Service Manual for QE8 Series High Torque
Contents
1. GEA40 CORD 3M 90 106 Power Cord Assembly 90 Deg 10 Meter GEA40 CORD 10M 90 107 Power Cord Extension Assembly 10 Meter GEA40 EXT 10M 108 Power Cord Extension Assembly 20 Meter GEA40 EXT 20M 109 Power Cord Extension Assembly 40 Meter GEA40 EXT 40M 110 Suspension Bail 2e eee ker te 7L 365 111 Spanner Wrench 222525222 0 666 tea dene eae eee 40 478 7 FOR MODEL OES 150 NON FLANGED MODELS ONLY 13 QE8 TOOL ASSEMBLIES Angles Product Identification Code CL Sulmions d Dwg TP2161b In Lines Ingersoll Rand 67 Au 1 msani i 4 1 4 Float i e Float travel Product Identification Code Long gt Dwg TP2161a Table 1 Suggested Tools Parts List Item Tool Used Description Where Used 1 Spanner Wrench I R Part GEA40 478 Coupling Nut 2 Pin Spanner Wrench 3 mm or 1 8 pin Motor Housing Assembly Cable 3 Torque Wrench 1 2 Sq Drive 50 ft Ib capacity General use 4 Adjustable Pin Wrench In Lines Bearing Caps 5 Adjustable Wrench Coupling Nut with flats 6 5 64 Hex Key Cap Screws Low Socket Head 7 192. Sa amp Ut N m d ga 09 GEA120 D53 491 GEA120 D53 491 GEA240 D53 491 GEA240 D53 491 GEA240 D53 491 GEA400 D53 491 GEA400 D53 491 GEA40 98 1 255 GEA40 329 51 GEA40 273 40 273 51 TRP A528 GEA40 A2309 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 RENET tiu ma arb s Handle Grip sois victoria Handle Bes Handle Grip iia a o as NI EP Socket Cap Screw Low Head Socket Head Cap Screw Lever Short veces ss Lever Extended eset es 2 0233 EPIS GEA40 2309 104 40 136 211 GEA120 136 GEA40 99 GEA40 600 GEA40 208 GEA40 801 GEA40 329 52 GEA40 329 GEA40 135 GEA40 135SL GEA40 135EL GEA40 137 GEA40 135 68 GEA40 273EL 68 GEA40 273SL GEA40 273EL Also includes GEF400 491 104 HIGH TORQUE GEARING COMPONENTS A Ingersoll rand 67 OFF 68 81 Nm Dwg TP2160_B QE8 HIGH TORQUE GEARING COMPONENTS af When Ordering use applicable Part Number ANGLE QES High Torque Gearing Parts List 225 H QESSt 150 H orrser ANITA Item Part Description Part Number Part Number Part Number Part Number 31 O ring LD 1 563 139 32 Transducer Assembly GEA120 A756 90 GEA120 A
3. 7775 Edition 1 April 2004 04580973 Service Manual for 8 Series High Torque Angle Wrench and In Line DC Electric Tools For routine Maintenance Operation and Instruction information regarding this product see Publication manual P7609 located at www irtools com techdocuments or contact the nearest Ingersoll Rand Office or Distributor C Assembly MIT Dwg 2160 0 d a _1 Dwg TP2160b Refer All Communications to the Nearest Ingersoll Rand Office or Distributor IP Ingersoll Rand Company 2004 Assembly Solutions Printed in U S A QE8 HIGH TORQUE MOTOR HOUSING ASSEMBLY GRIPS AND LEVERS OFF 05 1 1 Nm 5 64 Dwg TP2155 it When Ordering use applicable Part Number QES High Torque Motor Housing Assembly Grips and Levers Parts List QE8 HIGH TORQUE MOTOR HOUSING ASSEMBLY GRIPS AND LEVERS Item Part Description Part Number Item Part Description Part Number 1 Motor Housing Assembly FOR MODELS OESZE 107010 uses rt ennt QESZ 109010 i ime FOR MODELS 12250 Joe 8 QE8S H50 F E usce erbe kn OBSZT FISO P esed e e FOR MODELS QE8A 400 Je eee OESS 230 F eres LED Board dhe da
4. Ensure that all the gears are free of debris 2 Apply 2 3 cc of IR 67 grease to the central area between the gears and the surface of the gear teeth of the 1 Stage Spindle Assembly 37 and the 214 Stage Spindle Assembly 39 3 Insert Bearing 51 into threaded end of Gear Case 48 and push it in until it seats against the shoulder in the Gear Case 4 Assembly the Retaining Ring 52 into the groove directly in front of the Bearing with internal snap ring pliers 5 Support the Gear Case Assembly threaded end down on the inner race of Bearing 51 6 Position the 274 Stage Spindle Assembly 39 on the inner race of the Bearing 51 inside the Gear Case with the splined end of the Spindle Assembly facing the Bearing 7 With an appropriate tool press the 2nd Stage Spindle Assembly into Bearing 51 until the Spindle Assem bly seats against the inner race of the Bearing 8 Coatthe inside and outside surfaces of the Ring Gear 43 with IR 67 grease 9 Insert the Ring Gear into the Gear Case with the end of the Ring Gear having an internal groove towards the motor 10 Align the Ring Gear teeth with those of the planets in the 294 Stage Spindle Assembly and slide the Ring Gear into the Gear Case until it stops against the shoul der inside the Gear Case 11 Install the Retainer 34 into the groove inside the motor end of the Gear Case to secure the Ring Gear 12 Insert the 1 Stage Spindle Assembly 37 into th
5. ne 85 32 531 FOr O1SO8 sickest CUR 120E6S8 586 74 Coupling GEA240 27 for SISOS Sir see 120E8S8 586 75 Retainer e asien aaa nk 160E4 29 65 Socket Retainer SUHD 718 FOR MODEL REFER TO THESE MANUALS QE8Z 070 QESZ 090 P7778 QE8Z 150 7778 QE8S 230 H P7777 QE8 ANGLE HEAD ATTACHMENTS gt C OFF 61 68 Nm ER OFF 61 68 Nm HUSKEY HTS 2 4557 30 D 3 When Ordering applicable Part Number Dwg TP2294 QES Angle Head Attachments Parts List Item Product Identification Code Part Number 81 8 225 A7S12 AA16S12 82 8 400 A8S12 AA20S12 12 QE8 HIGH TORQUE ACCESSORIES Dwg TP2292 qt When Ordering use applicable Part Number QES High Torque Accessories Parts List Item Part Description Part Number 100 t Reaction Bar Assembly DEA120 K48 101 f Mounting Plate Assembly 0 0 0 ee cee eee eee DAM120 K48 102 fMounting Plate Assembly GEM120 K48 103 Power Cord Assembly 3 Meter GEA40 CORD 3M 104 Power Cord Assembly 10 Meter GEA40 CORD 10M 105 Power Cord Assembly 90 Deg 3 Meter
6. Dwg 2293 TT QE8 HIGH TORQUE IN LINE ATTACHMENT COMPONENTS i When Ordering use applicable Part Number 8 In line Spindles Parts List Item Part Description Part Number Part Description Part Number In Line Spindle Assemblies 66 Socket Retaining Pin 804 716 QESS 150 41S08 1 2 Sq Drive amp 4 Long Shank 160E4S8 67 Coupler vic se Eu es QESS 150 61508 1 2 Sq Drive amp 6 Long Shank 160E6S8 Jof 4808 2 oci dede erbe pretio ere ee bate aloes 120E4 581 QESS 150 81S08 1 2 Sq Drive amp 8 Long Shank 160E8S8 for 61808 81508 120E6 581 61 Housing Assembly 68 Disengaging Spring JorAlS08 cvi RA Re naeh 160E4 A580 for 41808 viii iones 120E4 626 for 61508 bee ER ERI EE E Ee 160E6 A580 for 61508 81508 120 6 626 Jor 81808 creer IR ae 160E8 A580 69 Drive Spindle Assembly 160E4 A584 ea 120 4 105 70 120 4 106 120 4 106 71 Retaining 100 20 64 Square Drive Spindle 72 Rear Spindle GEA240 593 0 41506 cits hes oak Ense 120 458 586 73 Be ring
7. GEA240 406 GEF400 406 GEF400 406 QE8 HIGH TORQUE GEARING PARTSLIST Continued 3 When Ordering applicable Part Number QES High Torque Gearing Parts List Continued ANGLE 225F IN LINE QESS 150F QE8S 230F or QESA 400F Item Part Description Part Number Part Number Part Number 45 Spindle Assembly 3rd GEA240 A8 GEF400 A8 GEF400 A8 Spindle cas Planet Pili ae P Needle Rollers iiss t RR FER HERE EE Y da Pua une dictate eso eas D Ree awe Eo dedi Planet Gear 3rd ici ea eb a ea ep na 46 egw GEF240 29 N A N A 47 Coupling ar ren hans Geile GEA240 43 GEF400 43 GEF400 43 48 Gear laguna sant is GEF240 B37 GEP400 B37 GEF400 B37 49 Retaining Ring ts oda GEF400 29 50 i GEF400 584 51 BOO ee RU I Reda es Ue Du Rura 52 Retaining Ring 2 222 2222 24 01 QE8 HIGH TORQUE IN LINE ATTACHMENT COMPONENTS Ingersoll Ran d 67 o C OFF 61 68 Nm 4 lt gt
8. over Housing Assembly 61 19 Using an appropriate tool install Retainer 75 onto spline of Housing Assembly until seated into groove 20 Spin Coupling by hand to check freedom of movement FOR ALL OTHER SPINDLE ASSEMBLIES REFER TO THE APPROPRIATE MAINTENANCE MANUAL LISTED IN THE QE8 HIGH TORQUE IN LINE SPINDLE PARTS LIST Attachment Installation FOR MODELS QESA 225 H QESA 400 H 85 150 H 1 Position the Attachment appropriately Engage the spline on the input spindle of the Attachment with the matching internal spline of the zu Stage Spindle Assembly 45 and then engage the spline on the Attachment Housing with that of the Gear Case 48 Thread the Coupling Nut 74 onto the Gear Case 4 While holding the tool using an appropriate wrench on the wrench flats or spanner holes of the Gear Case torque Coupling Nut to between 45 50 Ib ft 61 68 Nm e FOR ALL OTHER MODELS 1 Insert Gear Case or Offset Gear Case into the Tool mounting plate 2 Insert Attachment to the Opposite side of the Mounting Plate and properly engage the drive spindle with the Gear Case or Offset Gear Case Output Spindle 3 Align the mounting holes of the Attachment to the Mounting plate and to the Gear Case or Offset Gear Case and insert the Cap Screws through the holes in the flange of the Attachment and mounting plate 4 Torque Cap Screws to the Gear Case or Offset Gear Case as follows ALL M
9. 64 Hex Key Cap Screws Regular Head 8 Internal Snap Ring Pliers General use yf en 14 MAINTENANCE DISASSEMBLY General Instructions e Refer to Table 1 Suggested Tools Parts List 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 Using appropriate tool loosen the Attachment Coupling Nut 74 2 Unthread Coupling Nut from Gear Case Assembly and remove Attachment 3 Using appropriate tool loosen the Gear Case Coupling Nut 47 4 Unthread Coupling Nut and remove Gear Case Assembly Disassemble Gear Case CA 15 e Clean and degrease all parts except for the bearings Stage Spindle Assembly 37 qe Stage Spindle Assembly 39 and the gn stage Spindle Assembly 45 7 Wipe clean the Spindle Assemblies with a clean dry and lint free rag 8 Oncecleaned
10. Spindle Assembly 37 214 Stage Spin dle Assembly 39 and a stage Spindle Assembly 45 slide out of the Gear Case 48 all together 4 Using internal snap ring pliers remove the Retaining Ring 36 from the Ring Gear 5 Tilt the ring gear and slide the 1 Stage Spindle Assembly 37 and gid Stage Spindle Assembly 39 out of the Ring Gear 6 With the output end of the Ring Gear resting on the table of an arbor press carefully press the gm Stage Spindle Assembly 45 from the Spindle Bearing 41 and out of the Ring Gear 7 From the output end of the Ring Gear push the Spindle bearing 41 out of the Ring Gear 8 Ifthe Coupling Nut requires replacement spread the ends of the Retaining Ring 46 and remove it from the Gear Case Assembly FOR GEF400 M37 AND GEP400 M37 1 Remove the Pinion Coupler Assembly 35 from the Motor Housing Assembly 2 If the Coupling Nut requires replacement slide the Coupling Nut off the Motor Housing Assembly 3 From the output end of the Gear Case Assembly push the 3 d Stage Spindle Assembly 45 until the Ring Gear 1 Stage Spindle Assembly 37 2 Stage Spin dle Assembly 39 and gn Stage Spindle Assembly 45 slide out of the Gear Case 48 all together 4 Using internal snap ring pliers remove the Retaining Ring 36 from the Ring Gear 5 Tilt the ring gear and slide the 15 Stage Spindle Assembly 37 and gud Stage Spindle Assembly 39 out of the Ring Gear 6 Fr
11. apply prescribed amounts of Ingersoll Rand 67 Grease as follows e 3 4 central area between gears of each Spindle Assembly 37 39 amp 45 e Thin layer on Ring Gear teeth 43 9 For Models with an Angle Head Attachment Using HUSKY HTS 2 Grease lubricate Angle Head 81 or 82 through Grease Fitting 10 For Models with an In Line Attachment Using Ingersoll Rand 67 Grease lubricate the Square Drive Spindle Bearings the Drive Spindle 64 and the Disengaging Spring 68 WARNING This procedure is to be performed by an autho rized trained repair person To ensure proper functioning of the tool When replacing the Motor Housing Assembly 1 always ensure that the Memory Chip 7 Communication Board 8 Gear Case Assembly and Attachment are all assembled as a set with the new Motor Housing Assembly CAUTION When replacing an Attachment always use the Angle Head Attachment designed for that model Never replace an Angle Head Attachment with an In Line Attachment When replacing a Gear Case Assembly always use the Assembly designed for that model General Instructions for Disassembly 1 2 w Do not disassemble the tool any further than necessary to replace or repair damaged parts To protect part surfaces and to prevent distortion of Housings and threaded joints use care when grasping the tool Avoid clamping non metal surfaces unless directed otherwise Do not remove any press fi
12. of the 34 Stage Spindle 45 with the large outer diameter end of the Ring Gear and insert it until its spindle bearing seats in the Ring Gear bearing bore 5 Apply a coating of Ingersoll Rand 67 grease to the Spacer 40 and install the spacer on top of the 3 Stage Spindle 45 from the small outer diameter end of the Ring Gear 6 Install the 274 Stage Spindle 39 Be sure to engage all gears properly prior to applying any force 7 Apply a coating of Ingersoll Rand 67 grease to the Spacer 38 and install the spacer on top of the 2nd Stage Spindle 39 8 Install the 1 Stage Spindle 37 Be sure to engage all gears properly prior to applying any force 9 Install the Retainer 36 into the groove inside the motor end of the Ring Gear 10 Install the Ring Gear containing the Spindles output end first into the Gear Case 48 11 Assembly O ring 31 into the proper internal groove in the output end of the Motor Housing Assembly 12 Slide the Coupling nut 47 threaded side first over the Motor Housing Assembly 13 FOR GEP400 M37 ONLY a Assemble Retaining ring 49 to groove in Spindle 50 b Insert Spline of Spindle 50 into 30 Stage Spindle 45 FOR OFFSET GEARING ASSEMBLY REFER TO THE APPROPRIATE MAINTENANCE MANUAL LISTED IN THE QE8 HIGH TORQUE GEAR ING PARTS LIST Gear Case Assembly Installation ALL MODELS 1 Install the Pinion Coupler Assembly 35 on the pinion of the motor 2 Rotate
13. 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 instruction on how to properly grease this tool WARNING This procedure is to be done by an authorized trained repair person To ensure proper functioning of the tool XS X gt S A e Ke N LEDs and Temperature Connector s Dwg TP2162a When replacing the Motor Housing Assembly 1 always ensure that the Memory Chip 7 Communication Board 8 Gear Case Assembly and Attachment are all assembled as a set with the new Motor Housing Assembly Internal Components 1 Insert the LED Board 2 through one of the Motor Housing Assembly s three large cavities and lay the 19 MAINTENANCE Continued Motor Common 2 at s O X S x Morgue Transavt Torque and Motor Connector s Dwg TP2162b Transducer Installation Insert Transducer Assembly 32 into the Motor Housing Assembly wire end first guiding Transducer s connector out through the cavity found at end of Motor Housing Assembly s long outer groove Carefully pull Transducer s connector and wiring through cavity of Motor Ho
14. 4 from behind Label Cover Lens 13 In a sliding motion pull Warning Label 12 and Label Cover Lens 13 off end of Motor Housing Assembly Slide Housing Cover 11 off Motor Housing Na N Assembly SLrque Trans E Remove O ring 10 located at front of Housing Cover Torque and Motor Connector s Dwg TP2162a Pr b x 2 er e Motor Tempera LEDs and Temperature Connector s Dwg TP2162b Disassembly of Internal Components 1 Remove Retainer 9 used to retain Communication Board 8 located at rear end of Motor Housing Assembly in Connector cavity 2 In large cavity area s of Motor Housing disconnect the Motor Phase connector Refer to TP2162b 3 Disconnect the Motor temperature sensor connector from the Communication Board Refer to TP2162b 4 Disconnect the Motor Commutation connector from the Communication Board Refer to TP2162a 18 MAINTENANCE Continued 5 Disconnect the Torque Transducer connector from the Communication Board Refer to TP2162a 6 Disengage female socket located on front end of Com munication Board from male connector located at center of LED Board 2 by gently sliding board from Motor Housing Assembly 7 Remove LED Board from Motor Housing Assembly Refer to TP2162b Transducer Removal 1 Locate the cavity found at end of long axial groove running along the outer surface of the Motor Housing Assembly 2 Make sure the Transd
15. 491 104 GEF400 491 104 32 Transd cer Assembly per re hts repran v rego GEA240 A756 160 GEF400 A756 230 GEF400 A756 230 33 PACS hater ee een se GEA240 945 N A N A Gear Case Assembly Ving POR Nu NY CPI pest E TE GEF240 M37 GEP400 M37 GEF400 M37 34 Retainer DERIT GEA240 208 N A N A 35 Pinion Coupler Assembly DEA120 17 GEF400 17 GEF400 17 36 Retaiming Ring o daly nase eat W64 118 W64 118 W64 118 37 Spindle Assembly Ist Stage DEA55 A216 DEA90 A216 DEA90 A216 PD PERI Planet seh ann is yer wi Planet Bearing ais RE ER oder ease QUESO dedere Planet Gear 180 DEA eaves 38 PACED We a ee GEA240 80 GEF400 80 GEF400 80 39 Spindle Assembly 2nd Stage GEA240 A216 GEF400 A216 GEF400 A216 SPINS ideas wane v bon eee ee Planet Pin RUP Planet Bearing u sre t be usa Sea nen Ex Planet Gear Ond eoe teorie Ondo Hewes Ree e 40 SPACED toes e ee osea de GEA240 80 GEF400 80 GEF400 80 41 Bearing cs snes ne he GEA240 606 43 Ring GOAT ne ee ee
16. 6 Using adjustable Pin Wrench unscrew Bearing Cap 73 7 Pull the Drive Spindle Assembly 69 out of Housing Assembly 61 8 If necessary using a bearing puller tool press the Rear 16 MAINTENANCE Continued Gear Case Disassembly FOR GEP120 M37 AND GEP150 M37 1 Remove the Pinion Coupler Assembly 35 from the Motor Housing Assembly 2 If the Coupling Nut requires replacement spread the ends of the Retaining Ring 46 and remove it from the Gear Case Assembly Slide Coupling Nut off the Gear Case Assembly 3 Work a pointed tool under the Ring Gear Retainer 34 and spiral it out of the Gear Case 48 4 Tilt the Gear Case Assembly so that the Ring Gear 43 and 1 Stage Spindle Assembly 37 slide out of the Gear Case Assembly 5 With the motor end of the Gear Case Assembly standing on the table of an Arbor press carefully press the 214 Stage Spindle Assembly 39 out of the Bearing 51 while lightly supporting the Spindle Assembly from beneath to avoid breakage 6 Using internal snap ring pliers remove the Retaining Ring 52 from the threaded end of the Gear Case 48 7 Remove Bearing 51 from the Gear Case FOR GEA240 M37 GEF240 M37 AND GEP240 M37 1 Remove the Pinion Coupler Assembly 35 from the Motor Housing Assembly 2 Work a pointed tool under the Ring Gear Retainer 34 and spiral it out of the Gear Case 48 3 Tilt the Gear Case Assembly so that the Ring Gear 43 1 Stage
17. 756 90 GEA240 A756 160 GEA240 A756 160 39 DEA120 945 DEA120 945 GEA240 945 GEA240 945 Gear Case Assembly 0 000 nannan eee eee GEP120 M37 GEP150 M37 GEP240 M37 GEA240 M37 34 Retainer web ne en DEA120 29 DEA120 29 GEA240 208 GEA240 208 35 Pinion Coupler Assembly DEA120 17 DEA120 17 DEA120 17 DEA120 17 36 Retaining Ring u ea seele W64 118 W64 118 W64 118 W64 118 37 Spindle Assembly 1st Stage DEA120 A216 DEA150 A216 DEA55 A216 DEAS55 A216 Spindle 14 e ann Planet Pil eb dues Planet Bearing une vae pore Planet Gear 1st BED PUT 38 SPACED Dd ON Eu d GEA240 80 GEA240 80 39 Spindle Assembly 2nd 5 DEA120 A8 DEA150 A8 GEA240 A216 GEA240 A216 Spindles soni ero pen ee Planet Pin sais here Planet Bearing Planet Gear 2 40 xpo M GEA240 80 GEA240 80 41 Bearing nenne m een GEA240 606 GEA240 606 43 Ring Gear ie es ae ie DEA 120 406 DEA200 406 GEA240 406 GEA240 406 HIGH TORQUE GEARING COMPONENTS Continued 3 When Ordering use applicable Part Number QES High To
18. ODELS 18 4 25 4 ft e Ibs 25 34 5 Nm MAINTENANCE Concluded QES Series Wiring Cable Chart Connector Pin Wire Color Cable Connector Pin A Red VCC 13 B Black COM 14 Gray Spare 1 12 D Pink Spare 2 27 E Brown Spare 4 15 F Yellow Sine 21 G Orange Cosine 28 H Violet Spare 3 7 J Green Ground Sense 20 K Blue RX 5 L Blue White RX 6 M White TX 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 NOTICE SAVE THESE INSTRUCTIONS DO NOT DESTROY When the life of the tool has expired it is recommended that the tool be disassembled degreased and the parts be separated by material so that they can be recycled 24 SERVICE NOTES 25 SERVICE NOTES 26 SERVICE CENTERS Centres d entretien Ingersoll Rand Niederlassungen Centri di Assistenza Centros de Servicio Service Centra Servicentre Servicecenter Servicesenter Huoltokeskus Centros de Assist ncia T cnica K vroa amp Ingersoll Rand UK India 1872 Enterprise Drive Ingersoll Rand amp Co Ltd Ingersoll Rand Wadco Rochester MI 48309 Swan Lane Gate 3 Tools Pvt Limited Phone 248 293 5700 Hindley Green 37 A Site 4 Sahibabad Fax 248 293 5800 Wigan WN2 4EZ UK Industrial Area P
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21. e Gear Case and engage the teeth of the gear on the Gear Head Assembly with the planet gears of the 2nd Stage Spindle Assembly while aligning the planet gears of the Gear Head Assembly with the Ring Gear 13 Install Retaining Ring 36 into groove in the end of the Ring gear 14 Slide the Coupling Nut 47 on the input end of the Gear Case 48 Using the proper tool slide the Retain ing Ring 46 over the end and into the groove of the Gear Case FOR GEA240 M37 GEF240 M37 AND GEP240 M37 Ensure that all the gears are free of debris 2 Apply 3 4 cc of IR 67 grease to the central area between the gears and the surface of the gear teeth of the 1 Stage Spindle Assembly 37 the 214 Stage Spindle Assembly 39 and the 3 Stage spindle 21 Assembly 45 3 Coatthe inside and outside surfaces of the Ring Gear 43 with IR 67 grease 4 Insert the Spindle Bearing 41 into the fine pitch end of the Ring Gear 43 with the flanged side of the bear ing facing out until the bearing rests in the interior bore deep inside the ring gear This may require moderate pressure 5 Engage the planets of the Stage Spindle 45 squared end out with the Ring Gear and insert it until it contacts the installed Spindle Bearing 41 6 Position the Assembly of the previous step with the 39 Stage Spindle resting on the table of arbor press 7 With an appropriate tool press the inner race of the Spindle Bearing 41 onto th
22. e 344 Stage Spindle Assembly until the Spindle Assembly seats against the inner race of the Bearing 8 Apply a coating of Ingersoll Rand 67 grease to the Spacer 40 and install the spacer on top of the Spindle Bearing 41 9 Install the 274 Stage Spindle 39 Be sure to engage all gears properly prior to applying any force 10 Apply a coating of Ingersoll Rand 67 grease to the Spacer 38 and install the spacer on top of the ond Stage Spindle 39 11 Install the 1 Stage Spindle 37 Be sure to engage all gears properly prior to applying any force 12 Install the Retainer 36 into the groove inside the motor end of the Ring Gear 13 Install the Ring Gear containing the Spindles output end first into the Gear Case 48 14 Install Retaining Ring 34 into the internal groove in the end of the Gear Case 15 Slide the Coupling Nut 47 onto the input end of the Gear Case 48 Using the proper tool slide the Retain ing Ring 46 over the end and into the external groove of the Gear Case FOR GEF400 M37 AND GEP400 M37 1 Ensure that all the gears are free of debris Apply 3 4 cc of IR 67 grease to the central area between the gears and the surface of the gear teeth of the 1 Stage Spindle Assembly 37 the 27 Stage Spindle Assembly 39 and the gm Stage spindle Assembly 45 3 Coat the inside and outside surfaces of the Ring Gear 43 with IR 67 grease MAINTENANCE Continued 4 Engage the planets
23. ee ends of the Socket Retaining Spring are faced away from the hole and the closed side of the Spring straddles the Socket Retaining Pin 4 Holding the Socket Retaining Pin steady push Spring down hole of square Spindle until the Socket Retaining Spring s wire engages Socket Retaining Pin 5 Socket Retaining Pin is properly installed when Socket Retaining Spring snaps into place 6 Lubricate the bearings of the Housing Assembly 61 with Ingersoll Rand 67 Grease 7 Slide Washer 62 and Washer 63 onto Square Drive Spindle and insert Square Drive Spindle 64 into Housing Assembly 61 8 Align the Coupler 67 to slide over spline of Square Drive Spindle 9 Slide Coupler into position in Housing Assembly 61 10 Slide Washer 70 on the Drive Spindle Assembly 69 11 Use snap ring Pliers to install the Retaining Ring 71 on top of the Washer 12 Press on Rear Spindle Bearing 72 to Drive Spindle Assembly 69 13 Place Disengaging Spring 68 over Drive Spindle Assembly 14 Align the Drive Spindle Assembly with spline of Coupler and insert Drive Spindle Assembly into Housing Assembly 61 15 Apply one drop of Perma Lok MM 115 to threads of Bearing Cap 73 16 Carefully grasp the Housing Assembly Note In the following step the Bearing Cap 73 has a left hand thread 17 Using the appropriate tool tighten Bearing Cap 73 to between 45 50 ft 61 68 Nm of torque 18 Slide Coupling Nut 74
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25. om the output end of the Ring Gear carefully pull the 34 Stage Spindle Assembly 45 out of the ring gear It may be necessary to push it from the opposite side 7 If necessary remove the O ring 31 from the Motor Housing Assembly FOR OFFSET GEARING DISASSEMBLY REFER TO THE APPROPRIATE MAINTENANCE MANUAL LISTED IN THE QE8 HIGH TORQUE GEARING PARTS LIST AWARNING This procedure is to be done by an authorized trained repair person To ensure proper functioning of the tool When replacing the Motor Housing Assembly 1 always ensure that the Memory Chip 7 Communication Board 8 Gear Case Assembly and Attachment are all assembled as a set with the new Motor Housing Assembly Grips 1 For models with levers use the appropriate hex key to loosen Cap Screws 23 from lever 24 or 25 and remove lever from Handle Grip 19 or 20 2 Use the appropriate hex key to loosen the Cap Screw 22 from Handle Grip 18 19 20 or 21 3 Slide Handle Grip off of Motor House Assembly 1 MAINTENANCE Continued Disassembly of External Components Communication Board Dislodge O rings 15 and remove Memory Chip 7 0 Motor from assembly A Remove Trigger mechanism 5 from Motor Housing Assembly Remove Spring 6 from Trigger mechanism Slide Reverse Ring 17 away from Motor Housing Assembly being careful not to lose the Detent Ball 3 or Springs 4 and 16 Remove Retaining Ring 1
26. rminals aligned with O ring groove Slide two O rings 15 into groove to retain Memory chip Install Spring 6 on post in middle of Trigger 5 and install Trigger into Motor Housing Assembly For models with Extended Lever 25 install an additional spring on Trigger s auxiliary post Slide Handle Grip 18 19 20 or 21 onto Motor Hous ing Assembly Apply a medium strength thread locker to Low Head Socket Cap Screw 22 Install Low Head Socket Cap Screw into Motor Housing Assembly Torque Socket Cap Screw to 10 to 15 16 in 1 1 to 1 7 Nm For models with Levers a Place Lever 24 or 25 in position against Handle Grip and install lever Socket Cap Screws 23 b Torque Socket Cap Screw 23 to 5 to 10 Ibe in 0 5 to 1 1 Nm AWARNING This procedure is to be performed by an autho rized trained repair person To ensure proper functioning of the tool In the course of disassembling or assembling this product beware of any attempt to separate the gear case from or tighten the gear case to the motor housing assembly Destruction of the transducer wire will result ACAUTION When replacing an Attachment always use the Angle Head Attachment designed for that model Never replace an Angle Head Attachment with an In Line Attachment When replacing a Gear Case Assembly always use the Assembly designed for that model MAINTENANCE Continued Gear Case Assembly FOR GEP120 M37 AND GEP150 M37
27. rque Gearing Parts List ANGLE ras EEEE OFFSET MITRE QE8Z 090 QE8Z 2250 H Item Part Description Part Number Part Number Part Number Part Number 45 Spindle Assembly 3rd GEA240 A8 GEA240 A8 uestes Be dits een E m wen zus Planet Pin ted ee see Needle Rollers cies bre eR er Pen sec SPACE Yan a Planet Gear 314 eee s an 46 IRE AMEE 1 6 etit de een DEF120 29 DEF120 29 GEF240 29 GEF240 29 47 Coupling Nut isse 0 GEF120 43 GEF120 43 GEA240 43 GEA240 43 48 Gear Case coser HERUM GER CE Qu bene ets GEP120 B37 GEP120 B37 GEP240 B37 GEA240 B37 49 Retaining 50 Spindle osado Ses 51 hr A m R38P 606 R38P 606 52 Retaining W64 118 W64 118 REFER ALSO THESE MANUALS P7781 P7781 P7781 QE8 HIGH TORQUE GEARING COMPONENTS Continued i When Ordering use applicable Part Number QES High Torque Gearing Parts List Continued ANGLE 225 400F IN LINE QES8S 150F QESS 230F Pe 2 Item Part Description Part Number Part Number Part Number 31 O ring LD 1 563 X 130 seci anne an nen a GEF400
28. t 47 with the appropriate tool and loosen the Coupling Nut while gripping the wrench flats of the Gear Case 48 with the appropriate wrench Case or Offset Gear Case 2 Unthread the Coupling Nut and pull the Gear Case Assembly off the Motor Housing Assembly 2 Pull Attachment from the Mounting plate and Gear 3 Pull remainder of the Tool from mounting plate FOR MODELS WITH OFFSET GEAR CASES Angle Head Attachments Disassembly QESZ 30701 U DISASSEMBLY OF ANGLE HEAD ATTACHMENTS QESZ j090 H uU 1 NOT RECOMMENDED OESZ 150 IA IO 1 Remove the screws around the flange of the Offset FOR 160 458 160E6S8 amp 160E8S8 IN LINE Gearing that attach it to the Gear Case assembly with ATT ACHMENTS the appropriate wrench while gripping the wrench flats of the Tool Gear Case with the appropriate wrench 1 Looking down the hole of the Square Drive Spindle s 2 Pull Offset Gearing from the Gear Case 64 square socket locate Retaining Pin 66 and Retaining Spring 65 2 Ifnecessary use a pointed metal probe to pull retaining Spring out of Spindle cavity 3 Also if necessary remove Pin from Square Drive Spindle 64 4 Using Spanner Wrench GEA40 478 or other appro priate wrench grasp the Spanner holes or flats of the Coupling Nut 74 5 If desired remove Coupling Nut Retainer 75 using the appropriate tool Note In the following step the Bearing Cap 73 has a left hand thread
29. t part or any part of an assembly unless its removal is necessary for repair or replacement Attachments A 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 CAUTION When installing or removing a Coupling Nut ALWAYS hold the tool by the Spanner holes or flats as provided on the Assembly Housing MAINTENANCE Continued Spindle Bearing 72 off the Drive Spindle Assembly 69 Then remove the Retaining Ring 71 and FOR MODELS Washer 70 9 Now tilt Spindle Housing causing the Disengaging 32251 Spring 68 Coupler 67 Square Drive Spindle 64 QESA 400 H and Washers 62 and 63 to slide out 85 150 Attachment Removal FOR ALL OTHER SPINDLES 1 Using Spanner Wrench GEA40 478 or other REFER TO THE APPROPRIATE MAINTENANCE appropriate wrench grasp the Spanner holes of the MANUAL LISTED IN THE QE8 HIGH TORQUE Coupling Nut 74 IN LINE SPINDLE PARTS LIST 2 Holding firmly onto tool with the wrench flats or Spanner holes of the Gear Case 48 unscrew Motor Housing Disassembly Coupling Nut and pull the Attachment out of the Gear Case Gear Case Removal FOR ALL OTHER MODELS FOR ALL MODELS 1 Remove screws around the flange of the Attachment 1 Carefully engage spanner holes on the Gear Case while supporting both ends of the tool Coupling Nu
30. the Gear Case Assembly to the desired orienta tion relative to the Motor Housing Assembly 1 3 Insert the Motor Housing Assembly 1 into the Gear Case 48 4 Align and engage the gear of the Pinion Coupler Assembly 35 with the Planets of the 1 Stage Gear Head Assembly 37 while engaging the Ring Gear 43 with the Transducer 32 teeth It may be necessary to rotate the ga Stage Spindle Assembly 39 to aid in assembly 5 Thread Coupling Nut 47 to the appropriate threads and while using the appropriate tool and the spanner holes on the gearcase torque the Coupling Nut 47 to 50 60 ft Ibs 68 81 Nm FOR MODELS WITH OFFSET GEAR CASES QESZ 107011 QESZ 10901 H 0 874 11501 Insert Gear Case into the Offset Gearcase Input Flange Align the flange holes of the Offset Gear Case flange and Tool Gear Case and thread the Cap Screws into the Tool Gear Case flange 3 Torque Cap Screws as follows QESZ 070 QESZ 090 and QE8Z 150 1 18 4 25 4 ft Ibs 25 34 5 Nm MAINTENANCE Continued Attachments In Line Attachment Assembly FOR 160E4S8 160E6S8 amp 160 858 IN LINE ATTACHMENTS 1 Install Socket Retaining Pin 66 into small hole provided in one of the flat walls of the square Spindle 2 With Pin in place locate Pin s groove inside large end hole of Square Drive Spindle 64 3 Position Spring 65 inside large hole of Square Drive Spindle such that the fr
31. ucer connector is disconnected from the Communication Board 3 Gently pull Transducer 32 out of the Motor Housing Assembly while feeding the Transducer wire and connector through the cavity in the Motor Housing Assembly 4 Carefully push Transducer s connector through the cavity of the Motor Housing Assembly three tabs of the LED Board against the three ledges of the Motor Housing Assembly Refer to TP2162a making sure that the motor commutation wires properly pass through the cutout in the LED board Using two of the three internal axial grooves located in the connector end of the Motor Housing Assembly slide Communication Board 8 into Motor Housing Assembly Press connector located on front end of Communica tion Board into socket located at center of LED Board Route Motor Commutation wiring to same side of Communication Board snap connector into socket marked Motor Refer to TP2162a Route Motor Temperature Sensor Connector cable to opposite side of Communication Board snap Motor Temperature Sensor connector into the Motor Temperature Sensor socket Refer to TP2162b Through large cavities of Motor Housing Assembly connect Motor Phase Female Connector to Male Connector of Motor Install Retainer 9 behind Communication Board in connector cavity in the end of the Motor Housing Assembly ASSEMBLY Communication Board Close Up Motor Housing Assembly X s General Instructions
32. using Assembly Align and engage Transducer s gear teeth with the gear teeth located inside the end of the Motor Housing Assembly Be certain that the Transducer wire exits the Transducer directly over the access cavity through which the wire was fed Continue inserting the Transducer assembly until it is fully seated Snap Transducer s connector into Communication Board 8 socket marked Torque Refer to TP2162a External Components Slide O ring 10 into groove located at front end of Motor Housing Assembly Slide on Housing Cover 11 ensuring that Transducer and Motor wires are not disturbed Slide Warning Label 12 into Label Cover Lens 13 Note Warning Label and Label Cover Lens slot and tab alignment features Slide Label Cover Lens and Warning Label over Motor Housing Assembly grip area Orient tabs of Label Cover Lens with mating slots in Motor Housing Assembly and slide together Install Retaining Ring 14 into groove behind Label Cover Lens Place Spring 16 into Reverse Ring 17 7 Install depress Ball 3 and Spring 4 and then slide Reverse Ring onto Motor Housing Assembly When replacing the Motor Housing Assembly 1 always ensure that the Memory Chip 7 Communication Board 8 Gear Case Assembly and Attachment are all assembled as a set with the new Motor Housing Assembly 8 9 10 11 12 13 14 15 16 20 Install Memory chip 7 into Housing with te
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