Ingersoll Rand Power Screwdriver ES45T User Manual

45527801

Edition 1

May 2007

Electric Screwdrivers

ES45T, ES50T and ES50TC

Maintenance Information

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10. Motor Assembly replacement

12. Gear replacement

a. Pull the Gear Case (37) away from the Motor Assembly.

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.

RED

BLUE

c. Remove the 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.

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.

c. 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.

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.

f. 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 in a

counterclockwise direction and tighten the joint to

21 ft-lb (28.5 Nm) torque.

13. Place the assembled motor, gearing and clutch unit in the left

side of the Housing.

14. For Models ES45T and ES5OT, place the right side of the

Housing against the left side and install the three Housing

Screws.

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.

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.

15. For Models ES45T and ES5OT, thread the Coupling (55) onto the

Gear Case and tighten it with a wrench.

d. After replacing both Pushrods, adjust the timing of the Switch

Plate (10) as described in Step 7(e).

For Model ES5OTC, thread the Nose Collar (61) onto the Gear

Case and tighten it with a wrench.

Troubleshooting Guide

Trouble

Probable Cause

Solution

1. Defective Power Cord Assembly (6). Replace the Power Cord

Assembly if necessary.

2. No power from the Controller. Repair or replace (see Controller

Service Manual).

Is there power to the tool?

Does the Trigger Switch click when the Trigger

is depressed?

Defective Trigger Switch (8). Replace the Trigger Switch.

Trigger pad worn. Replace the Trigger (17).

Does the Trigger Switch turn on power to

the Motor?

1. Planetary gearing defective. Replace the Planet Gears (39 or

41), Spindle Assembly (40) and Gear Head Assembly (38).

2. Clutch defective. Repair or replace the clutch.

Can the bit be turned by hand when the tool

is unplugged?

Screwdriver fails

to rotate (reverse or

forward)

1. Defective power cord. Replace the Power Cord Assembly (6).

2. Forward/Reverse Switch defective. Replace the Forward/

Reverse Switch (9).

Does the tool operate properly when bumped

and jiggled?

3. Defective solder connection.

Check all solder connections; resolder where necessary.

4. Defective Armature. Replace the Motor Assembly.

5. Brush contact defective. Replace the Brush Assembly.

1. Worn or defective Brushes. Replace the Brush Assemblies (24).

2. Defective Commutator. Replace the Armature (31).

Does brush wear appear normal?

1. Carbon buildup or dirt on Armature (31).

2. Clean the Armature using a good electrical contact cleaner

and blow dry.

Does motor appear to be in good condition?

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Trouble

Probable Cause

Solution

Are wire leads in good condition

and properly soldered?

Screwdriver runs in

one direction but

not the other

Defective solder connections. Resolder and rewire if necessary.

Does Reverse Switch operate properly?

Defective Reverse Switch (9). Replace it.

1. Armature (31) is in contact with the magnets. Replace the

motor.

2. Foreign material in the motor. Clean the motor.

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.

When gears are removed, will the motor

rotate?

Bit does not rotate

but motor hums.

Is planetary gearing smooth when bit is

rotated by hand?

Does the speed of the Bit exceed rated speed

by more than 100 rpm?

Motor magnet is demagnetized. Replace the motor.

Is 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.

1. Bent or worn Pushrod (35 or 46). Replace it.

Shutoﬀ brake

malfunctions more

than one index of

the Clutch.

Does Pushrod (35 or 46) function properly?

1. Cam is worn and not providing adequate lift.

Replace the Cam.

Controller malfunctioning or defective.

Repair or replace. See Controller Service Manual.

Does Cam (43) function properly?

1. Screws (2) are loose. Tighten all Screws.

2. Clutch Housing is loose. Tighten the Clutch Housing to the

proper torque.

Is there looseness at the assembly points?

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.

No grease on the gear train.

Tool makes

After removing the gear train does motor

sound normal when running?

abnormal sounds

when the motor is

running.

Apply a thin ﬁlm of the recommended grease to the gear train.

1. Spindle Bearing has failed.

Is the gear train properly lubricated?

Replace the Spindle Assembly (40).

2. Gears are worn or dirty. Clean or replace the Gears.

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 tooI much or too little grease.

Tool generates

abnormal heat when

operating.

After removing the gear train, does tool cool

down and motor run normally?

Is the shutoﬀ brake functioning properly?

Is Clutch properly lubricated?

Refer to Problem No. 4 to check shutoﬀ brake malfunctions.

No lubrication on the Clutch Components. Lubricate the Clutch

with recommended Grease.

Tool outputs high

torque.

Cam guide is worn. Replace the Bit Holder Assembly.

Is there wear on face of cam guide where it

contacts Spindle Assembly (40)?

Clutch Spring (51) is damaged. Replace Spring.

Loose joint between the Gear Case (37) and Clutch

Housing (53).

Tighten the joint iwth a torque wrench to speciﬁed torque.

Tool outputs low

torque.

Is the Clutch Housing joint tight?

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).