Atlas Copco PFD1500RA-180, Product Instructions

Page 1: ...d from Serial No B2420001 Product Instructions PFD1500RA 180 180 r min 8440150002 WARNING Read all safety warnings and instructions Failure to follow the safety warnings and instructions may result in electric shock fire and or serious injury Save all warnings and instructions for future reference ...

Page 2: ...vice Overview 11 Service Recommendations 11 Installation 12 Installation Requirements 12 Air quality 12 Air Lubrication Guide 12 Compressed Air Connection 12 Installation Instructions 12 Installing the rapid advance kit 12 Changing the spindle 17 Installing the scraper kit for drills with indexer 19 Installing the drill 21 Installing the indexer 23 Installing the ChipLet 25 Changing the air inlet ...

Page 3: ...ning 39 Lubrication guide 39 Motor valve 40 Range gear 40 Indexer 4141 0912 90 41 Range gear 42 Split gear 42 Indexer 4141 0306 91 43 Head 44 Motor 46 Repair Instructions 46 Release the spindle 46 Dismantling Assembling Instructions 49 Instructions for vane motor 49 Instructions for vane motor 51 Assembling Indexer 53 Troubleshooting 54 Troubleshooting overview 54 Test of overload clutch 55 Leak t...

Page 4: ... not related to personal injury Warranty Product warranty will expire 12 months after the product is first taken into use but will in any case ex pire at the latest 13 months after delivery Normal wear and tear on parts is not included within the warranty Normal wear and tear is that which requires a part change or other adjustment overhaul during standard tools maintenance typical for that period...

Page 5: ...o representative Safety Data Sheets MSDS SDS The Safety Data Sheets describe the chemical products sold by Atlas Copco Please consult the Atlas Copco website for more information www atlascopco com sds Country of Origin For the Country of Origin please refer to the information on the product label Dimensional Drawings Dimensional Drawings can be found either in the Dimensional Drawings Archive or ...

Page 6: ...e drill bit 3 Head Transfers rotational torque and feed from the motor to the spindle 4 Feed cassette Defines spindle feed rate Mea sured in inches per revolution IPR or millimeters per revolution mm rev 5 Air logic Operates the drill 6 Split gear Defines rotational speed Measured in revolutions per minute RPM 7 Range gear Defines RPM range 8 Vane motor Supplies power and rotation to the spindle 9...

Page 7: ...ns the spindle to the starting position at any time during drilling cycle The motor switches off auto matically after retract 13 Emergency stop Switches off the motor and stops the spindle at any time during drilling cycle Once pressed the emergency stop button locks in po sition You must manually reset the emergency stop to restart the drill Technical Product Data Technical Product Data can be fo...

Page 8: ... Controls the drilling depth Once the depth ring reaches the valve it activates the valve and the spindle retracts into the starting position The motor automatically switches off after retract 4 Starting position valve Controls the starting position for drilling Once the starting position ring reaches the valve it activates the valve that switches off the mo tor You can calculate the distance betw...

Page 9: ... 0043 92 1 1 180 4141 0043 92 High 200 4141 0043 90 Low 270 4141 0043 90 1 1 360 4141 0043 90 High 400 4141 0043 94 Low 530 4141 0043 94 1 1 700 4141 0043 94 High 670 4141 0043 93 Low 900 4141 0043 93 1 1 1200 4141 0043 93 High 1330 4141 0043 91 Low 1770 4141 0043 91 1 1 2360 4141 0043 91 High A split gear ratio can be set to high 1 1 or low depending on the position of the shaft 1 in the relation...

Page 10: ...e rpm Velocity rapid advance mm s 10 Velocity rapid advance inch s 10 PFD 1500RA 38 R 38 1 4 0 06 PFD 1500RA 50 R 50 1 9 0 07 PFD 1500RA 67 R 67 2 5 0 10 PFD1500RA 100 R 100 3 7 0 15 PFD1500RA 140 R 140 5 2 0 20 PFD1500RA 180 R 180 6 7 0 26 PFD1500RA 200 R 200 7 4 0 29 PFD1500RA 270 R 270 10 0 0 39 PFD1500RA 360 R 360 13 3 0 52 PFD1500RA 400 R 400 14 8 0 58 PFD1500RA 530 R 530 19 7 0 78 PFD1500RA ...

Page 11: ...you can change the feed rates as shown in the figure below Feed cassette IPR mm rev Ordering No 0 001 0 023 4141 0034 91 0 002 0 05 4141 0034 92 0 003 0 075 4141 0034 93 0 004 0 10 4141 0034 94 0 006 0 16 4141 0034 95 0 008 0 21 4141 0034 96 0 010 0 27 4141 0034 95 0 013 0 33 4141 0034 94 0 014 0 36 4141 0034 93 0 015 0 38 4141 0034 92 0 016 0 42 4141 0034 91 Service Overview Service Recommendatio...

Page 12: ...inue with the lubrication Air Lubrication Guide Brand Air lubrication Atlas Copco Optimizer 1 liter 9090 0000 04 Q8 Chopin 46 Shell Shell Air Tool Oil S2 A 320 Compressed Air Connection WARNING Risk of severe injury Air under pressure can cause injury Always shut off the air supply when not in use or before any adjustments Drain the hose of air pressure and disconnect the tool from air supply when...

Page 13: ...len key 14 Pull out the bevel gear straight up from the head 15 Pull out the cylinder straight down from the head 16 Replace the cylinder with the new one included in the kit Put it back in position 17 Replace the bevel gear with the new one included in the kit and put it back in position 18 Put the lower head back in original position Tighten it with screws 19 Loosen the drill Turn the drill over...

Page 14: ...d fasten it in the vise Connect the air hose to the nipple Do a functional test of the emergency stop button 1 Push the start button 2 Push the emergency stop button so that it locks in position The spindle must stop immediately 3 Pull the emergency stop button to reset it The motor must not restart 4 Disconnect the air hose ...

Page 15: ...PFD1500RA 180 EN Installation Atlas Copco Industrial Technique AB 9836 6024 01 15 ...

Page 16: ...Installation EN PFD1500RA 180 16 Atlas Copco Industrial Technique AB 9836 6024 01 ...

Page 17: ...sten the drill in a vise with rubber pads with the front part upward and the drill handle to the right Remove the front part and the drill bit 2 Turn the drill over and fasten it in the vise Remove the spindle guard 3 Remove the depth ring from the spindle with the fork shaped tool 4 Note the position of the feed cassette The markings on the cassette end closest to the spindle indi cate the actual...

Page 18: ...it in the vise Connect the air hose to the nipple Do a functional test of the emergency stop button 1 Push the start button 2 Push the emergency stop button so that it locks in position The spindle must stop immediately 3 Pull the emergency stop button to reset it The motor must not restart 4 Disconnect the air hose ...

Page 19: ... Vise Spanner Allen key Mounting tool Prerequisites Before installing the scraper kit make sure that the following components are removed Front part Drill bit Spindle Spindle guard 1 Fasten the drill in a vise 2 Remove the adapter and the screw 3 Put the indexer housing in position on the adapter shaft 4 Apply a few drops of thread locker on the nut threads and fasten the nut on the indexer housin...

Page 20: ...h to the nut surface with a tolerance level of less than 0 3mm above the surface 7 Remove the stop nuts on the spindle 8 Install a scraper ring on the spindle and fasten it with four screws Make sure that the chamfered edge of the scraper ring is pointing towards the drill bit 9 Install the spindle stop nut on the spindle 10 Install the spindle in the drill 11 Install the spindle stop nut on the s...

Page 21: ...rp cutting edges Only experi enced maintenance personnel can assemble or disassemble the product Required tools Vise Torx wrench Allen key Fork shaped tool Hexagonal tool Spanners 1 Fasten the drill in a vise with rubber pads with the air logic unit upward and the drill handle to the right 2 Note the position of the feed cassette The markings on the cassette end closest to the spindle indi cate th...

Page 22: ...cannot install the cassette easily turn its splines with the fork shaped tool to align them 9 Install the washers and the four screws in the original position Tighten the screws Install the lock and the lock screw Tighten the screw 10 Put the spindle guard back in the original position and secure it 11 Turn the drill upside down and fasten it in the vise Put the drill bit in the spindle Place span...

Page 23: ...nique AB 9836 6024 01 23 Installing the indexer WARNING Make sure that the air supply is not connected CAUTION Wear gloves to avoid personal injury because of sharp cutting edges Only experi enced maintenance personnel can assemble or disassemble the product ...

Page 24: ... the index housing is put in correct position the plug to the right of the screw hole will now fit into the index housing 4 Put the nut into the index housing with the threads downwards Tighten the nut with a pin spanner 5 Put the waved washer and the shaft with the splines downwards into the index housing 6 Push the button on the index housing so the nut easily moves down to the bottom Tighten th...

Page 25: ...t Spindle Spindle guard 1 Fasten the drill in a vise 2 Remove the screw and the feed cassette cover 3 Remove the four screws with the two washers and the feed cassette 4 Remove the depth position valve 5 Remove the two screws and the cap 6 Remove the thrust washer 7 Put the chiplet with the o ring in position A click sound is heard when the chiplet is in position 8 Fasten the chiplet with two scre...

Page 26: ...Installation EN PFD1500RA 180 26 Atlas Copco Industrial Technique AB 9836 6024 01 ...

Page 27: ... that the air supply is not connected CAUTION Wear gloves to avoid personal injury because of sharp cutting edges Only experi enced maintenance personnel can assemble or disassemble the product Required tools Vise Spanner 1 Remove the adapter Make sure that the filter is still in place 2 Replace the adapter with the new one included in the box Move the o ring from the old adapter to the new one 3 ...

Page 28: ...e removed Front part Drill bit Spindle Spindle guard 1 Fasten the drill in a vise 2 Remove the adapter 3 Remove the stop nuts on the spindle 4 Install a scraper ring on the spindle and fasten it with four screws Make sure that the chamfered edge of the scraper ring is pointing towards the drill bit 5 Install the spindle stop nut on the spindle 6 Install the spindle in the drill 7 Install the spind...

Page 29: ...PFD1500RA 180 EN Installation Atlas Copco Industrial Technique AB 9836 6024 01 29 Preparation for the spindles 4141 0253 XX Using this spindle you can define your own thread size ...

Page 30: ...pindle read the following instructions 1 Remove the rings from the spindle 2 Insert the spindle in a collet chuck with Ø16 mm 3 Clamp the collet chuck over the spindle thread The thread should not stick out more than L1 See figure below 4 Note the dimension of the drilling depth L2 and the thread size L3 See figure below ...

Page 31: ...k positions above shoulder level or with static holding during assembly operations When working above shoulder level reduce the load on the static muscles by reducing the weight of the load You can also reduce the load on the static muscles by holding the load close to the body Make sure to take frequent breaks Avoid extreme arm or wrist postures particularly for operations requiring a degree of f...

Page 32: ...he spline shaft 2 until the shaft 1 fits in place 5 Holding the pinion 3 in place with the fork shaped tool 4080 1114 00 turn the spline shaft 2 and gently push the split gear forward until the shaft 1 fits on the pinion 6 Gently push the split gear forward until it clicks in place 3 If applicable install a new range gear Otherwise restore the old one to its original position Turn the planetary ge...

Page 33: ...enced maintenance personnel can assemble or disassemble the product To replace a feed cassette do as follows 1 Remove the old cassette 2 Put the new cassette in position Before you secure the cassette read the marking on the cassette end closest to the spindle to make sure that the orientation of the cassette is correct 3 Before operating the drill do a functional test of the emergency stop button...

Page 34: ...ol during operation Following conditions apply prior to operating the drill Front part locked in the fixture Air hose connects to the drill Test the emergency stop button as follows 1 Push the start button 2 Push the emergency stop button so that it locks in position The spindle must stop immediately 3 Pull the emergency stop button to reset it The motor must not restart 4 Disconnect the air hose ...

Page 35: ...uickly advance the drill bit to the work surface push the rapid advance button optional Make sure to stop the drill bit at a safe distance from the work surface To start drilling push the start button To stop drilling and retract the spindle into the start po sition push the retract button To switch off the motor in case of emergency push the emergency stop button To reset the emergency stop and r...

Page 36: ...please see spare parts list Spindle Drill bit Material Drill bit Material Drill bit Material 1 2 Titan Alu 3 4 Titan Alu 1 1 4 Titan Alu Cycles Use kit Ordering No Use kit Ordering No Use kit Ordering No Every 1000 drilled holes Every 3000 drilled holes 4141 0087 80 4141 0087 90 Every 6000 drilled holes 4141 0087 80 4141 0087 90 4141 0087 80 4141 0087 90 Every 12000 drilled holes Every 24000 drill...

Page 37: ...an Alu Cycles Use kit Ordering No Use kit Ordering No Use kit Ordering No Every day Test function Test function Test function Every 1000 drilled holes Every 3000 drilled holes Every 6000 drilled holes Every 12000 drilled holes Every 24000 drilled holes 4141 0102 91 4141 0102 91 4141 0102 91 Every 48000 drilled holes Emergency stop Air logic Drill bit Material Drill bit Material Drill bit Material ...

Page 38: ... 3000 drilled holes Every 6000 drilled holes 4141 0051 90 Every 12000 drilled holes Every 24000 drilled holes 4141 0051 90 Every 48000 drilled holes Feed cassette Drill bit Material Drill bit Material Drill bit Material 1 2 Titan Alu 3 4 Titan Alu 1 1 4 Titan Alu Cycles Use kit Ordering No Use kit Ordering No Use kit Ordering No Every 1000 drilled holes Every 3000 drilled holes Every 6000 drilled ...

Page 39: ...rill bit Material Drill bit Material 1 2 Titan Alu 3 4 Titan Alu 1 1 4 Titan Alu Cycles Use kit Ordering No Use kit Ordering No Use kit Ordering No Every 1000 drilled holes Every 3000 drilled holes 4081 0457 90 4081 0457 90 Every 6000 drilled holes 4081 0457 90 Every 12000 drilled holes Every 24000 drilled holes Every 48000 drilled holes 4141 0168 90 4141 0168 90 4141 0168 90 Lubrication Instructi...

Page 40: ...dustrial Technique AB 9836 6024 01 Motor valve Pos Description A1 Apply a thin layer of lubricant A Range gear Total amount of lubrication 15 ml Turn gear while lubricating at least two turns Ensure that gear is running normally without hacking ...

Page 41: ...bricate with lubricant A before assem bly A2 Ensure that needle bearings are completely filled with lubricant A A3 Ensure that the O rings are well greased with lubricant A Indexer 4141 0912 90 Pos Description A1 Apply a thin layer of lubricant A A2 Ensure that the O rings are well greased with lubricant A A3 Ensure that all cog gaps are well filled with lubricant A ...

Page 42: ...sliding surface of the ra dial seals are lubricate with lubricant A before assem bly A2 Ensure that needle bearings are completely filled with lubricant A A3 Ensure that the O rings are well greased with lubricant A Split gear Total amount of lubrication 15 ml Pos Description A1 Ensure that the radial seals are filled with lubricant A before assembly also lubricate the outside and sliding surfaces...

Page 43: ...o Industrial Technique AB 9836 6024 01 43 Indexer 4141 0306 91 Pos Description A1 Apply a thin layer of lubricant A A2 Ensure that the O rings are well greased with lubricant A A3 Ensure that all cog gaps are well filled with lubricant A ...

Page 44: ...ation 28 ml Pos Description A1 Apply a thin layer of lubricant A A2 Ensure that the O rings are greased with lubricant A A3 Ensure that all cog gaps are well filled with lubricant A A4 Fill inner trapezoidal thread with lubricant A A5 Ensure that all cog gaps are well filled with lubricant A 5 ml per part ...

Page 45: ... A2 Ensure that the O rings are well greased with lubricant A A3 Ensure that all cog gaps are well filled with lubricant A A4 Apply a thin layer of lubricant A inside A5 Apply minimum 10 ml of lubricant A Only for models with rapid advance Pos Description A1 Ensure that all cog gaps are well filled with lubricant A 5 ml per part ...

Page 46: ...yer of lubricant B on end plates shall cover rotor diameter B3 Inside cylinder complete motor add two drops of lu bricant B through entrance hole at back end plate turn rotor so the oil will spread in motor Repair Instructions Release the spindle WARNING Make sure that the air supply is not connected CAUTION Wear gloves to avoid personal injury because of sharp cutting edges Only experi enced main...

Page 47: ...e with a wrench until the spindle is released 7 Pull out the pin spanner 8 Install the clutch in the original position 9 Put the feed cassette in the original position making sure that the markings on the cassette end clos est to the spindle indicate the required feed rate 10 If you cannot install the cassette easily turn its splines with the fork shaped tool to align them 11 Install the washers a...

Page 48: ...Service EN PFD1500RA 180 48 Atlas Copco Industrial Technique AB 9836 6024 01 ...

Page 49: ... ponents Do not smoke when servicing this product PTFE particles must not come in contact with open fire glow or heat Motor components must be washed with cleaning fluid and not blown clear with an air line Wash your hands before starting any other activity Dismantling Service tools are also included in the Basic Service Tools set For further information see ordering No 9835 5485 00 Dismantling to...

Page 50: ...included in the Basic Service Tools set For further information see ordering No 9835 5485 00 Dismantling tool Mandrel B Ordering No Ø D Ø C 4080 0567 04 12 5 5 2 4080 0567 11 14 5 6 5 4080 0567 01 15 5 5 2 4080 0567 05 18 5 6 2 4080 0567 02 18 5 8 2 4080 0567 06 21 5 7 5 4080 0567 03 21 5 8 2 4080 0567 07 25 5 10 5 4080 0567 08 27 5 12 5 4080 0567 09 31 5 15 5 4080 0567 10 34 5 18 5 ...

Page 51: ...oke when servicing this product PTFE particles must not come in contact with open fire glow or heat Motor components must be washed with cleaning fluid and not blown clear with an air line Wash your hands before starting any other activity Dismantling Service tools are also included in the Basic Service Tools set For further information see ordering No 9835 5485 00 Dismantling tool Mandrel A Order...

Page 52: ...included in the Basic Service Tools set For further information see ordering No 9835 5485 00 Dismantling tool Mandrel B Ordering No Ø D Ø C 4080 0567 04 12 5 5 2 4080 0567 11 14 5 6 5 4080 0567 01 15 5 5 2 4080 0567 05 18 5 6 2 4080 0567 02 18 5 8 2 4080 0567 06 21 5 7 5 4080 0567 03 21 5 8 2 4080 0567 07 25 5 10 5 4080 0567 08 27 5 12 5 4080 0567 09 31 5 15 5 4080 0567 10 34 5 18 5 ...

Page 53: ...hread of the nut from glue 3 Check the splines on the lower part that is attached to the front part of the indexer for damage Clean off any glue 4 Check the splines on the lock pin on the indexer s upper housing for damage and clean off any glue As the indexer is parted push the button to ensure that the lock pin on the indexer runs smoothly in and out of the housing 5 Replace the part or complete...

Page 54: ...ve 4 Overload clutch The table below describes the most common problems possible reasons and actions to troubleshoot them Problems Possible reasons Actions The motor stops after the release of the start button The rapid advance button functions properly Starting position valve leaks 1 Remove the starting position valve 2 Do a leak test of the valve see the section Leak test 3 If the results of the...

Page 55: ...d by reducing the feed rate or chang ing the drill bit Then complete the procedure If the test without load shows no improvement continue the procedure Overload clutch is stuck in the open position 9 Remove the feed cassette 10 Remove the overload clutch If the clutch makes a loud click it has been released Install the clutch in the original position and test the drill If the drill performance im ...

Page 56: ...it to 0 7 Nm See the figure below 3 Connect an air hose to the connector 2 4 Press the tool lever two to three times to supply the air pressure of 6 3 bar 90 psi 5 Measure the leakage with a leakage meter Air leakage during 10 seconds must be less than 0 3 l min 6 If the result of the test is unsatisfactory replace the valve If the test shows no fault continue the pro cedure 7 Install the valve in...

Page 57: ...1 57 Recycling Environmental Regulations When a product has served its purpose it has to be recycled properly Dismantle the product and recycle the components in accordance with local legislation Batteries shall be taken care of by your national battery recovery organization ...

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Page 60: ...authorized use or copying of the contents or part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings Use only authorized parts Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability Out of respect to wildlife and nature our technical literature is printed on environmentally friendly...