block.
VISE
.001
.006

12
Note: Spring washers must be stacked exactly as shown. A
spacer may be included in the spring stack and must be
installed under the bottom washer against the spring case.
Align the bore of the spring washers to clear the 7/8" O.D. of
the spindle.
RAPID ADVANCE CLUTCH (OMIT SHEAR PIN)
Assemble the clutch spring, clutch shaft 632598 pinion and
clutch hub 382526, ball bearing 844966, upper clutch jaw
382536, lower clutch jaw 382535. Compress in vise and install
roll pin 415019. Remove from the vise and drive pin to central
position. Press bearing 812219 into cap 382537.
HOUSING COVER ASSEMBLY:
Place the retract piston 382550, two (2) O-rings 863009,
spring 864681, and cylinder plug 382552, into housing cover,
382582, or 382591 (lubricate with 10W oil) and install retainer
ring 619017. Use Tool Maintenance Kit (823170).
Press the idler gear shaft 617208 through the cover until the
shoulder is 13/16" above the surface of the cover. Install ball
bearing 617220 and spindle drive gear 617200 in the cover.
Place one (1) spacer 843390 on each of the two (2) gear shafts
on the cover. Press two (2) ball bearings 619019 on the idler
gear shaft 617208. Recheck the 13/16" dimension and reset if
necessary. Install retainer ring 619017 in idler gear 382527
and assemble over ball bearings. Install ball bearing 619377
and differential drive gear 382545. Install signal valve assem-
bly and tighten cap screw 863337.
Grease two (2) O-rings 844301 and place one (1) in machined
pocket in housing and the other in machined pocket in cover.
Use grease to hold gear spacer 613687 in place. Align one (1)
notch in spacer with pin in head. Place assembled housing
cover on housing and snug up two (2) cap screws 865123.
FINAL HEAD REASSEMBLY:
Place eighteen (18) balls 842160 in spring case 382663 with
grease.
NOTE: The eighteen (18) balls 842160 should be replaced if
there is any indication of roughness.
Place spindle feed gear inside balls and install in housing. Align
and install gear holder 382557.
IMPORTANT: The tang (hooked end) on the gear holder must
be installed in the head first and the tang should be between
the differential drive gear, 382545, and differential feed gear.
Place differential feed gear in housing. Grease two (2) O-rings
844301 and place in machined pockets in upper block, and
assemble upper block to housing. Clamp head in vise and
compress. Firmly tighten two (2) cap screws 867839 and one
(1) cap screw 382539 on the upper block and two (2) cap
screws 865123 on the housing cover. Insert clutch assembly,
shear pin, and install pin guard and clutch cover.
Install spring 843259, retract lever 382544, and fulcrum screw
382512 in the upper block. Assemble the lift arm assembly
382665, pivot plate 382667, and two (2) cap screws 612789 on
the upper block. Use a thread locking liquid on the threads of
the slack adjust screw 382666 and adjust the screw until the
lift arm touches (but does not lift) the retract lever 382544.
FINAL ASSEMBLY:
Assemble planetary gear cases (complete with all gears) onto
head and tighten securely using flats on motor housing 382509.
Place tool in vise with inlet bushing down and clamp vise jaws
on handle 382480 flats. Loosen turnbuckle 382508 and motor
housing in unison CCW 1/4 turn. By adjusting turnbuckle and
tightening (CW) flats on motor housing 382509 position head
in desired location and tighten (CW) flats on motor housing
securely
Remove 1/8" NPT pipe plug (installed temporarily) from the
motor backhead. Install right angle fitting 382664 pointing
forward when tight. Install side hose assembly 382674 (long)
or 382673 (short).

14
POSITIVE FEED DRILL GEAR TRAINS & MOTOR
585,660,190V & 780V
190,240,310,825,960
75,100,120,150,390,480
1165,1500 375V & 1500V
190- 310 & 375V
75- 150 & 190V
382590
613279
629045
613271
617305
617370
PART NO
613278
SECTION B-B
844966
(629061)
612050
617369
864471
613281
617370
619421
864471
190- 310 & 375V
75-150 & 190V
RPM
617305
PART NO
613280
RPM
613271
613279
613281
75-150 & 190V
190- 310 & 375V
PART NO
617367
617610
RPM
202076
202187
202188
382519
.131
.129
.130
1165,1500 375V & 1500V
390-660 & 780V
825-1500 & 1500V
75,100,120,150,390,480
585,660,190V & 780V
190,240,310,825,960
613279
613271
619421
629045
382590
382522
617609
PART NO
617305
RPM
613280
PART NO
613281
RPM
390-660 & 780V
825-1500 & 1500V
864471
617370
PART NO
613278
RPM
390-660 & 780V
825-1500 & 1500V
612050
613277
PART NO RPM
PART NO
865416
864493
865417
864492
847525
864490
WIDTH
PART NO
382518
.126
.127
.128
.125
.123
.124
RPM
382515
382513
382514
382606
382682
382509
619394
842870
382521
382520
867377
382516
120,240,480,960
382524
DCE
382492
F
382503
D
C
E
867357
NONE
ALL OTHERS
382493
PART NO RPM
1500382745
585,1165
1500
382491
H
G
382668
382676
382489
863009
867758
863072
382480
202365
844303
867732
PART NO
ALL OTHERS
RPM
867183
1500382523
PART NO
867164
867358
867189
867188
382517 VARIABLE SPEED ONLY
100,190,390,825
75
150,310,660
867186
RPM
382490
844307
F
864522
382508
867369
864589
864532
1000-None
867184
864522
867187
867185
867214
.005864732
.020869562
THK
PART NO
844303
382489
382677
HG
867189
382621
847095
382619

15
POSITIVE FEED DRILL VARIABLE SPEED GOVERNOR
382664
780V & 1500V
SECTION E-E
629209 629209 382394 629543
SECTION G-G
   
185V
390 & 1500
375V
869850 869844 382502
SECTION C-C
382506 869460 386135
382501
382504
382673
PART NO
*


75 & 310
RPM
SECTION D-D
847031 812156
864681
382380 382507
844303 864387
381171
382732
382671
869712
382670
382484
382622
BACKHEAD - VARIABLE SPEED
382271 382620 202349 382264 382512
844288 382618 382238 382627 867437
SECTION H-H
202354 844301 381243 386156
SECTION F-F
512275 867502
629109 629110 629108
PART NO
629107
780V
844307
1500V
375V
RPM-MAX.
190V
382505
842161
382487 844303 844302 382488

16
PART NO
202076
202187
202188
202349
202354
202365
381117
381171
381243
381266
382238
382264
382271
382331
N/A
382379
382380
382480
382484
382487
382488
382489
382490
382491
382492
382493
382501
382502
382503
382504
382505
382506
382507
382508
382509
382512
382513
382514
382515
382516
382517
382518
382519
382520
382521
382522
382523
382524
382525
382526
382527
382528
382529
382530
382531
382532
382533
382535
382536
382537
382539
382540
NAME OF PART
.129" ROTOR COLLAR
.130" ROTOR COLLAR
.131" ROTOR COLLAR
SHIM (V MODEL ONLY)
BUSHING
THROTTLE VALVE
SIGNAL VALVE ASSEMBLY (INCL.
386095,386131,386132, 869290
844301,8477768)
DRILL BUTTON AND SHAFT ASSEMBLY
(INCL. 382484, 382670,
382671, 2 O-RINGS 869712)
STOP BUTTON ASSEMBLY (INCL.
202354,386156,844301)
DEPTH STOP ASSEMBLY (INCL. 382669,
382678, 865206, 882083, 382576, 614364)
GOVERNOR SPRING (V MODEL ONLY)
AUXILIARY SPRING CAP (V MODEL ONLY)
SPRING (V MODEL ONLY)
VALVE CAP
RETRACT VALVE (included in 382680)
LOWER CLUTCH JAWS (OPT.)
PRESSURE CAP (WITH SPACERS)
(825, 960, 1165, 1500, 1500V)
HANDLE
DRILL BUTTON
CHECK VALVE SEAT
CHECK VALVE SPRING
SPRING
LATCH PISTON
METERING SEAT
GASKET
MOTOR BACKHEAD (INCL. 386135)
RAPID ADVANCE VALVE
RAPID ADVANCE VALVE CAP
RAPID ADVANCE LEVER
5/16"-18 X 1/2 FLAT HEAD CAP SCREW
FILTER
MUFFLER PLATE
PRESSURE CAP (825 AND BELOW)
TURNBUCKLE COLLAR
MOTOR HOUSING
FULCRUM SCREW (10-32)
(V MODEL REQ. 2)
FLYWEIGHT
SPRING CAP
BLADE SPRING
EXHAUST DEFLECTOR
MUFFLER
7T ROTOR (INCL. 382513, 382514,
382515)
THREADED ROTOR (INCL. 382513,
382514, 382515)
ROTOR BLADE
FRONT BEARING PLATE
ROTOR NUT
REAR NUT (1500 R.P.M. ONLY)***
1/4-20 X 2 SOCKET HEAD CAP SCREW
CLUTCH SHAFT
PINION (13T) AND CLUTCH HUB
IDLER GEAR (27T)
CLUTCH SPRING - SEE CHART
CLUTCH SPRING - SEE CHART
CLUTCH SPRING - SEE CHART
SHEAR PIN - SEE CHART
SHEAR PIN - SEE CHART
SHEAR PIN - SEE CHART
LOWER CLUTCH JAW
UPPER CLUTCH JAW
CLUTCH COVER
6-32 X 1 SOCKET HEAD CAP SCREW
RETRACT VALVE SPRING
QTY.
1
1
1
*
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3
1
1
1
3
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
382544
382545
382546
382547
382548
382550
382551
382552
382557
382558
382559
382560
382561
382562
382563
382564
382565
382566
382567
382568
382576
382580
382582
382590
382591
382606
382618
382619
382620
382621
382622
382627
382637
382662
382663
382664
382665
382666
382667
382668
382669
382670
382671
382672
382673
382674
382675
382676
382677
382678
382680
382682
382683
382684
382685
382686
382687
382688
382732
386095
386131
386132
RETRACT LEVER
DIFFERENTIAL DRIVE GEAR (27T)
DOWEL PIN (SPECIAL)
GEAR STOP
FEED PISTON (INCL. 843281)
RETRACT PISTON (INCL. 842161)
THREADED BUSHING
CYLINDER PLUG
GEAR HOLDER
THRUST PACKET-2400 LBS. THRUST (OPT.)
THRUST PACKET-1800 LBS. THRUST (STD.)
THRUST PACKET-1200 LBS. THRUST (OPT.)
.0005" DIFFERENTIAL FEED GEAR (33T)****
.001" DIFFERENTIAL FEED GEAR (43T)****
.003" DIFFERENTIAL FEED GEAR (44T)****
.002" DIFFERENTIAL FEED GEAR (65T)****
.0045" DIFFERENTIAL FEED GEAR (50T)****
.006" DIFFERENTIAL FEED GEAR (56T)****
.008" DIFFERENTIAL FEED GEAR (51T)****
.012" DIFFERENTIAL FEED GEAR (52T)****
ROTATING THRUST PLATE
LOCK SCREW (1/4 - 28)
1-9/16" - 20 L.H. (INT.) HOUSING COVER
(INCL. 382551)
INTERNAL GEAR CASE (50T)
21/4 - 20 L.H. (EXT.) HOUSING COVER
(INCL. 382551)
NAME PLATE
GOVERNOR VALVE (V MODEL ONLY)
GOVERNOR CENTER (V MODEL ONLY)
GUIDE STUD (V MODEL ONLY)
SPIDER (V MODEL ONLY)
MOTOR BACKHEAD (V MODEL ONLY)
DETENT PAD (V MODEL ONLY)
10 - 32 X 1/4 SET SCREW
SPINDLE FEED GEAR (.001 & .003) (44T)
SPRING CASE
RIGHT ANGLE FITTING
LIFT ARM ASSY. (INCL 382666)
SLACK ADJ. SCREW
PIVOT PLATE
END CAP
LOCK SCREW (1/4)
DRILL BUTTON SHAFT
DRILL BUTTON GUARD
PIN GUARD
SIDE HOSE (SHORT)
SIDE HOSE (LONG)
REAR SPINDLE GUARD**
THROTTLE PISTON CYLINDER
THROTTLE PISTON
DEPTH COLLAR
UPPER BLOCK
TAPPING SCREW
SPINDLE FEED GEAR (.0005) (34T)
SPINDLE FEED GEAR (.0045) (49T)
SPINDLE FEED GEAR (.006) (54T)
SPINDLE FEED GEAR (.008) (48T)
SPINDLE FEED GEAR (.012) (47T)
SPINDLE FEED GEAR (.002) (66T)
SPRING
SIGNAL VALVE HEAD
SIGNAL VALVE CASING
SIGNAL VALVE GUIDE
NAME OF PART QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PART NO.
PARTS LIST FOR POSITIVE FEED DRILL

17
QTY.
1
1
1
1
1
1
1
1
1
2
6
1
1
3
3
1
1
*
*
1
1
1
1
1
3
1
1
1
1
1
2
2
1
1
1
*
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
18
1
1
1
1
1
1
2
2
1
1
4
1
4
1
NAME OF PART
RAPID ADVANCE VALVE BUSHING
STOP BUTTON SHAFT
LOWER CLUTCH JAWS (OPTIONAL)
PRESSURE CAP (825 AND BELOW)
RETRACT COLLAR
ROLL PIN
SPRING (V MODEL ONLY)
SEAL
SPIDER
8 - 32 X 1/4 SOCKET HEAD CAP SCREW
NEEDLE BEARING (DOUBLE REDUCTION
REQUIRES 12)
SPIDER
WASHER
IDLER GEAR PIN (DOUBLE REDUCTION
REQUIRES 6)
IDLER GEAR (21T)
BALL BEARING (DOUBLE REDUCTION
REQUIRES 2)
SPACER
.005" SHIM
.010" SHIM
RETAINER RING
DRIVE GEAR (28T)
IDLER GEAR SHAFT
BALL BEARING
NEEDLE BEARING
IDLER GEAR (17T) (190 - 310 R.P.M
REQUIRES 6)
SPIDER (16T)
INTERNAL GEAR AND HOUSING (50T)
WASHER (190 - 310 R.P.M. REQUIRES 2)
PINION GEAR (16T)
SPIDER (16T)
RETAINER RING
BALL BEARING
BALL BEARING
SPRING
LOCK RING
SHIMS
SPRING WASHER
PINION GEAR
DRIVEN GEAR
AIR TUBE FITTING
BEARING
HOUSING
SPEED CAM 190V (V MODEL ONLY)
SPEED CAM 375V (V MODEL ONLY)
SPEED CAM 780V (V MODEL ONLY)
SPEED CAM 1500V (V MODEL ONLY)
UPPER BLOCK ASSEMBLY
9/32- STEEL BALL
CYLINDER PIN
10 - 32 X 3/8 BUTTON HEAD CAP SCREW
SCREW
BALL (7/32")
3/16- STEEL BALL
1/4- STEEL BALL
FRONT ROTOR BEARING
SPRING
DOWEL PIN (1/8"X 3/4")
DOWEL PIN (3/32" X 1/2")
SPACER
GREASE FITTING (NOT SHOWN)
DOWEL PIN (1/8" X 5/8")
SCREW (V MODEL ONLY)
006B00 "O"-RING 1/8" X 1/4"
007B00 "O"-RING 5/32" X 9/32"
008B00 "O"-RING 3/16" X 5/16"
011B00 "O"-RING 5/16" X 7/16"
PART NO
386135
386156
382379
382507
382733
415019
512275
512442
612050
612789
613271
613277
613278
613279
613280
613281
613687
614269
614270
614364
617200
617208
617220
617253
617305
617367
617369
617370
617609
617610
619017
619019
619377
619394
619421
624358
629044
629045
629046
629053
629057
629061
629107
629108
629109
629110
631741
812156
812166
812667
812962
842160
842161
842162
842870
843259
843280
843281
843390
843589
844111
844288
844301
844302
844303
844306
844307
844966
847031
847095
847210
847525
847768
863009
863072
863337
863926
864387
864471
864490
864492
864493
864522
864532
864589
864681
864732
865123
865206
865416
865417
867164
867183
867184
867185
867186
867187
867188
867189
867214
867357
867358
867369
867377
867380
867437
867502
867732
867758
867839
869290
869460
869559
869562
869712
869844
869850
882083
884125
PART NO.
012B00 "O"-RING 3/8" X 1/2"
(V MODEL REQUIRES 2)
BALL BEARING
DOWEL PIN (1/8- X 1")
BALL BEARING (V MODEL ONLY)
THRUST BEARING
.124" ROTOR COLLAR
SPRING
"O"-RING
THROTTLE VALVE SPRING
6 - 32 X 1/2 SOCKET HEAD CAP SCREW
.005"- SHIM
PLUG
BALL BEARING (DOUBLE REDUCTION
REQUIRES 3)
.123" ROTOR COLLAR
.125" ROTOR COLLAR
.126" ROTOR COLLAR
REAR ROTOR BEARING
PIN RETAINER
"O" -RING 2- 1/8" X 2- 1/4"
SPRING
SHIM .005" (V MODEL ONLY)
1/4 - 20 X 7/8 SOCKET HEAD CAP SCREW
THRUST RACE
ROTOR COLLAR
.128" ROTOR COLLAR
GOVERNOR WEIGHT***
GOVERNOR SPIDER***
WEIGHT PIN
GOVERNOR VALVE***
GOVERNOR SPRING***
PlN***
GOVERNOR WEIGHT***
GOVERNOR WEIGHT
GOVERNOR ADJUSTING RING***
GOVERNOR WEIGHT***
GOVERNOR WEIGHT***
REAR BEARING PLATE
CYLINDER (INCL. 812166-7)
THRUST RACE
PIN (V MODEL ONLY)
SET SCREW (V MODEL ONLY)
"O" -RING 1- 1/8" X 1- 5/16"
INLET BUSHING
1/4 -20 X 2-1/4" SOCKET HEAD CAP SCREW
PIN
RETAINER RING
.010" SHIM
SHIM .020" (V MODEL ONLY)
"O"-RING 5/64" X 13/64"
EXHAUST DEFLECTOR
MUFFLER
THRUST BEARING
DOWEL PIN (1/8" X 1/2")
* NUMBER OF SHIMS REQUIRED IS VARIABLE
** FOR SPINDLE LENGTHS UP TO 9 INCHES IF
SPINDLE
LENGTH IS OVER 9 INCHES, OTHER REAR
SPINDLE
GUARDS ARE AVAILABLE
*** SINGLE SPEED MODEL ONLY
****INCLUDES 842162
NAME OF PART QTY.
1
2
1
1
1
1
1
4
1
1
*
1
2
1
1
1
1
1
1
2
*
2
1
1
1
2
1
2
1
1
1
2
2
1
2
2
1
1
1
2
1
1
1
2
1
1
*
*
2
1
1
1
3
PARTS LIST FOR POSITIVE FEED DRILL

18
SOLID SPINDLES AND GUARDS — GUARD CAP - 624359 (1)
SPINDLE GUARD
382390 624397
382628 6"
382391 624500
7"
382617 624398
382708 8"
382349 624399
382616 9"
382631 624402
623853 13"
382639 624403
15"
FLUID SPINDLES AND GUARDS — GUARD CAP - 624359 (1) — GUARD SHIM (.010) - 624358 (4)
SPINDLE GUARD
624404
4"
382373 624505
5"
624405
6"
382346 624406
382599 7"
382614 624407
8"
382607 624408
623856 9"
382554 624409
382636 10"
382661
382605 624506
11"
624410
12"
382399 624411
382555 13"
382371 624502
623855 14"

19

20
TOOL MAINTENANCE AND PRESSURE
TEST KIT - 381273
This kit and instructions are for use in conjunction with the Operating
Instructions and Service Manual provided with the above drills.
381273 (ALL ITEMS INCLUDED IN KIT)
382370 Tool Box
823170 Contents list, diagram, and instructions
381272 Guage and fitting assembly
382360 Hex wrench bar
382361 Offset hex wrench
382362 3/16 inch pin wrench
382363 Bevel pinion socket
844767 Dowel Pin
382364 Cage Holder
382365 Throttle Cylinder Wrench
622466 Spindle Wrench
The hex wrench bar is to assist tightening cap screws, to straighten stack
of 5 belleville springs (if required), and to install cylinder plug 382552. The
cage holder holds spider 612050 or 613277.
1/2 " Tee
Top End
Throttle Piston
Performing Pressure Tests
This is a governed air motor, and air flow usually increases as the load
increases.
A variable speed drill motor will use more air at higher speed settings.
For all tests on the following pages, screw the 1/2 inch pipe nipple and
tee directly into the inlet bushing of the air tool. Do not use a quick
disconnect fitting between the tee and the inlet bushing (see diagram).
The 1/8 inch tee need not be installed at this time.
Adequate Air Supply
This includes valves, hoses, couplings, supply pressure, etc. Normally
this test would be performed at the drilling site with the length of hoses
and couplings in use.
Attach the air hose or the large quick disconnect coupling to the 1/2 inch
tee. Plug the air guage into the fitting on the tee. Rapid advance the tool
and read the guage pressure before and during rapid advance.
All 230 Drills
Maximum Allowable Pressure Drop At Tool
Inlet (RAP/ADV Flow Test):
psig psig
Before During
90 82
100 90
110 98
115 102
See Appendix I for unusual conditions.
The following tests should be done in the tool crib or repair-maintenance
area. NOTE: Remove the tool nose and spindle.
Air control system (A.C.S.) pressure checks. The 1/8 inch tee should
also be installed at this time (see diagram).
Feed piston pressure—plug air guage into the A.C.S. Start motor with
the drill button. The tool automatically goes into feed with the motor
running. The A.C.S. pressure must be over 60 psig.
Inlet Pressure Tap
Air Control System
Pressure Tap,
1/8 " Tee