Maintenance Information, Electric Screwdrivers
Contents
1. 1 Camis worn and not providing adequate lift Replace the Cam Controller malfunctioning or defective Repair or replace See Controller Service Manual Tool makes abnormal sounds when the motor is running s there looseness at the assembly points 1 Screws 2 are loose Tighten all Screws 2 Clutch Housing is loose Tighten the Clutch Housing to the proper torque After removing the gear train does motor sound normal when running 1 Armature 31 is in contact with the Magnet Replace the motor 2 Foreign material has gotten into the motor Clean or replace the motor 3 Ball Bearings are defective Replace the Motor 4 Armature is defective Replace the Motor Is the gear train properly lubricated No grease on the gear train Apply a thin film of the recommended grease to the gear train 1 Spindle Bearing has failed Replace the Spindle Assembly 40 2 Gears are worn or dirty Clean or replace the Gears Tool generates abnormal heat when operating After removing the gear train does tool cool down and motor run normally Motor is defective Replace the motor Planetary gears and the Clutch require lubrication Lubricate the Clutch and gear train with the recommended grease Note Do not apply tool much or too little grease Tool outputs high torque Is the shutoff brake functioning properly Refer to Problem No 4 to check shutoff brake malfunctions Is Clutch2. Cam 43 two Cam Pins 44 Thrust Washer 42 Spindle Assembly 40 and Gear Head Assembly 38 from the clutch end of the Gear Case d Inspect the Gear Head Planet Gears 39 Spindle Planet Gears 41 and the gear teeth in the Gear Case for chipped or broken teeth Apply a small amount of Ingersoll Rand No 67 Grease to the Gears Gear Case and Cam e Insert the Gear Head Assembly Planet Gears first into the clutch end of the Gear Case Make certain the Planet Gears mesh with the gear case spline L Insert the Spindle Assembly gear end leading into the Gear Case Make certain the Spindle Planet Gears mesh with the pinion of the Gear Head Install the Thrust Washer Cam Cam Pins and Collar into the Gear Case g The joint connecting the Gear Case to the Clutch Housing is a left hand thread Thread the Housing onto the Gear Case ina counterclockwise direction and tighten the joint to 21 ft lb 28 5 Nm torque Place the assembled motor gearing and clutch unit in the left side of the Housing For Models ES45T and ES5OT place the right side of the Housing against the left side and install the three Housing Screws For Model ES5OTC place a bead of Perma Lok GasketMaker HH190 around the edge of Shield Plate and the mating edges of the Housing Place the right side of the Housing against the left side and install the three Housing Screws For Models ES45T and ES5OT thread the Coupling 55 onto the
3. Does motor appear to be in good condition Carbon buildup or dirt on Armature 31 Clean the Armature using a good electrical contact cleaner and blow dry 45527801_ed1 Trouble Probable Cause Solution Screwdriver runs in one direction but not the other Are wire leads in good condition and properly soldered Defective solder connections Resolder and rewire if necessary Does Reverse Switch operate properly Defective Reverse Switch 9 Replace it Bit does not rotate but motor hums Shutoff brake malfunctions more than one index of the Clutch When gears are removed will the motor rotate Armature 31 is in contact with the magnets Replace the motor Foreign material in the motor Clean the motor s planetary gearing smooth when bit is rotated by hand Does the speed of the Bit exceed rated speed by more than 100 rpm 2 1 Bearing has failed Replace the Spindle Assembly 40 2 Gears are worn or damaged Replace any defective gearing 3 Clutch Assembly is worn Replace damaged or worn parts Motor magnet is demagnetized Replace the motor s Brake Switch functioning Does it click when button is depressed and does it test correctly with an ohmmeter Defective Brake Switch 15 Replace the Brake Switch Does Pushrod 35 or 46 function properly 1 Bent or worn Pushrod 35 or 46 Replace it Does Cam 43 function properly
4. Gear Case and tighten it with a wrench For Model ES5OTC thread the Nose Collar 61 onto the Gear Case and tighten it with a wrench Trouble Probable Cause Solution Screwdriver fails to rotate reverse or forward Is there power to the tool Defective Power Cord Assembly 6 Replace the Power Cord Assembly if necessary No power from the Controller Repair or replace see Controller Service Manual Does the Trigger Switch click when the Trigger is depressed Defective Trigger Switch 8 Replace the Trigger Switch Does the Trigger Switch turn on power to the Motor Trigger pad worn Replace the Trigger 17 Can the bit be turned by hand when the tool is unplugged Planetary gearing defective Replace the Planet Gears 39 or 41 Spindle Assembly 40 and Gear Head Assembly 38 Clutch defective Repair or replace the clutch Does the tool operate properly when bumped and jiggled Defective power cord Replace the Power Cord Assembly 6 Forward Reverse Switch defective Replace the Forward Reverse Switch 9 Defective solder connection Check all solder connections resolder where necessary Defective Armature Replace the Motor Assembly Brush contact defective Replace the Brush Assembly Does brush wear appear normal Worn or defective Brushes Replace the Brush Assemblies 24 Defective Commutator Replace the Armature 31
5. 45527801 Edition 1 May 2007 Electric Screwdrivers ES45T ES50T and ES50TC Maintenance Information MW Save These Instructions AR Ingersoll Rand WARNING Always wear eye protection when operating or performing maintenance on this tool Always turn off the air supply and disconnect the air supply hose before installing removing or adjusting any accessory on this tool or before performing any maintenance on this tool Note When reading the instructions refer to exploded diagrams in parts Information Manuals when applicable see under Related Documentation for form numbers Clutch Spring Selection Chart Model ES45 Part Number Torque Range ES50T 43 1 0 3 to 2 6 in Ib 0 04 to 0 30 N m ES50T 462 1 2 to 6 5 in Ib 14 to 74 N m Model ES50T and ES50TC Part Number Torque Range ES50T 431 0 5 to 3 0 in Ib 0 06 to 0 34 N m ES50T 462 2 0 to 9 0 in Ib 0 23 to 1 02 N m Disassembly 1 For Models ES45T and ES5OT unscrew and remove the Coupling 55 This is a left hand thread turn clockwise to remove For Model ES5OTC unscrew and remove the Nose Collar 61 2 Using a Phillips Screwdriver remove the three Housing Screws 2 This is a left hand thread turn clockwise to remove 3 Carefully separate the right side of the Housing from the left side of the Housing NOTICE The Model ES5OTC Screwdriver housing is assembled using a liquid gasket as a sealing mater
6. ial Carefully pry the housing sections apart using a thin flat piece of metal Do not use heat or chemical solutions to seperate the two halves 4 Lifting the spindle end of the assembly slightly carefully pull the Gear Case 37 and assembled clutch away from the Motor 5 Trigger Switch 8 replacement a Lift the Trigger Switch out of its recess in the left side of the Housing 1 and unsolder the connections b Solder the leads to a new Trigger Switch and reposition the Switch in the Housing Refer to the wiring diagram below 6 Reverse Switch 9 replacement a The Reverse Switch is fitted into the left side of the Housing Remove the Switch by depressing the locking tab of the switch mount from the rear with a flat blade Screwdriver and pushing the Switch out of the Housing b Unsolder the wiring to the Switch and install a new Switch Refer to the wiring diagram below Wiring diagrams for ES45T ES50T and ES5OTC Electric Screwdrivers MOTOR BRAKE SWITCH da TRIGGER SWITCH FORWARD REVERSE SWITCH VIEWED FROM REAR POWER CORD GREEN RED YELLOW BLU 10 20 504 m lac Dwg TPD1114 7 Brake Switch 15 replacement a Remove the two Screws 16 holding the Brake Switch b Unsolder the wiring to the Brake Switch and install a new Switch Refer to the wiring diagram above c Position the Brake Switch and instal
7. l the two Screws to secure it to the Shutoff Switch Plate 10 d After installing the Brake Switch loosen the Switch Plate Screw 11 that holds the Switch Plate in the Housing e Move the Switch Plate toward the Motor and tighten the Screw when the Switch is pushed 014 or 002 beyond the ON point point that the Switch clicks Placing a 014 shim on the arm of the Switch and moving the Switch until it clicks is a simple method of setting the Brake Switch gap Models ES45T ES50T and ES50TC Electric Screwdrivers ON POINT SWITCH CLICKS BRAKE qp 002 ae SWITCH PLATE SCREW Dwg TPD1113 8 Brush Assembly 24 replacement a Unsolder the brush lead b Lift the brush spring end upward and over the corner of the phenolic tab Remove the brush c Solder the brush lead onto a new brush install the brush and reposition the brush spring d Repeat steps a b and c for the remaining brush 9 Power Cord Assembly 6 replacement a Unsolder the wires to the Trigger Switch S Brake Switch 15 and the green and yellow wires of the Power Cord where the leads from the Reverse Switch 9 are spliced b Install a new Power Cord Assembly and solder the wires to the Trigger Switch Brake Switch and two leads from the Reverse Switch as shown in the wiring diagram on page 12 Trademark of Permabond International 45527801_ed1 10 Motor Assembly replacemen
8. properly lubricated No lubrication on the Clutch Components Lubricate the Clutch with recommended Grease Is there wear on face of cam guide where it contacts Spindle Assembly 40 Cam guide is worn Replace the Bit Holder Assembly Clutch Spring 51 is damaged Replace Spring Tool outputs low torque Is the Clutch Housing joint tight Loose joint between the Gear Case 37 and Clutch Housing 53 Tighten the joint iwth a torque wrench to specified torque 1 Cam 43 is worn Replace the Cam 2 Clutch Spring 51 is damaged Replace the Clutch Spring 3 Cam guide is damaged Replace the Bit Holder Assembly 48 Related Documentation For additional information refer to Product Safety Information Manual 16602963 Product Information Manual 45527702 Parts Information Manual 45527777 Manuals can be downloaded from www irtools com 45527801_ed1 Notes Notes Notes www irtools com Y Ingersoll Rand 2007 Ingersoll Rand Company
9. t 12 Gear replacement a Pull the Gear Case 37 away from the Motor Assembly NOTE HOLE LOCATION Dwg TPD1052 a Unsolder the two motor leads Note the location of the red and blue leads to the hole in the side of the motor b Solder the motor leads to a new motor as illustrated above Carefully check the Reverse Switch 9 to make sure that the motor runs in the correct rotation as indicated on the Switch If the motor does not run in the correct rotation reverse the leads NOTICE Model ES5OTC has a Shield Plate 20 separating the motor from the switches When installing the assembled motor make certain Perma Lok GasketMaker HH190 liquid gasket material forms a seal around the edge of the Plate and also at the opening in the Plate for the motor leads 11 Pushrod replacement a Remove the Gear Case 37 from the Motor Assembly b Pull the Pushrod 35 out of the motor and replace it with a new one c Pull the Pushrod 46 out of the Gear Case Lightly coat a new Pushrod with Ingersoll Rand No 67 Grease and insert it into the Gear Case d After replacing both Pushrods adjust the timing of the Switch Plate 10 as described in Step 7 e Troubleshooting Guide b The joint between the Gear Case and Clutch Housing 53 is a left hand thread Using one wrench on the gear case flats and another on the flats of the Clutch Housing turn the Housing clockwise to separate the two parts c Remove the
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