Ingersoll-Rand 41 Series Setup guide

16575284
Edition 1
May 2006
Air Screwdrivers
Series 41
Maintenance Information
Save These Instructions

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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).
Lubrication
Each time a Series 41 Screwdriver is disassembled for
maintenance and repair or replacement of parts, lubricate the
tool as follows:
1. Lubricate the clutch with Ingersoll Rand No. 105 or
Ingersoll Rand No. 115 Grease.
2. Lubricate the gearing with Ingersoll Rand No. 105
Grease.
3. 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.
Disassembly
General Instructions
1. Do not disassemble the tool any further than necessary
to replace or repair damaged parts.
2. 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 present distortion. This is
particularly true of threaded members and housings.
3. Do not remove any part which is a press fit in or on a
subassembly unless the removal of that part is necessary
for repairs or replacement.
4. Do not disassemble the tool unless you have a complete
set of new gaskets and O-rings for replacement.
Disassembly of the Clutch
NOTICE
The Clutch Housing (105) has left-hand threads.
1. Secure tool in vise with leather-covered or copper-
covered jaws, clamping on Inlet Adapter (25). Using a
strap type wrench, remove Clutch Housing.
2. Remove clutch assembly from tool.
NOTICE
Springs (82) and (83) are loose and may fall out.
3. Secure a 1/4” hex wrench in a vise. Then place Bit Holder
(100) and clutch assembly on it.
4. Remove Snap Ring (84). Using a 7/8" wrench, remove
Adjustment Nut (85).
5. Remove Adjustment Washer (86) and Clutch Spring (87).
6. Remove Retaining Rings (88).
NOTICE
Removal of Ball Sleeve (91) releases six Balls (97).
7. Slide off Guide (89), Spring (90), Ball Sleeve, Thrust
Race (92) and Thrust Bearing (93).
8. Remove Thrust Race (94), releasing six Balls (98).
9. Remove Retaining Ring (103) and rotate Bit Holder (100)
to remove twelve Balls (99).
10. Separate Bit Holder and Spindle (96), releasing eleven
Balls (99).
Disassembly of the Gearing
1. Remove clutch from tool. Refer to section on Clutch
Disassembly.
2. Using a wrench on flats, remove Ring Gear (67) or (81).
3. Remove Snap Ring (71) and Washer (70).
NOTICE
Keep gears grouped with mating spindle when
disassembling double reduction gearing.
Do not remove Bearing (69) and Spacer (68) unless
damage is evident.
4. Remove spindle(s) and Gears from Ring Gear.
5. To remove Bearing and Spacer from Ring Gear, press on
Spacer (68) from inside splined end of Ring Gear.
NOTICE
Do not remove Gears (62), (72) or (76) from Carrier
Assembly (75) unless damage is evident. Gears are press
fit on Carrier Assembly.
Disassembly of the Motor
1. Remove Clutch and Gearing from tool.
2. Remove Spacer (60) and O-Ring (59).
3. Tap front edge of housing to remove motor assembly.
Locating pin should also come out.
4. Tap drive end of Rotor (52) with a soft face hammer; motor will
come apart.
NOTICE
Bearings are light press fit in End Plate (50) or (57).
Bearing (51) is press fit on Rotor.
5. Remove End Plate and Bearing from Rotor.
Disassembly of the Motor Housing
Lever Throttle
1. Secure Air Inlet Adapter (2) in a vise with leather-covered
or copper-covered jaws.
2. Using a strap type wrench, unthread Housing (15).
3. Remove Spacer (3), Diffuser Washer (4), Exhaust Cap
(5), Filler (6), Spring (7) and Valve Assembly (8).
4. Remove Cap (21) and Spring (19), releasing Valve Stem
(18).
5. Remove Valve Block (10) and Spring (11), releasing valve
Assembly (12).
NOTICE
Do not remove or adjust rubber portion of Valve
Assemblies (8) and (12), as they are preset at the factory.
6. Remove O-Ring (13) and Reverse Sleeve (14), releasing
Valve Body (17) and Spring (16).

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Pistol Grip Housing
1. Remove End Cap (32) and O-Ring (33), releasing Spring
(34) and Valve Rod (35).
2. Remove Top Cap (39) and O-Ring (38), releasing Spring
(37) and Reverse Valve (36).
NOTICE
Do not remove Roll Pin (47) or Bushing (48) unless
damage is evident.
3. To remove Roll Pin or Bushing, press thru to reverse
valve cavity.
4. To remove Trigger (44) or Button (46), Drive Pin (40) out
of Housing, releasing Trigger or Button, Reverse Cam
(43) and Springs (41).
5. For Models 41TS and 41TP, remove O-Ring (42),
releasing Trigger from Reverse Cam (43).
6. Remove Inlet Adapter (25) and Screen (1).
7. For Models 41TS and 41TP, remove Spring (26) and
Valve Rod (27).
8. Remove Retaining Ring (29), releasing Screen (30) and
Muffler (31).
Assembly
General Instructions
1. Always press on the inner ring of a ball-type bearing
when installing the bearing on a shaft.
2. Always press on the outer ring of a ball-type bearing
when pressing the bearing into a bearing recess.
3. 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.
4. Always clean every part and wipe every part with a thin
film of oil before installation.
5. Apply a film of O-ring lubricant to all O-rings before final
assembly.
6. 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.
7. Sealed or shielded bearings should never be
cleaned. Work grease thoroughly into every open
bearing before installation.
Assembly of the Motor Housing
Lever Throttle
1. Install Spring (16) in Housing, securing with Valve Body
(17).
2. Install Reverse Sleeve (14) and O-Ring (13) in Housing,
securing Valve Body.
3. Lubricate and install O-Ring (9) in Valve Block (10).
NOTICE
Install Valve Block (10) with counterbore towards Cap
(21).
4. Install Valve Assembly (12) and Spring (11) in Housing,
securing with Valve Block (10).
5. Lubricate and install O-Ring (20) in Cap (21).
6. Assembly Valve Stem (18) and Spring (19) to Housing,
securing with Cap.
NOTICE
Assembly Valve Stem with slot turned to accept Valve
Assembly (8).
7. Install Filler (6) and Exhaust Cap (5) in Housing, aligning
lever with Valve Stem.
8. Install Valve Assembly (8) in Housing, being certain Valve
Assembly seats in slot in Valve Stem.
9. Install Spring (7) in Housing, securing with Diffuser
Washer (4), Spacer (3) and Inlet Adapter (2).
10. Clean and install Screen (1) in Inlet Adapter.
Pistol Grip Housing
1. Assemble Muffler (31) and Screen (30) into Housing,
securing with Retaining Ring (29).
2. For Models 41TS and 41TP, coat Valve Rod (27) with the
recommended oil and install Valve Rod and Spring (26) in
Housing.
3. Install Inlet Adapter (25) in tool.
4. Clean and replace Screen (1) in Inlet Adapter.
5. Coat Trigger (44) or Button (46) with the recommended
oil and install in Reverse Cam (43).
6. For Models 41TS and 41TP, lubricate and install O-Ring
(42) on Trigger (44).
7. Install Springs (41) on Reverse Cam, flat side away from
Reverse Cam, and install Reverse Cam and components
in Housing, aligning holes in Trigger and Housing.
8. Install Pin (40) in Housing, securing Reverse Cam and
Trigger.
9. Install Bushing (48) in Housing, pressing flush with
counterbore in bottom of motor cavity.
10. Install Roll Pin (47) in Housing, pressing flush with bottom
of motor cavity.
11. Coat Reverse Valve (36) with the recommended oil and
install in Housing, aligning slot in Reverse Valve with Roll
Pin (47).
12. Install Spring (37) in Housing.
13. Lubricate and install O-Ring (38) in Top Cap (39) and
install Cap in Housing, securing Spring (37) and Reverse
Valve (36).
14. Coat Valve Rod (35) with the recommended oil and install
in Housing.
15. Install Spring (34) in Housing, where applicable.
16. Lubricate and install O-Ring (33) in End Cap (32) and
install Cap in Housing, securing Valve Rod and Spring.
Assembly of the Motor
1. Lubricate Bearing (51) with the recommended grease
and install on End Plate (50) or (57), pressing on outer
race of Bearing.
2. Install End Plate on Rotor, pressing on inner race of
Bearing.
3. Coat Vanes (53) with the recommended oil and install in
rotor slots, straight side out. Coat inside of Cylinder (54)
with the recommended oil and install over Rotor, aligning
air inlet slots of Cylinder with air inlet slots in End Plate.
4. Install Bearing (56) on End Plate (55), pressing on outer
race of Bearing. Install End Plate on Rotor, pressing on
inner race of Bearing. Be sure Rotor turns without
binding.
5. Insert Locating Pin (58) or (61) into 0.081" diameter blind
hole at bottom of motor cavity in Housing.
6. Align notches of End Plates and Cylinder and install
motor into Housing, aligning notches with Pin.
7. Lubricate and install O-Ring (59) in End Plate.
8. Install Spacer (60) in motor.
9. Install Gearing and Clutch in tool.
Assembly of the Gearing
1. Assemble Spacer (68) into Ring Gear (67) or (81).
NOTICE
Press on outer race of Bearing (69) and press to
shoulder or Ring Gear.
2. Press Bearing into Ring Gear.
3. Coat shafts of spindle with the recommended grease.

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4. Assemble gears to shafts of mating spindle.
5. Assemble Carrier Assembly to Spindle Assembly of
double reduction gearing. Install Spindle(s) and gearing
into Ring Gear. Rotate Spindle and Gears to align gear
teeth with splines of Ring Gear.
6. Thread Ring Gear to tool and tighten with a wrench of
flats.
7. Install Clutch in tool.
Assembly of Clutch
1. Assembly Thrust Race (115) and Wave Washer (114) to
Clutch Housing (105), where applicable.
2. Lubricate ball grooves of Clutch Spindle (96) using the
recommended grease.
3. Install eleven Balls (99) into groove.
4. Slide Spindle (96) into Bit Holder (100), securing Balls.
5. Assemble twelve Balls (99) into Bit Holder and secure
with Retaining Ring (103).
6. Lubricate ball pockets of bit holder using the
recommended grease and install six Balls (98) into
pockets, securing with Thrust Race (94).
7. Lubricate and assemble Thrust Bearing (93) and Thrust
Race (92) to Spindle.
8. Coat Plunger (95) with the recommended oil and
assemble to spindle, securing with Balls (97).
NOTICE
Assemble two balls per hole. Secure balls with Ball
Sleeve (91).
9. Assemble Spring (90) and Guide (89) to Spindle,
securing with Retaining Rings (88). Install Clutch Spring
(87).
10. Lubricate face of Adjustment Washer (86) and install on
Spindle.
11. Thread Adjustment Nut (85) onto Spindle, securing with
Snap Ring (84).
12. Lubricate Ball (101) of Bit Holder, using the
recommended lubricant.
13. Assemble Springs (82) and (83) into Spindle.
NOTICE
Assemble Spring (82) with large diameter into Spindle
first.
14. Install Clutch Assembly in tool.
NOTICE
The Clutch Housing (105) has left-hand threads.
15. Install Clutch Housing on tool.
16. Refer to Clutch Adjustment section in Product
Information Manuals 80167356 or 80167364.
Related Documentation
For additional information refer to:
Product Safety Information Manual Form 04585006.
Product Information Manuals Form 80167356 or Form 80167364.
Product Parts List Manual Form 16574592.
Manuals can be downloaded from www.irtools.com

Notes

Notes

Notes

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© 2006 Ingersoll Rand Company