400QGDBV Series S400 & S600 In-line Positive Feed Drills

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1 Parts Manual 8 06/0/0 400QGDBV Series S400 & S600 Inline Positive Feed Drills For additional product information visit our website at

2 Safety Recommendations For your safety and the safety of others, read and understand the safety recommendations and operating instructions before operating any drill motor. Always wear protective equipment: WARNING Impact resistant eye protection must be worn while operating or working near this tool. For additional information on eye and face protection, refer to Federal OSHA Regulations, 9 Code of Federal Regulations, Section 90.., Eye and Face Protection, and American National Standards Institute, ANSI Z87., Occupational and Educational Eye and Face Protection. Z87. is available from the American National Standards Institute, Inc. West 4nd Street, New York, NY 006. Before the tool is connected to the air supply, the throttle should be checked for proper operation (i.e., throttle valve moves freely and returns to closed position). 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 drill motors are sharp. Handle them carefully to avoid injury. CAUTION CAUTION 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. CAUTION Lock Screws Tool Nose Personal hearing protection is recommended when operating or working near this tool. Hearing protectors are required 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, 9 Code of Federal Regulations, Section 90.95, Occupational Noise Exposure, and American National Standards Institute, ANSI S.6, Hearing Protectors. Tooling Fixture Standard Threaded Drill Bushing 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 Follow good machine shop practices. Rotating shafts and moving components entangle and entrap, and may result in serious injuries. Never wear long hair, loosefitting clothes, gloves, ties, or jewelry when working with or near a drill of any type. Always remove chuck key or drill drift before operating tool. WARNING Wear respirator where necessary. Do not wear loose fitting clothes, long hair, gloves, ties or jewelry. Quackenbush drills are designed to operate on 90psig (6. bar) maximum air pressure using the proper hose. Excessive air pressure increases the loads and stresses on tool parts and drills, and may result in breakage. The installation of a filterregulatorlubricator in the air supply line ahead of the tool is highly recommended. 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 of any cutting fluids or materials involved in the drilling process. CAUTION Some nonferrus metal chips (or dusts) are combustible. Examples: Aluminum, magnesium, Titanium, and Zirconium. See the material safety data sheets for combustibility of materials drilled. Never collect spark generating material with combustible material. Examples: Collecting both steel and aluminum or steel and titanium.

3 Safety Recommendations CAUTION Slip and fall hazard. Lubricant and coolant systems must be properly maintained to avoid leakage. Hoses must be organized and care taken to avoid tripping. Quackenbush drills are often used with lubricant or cooling systems which must be properly maintained to avoid leakage. Failure to do so can result in serious injuries from slipping on oily surfaces. Nose pieces usually used with these drills are generally slotted for visibility and access to chuck and cutter. WARNING Keep hands and fingers away from slot in spindle guard and nose piece when handling or operating tool. Keep fingers and hands away from slots in the tool nose at all times. Rapid spindle retraction occurs automatically on most models after drilling cycle and can be activated manually even with the air supply disconnected on some models. CAUTION Due to the multitude and variety of tooling applications, the User's Methods Engineering, Standard Tooling Engineering, and/or Safety Engineering Departments, etc., must consider any hazards that may be associated with each specific application of this product and provide adequate operator protection from inadvertent contact with any moving components. Some individuals are susceptible to disorders of the hands and arms when exposed to vibration and/or 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 from prolonged symptoms of tingling, numbness, blanching of fingers, clumsiness or weakened grip, inability to hold objects, nocturnal pain in the hand, or any other disorder of the shoulders, arms, wrists, or fingers should notify their employer so that a review of what steps might be taken to prevent further occurances. These steps might include but are not limited to, repositioning the workpiece or redesigning the workstation, reassigning tool users to other jobs, rotating jobs, changing worker pace, and/or changing the type of tool used so as 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 OK Avoid Avoid OK Avoid Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation Avoid awkward postures Keep wrists as straight as possible Interrupt work, activities, or rotate jobs to provide periods free from repetitive work motions Safety Labels The safety 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 safety labels when missing or when the information can no longer be read. Safety labels should always be placed on any tool nose before installing on tool. Replacement labels can be ordered using number below.

4 C B A OPERATING INSTRUCTIONS The 400QGDBV power unit is designed to operate on 90 psig air pressure using a /4" air hose. The unit is available with three () governed variable speed ranges; 55/5 RPM, 5/0 RPM, and 5/750 RPM. The RPM setting is changed by depressing the indexing blade, No. 86, and rotating the speed adjusting cap to the desired speed. Adjustment and Operation Three rotatable collars A, B, and C control the adjustment and operation of the drill. Collar C (Forward Stroke Adjustment) limits forward motion of spindle, and automatically retracts the spindle. To increase stroke turn collar in direction of arrow. Collar B manually starts forward motion of the spindle, and manually retracts the spindle. To start forward motion turn collar in direction of arrow. Collar A (Rear Stroke Adjustment) adjusts the retracted position of the spindle. To move retracted position of spindle forward turn collar in direction of arrow.. Lock unit into drill fixture. Turn collar B clockwise, disengaging positive feed mechanism.. Rotate collar A counterclockwise, advancing drill tip close to the work.. Start motor, and rotate collar B counterclockwise maintaining steady pressure on collar until teed mechanism is engaged, starting drilling operation. The operation can be stopped at any time by rotating collar B clockwise, disengaging positive feed mechanism and retracting spindle. 4. To adjust unit for depth control rotate collar C. (Clockwise rotation increases length of stroke.) On retraction of spindle rotate collar B clockwise allowing it to move back longitudinally resetting feed mechanism. LUBRICATION An automatic inline filterlubricator is recommended as it increases tool life and keeps the tool in sustained operation. The inline lubricator should be regularly checked and filled with a good grade of 0W machine oil. Proper adjustment of the inline lubricator is performed by placing a sheet of paper next to the exhaust ports and holding the throttle open approximately 0 seconds. The lubricator is properly set when a light stain of oil collects on the paper. Excessive amounts of oil should be avoided. Application of the tool shouid govern now frequentiy it is greased. When the tool is serviced, the recommended grease is "Lubriplate #907". Use a good "O"ring lubricant on all "O"rings when servicing the tool. STORAGE In the event that it becomes necessary to store the tool for an extended period of time (overnight, weekend, etc.), it should receive a generous amount of lubrication at that time and again when returned to service. The tool should be stored in a clean and dry environment. SERVICE INSTRUCTIONS DISASSEMBLY DRILL HEAD Clamp the gear housing, No. 86, in a softjawed vise. Unscrew and remove the power unit from the tool. Unscrew the tool nose (left hand threads), the chuck and spindle adaptor, No , being careful not to damage the extension spindle, No (S400), 6465 (S600). Remove the No snap ring to allow the No spring cover and spring, No. 6994, to be slipped off. Loosen the two screws, No. 6785, and remove the forward stop collar. Remove the No screw and rotate the No feed collar past the cam section and pull it off toward the front. Remove the No set screws and with a face spanner wrench loosen, but do not remove No bearing retainer (left hand threads). Use an appropriate wrench on the fiats on the forward end of the shaft housing and unscrew it from the No. 696 gear body (left hand threads). The No bearing retainer can now be unscrewed the rest of the way for removal of the spindle spring. The extension spindle with associated parts can now be removed. Remove the No stop collar snap ring and remove the return stop collar. Remove the gear cover screws and remove the gear cover, No This will allow removal of the spindle gear, gear spacer, No. 6940, and idler gear. The drive shaft with mating parts can now be removed throughthe rear of the tool. Removethethree bolts, No and pull back the gear housing, No from the gear body, No Remove thesnap ring, No from the lead screw driver through the rear of gear body and press the lead screw driver from the ball bearing, No Remove snap ring No. 8 and remove the ball bearing from the gear body. Remove the No. 8 snap ring from the front of the lead screw and pull the extension spindle and ball bearing from the lead screw. Remove the snap ring, No to remove the ball bearing from the extension spindle. To remove the worm wheel and cross shaft, No. 6978, remove the snap rings, No. 6976, No. 6906, and plugs, No , No. 698, from each end of the gear body. Press the cross shaft out through the side with the larger opening. Remove the No snap ring and press the pinion and shaft, No. 698 out of the gear housing. The various assemblies can be broken down into their individual components for inspection and replacement of parts if necessary. POWER UNIT Clamp the stepover gear housing, No. 86, in a vise with the power unit in a vertical position. Remove the speed lock body, No. 876, and set screw, No. 8649, and unscrew the speed adjustment cap, No Remove the screw, No. 8449, and retainer ring, No This will allow the pressure cap, No. 865, governor valve, No. 809, and related components to be removed from the backhead. Unscrew the clamp nut, No. 8, and remove the backhead. Slip the motor unit out the rear of the motor housing. Use a soft faced hammer to drive the rotor out of the front rotor bearing. Note: rotor pinion, No. 80, used on 5/0 RPM tools, must be removed first. Clamp the rotor in the vise and unscrew the governor assembly. Unscrew and remove the gear case, No. 85, from the motor adapter, No. 8, for inspection of the gear train. Remove the gear cover, No. 87, for inspection of the step over gears. REASSEMBLY POWER UNIT All parts should be thoroughly cleaned in a solvent and inspected for wear or damage. Particular attention should be paid to the rotor blades and all bearings, as failure of these parts could cause damage to more expensive components. Rotor blades should be replaced at every repair cycle or if they measure less than 5/64" at either end. Must be replaced if 5/64" (9.9mm) or less at either end. 4

5 The power unit gear train and step over gearing should receive a generous amount of "Lubriplate #907" grease during reassembly. SOCKET HEAD CAP SCREW During reasembly of the motor unit, care must be exercised to prevent the rotor from rubbing the front bearing plate..005" Gap After Assembly Never supply pressurized air to the tool, unless the speed adj. cap, No and retaining ring, No , which secures the pressure cap, No. 865 in place. Place a temporary /8 NPTplug in the air supply swivel and pour a few drops of 0W machine oil in the inlet bushing. Loosen clamp nut, No. 8, and retighten finger tight. Hook up air hose and run the motor at very low pressure, tapping the motor housing to allow seal line clearance between the rotor O. D. and the cylinder bore. When the motor is spinning freely, securely tighten the clamp nut. Using an unrestricted /" x 8' supply hose, adjust the triplelead threaded speed adjust cap, placing the index blade into the notch where the motor RPM is closest to 800 RPM (555) or 800 RPM (50) or 8000 RPM (5750). Now mark the speed adjust cap at the index notch (800, 800 or 8000RPM) to facilitate assembly of the speed indicating ring (No. 85, No. 84 or No. 8658). Remove the speed adj. cap No.86987, and press on the speed indicating ring with 80 RPM, 00 RPM or 500 RPM over the notch consistent with 800 RPM, 800 RPM or 8000 RPM rotor speed. Replace the speed adj ust cap, checking speed to ensure the correct thread lead (triplethread) has been found. Screw in the set screw so the speed cap can be rotated full range but, can't be removed from the backhead. The gear train and step over gearing are reassembled in the reverse order of disassembly. DRILL HEAD The drill head is reassembled in the reverse order of disassembly. Inspect all parts for damage or wear. NOTE: During reassembly of the cross shaft, hold the cross shaft with the worm wheel to the right and press the clutch spring, No. 6995, over the hub of the worm wheel, engaging the steel balls with the holes in the clutch spring. To properly set the rotor collar, No. 8, assemble the rear rotor bearing into the rear bearing plate. Hold the inner race of the bearing forward and measure the depth of the inner race from the face of the bearing plate. Select or fit by sanding a rotor collar.00 " to.00" larger than this dimension and assemble the collar, rotor bearing, bearing plate, and governor assembly to the rotor. After final assembly of the motor unit has been completed, inspect it to ensure that the rotor does not rub the front bearing plate. Install motor unit into the motor housing; replace the backhead, and tighten the clamp nut lightly. Be sure governor weights are swung inward. Install governor center, ball bearing, and governor valve; adjusting shims until a measurement of.875" is achieved from the back end of the aluminum backhead to the large face on the governor valve. NOTE: The clutch spring must wrap on the hub away from you with respect to the holes in the spring. NOTE: Wrapping the spring in the opposite direction will decrease the holding power of the clutch. The cavities in and around the lead screw driver should be packed with Lubriplate #907" grease to aid in cushioning the return cycle. Install remaining parts to complete backhead assembly. Use small socket head cap screw to prevent pressure cap, No. 865, from moving forward when backhead is evacuated. Leave speed indicating ring off. 5

6 6 Charts are on page 0.

7 DRILL HEAD 400 & 600 PART NO. NAME OF PART MODEL QUANITY S400 S Safety Labels Drive Shaft Drive Shaft Extension Spindle Extension Spindle Return Stop Collar Forward Stop Collar Key Retainer Screw Forward Stop Collar Retainer Ring Pinion Shaft Needle Bearing Plug (Small) Spring Retainer Pin Collar Retainer Key Gear Body Plug Retainer Ring (Large) Cross Shaft Bearing Cross Shaft Thrust Washer Spacer Lead Screw Driver Pinion & Shaft Collar Screw Spring Retainer Screw Forward Stop Spring Cover Stop Collar Retainer Ring Spindle Spring Spring Clutch Spring Spring Cover Retainer Ring Spacer Spindle Adaptor Driver Key Plug (Large) HalfNut Spring Return Stops (Matched Pair) Feed Collar Helical Gear Lead Screw Driver Gear Driver Needle Bearing Shaft Housing Set Screw Bearing Retainer Return Stop Collar Lead Screw Driver Spindle Spring Thrust Washer Bumper Ring Spindle Spring Spindle Needle Bearing Grease Seal Worm Roller Shaft Housing Bearing Retainer Ring "O"Ring /8" X /4" Driver Gear Key Steel Ball Spring Bearing Retainer Ring Worm Retainer Ring Steel Ball Ball Bearing Helical Gear Pin Ball Bearing 7

8 8

9 400QGDBV POWER UNIT PART NO. NAME OF PART QTY. PART NO. NAME OF PART QTY * 87* * 80* 8 8 8* * 87* * * 854* * GOVERNOR VALVE GOVERNOR CENTER CLAMP NUT ROTOR COLLAR ND REDUCTION IDLER GEAR ST REDUCTION IDLER GEAR (55/5)(NCL. 8659) STEP OVER GEAR POST STEP OVER NEEDLE BEARING MOTOR PLATE AIR SUPPLY SWIVEL (INCL ) ROTOR PINION (5/0) ST REDUCTION SPIDER t5/0) (INCL. 85) ST REDUCTION SPIDER (55/5) (INCL ) GOVERNOR SPIDER BACKHEAD ROTOR REAR BEARING PLATE MOTOR HOUSING FRONT BEARING PLATE STEP OVER IDLER GEAR STEP OVER FINAL GEAR MOTOR ADAPTER CYLINDER (INCL. 86, ) STEP OVER PINION ND REDUCTION SPIDER GEAR CASE GEAR HOUSING GEAR COVER GOVERNOR SPRING ST REDUCTION IDLER GEAR (5/0) EXHAUST DEFLECTOR MUFFLER RETAINER RING SPEED INDICATING RING (5/0) SHAFT KEY RETAINER RING SPEED INDICATING RING (555) SHAFT BEARING FLAT HEAD SCREW INDEXING BLADE SPEED ADJUSTING STUD AUXILIARY SPRING CAP PRESSURE CAP (INCL. 8449) SPRING SPEED LOCK BODY SPEED LOCK SCREW SPIDER (5/750) SPEED RING INDICATING RING (5/750) METERING SLEEVE THROTTLE VALVE SPRING THROTTLE LEVER BUSHING GREASE FITTING (NOT SHOWN) NAME PLATE (NOT SHOWN) FRONT CYLINDER PIN IDLER GEAR PIN (5/0) "O"RING /6" X " DRIVE SCREW (NOT SHOWN) BALL BEARING * 8479* * * * BALL BEARING PIN RETAINER RING PIPE PLUG (NOT SHOWN) "O"RING 7/ X /" RETAINER RING SCREW IDLER GEAR PIN (55/5) IDLER GEAR BEARING (5/0) REAR CYLINDER PIN BALL BEARING SPRI NG "O"RING /6" X /6" THROTTLE VALVE (INCL ) SCREW NEEDLE BEARING SPEED ADJUSTMENT CAP PIN SET SCREW BALL BEARING SHIM (.005") IDLER GEAR BEARING (55/5) THRUST RACE PIN GOVERNOR WEIGHT "O"RING /8" X 5/6" "O"RING /8" X /" THROTTLE PLUG THROTTLE VALVE PIN THROTTLE VALVE BUSHING INLET BUSHING THUMB THROTTLE ROTOR BLADE THROTTLE VALVE SEAL SHIM (.00") "O"RING 5/64" X /64" REAR ROTOR BEARING AIR FITTING (NOT SHOWN) AIR LINE (SPECIFY LENGTH) (NOT SHOWN) IDLER GEAR PIN SCREW * DENOTES PARTS NOT INCLUDED IN POWER UNIT SUBASSEMBLIES. **QUANTITY OF SHIMS REQUIRED IS VARIABLE. IDLER GEAR INCLUDES NEEDLE BEARING. THE COMPLETE POWER UNIT CAN BE PURCHASED AS SUBASSEMBLY. 55/5 CODE NO /0 CODE NO /750 CODE NO ** 4 ** 9

10 CHARTS SPINDLE FEEDS FEED WORM WORM WHEEL S400 LEAD SCREW S600 LEAD SCREW HALF NUTS CROSS SHAFT SUB ASSY NOSES S400 THREAD INSERT S /4" 6L.H. " 4L.H. /4" L.H. /" L.H. " 6L.H CHUCK AND MORSE TAPER ADAPTORS PART NO. NAME OF PART NO. 4 MORSE TAPER NO. MORSE TAPER NO. MORSE TAPER NO. MORSE TAPER CHUCK KEY /" CAP. CHUCK 0

11 NOTES

12 Sales & Service Centers Note: All locations may not service all products. Please contact the nearest Sales & Service Center for the appropriate facility to handle your service requirements. Dallas, TX Detroit, MI Houston, TX Lexington, SC Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group Sales & Service Center Sales & Service Center Sales & Service Center 670 Industrial Drive 470 Post & Paddock 60 Superior Court 6550 West Sam Houston Lexington, SC 907 Grand Prairie, TX Auburn Hills, MI 486 Parkway North, Suite 00 Tel: Tel: Tel: Houston, TX 7704 Tel: Fax: Fax: Tel: Fax: Fax: Los Angeles, CA Seattle, WA York, PA Canada Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group Sales & Service Center Sales & Service Center Sales & Service Center Sales & Service Center 550 Blackburn Avenue 865 5nd Avenue N.E. 990 East Market Street 595 McLaughlin Road Norwalk, CA Redmond, WA 9805 York, PA 740 Mississauga, Ont. L5R B8 Tel: Tel: Tel: Canada Fax: Fax: Fax: Tel: Fax: Germany England France China Cooper Power Tools Cooper Power Tools Cooper Power Tools SAS Cooper (China) Co., Ltd. GmbH & Co. OHG GmbH & Co. OHG a company of a company of a company of a company of Apex Tool Group, LLC Apex Tool Group, LLC Apex Tool Group, LLC Apex Tool Group, LLC 5 rue Maurice Chevalier 955 Sheng Li Road, Industriestraße C/O Spline Gauges 770 OzoirLaFerrière Heqing Pudong, Shanghai 746 Westhausen Piccadilly, Tamworth France China 00 Germany Staffordshire B78 ER Tel: Tel: Tel: +49 (0) United Kingdom Fax: Fax: Fax: +49 (0) Tel: Fax: Mexico Brazil Hungary Cooper Tools Cooper Tools Industrial Ltda. Cooper Tools Hungaria Kft. de México S.A. de C.V. a company of a company of a company of Apex Tool Group, LLC Apex Tool Group, LLC Apex Tool Group, LLC Av. Liberdade, 4055 Berkenyefa sor 7 Vialidad El Pueblito #0 Zona Industrial Iporanga Pf: 640 Parque Industrial Querétaro Sorocaba 907 Györ Querétaro, QRO 760 SP Brazil Hungary Mexico Tel: Tel: Tel: +5 (44) 800 Fax: Fax: Fax: +5 (44) 0044 Apex Tool Group, LLC 000 Lufkin Road Apex, NC 759 Phone: Fax: /Printed in USA 06/0/Copyright Apex Tool Group, LLC

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