Ingersoll-Rand 1R Series Setup guide

16575243
Edition 2
October 2013
Save These Instructions
Air Screwdrivers
1R Series
Maintenance Information

2 16575243_ed2
Product Safety Information
WARNING
Failure to observe the following warnings, and to avoid these potentially hazardous situations, could result in death or serious injury.
Read and understand this and all other supplied manuals before installing, operating, repairing, maintaining, changing accessories on, or
working near this product.
Always wear eye protection when operating or performing maintenance on this tool. The grade of protection required should be assessed
for each use and may include impact-resistant glasses with side shields, goggles, or a full face shield over those glasses.
Always turn o the air supply, bleed the air pressure and disconnect the air supply hose when not in use, before installing, removing or
adjusting any accessory on this tool, or before performing any maintenance on this tool or any accessory.
Note: When reading the instructions, refer to exploded diagrams in Parts Information Manuals when applicable (see under Related Documentation
for form numbers).
Lubrication
•
•
•
•
Each time a Series 1R Screwdriver is disassembled for maintenance
and repair or replacement of parts, lubricate the tool as follows:
Gearing
For L ratio, coat gears with 2 to 4 cc of Ingersoll Rand No. 28 Grease.
For M, N or Q ratios, coat gears with 4 to 6 cc of
Ingersoll Rand No. 28 Grease.
2. Use Ingersoll Rand No. 10 Oil for lubricating the motor. Inject
approximately 1 to 2 cc of oil into the air inlet before attaching
the air hose.
3. For Cushion Clutch Models, unscrew and remove the clutch attachment.
For L gear ratio, inject 4 to 6 cc of Ingersoll Rand No. 28
Grease through the center hole of the spindle to lubricate
the gearing.
For M or N gear ratio, inject 6 to 8 cc of Ingersoll Rand
No. 28 Grease through the center hole of the spindle to
lubricate the gearing.
Work approximately 6 to 8 cc of Ingersoll Rand No. 67 Grease
into the ball pockets, jaws, adjusting nut lock and shaft
threads of the clutch mechanism.
1.
a.
b.
a.
b.
c.
4. For Automatic Shuto Clutch Models, unscrew and remove the
clutch attachment. Remove the Push Rod.
For L gear ratio, inject 4 to 6 cc of Ingersoll Rand No. 28
Grease through the center hole of the spindle to lubricate
the gearing.
For M, N, or Q gear ratio, inject 6 to 8 cc of Ingersoll Rand
No. 28 Grease through the center hole of the spindle to
lubricate the gearing.
Work approximately 6 to 8 cc of Ingersoll Rand No. 67 Grease
into the ball pockets, jaws, adjusting nut lock and shaft
threads of the clutch mechanism.
Insert the Push Rod into the spindle.
5. Thread the clutch attachment onto the Gear Case and hand
tighten.
NOTICE
This is a left-hand thread; turn counterclockwise to tighten.
a.
b.
c.
d.
Disassembly
General Instructions
Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
Whenever grasping a tool or part in a vise, always use leather-
covered or copper-covered vise jaws to protect the surface of
the part and help prevent distortion. This is particularly true of
threaded members and housings.
Do not remove any part which is a press t in or on a subassembly
unless the removal of that part is necessary for repairs or
replacement.
Do not disassemble the tool unless you have a complete set of
new gaskets and O-rings for replacement.
Disassembly of the Tool
Each Series 1R Air Screwdriver is comprised of three modules
or units - a motor housing and motor unit, a gear unit and an
adjustable clutch unit. Each module or unit can be removed,
disassembled for repairs and reassembled independently of the
other units.
Unscrew and remove the Clutch Housing Assembly (100) from the
Gear Case Assembly (39).
NOTICE
This is a left-hand thread and should only be handtight. Turn
clockwise to remove.
3. Unscrew the Gear Case Assembly from the Motor Housing, and
lift o the entire gear unit.
NOTICE
This is a right-hand thread; turn counterclockwise to remove.
1.
2.
3.
4.
1.
2.
Disassembly of the Adjustable Cushion Clutch and
Adjustable Shuto Clutch
Withdraw the Clutch Driver Assembly and Bit Holder (125 or 128)
from the Clutch Housing.
For Models 1RP and 1RT ending in C1, C3, S1, S3, C9D or S9D,
grasp the Clutch Return Spring (104) near the Spring Seat
Stop (114) to avoid elongating the Spring and pull the Spring
from the Clutch Driver (106).
For Models 1RL ending in S1 or S3, grasp the Clutch Return
Spring (104) near the Spring Seat Stop (114) to avoid elongating
the Spring and pull the Spring from the Clutch Driver (106).
For Models 1RA and 1RL ending in C1, C3 or C9D, use a hooked
tool to reach into the end of the Clutch Driver and pull the
Disengaging Spring (133) from the Driver.
For Models 1RL, 1RP and 1RT ending in S1, S3 or S9D, remove
the Shuto Plunger (120). Using a hooked tool to reach into the
end of the Clutch Driver, hook the Plunger Return Spring (122)
and pull it from the Driver.
Using a thin blade screwdriver, pry the Spring Seat Stop (114)
adjacent to the Adjusting Nut (116) o the Clutch Driver.
Carefully clamp the external hex end of the Clutch Driver in
copper-covered vise jaws. Using a wrench on the ats of the
Adjusting Nut, unscrew the Nut.
NOTICE
This is a right-hand thread.
5. Remove the Clutch Driver from the vise, and remove the
Adjusting Nut, Adjusting Nut Lock (115), Thrust Bearing (112),
Clutch Spring Seat (113) and Clutch Spring (105) from the Clutch
Driver.
6. For Models 1RA, 1RL and 1RP ending in C1, C3 or C9D, use a
thin blade screwdriver to pry o the remaining two Spring Seat
Stops (114) from the Clutch Driver.
1.
2.
3.
4.

16575243_ed2 3
NOTICE
Place a container under the assembly before removing the
retainer nearest the Clutch Ball Seat (111). Removal of this
retainer allows the eleven Clutch Balls (108) and ten Jaw Bearing
Balls (109) to fall from the Assembly.
Slide the Clutch Ball Seat, Clutch Ball Spacer (110) and Clutch
Jaw (107) o the Clutch Driver.
For Models 1RL, 1RP and 1RT ending in S1, S3 or S9D, use a thin
blade screwdriver to pry o the remaining Spring Seat Stop (114)
from the driver.
NOTICE
Place a container under the assembly before removing the
Spring Seat Stop. Removal of this retainer allows the four Shuto
Plunger Balls (121) and three Clutch Cam Balls (123) to fall from
the Assembly.
Slide the Collar Return Spring (119), Shuto Collar (118) and Clutch
Ball Seat (111) o the Clutch Driver. Using a thin blade screwdriver,
carefully pry o the Ball Retaining Spring (117). Dump the ten Bit
Holder Bearing Balls (124) into a container. Remove the Bit Holder
Assembly (125) from the Clutch Driver. Remove the Clutch Driver
Seal (106A) from the groove at the front end of the Clutch Driver.
Remove the Clutch Driver Spacer (106B) from Models 1RP and 1RT
ending in S9D.
7. If the Clutch Housing Bushing (101 or 151) is worn, proceed as
follows:
For Models 1RA, 1RL, 1RP and 1RT ending in 9D
Unscrew and remove the Clutch Housing Cap (103) from the
Clutch Housing (100).
Stand the Clutch Housing on a workbench with the bit end
upward.
Using a hammer and a blunt rod smaller in diameter than
the bushing opening, drive the rearmost Bushing out of the
Housing by tapping random locations on the face of the
Bushing.
Using a press and supporting the front face of the Housing,
press the forward Bushing out the bit end of the Housing.
For all other Models, press the single Clutch Housing Bushing from
the Clutch Housing (100).
Disassembly of the Direct Drive Attachment
Unscrew and remove the Screwdriver Housing Assembly (150).
NOTICE
This is a left-hand thread and should only be hand tight. Turn
clockwise to remove.
2. Using a pair of snap ring pliers, reach into the Screwdriver
Housing and remove the Bit Holder Retaining Ring (153) at the
Gear Case end of the Bit Holder (154). Slide the Bit Holder out of
the Screwdriver Housing.
3. If the Housing Bushing (151) requires replacement, press the
Bushing from the Housing toward the Gear Case end of the
Housing.
4. Using a pair of snap ring pliers, remove the Bit Holder Retaining
Ring near the Bit Retaining Sleeve (155).
5. Remove the Bit Retaining Sleeve from the Bit Holder.
6. Using a pointed rod, spiral the Retaining Sleeve Spring (156) from
the bit end of the Bit Holder.
7. Remove the Bit Retaining Ball (152) from the Bit Holder.
a.
b.
c.
d.
1.
Disassembly of the Gearing
Using a thin blade screwdriver, work the Clamp Washer Retaining
Ring (50) from the groove in the Gear Case Assembly (39) and
withdraw the Motor Clamp Washer (49).
For Models 1RLM and 1RLN, tap the motor end of the Gear Case
Assembly against the top of the workbench to remove the Gear
Head (47), Gear Head Planet Gears (48), Rotor Pinion (45) and Gear
Head Spacer (46).
Using a pair of snap ring pliers, remove the Spindle Retaining
Ring (44) from the groove in the front of the Spindle (43).
Lightly tap or press the Spindle and Spindle Planet Gears (42)
from the Gear Case Assembly.
Using a pair of snap ring pliers, remove the Spindle Bearing
Retainer (41) from the groove in the front of the Gear Case.
Using a sleeve that contacts the outer ring of the bearing, press
the Spindle Bearing (40) from the front of the Gear Case.
Disassembly of the Motor
Grasp the splined end of the Rotor (29) and pull the motor from
the Motor Housing (1).
Withdraw the Rear End Plate Gasket (38) from the bottom of the
housing bore.
While grasping the Cylinder (36) in one hand, lightly tap on the
splined end of the Rotor to drive the Rotor from the bore of the
Front Rotor Bearing (32), thus freeing the Front End Plate (30) and
Bearing.
Using snap ring pliers remove the Front Rotor Bearing
Retainer (34) and remove the Front Rotor Bearing from the Front
End Plate.
Slide the Cylinder o the Rotor, and withdraw the Vanes (35) from
the vane slots.
Remove the Rear Rotor Bearing Retainer (33) from the groove in
the hub of the Rotor.
Support the Rear End Plate (31) as close to the rotor body as
possible on the table of an arbor press, and press the Rotor from
the Rear Rotor Bearing.
Disassembly of the Reverse Valve and Throttle
Mechanism
Using a l/16” Allen Wrench, remove the Retainer Set Screw (5)
from the Reverse Valve (2).
With the Reverse Valve facing downward, lightly tap the Motor
Housing on the workbench until the Lock Pin Retainer (6) falls out
of the Reverse Valve.
Hold the Motor Housing horizontally with the Reverse Valve
on your left as you face the rear of the tool. With slight inward
pressure on the Reverse Valve tap the Motor Housing on a
workbench until the Valve Lock Pin (4) drops into the opening
vacated by the Lock Pin Retainer.
Remove the Reverse Valve along with the Reverse Valve
Seal (2A). Reverse Valve Spring (3) and Valve Lock Pin from the
Motor Housing.
For 1RA and 1RT Models, lightly grasp the handle of the Motor
Housing (1) in copper-covered vise jaws so that the Inlet
Bushing (26) is upward. Unscrew the Inlet Bushing and remove
the Inlet Bushing Spacer (27), Muer Assembly (18), Muer
Element (17), Inlet Screen (25), Throttle Valve Spring (7), Throttle
Valve (8) and Trigger Assembly (23). Remove the Trigger Pin
Seal (23A) from the Trigger Assembly. If the Valve Seat (9) needs
to be replaced, use a sti wire hook and insert it through the
Valve Seat and Valve Seat Support (10) to grasp the underside of
the Valve Seat Support. Withdraw the Valve Seat and Valve Seat
Support from the handle.
For 1RT Models, use an adjustable wrench on the ats of the
Back Cap Assembly (24) to unscrew and remove the Back Cap
Assembly from the Motor Housing.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.

4 16575243_ed2
CAUTION
Place a container under the Assembly to catch the Throttle Ball
Spring (14) and Throttle Ball (15) when removing the Back Cap
Assembly.
Remove the Push Rod (135) from the Motor Housing. If removal
of the Throttle Ball Seat (16) is necessary, use a sti wire hook
inserted through the Seat and withdraw it from the Motor
Housing.
For 1RL Models ending in C1, C3, 9D or D1, remove the Throttle
Valve Cap (12), Throttle Valve Spring (7), Throttle Valve Ball ( 13)
and Throttle Valve Plunger (11) from the Motor Housing.
WARNING
The Throttle Valve Cap is under pressure from the Throttle Valve
Spring and care must be exercised when removing the Throttle
Valve Cap.
Using an adjustable wrench, unscrew the Inlet Bushing
Assembly (28). Remove the Exhaust Deector (20) from the Motor
Housing. Insert the eraser end of a wooden pencil into the small end
of the Inlet Bushing Assembly and push the Inlet Screen (28A) out
through the large end of the Inlet Bushing. Work the four Muer
Elements (17) out of the Exhaust Deector and remove the Exhaust
Deector Seal (18B).
The Throttle Lever is attached to the Exhaust Deector with two
Throttle Lever Pins (25) which are two-piece rivets. Lightly grasp
the Exhaust Deector in copper-covered vise jaws taking care not
to distort the Deector. Using a pin punch and hammer carefully
drive the pin in the center of the rivet inward until it clears the rivet.
Repeat this procedure to remove the other pin. Working inside the
Exhaust Deector and using needle nose pliers, squeeze the ends of
rivets and push the rivets through the opposite side of the Exhaust
Deector. Remove the Throttle Lever (22).
For 1RL Models ending in S1 or S3, remove the Push Rod (135).
Remove the Throttle Valve Cap (12) Throttle Valve Spring (7), Throttle
Valve Ball (13) and Throttle Valve Plunger (11) from the Throttle Valve
Housing (6A).
WARNING
The Throttle Valve Cap is under pressure from the Throttle Valve
Spring and care must be exercised when removing the Throttle
Valve Cap.
Using an adjustable wrench, unscrew the Inlet Bushing
Assembly (28). Remove the Exhaust Deector (20) from the Throttle
Valve Housing. Insert the eraser end of a wooden pencil into the
small end of the Inlet Bushing Assembly and push the Inlet
Screen (28A) out through the large end of the Inlet Bushing. Work the
four Muer Elements (17) out of the Exhaust Deector and remove
the Exhaust Deector Seal (18B).
The Throttle Lever is attached to the Exhaust Deector with two
Throttle Lever Pins (25) which are two-piece rivets. Lightly grasp
the Exhaust Deector in copper-covered vise jaws taking care not
to distort the Deector. Using a pin punch and hammer, carefully
drive the pin in the center of the rivet inward until it clears the rivet.
Repeat this procedure to remove the other pin. Working inside the
Exhaust Deector and using needle nose pliers, squeeze the ends of
rivets and push the rivets through the opposite side of the Exhaust
Deector. Remove the Throttle Lever (22). Using a 5/64”hex wrench,
loosen and remove the Throttle Valve Housing Cap
Screws (13E) and Lock Washers (13F). Remove the Throttle Valve
Housing and the Throttle Valve Housing Seal (13D) from the Motor
Housing (1). Remove the Throttle Valve Housing Adapter Seal (13B)
from the Throttle Valve Housing Adapter (13A). Unscrew and remove
the Throttle Valve Housing Adapter, Throttle Ball Spring (13H),
Throttle Ball (13G) and the Muer Element (17).
For 1RP Models, use an adjustable wrench to unscrew and remove
the Inlet Bushing Assembly (28).
CAUTION
Place a container under the Exhaust Deector (19) to catch the
Throttle Ball Spring (14) and Throttle Ball (15) when removing
the Inlet Bushing Assembly (28).
Remove the Push Rod (135). If removal of the Throttle Ball Seat (16)
is necessary, use a sti wire hook inserted through the Throttle Ball
Seat and withdraw it from the Motor Housing. Insert the eraser end
of a wooden pencil into the small end of the Inlet Bushing Assembly
and push the Inlet Screen (28A) out through the large end of the
Inlet Bushing. Work the four Muer Elements (17) out of the Exhaust
Deector.
Assembly
General Instructions
Always press on the inner ring of a ball-type bearing when
installing the bearing on a shaft.
Always press on the outer ring of a ball-type bearing when
pressing the bearing into a bearing recess.
Whenever grasping a tool or part in a vise, always use leather-
covered or copper-covered vise jaws. Take extra care with
threaded parts and housings.
Always clean every part and wipe every part with a thin lm of oil
before installation.
Apply a lm of O-ring lubricant to all O-rings before nal
assembly.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a suitable cleaning solution and
dry with a clean cloth. Sealed or shielded bearings should
never be cleaned. Work grease thoroughly into every open
bearing before installation.
1.
2.
3.
4.
5.
6.
Assembly of the Reverse Valve and Throttle Mechanism
Coat the Reverse Valve Seal (2A) with O-ring lubricant and install it
in the groove between the head and lock pin hole on the body of
the Reverse Valve (2).
Insert the Reverse Valve Spring (3) into the plain end of the
Reverse Valve.
Insert the Valve Lock Pin (4) into the small hole in the side of the
Reverse Valve.
Start the Reverse Valve into the bushing, aligning the Valve Lock
Pin with the timing notch on the bushing.
Holding the tool with the lock pin hole in the Reverse Valve facing
downward, push the Reverse Valve into the bushing against the
compression of the Reverse Valve Spring.
Using a small diameter rod inserted into the end of the Reverse
Valve and while maintaining valve pressure on the Spring, use
the rod to force the Valve Lock Pin into the slot in the wall of the
bushing.
After the Valve Lock Pin has engaged the slot in the bushing,
slowly release the Reverse Valve and it will stay in position.
Insert the Lock Pin Retainer (6) in the tapped end of the Reverse
Valve and install the Retainer Set Screw (5).
1.
2.
3.
4.
5.
6.
7.
8.

16575243_ed2 5
For 1RA and 1RT Models
Lightly grasp the handle of the Motor Housing (1) in copper-
covered vise jaws so that the inlet end of the Housing is
upward.
Install the Throttle Valve Seat Support (10) by pushing it into
place with a 1/2” (13 mm) diameter dowel.
Follow this with the Throttle Valve Seat (9).
Apply O-ring lubricant to the Trigger Pin Seal (23A) and
install it in the groove on the trigger stem. Insert the Trigger
Assembly (23) into the trigger bushing.
Installation of the Throttle Valve (8) is sometimes a bit tricky
due to the smallness of the Valve and the depth of the bore
in which it is located. The dicult part is in holding the Valve
while inserting the long end of the valve stem through the
hole in the trigger stem. Although the Valve can be held
with a push-button mechanical drafting pencil or a wooden
dowel, one of the easiest ways to hold it is by using a common
wooden pencil with rubber eraser. Insert the short end of the
valve stem into the rubber eraser full depth, then back it out
far enough so that the Valve is just nicely supported. Insert the
Valve into the bore of the handle so that the long end of the
stem enters the hole in the trigger stem. Pull outward on the
Trigger to hold the Valve while removing the pencil.
Place the Inlet Screen (25), closed end rst, inside the large
end coil of the Throttle Valve Spring (7).
Insert the Throttle Valve Spring and Screen, small coil rst,
into the handle so that the Spring encircles the end of the
Throttle Valve.
Work the Muer Element (17) into the exhaust cavity in
the handle of the Motor Housing until the trailing end of
the Muer Element is approximately 1/4”(6 mm) into the
Housing.
Lubricate the Muer O-ring (18A) with O-ring lubricant and
place it over the exhaust port of the Muer.
Place the Muer Assembly (18) on the face of the handle so
that the exhaust port extends into the handle.
Slide the Inlet Bushing Spacer (27) over the threaded end
of the Inlet Bushing (26), and install the Inlet Bushing in the
handle. Tighten it to a minimum of 26 ft-lb (35 N m) of torque.
NOTICE
The Inlet Bushing must securely clamp the Exhaust Deector.
For 1RT Models only
Lubricate the Back Cap O-ring (24A) with O-ring lubricant and
place it into the recess of the back cap.
If the Throttle Ball Seat (16) was removed, install a new Seat
using a 5/16” (8 mm) diameter dowel to push it into place.
Insert the Push Rod (135) through the Throttle Ball Seat and
into the Motor Housing (1) followed by the Throttle
Ball (15) and Throttle Ball Spring (14). If a new Push Rod is
being installed, proceed as follows:
9. Assemble the complete Clutch Assembly, Gear Case Assembly
and the Motor Housing Assembly without the Back Cap
Assembly (24), Throttle Ball (15) and Throttle Ball Spring (14).
10. While pushing the Clutch Assembly against the Spindle (43),
insert the new Push Rod through the Throttle Ball Seat ( 16) in the
rear of the Motor Housing until it contacts the Shuto
Plunger (120).
NOTICE
Exert a slight pressure on the Push Rod to make certain the
Shuto Plunger contacts the Shuto Plunger Balls (121).
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
a.
b.
c.
11. The length of the Push Rod must be trimmed so that 0.04’’ to
0.09” (1.0 mm to 2.3 mm) protrudes above the Throttle Ball Seat.
There are numerous ways to determine how much material
must be trimmed from the Push Rod and experience will dictate
the best method to use. Following is one method requiring
only a narrow -depth scale. If the Push Rod extends beyond the
Housing, measure the distance from the end of the Push Rod to
the face of the Throttle Ball Seat. Subtract 5/64” (2 mm) from that
distance and cut the remaining dierence from the end of the
Push Rod. If the Push Rod does not extend beyond the Housing,
measure the distance from the end of the Housing to the face of
the Throttle Ball Seat. Record that distance. Measure the distance
from the end of the Push Rod to the end of the Housing and add
5/64” (2 mm) to that distance. Subtract the added distance from
the rst measurement and trim the remaining dierence from the
end of the Push Rod.
12. Insert the Push Rod through the Throttle Ball Seat and into the
Motor Housing followed by the Throttle Ball and Throttle Ball
Spring. Install the Spring with the small end against the Throttle
Ball.
13. Retain these parts with the Back Cap Assembly (24) and tighten
the Cap between 7 and 10 ft-lb (9 and 13 Nm) torque.
CAUTION
Do not over tighten the Cap but do not allow a gap to exist
between the Back Cap and Motor Housing.
For 1RL Models ending in C1, C3, 9D or D1
Position the Throttle Lever (22) on the Exhaust Deector with
the Lever covering the timing notch at the front end of the
Deector.
Insert the two Throttle Lever Pins (21) through the Lever and
into the Exhaust Deector. Using copper-covered vise jaws as
a press, press the pins in the center of the Throttle Lever Pins
ush with the head of the rivets.
CAUTION
Do not apply a force strong enough to distort the Exhaust
Deector.
c. Work four new Muer Elements (17) into the Exhaust
Deector (20).
d. Center the Inlet Screen (28A) over the air line end of the Inlet
Bushing Assembly (28) and, using the eraser end of a wooden
pencil, push the Screen into the Bushing until it bottoms on
the internal shoulder.
e. Slide the Exhaust Deector Seal (18B) onto the rear of the
Motor Housing (1). Place the Exhaust Deector on the rear
of the Motor Housing, aligning the Notch in the Deector
with the timing pin in the Housing. Tighten the Inlet Bushing
Assembly to a minimum of 15 ft-lb (20 Nm) torque.
NOTICE
The Inlet Bushing must securely clamp the Exhaust Deector.
f. With the Throttle Lever downward, insert the Throttle Valve
Plunger (11), Throttle Valve Ball (13) and Throttle Valve
Spring (7) into the Motor Housing.
g. Position the Throttle Valve Cap (12) on the Throttle Valve
Spring. Screw the Valve Cap into the Housing until the Cap
is within approximately two threads of being ush with the
Housing. Apply a light, uniform coat of a thread locking
compound to the remaining two threads. Tighten the Valve
Cap securely and place the Housing on a workbench with
the Valve Cap facing downward. Allow the Loctite to cure
approximately ve minutes.
a.
b.

6 16575243_ed2
For 1RL Models ending in S1 or S3
Place the Throttle Valve Housing Seal (13D) on the smaller
shoulder of the Motor Housing (1). To hold the Seal in position,
lightly coat both the Seal and the shoulder with
Ingersoll Rand No. 28 Grease. Install the Throttle Ball (13G)
and the Throttle Ball Spring (13H).
Place one new Muer Element (17) on the threaded side
of the Throttle Valve Housing Adapter (13A) and thread the
Adapter into the Motor Housing until the adapter ange
contacts the Housing. Center the notch or depression on the
Adapter with the housing alignment pin by backing out the
Adapter 1/4 turn maximum, if necessary.
Place the Throttle Valve Housing Adapter Seal (13B) on the
Adapter.
Place the Throttle Valve Housing over the Adapter and onto
the rear of the Motor Housing, making sure that the notch in
the Throttle Valve Housing is aligned with the alignment pin
on the Motor Housing.
Secure the Throttle Valve Housing with the two Throttle Valve
Housing Cap Screws (13E) and Lock Washers (13F). Tighten the
Screws between 8 and 10 in-lb (0.90 and 1.13 Nm) torque. If
the Cap Screws cannot be started into the Adapter, then the
Adapter is not in proper alignment with the Housing. Refer
to Step “b”.
Work three new Muer Elements into the Exhaust
Deector (20) to a point beyond the two throttle lever pin
holes.
Position the Throttle Lever (22) on the Exhaust Deector
with the Lever covering the timing notch at the front of the
Deector. Insert the Two Throttle Lever Pins (21) through the
Lever and into the Exhaust Deector. Using pliers, press the
pins in the center of the Throttle Lever Pins ush with the
head of the rivet.
CAUTION
Do not apply a force strong enough to distort the Exhaust
Deector.
h. Center a new Inlet Screen (28A) over the air line end of the
Inlet Bushing Assembly (28) and, using the eraser end of a
wooden pencil, push the Screen into the Bushing until it
bottoms on the internal shoulder.
i. Slide the Exhaust Deector Seal (18B) onto the rear of the
Throttle Valve Housing. Place the Exhaust Deector on the
rear of the Throttle Valve Housing, aligning the notch in the
Deector with the alignment pin in the Housing. Tighten the
Inlet Bushing Assembly to a minimum of 15 ft-lb (20 Nm)
torque.
NOTICE
The Inlet Bushing must securely clamp the Exhaust Deector.
j. With the Throttle Lever downward, insert the Throttle Valve
Plunger (11), Throttle Valve Ball (13) and Throttle Valve
Spring (7) into the Throttle Valve Housing.
k. Position the Throttle Valve Cap (12) on the Throttle Valve
Spring. Screw the Valve Cap into the Housing until the Cap
is within approximately two threads of being ush with
the Housing. Apply a light, uniform coat of thread locking
compound to the remaining two threads. Tighten the Valve
Cap securely and place the Housing on a workbench with
the Valve Cap facing downward. Allow the Loctite to cure
approximately ve minutes.
For 1RP Models only
Work four new Muer Elements (17) as far as possible into the
Exhaust Deector (20).
Center the Inlet Screen (28A) over the air line end of the Inlet
Bushing Assembly (28) and, using the eraser end of a wooden
pencil, push the Screen into the Bushing until it bottoms on
the Internal shoulder.
a.
b.
c.
d.
e.
f.
g.
a.
b.
If the Throttle Ball Seat (16) was removed, install a new Seat
using a 5/16” (8 mm) diameter dowel to push it into place.
Slide the Exhaust Deector Seal (18B) onto the rear of the
Motor Housing (1). Place the Exhaust Deector (20) on the rear
of the Motor Housing.
Insert the Push Rod (135) through the Throttle Ball Seat and
into the Motor Housing followed by the Throttle Ball (15) and
Throttle Ball Spring (14). Install the Spring with the small end
against the Throttle Ball.
NOTICE
If a new Push Rod is being installed, refer to the section above
for 1RT Models for the proper installation procedure. For 1RP
Models, the Inlet Bushing Assembly replaces the Back Cap
Assembly of the 1RT Models.
f. Secure the throttle parts and the Exhaust Deector with the
Inlet Bushing Assembly. Tighten the Bushing to a minimum of
15 ft-lb (20 Nm) of torque.
NOTICE
The Inlet Bushing must securely clamp the Exhaust Deector.
Assembly of the Motor
Place the Rear End Plate (31) on the short, unsplined shaft of the
Rotor (29) with the counterbore away from the body of the Rotor.
Using a sleeve that contacts the inner ring of the Rotor
Bearing (32), press the Bearing onto the shaft until the Rear End
Plate just contacts the rotor body.
The clearance between the Rear End Plate and Rotor is critical.
While pressing down with your nger the outer edge of the End
Plate on the Bearing side, insert a .002” (.05 mm) feeler gauge
between the face of the Rotor and End Plate directly opposite the
point where pressure is applied.
NOTICE
This measurement must be made at the outside diameter of the
rotor body.
Supporting the End Plate, lightly tap the shaft with a plastic hammer
to increase the space. Press the Bearing farther onto the shaft if the
space is too wide. When the proper clearance is obtained, install the
Rear Rotor Bearing Retainer (33) on the shaft.
Measurement of Rear End Clearance
Pressure
Feeler Gauge
(Dwg. TPD789)
4. Place the Rotor, with the splined end up, in a block which has
clearance for the Rotor Bearing and supports the End Plate.
5. Wipe each Vane (35) with a light lm of Ingersoll Rand No. 10 Oil
and place a Vane in each slot in the Rotor.
c.
d.
e.
1.
2.
3.

16575243_ed2 7
6. Note that the Cylinder (36) has a notch in one end. Place the
Cylinder, notched end up, over the Rotor and against the Rear
End Plate, aligning the dowel hole in the Cylinder with the U-
shaped notch in the rim of the End Plate. The notch in the end of
the Cylinder should be against the Front End Plate.
7. Install the Front Rotor Bearing in the Front End Plate (30) and
retain it with the Front Rotor Bearing Retainer (34).
8. Using a sleeve that contacts the inner ring of the bearing, press
the assembled Front End Plate, at side rst, onto the splined end
of the Rotor until the End Plate just contacts the Cylinder.
9. Install the Rear End Plate Gasket (38) in the Motor Housing,
aligning the small notch in the Gasket with the dowel pin hole in
the Housing.
10. Insert a thin, rigid wire into the dowel pin hole at the bottom of
the motor recess in the Motor Housing. Grasping the assembled
motor by the spline on the Rotor and with the dowel pin holes of
the Front End Plate and Cylinder aligned with the U-shaped notch
in the Rear End Plate, install the assembled motor in the Motor
Housing. Maintain alignment between the motor and Motor
Housing by passing the aligned dowel holes in the assembled
motor over the wire positioned in the Motor Housing. Withdraw
the wire and install the Cylinder Dowel (37), making certain the
Cylinder Dowel is ush with or below the Front End Plate.
11. For 1RL Models ending in S1 or S3, insert the Pushrod (135)
through the center of the Rotor. If a new Pushrod is being
installed in these models. Proceed as follows:
Assemble the complete Clutch Assembly, Gear Case Assembly
and the Motor Housing Assembly without the assembled
Throttle Valve Housing (6A). Exhaust Deector Assembly,
Throttle Valve Housing Adapter (13A), Throttle Ball
Spring (13H), Muer Element (17) and Throttle Ball (13G).
Insert the new Push Rod through the central opening where
the Throttle Ball seats at the rear of the Motor Housing until it
contacts the Shuto Plunger (120).
NOTICE
Exert a slight pressure on the Push Rod to make certain the
Shuto Plunger contacts the Shuto Plunger Balls (121).
c. The length of the Push Rod must be trimmed so that 0.04 to
0.09” (1.0 mm to 2.3 mm) protrudes above the seating surface
for the Throttle Ball. There are numerous ways to determine
how much material must be trimmed from the Push Rod and
experience will dictate the best method to use. Following is
one method requiring only a narrow-depth scale. If the Push
Rod extends beyond the Housing, measure the distance from
the end of the Push Rod to the face of the surface where the
Throttle Ball seats. Subtract 5/64”(2 mm) from that distance
and cut the remaining dierence from the end of the Push
Rod. If the Push Rod does not extend beyond the Housing,
measure the distance from the end of the Housing to the
surface where the Throttle Ball seats. Record that distance.
Measure the distance from the end of the Push Rod to the end
of the Housing and add 5/64” (2mm) to that distance. Subtract
the added distance from the rst measurement and trim the
remaining dierence from the end of the Push Rod.
Assembly of the Gearing
Set the Gear Case (39) on the table of an arbor press with the
notched end upward.
Using a sleeve that will contact the outer ring of the bearing,
press the Spindle Bearing (40), open side rst, into the bearing
recess until it seats.
Install the Spindle Bearing Retainer (41) in the groove adjacent
to the Bearing.
Work some Ingersoll Rand No. 28 Grease into the teeth of the
Spindle Planet Gears (42) and onto the planet gear shafts on the
Spindle (43).
Slide the Spindle into the Gear Case so that the spindle shaft
passes through the bore of the Spindle Bearing.
a.
b.
1.
2.
3.
4.
5.
Install the Spindle Retaining Ring (44) in the groove on the
spindle shaft.
Slide the Spindle Planet Gears onto the planet gear shafts, making
certain the teeth of the Gears mesh with the teeth of the Gear
Case.
For M or N Gear Ratio, coat the Gear Head Spacer (46) with
grease and place it in the Gear Case against the Spindle Planet
Gears. Work some grease into the teeth of the Gear Head Planet
Gears (48) and onto the planet gear shafts on the Gear
Head (47). Slide the Gear Head into the Gear case so that the teeth
on the gear head shaft mesh with the Spindle Planet Gears. Slide
the Gear Head Planet Gears onto the planet gear shafts making
certain the teeth of the Gears mesh with the teeth of the Gear
Case. Work some grease into the teeth of the Rotor Pinion (45)
and place the Rotor Pinion in the Gear Head so that it meshes
with the Gear Head Planet Gears.
Place the Motor Clamp Washer (49) in the Gear Case against the
internal gear. Install the Clamp Washer Retaining Ring (50). Thread
the Gear Case with its assembled gearing into the Motor Housing,
and tighten it between 15 and 18 ft-lb (20 and 25 Nm) torque.
NOTICE
This is a right-hand thread; turn clockwise to tighten.
Assembly of the Adjustable Cushion Clutch and
Adjustable Shuto Clutch
If the Clutch Housing Bushing was removed, proceed as follows:
For Models 1RA and 1RL ending in D1, standing the Clutch
Housing Assembly (150) on an arbor press table with the internal
thread upward, press the Clutch Housing Bushing into the Clutch
Housing until the shoulder of the Bushing seats.
For Models 1RA, 1RL, 1RP and 1RT ending in C1, C3, S1 or S3,
stand the Clutch Housing Assembly (100) on an arbor press table
with the internal thread upward. Using a step arbor that pilots the
inside of the Bushing with the large bore of the Clutch Housing.
Press the Clutch Housing Bushing (101) into the Clutch Housing
to a depth between 2.564” and 2.569”(65.12 and 65.25 mm)
below the top face. The bore of the Bushing must be parallel with
the large bore of the Housing within .0012”(0.03 mm).
For Models 1RA, 1RL, 1RP and 1RT ending in S9D or C9D
With the Clutch Housing Cap (103) removed, stand the
Clutch Housing Assembly (100) on an arbor press table with
the internal thread upward. Press one of the clutch housing
bushings into the Clutch Housing until the shoulder of the
bushing seats.
Invert the Housing and press the remaining bushing into the
front end of the Housing until the shoulder of the bushing
seats.
Thread the Clutch Housing Cap (103) onto the Housing.
For Models 1RA, 1RL and 1RP ending in C1, C3 or C9D
Apply a coat of the recommended grease to the ten Jaw
Bearing Balls (109), eleven Clutch Balls (108), the internal hex
of the Clutch Driver (106) and the Thrust Bearing (112).
Holding the Clutch Driver (106) in one hand with the external
hex end down, slide the Clutch Jaw onto the external hex end
of the Driver. Move the Jaw along the Driver to a point near
the front shoulder of the Driver where the ten Jaw Bearing
Balls can be installed in the Jaw.
Install the Balls and pull the Jaw toward the shoulder of the
Driver to capture the Balls.
While maintaining pressure against the Clutch Jaw, invert
the Clutch Driver and install the Clutch Ball Spacer ( 110) on
the Driver.
Place the eleven Clutch Balls in the openings of the Clutch Ball
Spacer and install the Clutch Ball Seat (111) with the recess on
the face of the Seat toward the Clutch Balls.
6.
7.
8.
9.
1.
a.
b.
c.
a.
b.
c.
d.
e.

8 16575243_ed2
Lock all the components in place by installing two of the
Spring Seat Stops (114) in the grooves on the Driver nearest
the Clutch Jaw.
For Models 1RL, 1RP and 1RT ending in S1, S3 or S9D
Apply some of the recommended grease to the groove at
the front end of the Clutch Driver (106) and install the Clutch
Driver Seal (106A) in the groove.
Install the Clutch Driver Spacer (106B) into the Bit Holder
Assembly (125) or Bit Holder (106).
Put some of the recommended grease into the opening in the
front end of the Clutch Driver (106) and slide the Bit Holder
Assembly or Bit Holder onto the anged end of the Clutch
Driver.
Apply a coat of the recommended grease to each of the ten
Bit Holder Bearing Balls (124) and insert the Balls into the bit
holder bearing hole.
Install the Ball Retaining Ring (117) into the groove of the Bit
Holder Assembly or Bit Holder to retain the Bit Holder Bearing
Balls.
Apply a coat of the recommended grease to the cam surface,
clutch ball pockets, and shaft of the Clutch Driver.
Holding the Bit Holder, Clutch Driver upward, insert each of
the three Clutch Cam Balls (123) into the three sections of the
Bit Holder Assembly.
Install the Clutch Ball Seat (111) over the end of the driver with
the large circular groove toward the Clutch Cam Balls.
Insert the four Shuto Plunger Balls (121) into the hole on the
side of the Clutch Driver.
Install the Shuto Collar (118), relieved end rst, over the end
of the Clutch Driver until it contacts the face of the Clutch
Spring Seat (113).
Slide the Collar Return Spring (119), large end rst, over the
Clutch Driver until it contacts the Shuto Collar and retain all
components with the Spring Seat Stop (114).
Apply a light coat of the recommended grease to the Shuto
Plunger (120) and insert the Plunger Return Spring (122) and
Shuto Plunger into the hex of the Clutch Driver.
2. Position the Clutch Spring (105) on the hub of the Clutch Ball Seat
and install the Clutch Spring Seat (113) on the Clutch Driver with
the hub inside the Clutch Spring.
3. Lubricate and install the Thrust Bearing (112) and the Adjusting
Nut Lock (115), with the at side of the Lock toward the Bearing,
on the Clutch Driver. Lubricate the side of the Adjusting Nut Lock
that is not at.
4. Thread the Adjusting Nut (116) onto the Clutch Driver, with the
smooth face away from the Nut Lock, until the Nut passes the
remaining Spring Seat Stop groove in the Clutch Driver.
5. Install the Spring Seat Stop (114) into the groove adjacent to the
Adjusting Nut.
For Models 1RA and 1RL ending in C1, C3 or C9D, insert the
Disengaging Spring (133) into the front end of the Clutch Driver.
Inject a small quantity of the recommended grease into the
opening in the bit end of the Clutch Driver and slide the pilot end
of the Bit Holder Assembly (128) into the Clutch Driver.
For Models 1RL, 1RP and 1RT ending in C1, C3, S1, S3, C9D
or S9D, insert the Clutch Return (104), small end rst, over the
hex end of the Clutch Driver until it stops against the Spring Seat
Stop (114).
For Models 1RP ending in C1, C3 or C9D, inject a small quantity
of the recommended grease into the opening in the bit end
of the Clutch Driver and slide the pilot end of the Bit Holder
Assembly (128) or (125) into the Clutch Driver.
6. Apply a light coat of the recommended grease to the hex end of
the Clutch Driver and to the bearing surface of the Bit Holder.
7. Slide the assembled Clutch into the Clutch Housing (100).
8. Screw the Clutch Housing Assembly onto the Gear Case securely.
f.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
NOTICE
The clutch should only be hand tight. It has a left-hand thread.
Turn counterclockwise to tighten.
Assembly of the Direct Drive Attachment
If the Housing Bushing (151) was removed, press the new Bushing
into the Screwdriver Housing (150) until the shoulder of the
Bushing is against the face inside the Housing.
Install one of the Bit Holder Retaining Rings (153) in the groove at
the Gear Case end of the Bit Holder (154).
Apply a light coat of the recommended grease to the surface of
the Bit Holder that ts into the Bushing and slide the Bit Holder
into the Bushing until the Bit Holder Retaining Ring stops against
the shoulder of the Bushing.
Install the remaining Bit Holder Retaining Ring in the groove
nearest the bit end of the Bit Holder.
Apply some of the recommended grease to the Bit Retaining
Ball (152) and install the Ball in the hole in the Bit Holder.
Slide the Bit Retaining Sleeve (155) onto the Bit Holder until it
stops against the Bit Holder Retaining Ring at the bit end of the
Bit Holder.
Install the Retaining Sleeve Spring (156), large end rst, onto the
Bit Holder and into the Bit Retaining Sleeve. Continue pushing
until the small end of the Spring is captured by the groove at the
bit end of the Bit Holder.
Thread the Screwdriver Housing Attachment onto the Gear Case
Assembly until it is hand tight.
NOTICE
This is a left-hand thread. Turn counterclockwise to tighten.
1.
2.
3.
4.
5.
6.
7.
8.

16575243_ed2 9
Troubleshooting Guide
Trouble Probable Cause Solution
Loss of Power Low air pressure Check air supply. For top performance, the air pressure must
be 90 psig (6.2 bar/620 kPa) at the inlet.
Plugged Air Strainer Screen or Inlet
Screen
Clean the Air Strainer or screen in a clean, suitable, cleaning
solution. If the Screen cannot be cleaned, replace it.
Clogged Muer or Exhaust Silencer Clean the Muer Element in a clean, suitable, cleaning
solution. If it cannot be cleaned, replace it.
Worn or broken Vanes Replace the complete set of Vanes.
Damaged Rear End Plate Gasket Install a new Rear End Plate Gasket.
Worn or broken Cylinder Replace the Cylinder if it is cracked or if the bore appears wavy
or scored.
Improper lubrication or dirt build-up Clean the Motor Unit parts and lubricate as instructed.
Leaky Throttle Valve Worn Throttle Valve and/or Throttle
Valve Seat
Install a new Throttle Valve and/or a Throttle Valve Seat.
Dirt accumulation on Throttle Valve
and/or Throttle Valve Seat
Pour about 3 cc of a clean, suitable, cleaning solution in the
air inlet and operate the tool Valve for about 30 seconds.
Immediately pour 3 cc the recommended oil in the air
inlet and operate the tool for 30 seconds to lubricate all the
cleaned parts.
Inconsistent disengagement of
Adjustable Clutch
Improper lubrication Remove Adjustable Clutch mechanism and examine parts.
Lubricate as instructed.
Wrong Clutch Spring (using Heavy
Clutch Spring on light torque
application)
Change to Medium or Light Clutch Spring.
Motor stalls before Adjustable
Clutch ratches
Improper Clutch adjustment or
improper tool ratio for application
Check Clutch Adjustment and review tool performance vs.
requirements.
Low air pressure at the inlet Check the air supply. For top performance, the air pressure
must be 90 psig (6.2 psig/620 kPa) at the inlet.
Insucient grease Lubricate the Clutch as instructed.
Related Documentation
For additional information refer to:
Product Safety Information Manual 04585006.
Product Information Manual 80167265.
Parts Information Manual 16574550.
Manuals can be downloaded from ingersollrandproducts.com.

Notes:

Notes:

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