Ingersoll Rand Power Screwdriver ES45T User Manual

45527801  
Edition 1  
May 2007  
Electric Screwdrivers  
ES45T, ES50T and ES50TC  
Maintenance Information  
Save These Instructions  
 
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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3
 
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).  
Related Documentation  
For additional information refer to:  
Product Safety Information Manual 16602963.  
Product Information Manual 45527702.  
Parts Information Manual 45527777.  
4
45527801_ed1  
 
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© 2007 Ingersoll Rand Company  
 

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