PL12-17EA V4.0.qxd
Contents
1. 425 497 0496 Cooper Tools 5925 McLaughlin Road Mississauga Ontario Canada L5R 1B8 905 501 4785 Fax 905 501 4786 Cooper Tools de M xico S A de C V Libramiento La Joya No 1 Bodega No 2 Esq Polit cnico Barrio San Jos Cuautitl n Edo de M xico C P 54870 Phone 52 55 5899 9510 Fax 452 55 5870 5012 PL92 5000EN Printed in USA 03 2010 Copyright 2010 Cooper Industries York PA Cooper Tools Sales amp Service Center 3990 East Market Street York PA 17402 Tel 717 755 2933 Fax 717 757 5063 Canada Cooper Tools Sales amp Service Center 5925 McLaughlin Road Mississauga Ont L5R 1B8 Canada Tel 905 501 4785 Fax 905 501 4786 Cooper Tools Industrial Ltda Av Liberdade 4055 Zona Industrial Iporanga 18087 170 Sorocaba SP Brazil 55 15 3238 3929 Fax 55 15 228 3260 Cooper Power Tools SAS Zone industrielle B P 28 77831 Ozoir la Ferriere Cedex France T l phone 33 1 6443 2200 T l fax 33 1 6440 1717 Westhausen EMEA Cooper Power Tools GmbH Co OHG Postfach 30 D 73461 Westhausen Germany Phone 49 0 73 63 81 0 Fax 49 0 73 63 81 222 HTWE sales Qcooperindustries com Coventry UK Cooper Power Tools GmbH amp Co OHG Unit G Quinn Close Seven Stars Industrial Estate Whitlet Coventry 4LH UK Phone 44 2476 3089 60 Fax 44 2476 3089 69 Cooper Power Tools GmbH amp Co OHG Postfach 30 D 73461 Westhaus2. 9 10 _ 624100 1 O 11 864287 1 2 Dowel Pin Trige S 12 6729 gt gt O 13 617246 4 4 Screw gt O 14 6565 111 StopColar O 15 6 23 1 2 Screw 832UNC 16 6950 1 3 Spring 2 17 1 Spindle Guard and Fluid Inducer S O 18 842160 1 3 SKK 19 617247 1 Tigger o O 20 845 1 2 LeverPin gt gt 21 617252 1 2 Trigger Plunger 0 O 842005 __ 1 3 Reverse Stop Spring __ ___ 882209 3 3 TubngElbow 2 O 4847 2 2 Arline O 6795 ___1 VaveBody 8830755 1 PuhRoed O 842100 1 3 SteelBal 3 46 2 Quantity X Recommended Spare Parts Table D Ref Description Part Number Feed Rate uu Head Assembly 621915 001 NINININININI N ONTDOEN Head Assembiy i 62946 002 Table D1 Solid Guard Variable Solid Guard Fluid Guard Ref Description Number Length Fluid Inducer Number Length Fluid Inducer Number Length Fluid Inducer Spindle Guard 1 624360 641983 7 dl 624375 a Spindle Guard 641983 8 624376 Spindle Guard 6419839 9 624322 Spindle Guard 641947PT 641983 10 10 641947PT 624377 621448 Spindle Guard 641983 11 624323 E Spindle Guar
3. Assemble the drill head in reverse order of disassembly Clean and inspect all parts for excessive wear or damage and replace as necessary with Quackenbush replacement parts Apply a generous amount of Acculube grease to all gears and bearings during assembly Assembly Note When installing the 617168 ball bearing make sure the ball loading notches are facing the drill head housing Assembly Note Always install the spindle from the drive gear side of the drill head housing Figure 4 Page 7 Quackenbush Handle amp Sensor Assemblies Ey Hand Tighten RH Thread Page 8 Quackenbush PL92 5000EN 10 Handle amp Sensor Assemblies za Illustration A Handle Assembly Ref Number X gt Description 642014PT 1 Handle Assembly includes Ref 1 15 1 642015PT 1 Throttle Hande 2 613254 1 VaveAssemby gt 3 1e 12 6 ORig ______ 4 5 6 7 8 9 613253 1 Washer gt 10 11 12 13 __ 6133302 1 HoseAdaptr O 14 613282 11 15 X 613288 1 HandeNu 16 _ 642013PT 1 Sensor Assembly includes Ref 16 20 17 18 19 20 633753PT_ 1 ProtetionCap _ _ Quantity X Recommended Spare Parts 9 PL92 5000EN Quackenbush 03 10 2010 Motor Module 642011PT Motor Module Page 10 Quackenbush PL92 5000EN Motor Module Illustration B Mo
4. angle head CAUTION Always disconnect the tool from its air supply before installing or removing a cutter and other accessories or performing any maintenance 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 Figure 1 Tool Nose Lock Screws Standard Threaded Drill Bushing Tooling Fixture Warning Labels The warning labels on these tools are essential parts of the product and are not to be removed Check labels regularly and replace any that are not clearly legible The Nosepiece safety label number is 202691 Storage If it is necessary to store this tool for an extended period of time overnight weekend etc it should receive a generous amount of lubricant at that time and again when returned to service Always store the tool in a clean dry environment Page 5 PL92 5000EN 03 10 2010 Quackenbush Service Instructions General Instructions Torque Specifications for Fasteners Basic engineering practice should be used when assembling threaded components Tightening torque values are shown on the exploded views as a guide for disassembly and re assembly The Hand image indicates Han
5. from the motor shaft to permit disassembly of the rear bearing plate and bearing Using a soft mallet tap the motor shaft out of the front ball bearing This will allow the disassembly of the front bearing plate cylinder rotor blades and rotor To remove the ball bearing from the front bearing plate unthread the bearing retainer LH thread from the front bearing plate Assembly The rotor blades should be replaced during each maintenance cycle or if they are worn 1 16 below the rotor surface Figure 3 Assembly Note The beveled edge of the blade is the trailing edge The rotor and cylinder have an R etched on one end The R should be facing the rear to insure clockwise rotation Figure 3 Figure 3 1 16 Maximum f t R Toward Air Inlet Rotor Blade Beveled Edge mm is Trailing Edge 158 Drill Head Refer to Illustrations D amp E Disassembly Remove the stop body assembly 4 screws from the drill head housing Loosen the two set screws in the side of the housing and remove the gear stop Remove the cylinder assembly 3 screws from the drill head housing Remove the housing cover 3 screws from the drill head housing The gearing components can now be disassembled as shown in Illustration E Page 6 Quackenbush PL92 5000EN 03 10 2010 Service Instructions Assembly Assemble the drill head in reverse order of disassembly Clean and inspect all parts for excess
6. 03 001 40 17 622945 1 Differential Feed Gear Page 24 Sales amp Service Centers Note All locations may not service all products Please contact the nearest Sales amp Service Center for the appropriate facility to handle your service requirements Dallas TX Cooper Tools Sales amp Service Center 1470 Post amp Paddock Grand Prairie TX 75050 Tel 972 641 9563 Fax 972 641 9674 Detroit MI Cooper Tools Sales amp Service Center 2630 Superior Court Auburn Hills MI 48326 Tel 248 391 3700 Fax 248 391 7824 Houston TX Cooper Tools Sales amp Service Center 6550 West Sam Houston Parkway North Suite 200 Houston TX 77041 Tel 713 849 2364 Fax 713 849 2047 Cooper Tools P O Box 1410 Lexington SC 29071 1410 USA Phone 800 845 5629 803 359 1200 Fax 803 359 0822 2630 Superior Court Auburn Hills MI 48326 Phone 248 391 3700 888 332 6061 Fax 248 391 7824 Cooper Tools 1000 Lufkin Road Apex NC 27539 Phone 919 387 0099 Fax 919 387 2614 www coopertools com Lexington SC Cooper Tools 670 Industrial Drive Lexington SC 29072 Tel 800 845 5629 Tel 803 359 1200 Fax 803 358 7681 Los Angeles CA Cooper Tools Sales amp Service Center 15503 Blackburn Ave Norwalk CA 90650 Tel 562 926 0810 Fax 562 802 1718 Seattle WA Cooper Tools Sales amp Service Center 2865 152nd Ave N E Redmond WA 98052 Tel 425 497 0476 Fax
7. Service Manual PL92 5000EN 03 10 2010 QUACKENBUSH 1580RA 4 158 15QRA Series Adaptive Positive Feed Drill COOPER Tools For additional product information visit our website at http www cooperpowertools com Quackenbush Model Nomenclature XXX R A Tool Series 158 Positive Feed 158 15 Positive Feed Brand Q Quackenbush Tool Style R Right Angle Revision Adaptive Drill RPM Spindle Speed Select Desired Speed 900 300 158 series 12 4 1200 400 158 15 series Feed Rate Select desired feed rate 10 001 IPR 20 002 IPR Spindle Length Length Specify 0 00 Stroke Non Thread Gear Head F No Spindle Spindle Interface Thread to Cutter A 1 4 28 5 16 18 3 8 24 9 16 18 Other specify Nose Attachment Thread 2 1 4 20 158 series B 1 9 16 20 158 series C 1 0 20 158 15 series Options 2 Concentric Collet 4 Indexer 5 None Accessories Nose B Spindle C Chuck D Fluid Chuck E Fluid Inducer F None Last three digits of material number Page 3 XX 9 50 X X PL92 5000EN 03 10 2010 X XXX XXX PL92 5000EN 03 10 2010 Quackenbush General Safety amp Tool Operation General Safety Instructions These safety instructions must be accessible to the operator at all times They must be shown and made available to all personnel involved in the use of this equipment Thes
8. bly 1 Mustaton F 2 622985 1 GearStop S 3 4 5 6 7 8 9 10 11 _ 865576 1 ThrustRace SS 12 622401 1 NoseAdapter SS O 13 Table G2 1 Spinde ____ 14 617962 111 StopColar 15 16 6945 11 JamNut Optiona 00000222 17 18 19 20 21 847609 Ball Bearing Pinion Shaft 22 23 24 6 2 1 er S SOS 25 26 64 4 1 Idler Gear Spacer Long 27 28 29 30 648505 1 lderGearSpacer Sbot 31 6290 1 lderGearshat 6224606 ___ 1 SpindleWrench Quantity X Recommended Spare Parts WIW AJOJN Table G Ref Description Part Number Feed Rate Drill Head Assembly 631778 001 Drill Head Assembly EN 631780 002 Page 23 Quackenbush 158 15 Right Angle Drill Head Gearing Table G1 Spindle Feed Gear Feed Number of Ref Description Part Number Revolution Teeth Spindle Feed Gear 623002 001 43 622943 1 Spindle Feed Gear Table G2 Spindles Description Part Overall Solid or Attachment Number Length Fluid Thread Spindle 1 615915 4 00 Fluid 3 8 24 Spindle 13 Spindle 1 623812 600 3824 Spindle 1 623284 900 Fluid 516 24 Spindle Note Other spindles avilable on request Table G3 Differential Feed Gear Ref Description Part Number dod gs Differential Feed Gear 6230
9. d 1 624104 6 641983 12 624376 Spindle Guard 1 641983PT 13 Spindle Guard Fluid Inducer Page 15 PL92 5000EN 03 10 2010 WARNING Spindle wrench 45 is used to hold the spindle when removing cutters The air supply must be disconnected from the tool before the spindle wrench is used Note Always replace Bevel Gear and Bevel Pinion in pairs since both should wear equally Note Not included in Drill Head Assembly Ey Hand Tighten RH Thread Quackenbush 158 Right Angle Drill Head Gearing w 24 ES 25 25 21 7 in 16 O 41 Page 16 2 1 4 20 Thread Adapter Optional 614228 42 1 1 8 1 1 8 Install Spindle from this direction 8 0 0 43 Lo 0 m 45 LLL ET LET TET I SN Quackenbush PL92 5000EN 158 Right Angle Drill Head Gearing Illustration E Right Angle Drill Head Gearing 158 series Ref Number X 28 Description Table E 1 Drill Head Assembly 1 Mustra on D 1 Housings SO 2 3 4 6260 1 GearStp 4 222022 5 6543 11 ThrustRace SS 6 614270 Shim 010 8 9 10 6458 1 ThustRae O 679 1 CamFolowr 64149 4 Pin ________ 21 98390 12 GearSpaer 613687 1 lderGearSpacer 6708 1 ld
10. d Tighten Disassembly Remove all external tubing from the unit Secure the tool in a smooth jawed vise by clamping lightly on the motor housing flats Loosen the lock ring and unthread the drill head assembly RH thread from the power unit 158 15 Series The drill head assembly utilizes a motor adapter for assembly to the power unit Gearing Refer to Illustration C Disassembly Remove the lock ring from the internal gear Using a suitable wrench unthread the internal gear RH thread from the motor housing The planet cage assembly can now be removed from the internal gear and the component parts disassembled 158 Series Unthread the bevel gear RH thread from the planet cage to permit disassembly of the front planet cage ball bearing and washer Assembly Apply a generous amount of No 2 Moly grease to all gearing components during assembly Assembly Note Assemble the tang end of the planet gear pins toward the front of the planet cage so the planet cage washer will lock them in position Figure 2 Figure 2 Planet Gear Pin tang Planet Cage Motor Module Refer to Illustrations A amp B Disassembly To remove the motor assembly from the motor housing invert the tool in the vise Unthread the handle nut RH thread and remove the handle assembly from the motor housing The complete motor assembly can now be removed through the rear of the motor housing Unthread the magnet rotor LH thread
11. e safety instructions are not intended to be all inclusive Study and comply with all applicable Federal State and Local Regulations If necessary contact your local Cooper Tools representative for assistance Always disconnect the tool from the air supply before adjusting or repairing Immediaely shut off the tool in the case of unusual sound or vibration Have a qualified person check the tool and repair before using Do not modify the tool any guard or accessory unless approved in writing by Cooper Tools Implement and follow a Safety Maintenence Program to provide inspection and maintenance of all phases of tool operation and air supply equipment Eye Protection WARNING Impact resistant eye protection must be worn while operating or working near this tool CAUTION Personal hearing protection is recommended when operating or working near this tool Hearing Protection Hearing protection is recommended in high noise areas 85 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 General Protection Follow good machine shop practices Rotating shafts and moving components can entangle or entrap and may result in serious personal injuries Never wear long hair loose fitting clothes gloves ties or jewelry when working with or near a drill of any ty
12. ed or distorted Now rotate the two set screws counter clockwise 90 180 degrees With this method it is easier to determine when the spring makes up solid so there is less tendency to force the screw in to deep causing damage to the spring Method 2 fully assembled unit The clutch rollers are normally sitting in the detents Turn the two set screws in the side of the housing clockwise until the springs just begin to go solid Care must be taken not to distort the springs Once the solid state is achieved rotate the set screws counter clockwise 2 1 4 full turns plus 90 180 degrees Important Too much tension can result in gear damage 158 15 Drill Head Refer to Illustrations F amp Disassembly Unthread the motor adapter LH thread from the drill head housing Remove the hex drive adapter drive coupling spacer bearing and bevel gear from the drill head housing Remove the retract body assembly 4 screws from the drill head housing If used unthread the upper jam nut LH thread from the spindle Loosen the set screw in the side of the upper stop collar and unthread the stop collar LH thread from the spindle Unthread the nose adpater LH thread from the drill head housing The spindle assembly can now be removed from the drill head housing Remove the cover 2 screws from the drill head housing The gearing components can now be disassembled as shown in Illustration Assembly
13. en Germany Phone 49 0 73 63 81 0 Fax 49 0 73 63 81 222 HTWE sales Cooper China Co Ltd 955 Sheng Li Road Heging Pudong Shanghai China 201201 Tel 86 21 28994176 86 21 28994177 Fax 86 21 51118446 www coopertools com COOPER Tools
14. erShat 617200 1 PinionGear o 31 624636 1 Hin Cover S 80688 3 6 Scew 1024UNO S 6246819 1 FeedGearBushing 64646 1 Piston ___ O 6246818 1 Cylinder 41 64501 3 6 Seew amp 32UNC 2 Table ES 1 Spindle 77 7 2 636 1 Stop Collar 6246 1 SpindeWrenh Quantity X Recommended Spare Parts ND Af O O COIN O O1 WININININININININ OIN OO O1 AJOJN BLD CO CO O dc oo 1 O CO1 AION gt 17 Quackenbush 158 Right Angle Drill Head Gearing Blank Page Page 18 Quackenbush PL92 5000EN 158 Right Angle Drill Head Gearing Table E Ref Description Part Number Feed Rate Drill Head Assembly 621915 001 Drill Head Assembly 621916 002 Table E1 Spindle Feed Gear Feed per Number of Ref Description E Part Number Revolution Teeth 10 opindle Feed Gear 615893 001 50 Spindle Feed Gear 615804 002 44 Table E2 Differential Feed Gear 2 42 Feed Number of Ref Description Part Number Revolution Teeth 17 Differential Feed Gear 624643 001 49 Differential Feed Gear FE 617356 02 4 Table Spindles Ba Description Part Overall Solid or Attachment Number Lengt
15. h Fluid Thread Spindle 1 615890 7 00 Fluid 9 16 18 Spindle 42 SPindle Spindle Spindle Spindle Note Other spindles avilable on request Page 19 Aidan Quackenbush _ 158 15 Right Angle Drill Head Housing 12 O 20 30 ft lbs 11 Ey Hand Tighten RH Thread Page 20 Quackenbush PL92 5000EN 03 10 2010 158 15 Right Angle Drill Head Housing Illustration F Right Angle Drill Head Housing 158 15 series Ref Number X E Description Table F 1 Drill Head Assembly 1 6229886 1 Housing 2 61388 11 Nameplate SS 3 4 62284 2 6 ClichRole 0 2 5 69685 2 6 Clutch Adjustment Spring S 6 86752 2 6 SetScew 1 420UNC 7 Illustration 1 Bevel Gear Driving 00 0 8 1 BallBeaing 9 679 1 Spacer o 10 6221 1 Drive Coupling o 625625 1 Hex Drive Adapter 12 625626 A 13 6404 1 RetrctBody 2 2 14 ND Af Al A O cd 0o 41 O O1 21 NIN WIN 2 I 6298 3 1 Retrectlevr 000000000000 617900 1 StopCola 294 620045 1 JamNut Opiond J Tabe Fi 1 Spindle Guard and Fluid Inducer 000000000024 62435 1 Spindle Guard Cap 000004 Quantity X Recommended Spare Parts Table F Ref Description Part Nu
16. ing material in the same dust collector with combustible material Examples Steel and Aluminum dust or Steel and Titanium dust e Never use flamable finishing lubricants Tool Operation This tool is designed to drill holes in different material stacks and is for use only with the Quackenbush DMP control box and should not be connected directly to a standard air line Refer to PL92 DMP for operation and use of the DMP control box these instructions must be read and understood before initiating any drilling operation The operating parameters for the tool are programmed using the adaptive interface kit and DMP TMS programming software refer to literature PL92 DMP PROG for details on programming the tool memory these instructions must be read and understood before initiating any drilling operation The power unit is started by turning the throttle valve lever 158 Gear Head The feed mechanism is engaged by depressing the feed cam knob while the tool is running 158 15 Gear Head The feed mechanism is engaged by pushing the feed retract lever 622973 down The spindle will automatically retract when the stop collar depresses the retract lever The spindle may be manually retracted at any stage by pulling up on the retract lever The tool must be shut off when the spindle is completely retracted 158 15 Gear Head The Gear Stop 622985 can be adjusted by turning the two 1 8 hex set screws 867502 on either side of the
17. ive wear or damage and replace as necessary with Quackenbush replacement parts Apply a generous amount of Acculube grease to all gears and bearings during assembly Assembly Note Always install the spindle from the drive gear side of the drill head housing Figure 4 Figure 4 Install spindle from this direction only The 158 series drill head does not require shims to set the bevel gears Correct engagement of the bevel gears is obtained by running the power unit at a very slow speed and threading it into the drill head until gear interference is felt Back off the power unit approximately 1 8 turn or until there is no gear interference then tighten the lock nut This procedure will attain maximum gear engagement After the tool is assembled place a few drops of 10W machine oil in the air inlet befoe attaching the air supply This will insure immediate lubrication of all parts as soon as air is applied Gear Stop Adjustment There are two methods that can be used to adjust the gear stop The preferred method is to make the adjustment during assembly of the dril before the retract body and it s related components are attached to the drill head see Method 1 Method 1 during assembly Place the gear stop in position with the two clutch rollers located on top of the cam lobes rather than in the detents Turn the two set screws in the side of the housing clockwise until the springs begin to make up solid but are not crush
18. mber Feed Rate Drill Head Assembly 1 631778 001 Drill Head Assembly 631780 Table F1 Ref 23 Description Spindle Guard Spindle Guard Spindle Guard Spindle Guard Spindle Guard Spindle Guard Spindle Guard Spindle Guard Fluid Inducer Solid Guard Variable Solid Guard Fluid Guard Number Length Fluid Inducer Number Length Fluid Inducer Number Length Fluid Inducer 1 624339 1 641984 7 624328 gi 641984 8 624329 MEN 641984 9 9 624330 641948PT 641984 10 641948PT 624331 631256 4194 1 624332 5 1 624096 6 641984 12 624333 641984PT Page 21 ee Quackenbush 158 15 Right Angle Drill Head Gearing 03 10 2010 Ye 12 _ 10 1 5 13 Note Always replace the Bevel Gears in pairs since both should wear equally 14 15 Ey Hand Tighten RH Thread 15 in lbs Page 22 Note Not included in Drill Head Assembly 8 bee gt y HE 16 1 1 8 WARNING Spindle wrench 34 is used to hold the spindle when removing cutters The air supply must be disconnected from the tool before the spindle wrench is used 34 Quackenbush PL92 5000EN 03 10 2010 158 15 Right Angle Drill Head Gearing Illustration G Right Angle Drill Head Gearing 158 15 series Ref Number X a Description Table G 1 Drill Head Assem
19. pe WARNING Do not wear loose fitting clothes long hair gloves ties or jewelry The spindle on right angle positive feed drills retracts at a much faster rate than it feeds Care must be taken to avoid entrapment Nosepieces 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 the tool Spindle guards in one inch increments are available to accommodate any length spindle Slotted spindle guards are available for tools with fluid swivels A WARNING B gt gt Keep hands and fingers away from slot in spindle guard and nosepiece when handling or operating tool Page 4 Quackenbush PL92 5000EN 03 10 2010 General Safety amp Tool Operation Respirator WARNING Wear respirator where necessary Drilling or other use of this tool may produce hazardous fumes and or dust To avoid adverse health effects utilize adequate ventiliation and wear a respirator if necessary Read the Material Safety Data Sheet MSDS for any cutting fluids or materials involved in the drilling process WARNING e Most dusts combustable See Material Safety Data Sheets for combustibility of a specific dust e Non ferrous metal dusts are particularly hazardous Examples Aluminum Magnesium Titanium Never collect Magnesium in a dry dust collector e Never collect spark generat
20. tor Module Ref Number X 641660 1 1 1 2 1 1 1 1 1 1 10 1 11 1 12 1 13 14 1 15 4 16 17 1 18 1 Quantity X Recommended Spare Parts 2 Ol 2 l O 2 1 2 4 2 EN Description Motor Housing Assembly includes Ref 1 5 Pin Page 11 eee Quackenbush 03 10 2010 Gearing Assembly 621251 Gearing Assembly Page 12 Quackenbush PL92 5000EN 10 Gearing Assembly 03 10 2010 Illustration C Gearing Assembly Ref Number 5 X En Description 1 619421 1 Lock Nut 2 613285 1 IntemalGear ooo 3 4 6730 1 Planet Cage Washer gt 5 620 1 PlaetCage SS 6 61735 13 6 PlaetGer 0 0 7 _ 61327 6 12 NeedeBeaing 7 8 61329 3 6 PlanetPin 613281 Ball Bearing Quantity X Recommended Spare Parts Page 13 en Quackenbush _ 158 Right Angle Drill Head Housing 4 in lbs O Ev Note Not included in Drill Head Assembly Page 14 Quackenbush PL92 5000EN 158 Right Angle Drill Head Housing Illustration D Right Angle Drill Head Housing 158 series Ref Number X zm Description Table D 1 Drill Head Assembly 1 _ 624622 1 Housing 2 3 624916 2 6 Clutch Adjustment Spring 4 5 _ 6138288 1 Nameplate S 6 848 12 DriveSerew z 6 26 __ 1 Cam gt O 8 6757 _ 2 6 CamSping SS
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