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Ingersoll-Rand 8658-B()-() and 8659-B()-() manual

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Table of contents for the manual

  • Page 1

    Tool Products OPERATOR’S MANUAL INCLUDING: OPERATION, INSTALLATION & MAINTENANCE LEAD SCREW TAPPER Models: 8655-B()-(), 8656-B()-(), 8657-B()-(), 8658-B()-() and 8659-B()-(). SECTION M 104 MANUAL 32 Released: 5/78 Revised: 8-11-95 Form: FEATURES: “NO-HOLE” SENSOR SYSTEM FIVE (5) ACCESSORY PORTS PRECISION MOUNTED SPINDLE 1/2”, 7/16”, 3[...]

  • Page 2

    GENERAL DESCRIPTION AND OPERATION The tapping cycle is started by manually actuating and releasing “START’ valve at the tool. The start valve must be held long enough to allow the stop signal valve to close (page 9); about one (1) second duration for most applications. NOTE: For very low spindle speeds with medium to fine pitch lead screw, the [...]

  • Page 3

    GENERAL DESCRIPTION AND OPERATION 32 Also contained in the valve section are five (5) 1/8” NPT ports for PORT “C” is pressurized during the advance and retract cycles accessory purposes. The ports and their functions are listed as and is not pressurized when the unit is stopped. This port can be - follows: used to control a valve for coolant,[...]

  • Page 4

    SET-UP PROCEDURE SET-UP PROCEDURE: The ARO Lead Screw Tapper is adapt- able to many applications. Its maximum stroke of 2” can be re- duced to a minimum stroke of 3/16” by adjusting the “RETRACT’ and “STOP” trip tabs, located beneath the nameplate door. Any stroke setting of less than 2” can be positioned at any point within the 2” [...]

  • Page 5

    SET-UP PROCEDURE M104 The following items must be given proper consideration to cor- rectly apply the ARO Lead Screw Tapper. 1. Accuracy of positioning the tapdrilled hole with the tapper (X, Y and Z axis). 2. Speed at which the material should be tapped (S.F.M., see page 29) 3. Size and diameter variation of the hole to be tapped (% of ef- fective[...]

  • Page 6

    AIR AND LUBE REQUIREMENTS FOR LUBRICATION OF GEARING ASSEMBLY FOR LUBRICATION OF GEARING ASSEMBLY LUBRICATION POINTS (GREASE FITTING LOCATIONS) Air pressure of 90 p.s.i.g. (6.2 bars) at the air inlet of the tool is re- quired for maximum motor efficiency. An air regulator should be’ installed to maintain this pressure when the tool is in operatio[...]

  • Page 7

    MODEL IDENTIFICATION M104 82 Model numbers are comprised of the basic model number, thread pitch or lead of the lead screw and American or Metric thread as shown in the following: Basic Number Dash Number lndicates Lead or Pitch The basic difference in the Lead Screw Tapper models is in the combination of gearing assemblies (gear ratio) which deter[...]

  • Page 8

    MAINTENANCE Disconnect air supply from the tool or shut off air supply and ex- haust (drain) line of compressed air BEFORE performing mainte- nance or service to tool. Tool maintenance and repair should be performed by authorized, trained, competent personnel. Maintenance and repair records should be maintained on all tools. Insure tool is receivin[...]

  • Page 9

    TYPICAL CROSS SECTION OF TOOL STOP SIGNAL VALVE OPEN SECTION A-A & INSTALL WIPER IN THIS POSITION M104 32 SPINDLE HAS ADVANCED SUFFICIENTLY TO ALLOW BRACKET TO MOVE CLEAR OF TRIP TAB, THUS ALLOWING STOP SIGNAL VALVE TO CLOSE. STOP SIGNAL VALVE CLOSED 9[...]

  • Page 10

    VALVE SECTION DISASSEMBLY To remove manifold (42432-1) remove six (6) cap screws (Y154-57) and four (4) washers (Y14-10). NOTE: Springs (31125) and balls (44967) are loose parts and may drop out. To remove valve stem (40522) and spring (31125) remove pipe plug (Y227-2-L). NOTE: Gaskets (40524 and 45459) should be re- placed with new gaskets if mani[...]

  • Page 11

    VALVE SECTION M104 32 I DO NOT USE WASHERS WHEN ASSEMBLING 40524 AND 45459 GASKETS AND 49164 PLATE BE- ON 2 CENTER SCREWS. TWEEN 42433-1 AND 42164-1 ASSEMBLIES, TORQUE THE SIX Y154-57 SCREWS DOWN EVENLY TO ABOUT 50 IN. LBS. FURTHER TIGHTEN EACH I 3 SCREW TO 70 5 IN. LBS USING THE PATTERN SHOWN. 42433-1 MANIFOLD AND VALVE ASSEMBLY Y227-2-L PIPE PLUG[...]

  • Page 12

    POWER UNIT SECTION GEARING INTERCHANGE CHART A CHANGE OF 41219-() AIR TUBES IS REQUIRED WHEN CONVERTING FROM SINGLE GEARING TO DOUBLE GEARING OR VICE VERSA. PRESENT DESIRED SPEED OF TAPPER SPEED 175 R.P.M. 325 R.P.M. 600 R.P.M. 1,300 R.P.M. 2,400 R.P.M. REMOVE ADD REMOVE ADD REMOVE ADD REMOVE ADD REMOVE ADD x 40834 40833 175 R.P.M. 40834 40834 4083[...]

  • Page 13

    POWER UNIT SECTION M104 32 41369 RING GEAR 37127 SPACER 37123 SPINDLE 37124 SHAFT (2) 33704 BEARING 41371 GEARING ASS’Y (7.43:1) 37126 SPACER 37128 SPACER -- Y154-55 CAP SCREW (4) l Y14-10 LOCK WASHER (4)* INCLUDES 37121 NEEDLE BEARING l NOT INCLUDED WITH GEARING ASSEMBLY AUXILIARY GEARING DISASSEMBLY REASSEMBLY Grasp ring gear in one hand and ta[...]

  • Page 14

    POWER UNIT SECTION MOTOR ASSEMBLY DISASSEMBLY Remove nut (33694) and sems fastener (33700). Grasp cylinder in one hand and tap splined end of rotor with a soft face hammer; motor will come apart. REASSEMBLY Pack bearings with 40036-1 grease, or equivalent, and coat i.d. of cylinder with 29665 spindle oil upon assembling. Assemble bearings into end [...]

  • Page 15

    POWER UNIT SECTION M104 32 MOTOR HOUSING AND AIR TUBES 41219-4 TUBE (2) Y325-14 “0” RING (2) (USE WITH SINGLE GEARING ONLY) 41219-5 TUBE (2) (USE WITH DOUBLE GEARING ONLY) ----- 7 I 0 NOTE: When assembling motor housing to gearing, it may be necessary to use one (1) or more gaskets (42338) for proper spacing. Use quantity supplied with tool. 0 [...]

  • Page 16

    SPINDLE AND LEAD SCREW SECTION DISASSEMBLY To remove spindle and sleeve assembly (41242-1) the valve section must be removed to gain access to bracket (41235) set screws and taper pin which hold the drive spindle (41239-1) and shaft (40516-1) together. Remove as outlined under “Valve Sec- tion”, page 8. See “Spindle and Lead Screw Section” [...]

  • Page 17

    SPINDLE AND LEAD SCREW SECTION 32 17[...]

  • Page 18

    RECOMMENDED POWER AIR INLET SYSTEM MALE THREAD CONNECTOR MODEL 23904-310, 3/8” N.P.T.F. MODEL 23104-400 COUPLER 1/2” FEMALE N.P.T.F. 1/2” I.D. HOSE WITH 1/2” N.P.T.F. MALE FITTlNG EACH END (REC- OMMENDED MAXIMUM LENGTH, 4 FEET) INSTALL LUBRICATOR AS CLOSE AS POSSIBLE TO TAPPER -MODEL C28241-810 FILTER-REGULATOR- GAUGE-LUBRICATOR ASSEMBLY MO[...]

  • Page 19

    BASIC REMOTE CONTROL FOR START M104 AND EMERGENCY RETRACT FUNCTIONS 32 Remote start is accomplished by introducing a momentary pres- sure signal to port “B”, using fitting, valve and signal quality tubing as shown. The pressure signal should be about one (1) second in duration, this is sufficient for most applications. NOTE: For very low spindl[...]

  • Page 20

    NO-HOLE SENSOR SYSTEM ‘TUBE 44638-010-M 7 PORT PORT ‘THIS NUMBER DENOTES A PACKAGE OF TEN (10). The “B” series Lead Screw Tapper models have a built-in system that will cause the unit to retract if there is no pre-drilled hole pres- ent in the workpiece or in an excessive mis-alignment of hole in workpiece with the tap of tool. To use this [...]

  • Page 21

    “TOOL IS BACK” CONNECTIONS M104 32 “Tool is back” signal, used to interlocktapper with machinery, acti- vate coolant, etc., may be accomplished by connecting port “c” as shown below. Air supply is taken from port “A” and the pilot pressure is taken from port “C”. When the tapper is retracted and shut off, the pilot valve is deac[...]

  • Page 22

    ACCESSORIES 448960-() TAP COLLET (SEE TABLE FOR DASH NUMBER) MUST BE USED WITH 44669 COLLET HOLDER COLLET HOLDER 44690-4 No. 12 I .220” 44890-5 No. 14 & 1/4 6.0 .255” 44890-6 5/16 7.0 - 0.0 .318” 44890-7 3/8 .361” 44890-8 7/16 10.0 .323” l FOR 1/16 PIPE & 1/8 S.S. PIPE TAPS 41374 (INCLUDES NUT WRENCH, BODY WRENCH AND HEX KEY FOR B[...]

  • Page 23

    ACCESSORIES M104 DUAL SPINDLE SECTION 32 DISASSEMBLY REASSEMBLY The dual spindle attachment can be serviced without removing the complete assembly from the tool. Using the 4 mm hex wrench supplied with the unit, loosen both adjusting screws (45992) - NOTE: Alternately unthread adjusting screws approximately 1/2 turn at a time or unthread screws sim[...]

  • Page 24

    ACCESSORIES MOUNTING THE DUAL SPINDLE ATTACHMANT TO THE LEAD SCREW TAP-[...]

  • Page 25

    ACCESSORIES M104 DUAL SPINDLE SECTION 32 DISASSEMBLY REASSEMBLY The dual spindle attachment can be serviced without removing the complete assembly from the tool. Using the 5 mm hex wrench supplied with the unit, loosen both adjusting screws (46036) NOTE: Alternately unthread adjusting screws approximately 1/2 turn at a time or unthread screws simul[...]

  • Page 26

    ACCESSORIES t - t MOUNTING THE DUAL SPINDLE ATTACHMENT TO THE LEAD SCREW TAP-[...]

  • Page 27

    CONNECT TO SENSOR VALVE-“F” PORT ACCESSORY PORT REMOTE START PORT SECONDARY EXHAUST EXIT REMOTE RETRACT PORT TO SUPPLY AIR TO SENSOR VALVE-PORT “G”: MANUAL START BUTTON 3/8 N.P.T. AIR INLET PRIMARY EXHAUST EXIT I (ALL PORTS 1/8 NPT) *B MAX. CHUCK AT min cap ACCESS PORT FOR LEAD NUT TENSION ADJUSTMENT *C MAX. WITH CHUCK AT MAX CAP - (APPROX.[...]

  • Page 28

    TROUBLE SHOOTING LISTED BELOW ARE SOME OF THE MOST COMMON CAUSES FOR THE LEAD SCREW TAPPER TO MALFUNCTION. MALFUNCTIONS BEYOND THE SCOPE OF THIS MANUAL SHOULD BE BROUGHT TO THE ATTENTlON OF YOUR ARO REPRESENTATIVE OR RETURN THE TOOL TO THE FACTORY FOR REPAIR. CONDITION LOW SPEED OR FAILURE TO OPER- ATE. UNIT WILL NOT RE- TRACT PROPERLY. UNIT RETRAC[...]

  • Page 29

    M104 32 CUTTING FACE ANGLES, SPEEDS AND LUBRICANTS FOR TAPPING VARIOUS MATERIALS ZINC, DIE CAST I I 10- 12° I 60 - 70 I SOLUBLE OIL Speeds listed apply to high speed steel taps only. Carbon taps are not recommended for production tapping. If used, however, they should be run at speeds no greater than 50% of those listed.[...]

  • Page 30

    TABLE OF SPEEDS FRACTIONAL SIZE TAPS REVOLUTIONS PER MINUTE MACHINE SCREW TAPS MACHINE 0 1 SCREW NO. 2 3 4 5 6 0 10 12 14 __..._. . .099 .112 .125 .138 .164 .190 .216 .242 REVOLUTIONS PER MINUTE 2 1 682 1 611 1 1 554 1 468 1 402 5 853 1 354 XA 1 co., I 1 1 co, , 1 1048 1 905 736 710 I 60 1 3820 1 3139 1 I I 70 75 1 1 1 1 , , 1 1149 , ,026 , I 80 1 [...]

  • Page 31

    COMMON TAP PROBLEMS TROUBLE CAUSE TAP BREAKAGE 1. WRONG TYPE OF TAP. 2. DULL TAP. 3. TAP INCORRECTLY GROUND. 4. TAP DRILL TOO SMALL. 5. DRILLED HOLE TOO SHALLOW. 6. MISALIGNMENT OF TAP AND HOLE. 7. WRONG MACHINE. 6. INCORRECT FIXTURE OR HOLDING DEVICE. 9. WORK HARDENED MATERIAL. 10. LACK OF LUBRICANT OR USE OF WRONG TYPE. TAP FAILURE 1. TAP CUTTING[...]

  • Page 32

    I PART I TAP SIZE I NUMBER I INCH I NO. I MM 46033-l 5i-64 47 2.0 I 46033-2 I I 45 I 2.1 4M33-2 44 2.2 I 46033-4 I I 43 I 2.3 46033-5 I 3l32 42 I 2.4 I IAE ’ I M I 75 I 46033-6 36 2.7 46o3se 7i64 36 2.6 46033-10 33 2.9 UIL~~ll I 83 3” 46633-12 31 3.1 46633-13 l/6 3.2 46033-14 30 3.3 AanXG1 6 29 3.4 46033-16 3.5 46033-17 w64 26 3.6 46033-16 26 3[...]