Ingersoll-Rand 4RSERIES User manual

03534809
Form P6782
Edition 5
January, 1994
OPERATION AND MAINTENANCE MANUAL
for
SERIES 4R SCREWDRIVERS
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ THIS MANUAL BEFORE OPERATING TOOL.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
l Always operate, inspect and maintain this tool in
accordance with American National Standards
Institute Safety Codefor Portable Air Tools
(ANSI B186.1).
l For safety,top performance and maximum
durability of parts, operate this tool at 90 psig
(6.2 bar/620 kPa) maximum air pressureat the
inlet with 1/4” (6 mm) inside diameter air supply
hose.
l Air powered tools can vibrate in use.Vibration,
repetitive motions or uncomfortable positions may
be harmful to your hands and arms. Stop using any
tool if discomfort, tingling feeling or pain occurs.
Seekmedical advice before resuming use.
l Always turn off the air supply and disconnect the
air supply hosebefore installing, removing or
adjusting any accessoryon this tool, or before
performing any maintenance on this tool.
l Keep hands, looseclothing and long hair away
from rotating end of tool.
l Anticipate and bealert for sudden changesin
motion during start up and operation of any power
tool.
l Tool accessorymay continue to rotate briefly after
throttle is released.
l Do not lubricate tools with flammable or volatile
liquids such askerosene,diesel or jet fuel.
l Do not remove any labels. Replaceany damaged
label.
l Useaccessoriesrecommended by Ingersoll-Rand.
The use of other than genuine Ingersoll-Rand replacement parts may result in safety hazards, decreased tool
performance, and increased maintenance, and may invalidate all warranties.
Ingersoll-Rand is not responsible for customer modification of tools for applications on which Ingersoll-Rand was not
consulted.
Repairs should be made only by authorized trained personnel. Consult your nearest Ingersoll-Rand Authorized
Servicenter.
It is the responsibility of the employer to place the information in this manual into the hands of the operator.
Refer All Communications to the Nearest
Ingersoll-Rand Office or Distributor.
© Ingersoll-Rand Company1994
Printed in U.S.A.

WARNING LABEL IDENTIFICATION
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
A WARNING
Always wear eye protection
when operating or perform-
ing maintenance on this
tool.
e, WARNING
Always turn off the air
supply and disconnect the
air supply hose before
installing, removing or
adjusting any accessory on
this tool, or before perform-
ing any maintenance on this
tool.
A WARNING I
Do not carry the tool by
the hose.
A WARNING
Keep body stance balanced
and firm. Do not overreach
when operating this tool.
A WARNING
Always wear hearing
protection when operating
this tool.
A WARNING
Air powered tools can
vibrate in use. Vibration,
repetitive motions or uncom-
fortable positions may be
harmful to your hands and
arms. Stop using any tool if
discomfort, tingling feeling
or pain occurs. Seek medi-
cal advice before resuming
use.
I
pI WARNING
Do not use damaged, frayed
or deteriorated air hoses
and fittings.
A WARNING
Operate at 90 psig
(6.2 bar/620 kPa)
Maximum air pressure.
2

PLACING TOOL IN SERVICE
LUBRICATION
Ingersoll-Rand No. 10 Ingersoll-Rand No. 28
Ingersoll-Rand No. 67
Alwaysuseanairlinelubricatorwith thesetools.
Werecommendthefollowing Filter-Lubricator-Regulator
Unit:
For USA - No. C05-02-G00
For International -No. C01-C2-T29
Before starting the tool and after eacheight hours of
operation, unlessanair linelubricatorisused,injecta
few dropsof Ingersoll-RandNo. 10Gil intotheairinlet.
ThecavityaroundoutsideofRearRotorBearing(42)in
Motor Housing(1)shouldbefilled 50to75percent
capacitywith Ingersoll-RandNo.28Grease.
Gearing
For models with L gearing,injectapproximately6 to
8ccof Ingersoll-RandNo. 28GreaseintotheGrease
Fitting (51)in theGearCase(50)aftereach50000cycles
or 100hoursof operation,whichevercomesfirst.
For modelswith M, N or P gearing, inject
approximately10to 12ccofIngersoll-RandNo.28
GreaseintotheGreaseFitting(51)in theGearCase(50)
aftereach50000cyclesor 100hoursof operation,
whichevercomesfirst.
Clutch
Lubricatethe4C15, 4C17or4Sl AdjustableClutchwith 6
to 8ccof Ingersoll-RandNo.67Greaseaftereach50000
cyclesoreach100hoursof operation,whicheveroccurs
first. LubricatetheClutchesasfollows:
Turn off the air supply and disconnect the air supply
hoseat the tool before performing any maintenance.
1. RotatetheAdjustingHoleCover(103,219or252)to
exposetheslotin theClutchHousing(101,201or
250).
2. For 4C15 or 4S1, inserta l/4” AllenWrenchintothe
Bit Holder(106or 270)androtatetheBit Holderuntil
theholein theClutchAdjustingNut (113or 256)is
alignedwith theslotin theClutchHousing.
For 4C17, inserta l/4” AllenWrenchintotheBit
Holder(217)and,whilepushingagainsttheBit
Holderto engagetheclutchjaws,rotatetheBit
Holderuntil theholeintheClutchAdjustingNut
(214)isalignedwith theslotin theClutchHousing.
3. For 4C15 or 4S1, inserttheClutchAdjustingKey
into theholein theClutchAdjustingNut and,while
holdingtheNut againstrotation,rotatetheBit Holder
4.
5.
6.
7.
clockwise forthe4C15and counterclockwise for the
4S1untilthereisnocompressionontheClutch
spring(112or261).
For 4C17, inserttheClutchAdjustingKeyintothe
holein theClutchAdjustingNut and,whileholding
theNutagainstrotationandpushingagainsttheBit
Holdertoengagetheclutchjaws,rotatetheBit
Holdercounterclockwiseuntil themisnocompression
ontheClutchSpring(209).
Usingawrenchontheflatsof theGearCaseandan
adjustablespannerwrenchin theslotof theClutch
Housing,unscrewtheClutchHousingfromtheGear
Case.
This is a left-hand thread; turn clockwise to
remove.
For 4C15,using snapringpliers,removetheSleeve
SpringRetainer(119)fromtheBit Holder. Slidethe
RetainingSleeveSpring(118)andBit Retaining
Sleeve(117)fromtheBit HolderandremovetheBit
RetainingBall (116).
WithdrawtheassembledclutchfromtheClutch
Housingandlubricateall bearingsurfaces,bearings
andballswith therecommendedgrease.
Do not getyour fingers betweenthe clutch
components.
ToreassembletheClutch,performsteps3through6
in Changing the Clutch Spring.
CLUTCH ADJUSTMENT
The4C15, 4C17and4Sl clutchescanbeexternally
adjustedwithin acertainrangetoratchetwhena
predeterminedtorquehasbeendelivered.Toadjustthe
clutch,proceedasfollows:
1. Turn off the air supply and disconnect the air
supply hoseat the tool before proceeding.
2. RotatetheAdjustingHoleCover(103,219or 252)to
exposetheslotin theClutchHousing(101,201or
250).
3. For 4C15 or 4S1,insert a l/4” Allen Wrench into
theBit Holder(106or 270)androtatetheBit Holder
untiltheholein theClutchAdjustingNut (113or
256) isalignedwith theslotintheClutchHousing.
For 4C17, inserta l/4” AllenWrenchintotheBit
Holder(217)and,while pushingagainsttheBit
Holdertoengagetheclutchjaws,rotatetheBit
Holderuntiltheholein theClutchAdjustingNut
(214)isalignedwith theslotin theClutchHousing.

PLACING TOOL IN SERVICE
4. For 4C15 or 4S1, inserttheClutchAdjustingKey
intotheholein theClutchAdjustingNut and,while
holdingtheNut againstrotation,rotatetheBit Holder
toadjustthetorqueoutput.
For 4C17, inserttheClutchAdjustingKey intothe
holein theClutchAdjustingNutand,whileholding
theNutagainstrotationandpushingagainsttheBit
Holderto engagetheclutchjaws,rotatetheBit
Holdertoadjustthetorqueoutput.
5. RotatingtheBit Holderclockwiseincreasesthe
compressionontheClutchSpring(112,209or261)
andraisesthetorqueatwhichtheclutchwill ratchet.
The most satisfactory adjustment is usually
obtained by useof the tool on the actual
application, and increasing or decreasingthe
delivered torque until the desired setting is
reached.In any event, it is recommendedthat the
final adjustment be made by gradual progression.
Theseclutches, when equipped with a Heavy
Spring, can he setbeyond the torque capacity of
the tool, in which casethe tool will stall before the
clutch ratchets. Do not adjust the clutch beyond
the torque capacity of the tool.
- CHANGING THE CLUTCH SPRING -
AdditionalClutchSpringsareavailablefor theseclutches
whichallowthetoolstobeusedwhenthedesiredtorque
doesnotfall within thetorquerangeof thefurnished
Spring.TochangeaClutchSpring(112,209or 261)
proceedasfollows:
1. WithdrawtheassembledclutchfromtheClutch
Housing(101,201or 250)afterperformingsteps1
through6asdescribedin thesection Clutch
Lubrication.
2. To changethe Clutch Spring in the 4C15 Clutch,
proceedasfollows:
a. Graspthesplineof theClutchShaftSupport
(120)in leather-coveredorcopper-coveredvise
jawswith theBit Holder(106)upward.
b. Usingsnapring piers,removetheBit Holder
stop(115).
c. Usingawrenchandkeepingpressureagainstthe
SpringSeat(110)topreventtheClutchBalls
(108)fromfalling outof position,unscrewand
removetheClutchAdjustingNut (113).
This is a left-hand thread; turn clockwise to
remove.
d. Lift off theAdjustingNutLock (114)andthe
ClutchSpring.
e. InstallthenewClutchSpringandreplacethe
AdjustingNutLock.
f. ThreadtheClutchAdjustingNut ontotheBit
HolderandreplacetheBit HolderStop.
g. Removetheassembledclutchfromthevise.
3. To changethe Clutch Spring in the 4C17
Clutch, proceedasfollows:
a.
b.
C.
d.
e.
f.
CarefullygrasptheFrontClutchJaw(204)in
leather-coveredorcopper-coveredvisejaws
with theClutchAdjustingNut (214)upward.
Usingawrenchontheflatsof theClutch
AdjustingNut (214),loosenandremovetheNut.
Withtheassemblyin theviseandwhile applying
slightdownwardpressureto theClutchBall Seat
(208),removetheAdjustingNut Lock (213),
SpringSeatBearing(212),ClutchSpringSeat
(211)andtheClutchSpringfromtheClutch
Driver(203).
ThoroughlygreasetheBearingandAdjustingNut
Lock,andin theordernamed,slidethefollowing
overtheClutchDriver:thenewClutchSpring,
theClutchSpringSeat,theSpringSeatBearing
andtheAdjustingNutLock,indentedside
trailing.
StarttheClutchAdjustingNut,detentsidefirst,
ontotheClutchDriverandrun it fingertight
againstthecompressionof theSpring.Witha
wrench,tightentheNutanadditionaloneortwo
turns.
Removetheassembledclutchfromthevise.
4. To changethe Clutch Spring in the 4Sl Clutch,
proceedasfollows:
a Graspa l/4” AllenWrenchin visejaws with a
sectionof thehexpointingupward.Positionthe
Bit Holder(270)ontheAllen Wrenchsothatthe
splinedendof theClutchDriver (253)isupward
b. RemovetheClutchReturnSpring(254)and
ReturnSpringCollar(255)from theClutch
Driver.
c. Usingsnapringpliers,removetheSpringSeat
Stop(260)fromthethreadedsectionof the
ClutchDriver.
d. Usingawrench,unscrewandremovetheClutch
AdjustingNut (256).

PLACING TOOLIN SERVICE
5.
6.
7.
e.
f.
h.
i.
j.
Lift off theAdjustingNut Lock (257),theThrust
Bearing(258),theClutchSpringSeat(259)and
theClutchSpringfromtheClutchDriver.
ThoroughlygreasetheBearingandAdjustingNut
Lock,andin theordernamed,slidethefollowing
overtheClutchDriver:thenewClutchSpring,
theClutchSpringSeat,theThrustBearingand
theAdjustingNutLock, indentedsidetrailing.
StarttheClutchAdjustingNut,detentsidefirst,
ontotheClutchDriverandrunit fingertight
againstthecompressionof theSpring.Witha
wrench, tightentheNut anadditionaloneortwo
turns.
Usingsnapring pliers,installtheSpringSeat
StopontheClutchDriver.
PlacetheReturnSpringCollar,concaveend
trailing,andtheClutchReturnSpringonthe
splinedendof theClutchDriver.
RemovetheassembledclutchfromtheAllen
Wrenchandthewrenchfromthevise.
Inserttheassembledclutch,Bit Holderendfirst,into
theClutchHousing.
For 4C15,inserttheBit RetainingBallintothehole
in theBit Driver.InstalltheBit RetainingSleeveon
thehubof theBit HolderagainsttheBit Retaining
SleeveStop(123). InstalltheRetainingSleeve
SpringontheBit HolderandinsidetheSleeve.Using
snapringpliersandcompressingtheSpring,install
theSleeveSpringRetainerin theexternalgroovenear
theoutputendof theBit Holder.
ThreadtheassembledClutchontotheGearCase.
This isa left-hand thread; turn clockwiseto
remove.
lighten theClutchHousingbetween2to5ft-lb
(3to7Nm) torque.
8. AdjusttheClutchasdirectedin thesectionClutch
Adjustment.
INSTALLATION
Air Supply and Connections
Alwaysusecleandryair.Dust,corrosivefumesand/or
excessivemoisturecanruin themotorof anairtool.An
airlinefilter cangreatlyincreasethelive of anairtool.
Thefilterremovesdustandmoisture.Low pressure(under
90psig;6.2bar/620kPa)reducesthespeedof all airtools.
Low airpressurenotonly wastestime,butalsocosts
money.Highairpressure(over90psig;6.2bar/620kPa)
raisesperformancebeyondtheratedcapacityof thetool
andcouldcauseinjury.Besureall hosesandfittingsate
thecorrectsizeandaretightly secured.
SeeDwg.TPD905-1foratypicalpipingarrangement.
MAIN LINES 3 TIMES
AIR TOOL INLET SIZE
TO
AIR
AIR TOOL INLET SIZE
DRAIN REGULARLY COMPRESSOR
(Dwg. TPD905-1)
The Model 4R Screwdriver is &signed for fastening applications in automotive and appliance assembly,the
electronic and aerospace industries and for woodworking.
HOW TO ORDER A SCREWDRIVER
REVERSIBLE WITH PISTOL GRIP HANDLE AND ADJUSTABLE CUSHION CLUTCH
Model
I
Torque Range (Soft Draw)
in-lb Nm
.----- -- .- -.. ..-
4RAMCl 15-65 l-7-7.4
4RANCl 20-80 2.3-9.1
4RAPCl 20-105 2.3-11.9
5

PLACING TOOL IN SERVICE
REVERSIBLE WITH IN-LINE HANDLE, PUSH THROTTLE AND SHUT-OFF CLUTCH
Torque Range (Soft Draw)
Model in-lb Nm
4RPLS1 15-40 1.7-4.6
4RPMS1 15-65 1.7-7.4
4RPNS1 15-80 1.7-9.1
REVERSIBLE PISTOL GRIP HANDLE AND SHUT-OFF CLUTCH
4RTLS1 15-40 1.74.6
4RLMSl 15-65 1.7-7.4
4RTNS1 14-80 1.7-9.1
4RTPSl 15-105 1.7-11.9
REVERSIBLE LEVER THROTTLE AND IN-LINE HANDLE WITH ADJUSTABLE
CUSHION CLUTCH
4RLLCl 15-40 1.74.6
4RLMCl 15-65 1.7-7.4
4RTNCl 20-80 2.3-9.1
REVERSIBLE PISTOL GRIP HANDLE WITH POSITIVE JAW CLUTCH
4RALPl 22 2.5
4FAMPl 36 4.1
4FANPl 44 5.0
4RAPPl I 58 I 6.6
REVERSIBLE WITH PISTOL GRIP HANDLE AND DIRECT DRIVE
Model
4RALDl
4RAMDl
4RANDl
Torque Range (Soft Draw) 50 psi Torque Range (Soft Draw) 90 psi
in-lb Nm in-lb Nm
22 2.5 40 4.6
36 4.1 65 7.4
44 5.0 80 9.1

MAINTENANCE SECTION

PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING --
t
t
*
1
*
*
2
3
4
l 5
5A
6
7
MotorHousingAssembly
for4RA Models ............
for4RL Models.............
for 4RPModels.............
for 4RTModels.............
Warning Label......................
MotorHousing
for4RA and4RTModels .....
for 4RL Models.............
for 4RPModels.............
Nameplate......................
NameplateRivet(2) ..............
TriggerBushing(for4RA and4RT
Models).........................
PlungerBushing(for4RL Models) ...
ReverseValve
for 4RA Models ............
for 4RL and4RPModels .....
for 4RTModels.............
ReverseValveSpring
for4RA and4RTModels .....
for4RL and4RPModels .....
ReverseValveBushingSeal(for4RL
and4RPModels)....................
ReverseValveLock Pin
(for4RL and4RPModels) ............
Lock PinRetainer(for4RL and
4RPModels). . . . . . .. . . .. . . . .. . . . .. . . 7RL-56
* Not illustrated
IndicatesTune-upKit part.
l Tokeepdowntimetoaminimum,it isdesirableto haveonhandcertainrepairparts.Werecommendtahtyoustockone(pairor set)of eachpartindicatedby
abullet(•) foreveryfour toolsin service.
4RA-A40
4RL-A40
4RP-A40
4RT-A40
WARNING-7-99
4RA-B40
4RL-B40
4RP-B40
4RA-301
BN403-302
4RA-91
5RLK2C-91
4RA-329
55RP-329
4RT-A329
4RA-515
55RP-515
6WRS-290
SPA1024668
8
9
l a 10
11
12
13
14
15
16
18
19
+ 20
+ 21
l 22
RetainerSetscrew(for4RL and
4RPModels).......................
ReverseValveSwitch(for4RA and
4RTModels).......................
ReverseValveSeal(for4RA and
4RTModels).......................
ReverseValveScrew(for4RA and
4RTModels).......................
ReverseValvePlug(for4RA Models)...
ThrottleLever(for4RL Models) .......
ThrottleLeverPin(for4RL Models)....
TriggerAssembly(for4RA and
4RTModels).......................
Trigger ........................
TriggerPin .....................
ThrottlePlungerAssembly(for
4RL Models) ......................
ThrottlePlungerSeal .............
PushThrottleValveAssembly(for4RP
and4RTModels) ...................
ThrottleValve(for4RA,4RL and
4RTModels).......................
PushrodThrottleValveSpring
for4RPModels...............
for4RTModels...............
7RL-669
4RA-658
ROOOA2-103
4RA-665
4RA-266
7L-L273
7L-120
7AH-A93
5RA-93
7AH-94
5RLK2C-A94A
8SL-259
4RP-A302
7RAK-302
7L-51
4RT-51

23
25
26
27
28
29
30
31
32
l 33
l *34
35
36
37
PART NUMBER FOR ORDERING
ThrottleValveSpring
for4RAand4RTModels .......
for4RL Models ..............
ThrottleValveSeat(for4RA,4RL and
4RTModels).......................
ThrottleValveSeatSupport(for4RA,
4RL and4RTModels) ...............
InletBushing
for4RA and4RTModels .......
for4RL and 4RP Models.. .....
InletBushingSpacer ................
Air StrainerScreen..................
Muffler Assembly(for4RA and
4RTModels) ......................
MufflerO-ring .....................
Muffler Assembly(For4RL and
4RPModels) ......................
MufflerElement.................
MufflerElement
for4RA and 4RT Models.......
for4RL and 4RP Models.......
HousingBackCap(for4RA and
4RTModels) ......................
BackCapSeal(for4RA and
4RTModels) ......................
ExhaustDeflectorSeaI(for4RL and
4RP Models) ......................
t
3RA-51
7L-51
7RAK-303
7RAK-304
7AH-565
7L-565
7AH-65
ROA2-61
3RA-A123
85H-167
6WS-A23
3RA-310
3RA-310
4RL-311
4RA-202
AF120-294
6AH-103
38
em39
•41
42
43
44
45
46
47
48
49
50
51
52
PART NUMBER FOR ORDERING
SilencerSealRing (for4RL and
4RPModels)
.......................
RearEndPlateGasket..................
RearRotorBearingRetainingNut .........
BearingThrustWasher .................
RearRotorBearing ....................
Rear End Plate
........................
Rotor for4RA and 4RL Models
.......
for4RP and 4RT Models
.......
Vane Packet (set of5Vanes)
.............
Cylinder .............................
Front End Plate.......................
FrontRotorBearing....................
CylinderDowel .......................
GearCaseAssembly
for L ratio ...................
forM,NorPratio ............
GreaseFitting .........................
Spindle forLratio ...................
forMorPratio ...............
forN ratio ...................
WWVlOOA1-43
4RL-739
6WT-118
6WT-117
DG20-22
4RL-12
4RLL-53
4RPL-53
4RL-42-5
4RL-3
4RL-11
WWAlOO-97
88V60-98
4RLL-B37
4RLM-B37
DOF9-879
4RLL-8
4RLM-8
4RLN-8
IndicatesTuneup Kit part.
l Tokeepdowntimetoaminimum,it isdesirabletohaveonhandcertainrepairparts.Werecommendthatyoustockone(pairor set)of eachpartindicatedby
abullet(•) foreveryfourtoolsin service.

53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
PART NUMBER FOR ORDERING --- PART NUMBER FOR ORDERING
t
SpindlePlanetGear(3for L orN ratio:
4for M or Pratio)
forLratio (20 teeth) ...........
forMorPratio (14 teeth). ......
for N ratio(17teeth)...........
SpindlePlanetGearBeariug(3forL or
Nratio; 4forMorPratio). ..............
GearHead
for M ratio ...................
forNratio ...................
forPratio ...................
GearHeadPlanetGear(3)
forMorNratio (14 teeth) ......
for Pratio(20teeth) ...........
GearHeadPlanetGearBearing(3) ........
Rotor Pinion (for MorNratio)...........
GearHeadSpacer(for M, N orPratio) .....
SpindleBearing .......................
SpindleBearingRetainer................
SpindleBearingSeal ...................
GreaseShield .........................
GreaseShieldRetainer..................
Gear Retainer.........................
Seal Support..........................
Seal.................................
4RLL-1OA
4RLM-1OA
4RLN-1OA
6WTM-500
4RLM-216
4RLN-216
4RLP-216
4RLM-1OA
4RLL-1OA
6WTM-500
4RLM-17
6LM-80
RlL-24
7L-28
6AH-103
5R-701
6LL-343
6LG81
5RAK-5
182A53-610
68
69
70
*
*
*
*
*
*
*
*
*
HousingGrip(for4RL and4RPModels)
forLratio ....................
for M, N orPratio .............
HousingSleeve(for4RA and4RTModels)
forLratio ....................
forM,NorPratio .............
SleeveSupport(for 4RAand4RT
Models)(2) ............................
VerticalHanger(for4RL and4RPModels) . .
HorizontalHanger(for4RA and
4RTModels) ..........................
Piped-AwayExhaustKit (for4RL and
4RPModels) ..........................
GreaseGun............................
Tune-upKit (forModels4RAand4RT)
(includesillustrateditems:5, 10, 20, 21, 22,
23, 25, 26, 28, 29, 31, 34, 36, 39, 40, 42,
45, 48, 62, 67and70) ...................
Tune-upKit (forModels4RL and4RP)
(includesillustrateditems:5,20, 21, 22,
25, 26, 28, 29, 34, 37, 38, 39, 40,
42, 45, 48, 62, 67and70) ................
Dead Handle
...........................
HandleAdapter(2) .....................
HandleBolt ...........................
t
4RLL-747
4RLM-747
4RAL-747
4RAM-747
ROOA2-103
7L-365
ROOH-365
7L-K284
ROOOA2-228
4RA-TKl
4RL-TKI
RlA-48
4R-49
510-638
* Not illustrated
IndicatesTune-upKit part.
l Tokeepdowntimetoaminimum,it isdesirabletohaveonhandcertainrepairparts.Werecommendthatyoustockone(pairor set)of eachpartindicatedby
abullet(•) foreveryfour toolsin service.

MAINTENANCE SECTION
PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING
101
102
103
l l04
l 105
106
l 107
•108
l 109
l 110
111
112
AdjustableClutchAttachment
for Models4RLLC1, 4RLMCl,
4RPLCl,4RPMC1, 4RALCl,
and(4RAMCl) . . . .. . .. .. . . .
ClutchHousingAssembly . . .
HousingBushing . . . .. . . .
AdjustingHoleCover. . . . . . .
ClutchDriver . . . .. . . . .. . . .
ClutchDriverRetainer. . . . . .
Bit HolderAssembly . . . . . . .
Bit Holder . .. . .. . . . .. . . .
FrontClutchJaw. . . . . . . . .
ClutchBall (24) . . . . .. . . .
ClutchBall Spacer . . . . . . .
ClutchSpringSeat(2) . . . .
SpringSeatBearing . .. . . .
Light ClutchSpring(Black)
4C15
4C17-A580
7C3-781
5C1-415
4C3-581
W22-6
5Cl-AL586
5Cl-586
5Cl-589A
RX1-629
5C1-401A
5Cl-627
5Cl-105
5Cl-L583
113
114
l
115
l
116
l
117
l
118
119
120
121
l
122
l
123
*
*
278
ClutchAdjustingNut .......
AdjustingNut Lock ........
Bit HolderStop............
Bit RetainingBall ............
Bit RetainingSleeve
..........
SleeveReturnSpring .........
SleeveSpringRetainer(Blue) . .
ClutchShaftSupport .........
DisengagingPlunger .........
PlungerSpring ..............
Bit RetainingSleeveStop
......
HeavyClutchSpring(Green)
...
ClutchAdjustingKey .........
Pushrod
for Model4RPLCl .......
forModel 4RPMCl........
5Cl-582A
5Cl-588
5Cl-729
RX1-629
5Cl-930-4
5Cl-93l-4
5C1-853
4C3-584
7Pl-584
4C-626
5Cl-729
5Cl-H583
5C1-416
4RPL-435
4RPM-435
* Not illustrated.
l Tokeepdowntimetoaminimum,it isdesirabletohaveonhandcertainrepairparts.Werecommendthatyoustock
one(pairor set)of eachpartindicatedbyabullet(•) for everyfourtoolsin service.
201
202
•203
•204
l 205
•206
•207
•208
209
PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING
AdjustableClutchAttachment
forModels4RLNC1, 4RLPCl,
4RPNCl,4RANCl and4RAPCl) .
ClutchHousingAssembly .. . . .
HousingBushing . . . . . . . . . . .
ClutchDriverAssembly
(Assembledwith Medium
Clutch Spring) .. . . . . . . . .. . . ..
ClutchDriver . . . . . . . . . . . . . .
FrontClutchJaw . .. . . . . . . . . .
JawBearingBall (12) . . . . . . . .
ClutchBall Spacer . . . . . . . . . .
ClutchReleaseBall (9) . .. . . ..
ClutchBall Seat . . .. . . . . . . . .
ClutchSpring
4C17
4C17-A580
7Pl-781
7C-A581A
7C-581A
7Cl-589A
2U-696
7C-401A
4U-31
7C-627
Light (Black) . . . .. . . . . . .. . 7C-L583A
Medium( Yellow) . . . . . . . . . 7C-583A
Heavy( Green) . .. . . . . . . . . 7C-H583A
210
springseatstop ........... 7C-704B
211 ClutchSpringSeat ......... 7C-623
212 SpringSeatBearing ........ R02W-696
213 AdjustingNut Lock ........ 7C-588A
214 ClutchAdjustingNut ....... 7C-582A
l 215 PlungerSpring ............ 4C-626
l 216 DisengagingPlunger
........ 7Pl-584
217 Bit Holder .................. 7Cl-586A
•218 Bit RetainingSleeve .......... 5Cl-930-4
219 AdjustingHoleCover......... 4C3-415
l 220 RetainingSleeveSpring ....... 5Cl-931-4
l 221 SleeveSpringRetainer(Blue) . . 5Cl-853
222 Bit RetainingBall ............ RX1-629
* ClutchAdjustingKey ......... 5C1-416
278 Pushrod(forModel4RPNCl) .... 4RPM-438
* Not illustrated
. Tokeepdowntimetoaminimum,it isdesirableto haveonhandcertainrepairparts.Werecommendthatyoustock
one(pairor set)of eachpartindicatedbyabullet(•) for everyfourtoolsin service.
12

MAINTENANCE SECTION
CLUTCH ATTACHMENTS
13
(Dwg. TPA1148)

MAINTENANCE SECTION
PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING
250
251
252
253
l 254
255
256
257
•258
259
260
•261
•262
263
AdjustableClutchAttachment
(forModelsendingin Sl) .....
ClutchHousingAssembly.....
HousingBushing ..........
AdjustingHoleCover.......
ClutchDriver .............
ClutchReturnSpring .......
ReturnSpringCollar .......
ClutchAdjustingNut .......
AdjustingNutLock ........
ThrustBearing ............
ClutchSpringSeat .........
Spring Seat Stop (2)........
ClutchSpring
Light (Black) ..........
Medium(Yellow) ......
Heavy(Green).........
ShutoffCollarReturnSpring .
ShutoffCollar .............
4Sl
4Sl-A580
4S3-781
4S3-415
4S3-581
433-591
4S3-592
4S3-582
4S3-588
55S1-105
433-626
5C1-853X
4S3-L583
4S3-583
55Sl-H583
55Sl-405
433-402
264
•265
266
267
268
269
270
•271
272
273
274
275
276
277
*
278
ClutchBall Seat.............
ClutchCamBall (4) ..........
ShutoffPlunger .............
ShutoffPlungerBall (4) .......
PlungerReturnSpring ........
ReturnSpringRetainer .......
Bit Holder. .................
Bit HolderBall Bearing(12) ...
BallBearingRetainer.........
BallRetainingSpring.........
Bit RetainingBall ...........
Bit RetainingSleeve .........
RetainingSleeveSpring.......
SleeveSpringRetainer(Blue) . .
ClutchAdjustingKey ........
Pushrod
forLratio ............
forforM,NorPratio ...
483-627
G601-65
4RTPSS-4O8
ROOOB-263
55S1-420
4S3-95
4Sl-586
2U-696
4S3-669
4S3-625
AVl-255
5Cl-930-4
SCl-931-4
5C1-853
5C1-416
4RPL-435
4RPM-435
* Notillustrated
. Tokeepdowntimetoaminimum,it isdesirableto haveonhandcertainrepairparts.Werecommendthatyoustock
one(pairor set)of eachpartindicatedbyabullet(•) for everyfourtoolsin service.
PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING
DirectDriveAttachment
l 305 Bit Holder. ................. 7Dl-586
(forModelsendingin Dl) ..... 7Dl
l 306 Bit RetainingBall ........... RX1-629
301 HousingAssembly......... 7Pl-A580
l 307 RetainingSleeveSpring....... 5Cl-931-4
302 HousingBushing ........ 7Pl-781 308 SleeveSpringRetainer(Blue) .. 5C1-853
303 Spacer
................... 7Dl-211 309 Bit RetainingSleeve ......... 5Cl-930-4
304 SpacerRetainer
............ 7AH-118
l Tokeepdowntimetoaminimum,it isdesirabletohaveonhandcertainrepairparts.Werecommendthatyoustock
one(pairor set)of eachpartindicatedbyabullet(•) for everyfourtoolsin service.
14

MAINTENANCE SECTION
PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING
PositiveDriveAttachment 407 ClutchDriverSpacer .. . . .. . 7Pl-211
(forModelsendingin Pl) .. . . . 7Pl 408 DisengagingPlunger . . . . . .. 7Pl-584
401 ClutchHousingAssembly . . . 7Pl-A580 409 PlungerSpring .. . . . . . . . . .. RX2-426
402 HousingBushing . . . .. . . . 7Pl-781 l 410 ClutchDriverSpacerRetainer 7AH-118
403 Bit Holder . .. . . . .. . . . .. . . . 7Pl-586 l 411 Bit RetainingBall . . . .. . . . . . RX1-629
•404 ClutchJaw(2) l
. . .. . . . .. . . . PX3-587 412 Bit RetainingSleeve. .. . . . . . 5Cl-930-4
l 405 ClutchJawRetainingRing . . . R2-285 l 413 SleeveSpringRetainer(Blue) 5C1-853
•406 ClutchDriver . . . . . . . . .. . . . 7P-581 414 RetainingSleeveSpring. .. .. 5Cl-931-4
l
Tokeepdowntimetoaminimum,it isdesirableto haveonhandcertainrepairparts.Werecommendthatyoustock
one(pairor set)of eachpartindicatedby abullet(•) for everyfourtoolsin service.
Model
4RALCl
4RAMCl
4RANCl
4RAPCl
4RLLCl
4RLMCl
4RLNCl
4RLPCl
4RPLCl
4RPMCl
4RPNCl
4RPLS1
4RPMSl
4RPNS1
4RTLS1
4RTMS1
4RTNS1
4RTPS1
CLUTCH SPRING SELECTION CHART
Light Clutch Spring
(Black)
15to30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
15to30in-lb (1.7to 3.4Nm)
15to 30in-lb (1.7to 3.4Nm)
T
TORQUE RANGE (Soft Draw)
Medium Clutch Spring
(Yellow)
20to40in-lb (2.3to4.5Nm)
20to55in-lb (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
20to40in-lb (2.3to4.5Nm)
20to55in-lb (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
20to40in-lb (2.3to4.5Nm)
20to55in-lb (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
20to40in-lb (2.3to4.5Nm)
20to55in-lb (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
2o.t~55in-Ib (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
20to55in-lb (2.3to6.2Nm)
Heavy Clutch Spring
(Green)
35to65in-lb (3.9to7.3Nm)
40to80in-lb (4.5to 9.0 Nm)
40to 105in-lb (4.5to 11.8Nm)
35to65in-lb (3.9to7.3Nm)
40to 80in-lb (4.5to9.0 Nm)
40to 105in-lb (4.5to 11.8Nm)
35to65in-lb (3.9to7.3Nm)
40to 80m-lb (4.5to9.0Nm)
35to 65in-lb (3.9to 7.3Nm)
40to 80in-lb (4.5to9.0Nm)
35to65m-lb (3.9to7.3Nm)
40to80in-lb (4.5to9.0Nm)
15

MAINTENANCE SECTION
Always wear protective eyewear when operating or
performing maintenance on this tool.
Always turn off the air supply and disconnect air
supply hosebefore installing, removing or adjusting
any accessoryon this tool, or before performing any
maintenance on this tool.
DISASSEMBLY
General Instructions
1. Donotdisassemblethetoolanyfurtherthan
necessarytoreplaceorrepairdamagedparts.
2. Whenevergraspingatoolorpartin avise,alwaysuse
leather-coveredor copper-coveredvisejawsto
protectthesurfaceof thepartandhelpprevent
distortion.Thisisparticularlytrueof threaded
membersandhousings.
3. Donotpressanyneedlebearingfromapartunless
youhaveanewneedlebearingonhandfor
installation.Needlebearingsarealwaysdamaged
duringtheremovalprocess.
4. Donotremoveanypartwhichisapressfit in orona
subassemblyunlesstheremovalof thatpartis
necessaryfor repairorreplacement.
Disassembly of the Tool
1.
2.
3.
EachSeries4RScrewdriveriscomprisedof three
modulesor units-amotorhousingandmotorunit,a
gearunit,andanadjustableclutchunit.Eachmodule
or unitcanberemoved,disassembledforrepairsand
reassembledindependentlyof theotherunits.
UnscrewandremovetheClutchHousingAssembly
(101, 201, 250, 301or401)fromtheGearCase
Assembly(50).
This is a left-hand thread and should only be
hand-tight. Turn c1ockwiseto remove.
UnscrewtheGearCaseAssemblyfromtheMotor
Housing,andlift off theentiregearunit.
This k a right-hand thread. Turn counterclockwise
to remove.
When the Gear Casesand Motor Housings are
separated on Models 4RA and 4RT, the Housing
Sleeve(69) and one SleeveSupport (70) wig remain
with the Gear Case.The other SleeveSupport will
remain on the Motor Housing. When the Gear
Casesand Motor Housings are separated on
Models 4RL and 4RP,the Housing Grip (68) will
remain on the Gear Case.If it must beremoved,
cut the Grip off the Gear Casewith a sharp knife.
Make certain a new Grip is available for
installation.
4. For Models 4RPand 4RT, removethepushrod
(278).
Disassembly of the 4C15 Adjustable Cushion
Clutch
1.
2.
3.
4.
5.
6.
7.
8.
Usingsnapringpliers,removetheSleeveSpring
Retainer(119)fromtheBit Holder(106)andslidethe
RetainingSleeveSpring(118)andBit Retaining
Sleeve(117)fromtheBit HolderandremovetheBit
RetainingBall(116).
Usingsnapringpliers,removetheBit Retaining
SleeveStop(123)fromtheBit Holder.
WithdrawtheassembledclutchfromtheClutch
Housing(101)andgraspthesplineof theClutch
ShaftSupport(120)in copper-coveredvisejawswith
theBit Holderupward.
Usingsnapringpliers,removetheBit HolderStop
(115).
Usingawrenchontheflatsof theClutchAdjusting
Nut (113)andkeepingpressureagainsttheSpring
Seat(110)topreventtheClutchBalk (108)from
fallingoutofposition,unscrewandremovethe
ClutchAdjustingNut.
This is a left-hand thread.
Carefullyremovetheclutchfromtheviseandwhile
holdingit overacontainertocatchthetwenty-four
ClutchBalls,removetheAdjustingNut Lock (114),
ClutchSpring(112),two ClutchSpringSeats(1l0),
SpringSeatBearing(1ll), ClutchBall Spacer(109)
andFrontClutchJaw(107)fromtheBit Holder.
SlidetheClutchDriver(104)off theClutchShaft
Supportandpull theSupportoutof theBit Holder.
ToremovetheDisengagingPlunger(121)and
PlungerSpring(122)fromtheBit Holder,rapthe
plungerendof theBit Holderagainstablockof wood
asoftenasnecessaryuntil thePlungercanbegrasped
andpulledwith theSpringfromtheBit Holder.
16

MAINTENANCE SECTION
9. If theHousingBushing(102)mustbereplaced,press
it fromtheClutchHousing.
Disassembly of the 4C17 Adjustable Cushion
Clutch
1.
2.
3.
4.
5.
6.
7.
Usingsnapring pliers,removetheSleeveSpring
Retainer(221)andslidetheRetainingSleeveSpring
(220)andBit RetainingSleeve(218)fromtheBit
HolderandremovetheBit RetainingBall (222).
WithdrawtheassembledclutchfromtheClutch
Housing(201)andgrasptheflatsof theClutch
AdjustingNut (214)in copper-coveredvisejawswith
theBit Holder(217)upward.
Inserta l/4” Allen WrenchintotheBit Holderand
rotatetheHoldercounterclockwiseuntil thetension
ontheClutchSpring(209)isrelieved.
Removetheassemblyfromtheviseand,while
holdingit overasmallboxorcontainer,unscrewthe
ClutchAdjustingNut fromtheClutchDriver(203).
RemovetheAdjustingNutLock (213),SpringSeat
Bearing(212),ClutchSpringSeat(21l), Clutch
Spring(209),ClutchBall Seat(208)andClutch
ReleaseBalls(207).
If it isnecessarytoreplacetheClutchBall Spacer
(206),FrontClutchJaw(204)orJawBearingBalls
(205),removetheSpringSeatStop(210)fromthe
groovein theClutchDriver.
ToremovetheDisengagingPlunger(216)and
PlungerSpring(215)fromtheClutchDriver,rapthe
plungerendof theDriveragainstablockof woodas
oftenasnecessaryuntil thePlungercanbegrasped
andpulledwith theSpringfromtheClutchDriver.
If theHousingBushing(202)mustbereplaced,press
it fromtheClutchHousing.
Disassembly of the 4Sl Adjustable Shutoff Clutch
1.
2.
3.
4.
5.
Graspthesplinedshaftof theClutchDriver(253)and
pulltheassembledclutchfromtheClutchHousing
(250).RemovetheClutchReturnSpring(254)and
ReturnSpringCollar(255).
Usingsnapringpliers,removetheSpringSeatStop
(260)fromthethreadedsectionof theClutchDriver.
GrasptheflatsoftheClutchAdjustingNut (256)in
copper-coveredvisejawswith theBit Holder(270)
upward.
Inserta l/4” Allen WrenchintotheBit Holderand
rotatetheHoldercounterclockwiseuntil thetension
ontheClutchSpring(261)isrelieved.
Removetheassemblyfromtheviseandremovethe
ClutchAdjustingNut, theAdjustingNutLock (257),
theThrustBearing(258),theClutchSpringSeat
(259)andtheClutchSpringfromtheClutchDriver.
6.
7.
8.
9.
10.
11.
Holdingtheassemblyoveracontainerandusingsnap
ringpliers,removetherenamingSpringSeatStop.
RemovetheShutoffCollarReturnSpring(262),the
ShutoffCollar(263),theClutchBall Seal(264),four
ClutchBalls(265)andfourShutoffPlungerBalls
(267).
UseathinbladedscrewdrivertospiraltheBall
RetainingSpring(273)outof thegroovein theBit
Holder.
Usea l/8” AllenWrenchtoremovetheBall Bearing
Retainer(272).WiththeRetaineropeningdownward
overacontainer,rotatetheClutchDriverallowingthe
twelveBit HolderBall Bearings(271)tofall outthe
openingoneatatime.
If the Bearings are stuck in grease, tap the Driver
lightly after aligning eachBearing with the
opening.
PulltheClutchDriverfromtheBit Holder,andusing
awrench,unscrewtheReturnSpringRetainer(269)
andremovethePlungerReturnSpring(268)andthe
ShutoffPlunger(266).
Usingsnapringpliers,removetheSleeveSpring
Retainer(277)andslidetheRetainingSleeveSpring
(276)andBit RetainingSleeve(275)fromtheBit
HolderandremovetheBit RetainingBall (274).
If theHousingBushing(251)mustbereplaced,usea
flatfacedrill aroundtheedgeof theBushingtotap
theBushingoutthelargeendof theClutchHousing.
Disassembly of the 7Dl Direct Drive Attachment
Usingsnapringpliers,removetheSleeveSpring
Retainer(308)fromtheBit Holder(305)andslidethe
RetainingSleeveSpring(307)andBit Retaining
Sleeve(309)fromtheBit Holder.RemovetheBit
RetainingBall (306).
PulltheBit HolderfromtheClutchHousing(301)
andremovetheSpacerRetainer(304)andSpacer
(303).
If theHousingBushing(302)requiresreplacement,
pressit fromtheClutchHousing.
Disassembly of the 7Pl Positive Jaw Clutch
1. PulltheClutchDriver(406)outof theBit Holder
(403)oroutof thegearingif it remainedwith the
GearCase(50)duringseparation.
2. RemovetheClutchDriverSpacerRetainer(410)from
theClutchdriverandwithdrawtheClutchDriver
Spacer(407)andrearClutchJaw(404).
17

MAINTENANCE SECTION
3.
4.
5.
6.
Usingsnapring pliers,removetheSleeveSpring
Retainer(413)fromtheBit Holderandslidethe
RetainingSleeveSpring(414)andBit Retaining
Sleeve(412)fromtheBit Holder.RemovetheBit
RetainingBall (411).
Pull theBit Holderoutof theClutchHousing(401)
andremovetheClutchJawRetainingRing(405).
PullthefrontClutchJawfromtheBit Holder.
ToremovetheDisengagingPlunger(408)and
PlungerSpring(409),taptheplungerendof theBit
Holderagainstablockof woodasoftenasnecessary
until thePlungercanbegraspedandpulledwith the
SpringfromtheBit Holder.
If theHousingBushing(402)requiresreplacement,
pressit fromtheClutchHousing.
Disassembly of the Gear Case
1.
2.
3.
4.
5.
6.
7.
8.
9.
Usingsnapring pliers,removetheGearRetainer(65).
For M or N ratio, the RotorPinion(58)maycome
outwith theGearCase(50),orit mayhaveremained
with theRotor(44)whentheGearCasewasremoved.
RemovetheRotorPinion.
For M, N or P ratio, removetheGearHeadPlanet
Gears(56),GearHeadPlanetGearBearings(57),
GearHead(55)andGearHeadSpacer(59).
RemovetheSpindlePlanetGears(53)andSpindle
PlanetGearBearings(54).
PositiontheGearCaseverticallyinanarborpress,
with themotorenddown.Usinga7/16”(11mm)
diameterbrassrodagainsttheouterrim of theSpindle
(52),presstheSpindlefromtheGearCase.
Usingsnapring pliers,removetheSpindleBearing
Retainer(61).
Taptheexternallythreadedendof theGearCaseona
workbenchtoremovetheGreaseShield(63),Spindle
Bearing(60)andSpindleBearingSeal(62).
RemovetheSeal(67)andSealSupport(66)fromthe
Spindle.
If theGreaseShieldRetainer(64)mustberemoved,
insertathinbladescrewdriverunderthetabandusing
arotarymotion,spiraltheRetaineroutof thegroove
inthe Gear Case.
Disassembly of the Motor
1. Graspthesplinedendof theRotor(44)in copper-
coveredvisejawsandpull theassembledmotorfrom
theMotor Housing(1).
2. RemovetheRearEndPlateGasket(39)fromthe
Motor Housing.
3. Usingawrench,unscrewandremovetheRearRotor
BearingRetainingNut (40).
4.
5.
6.
RemovetheRotorfromtheviseandremovethe
BearingThrustWasher(41),RearEndPlate(43),
Cylinder(46),CylinderDowel (49)andVanes(45).
ChecktheFrontRotorBearing(48)for damageor
roughness.If replacementisnecessary,supportthe
FrontEndPlate(47)betweentwo blocksof woodon
thetableof anarborpress.PresstheRotor from the
FrontRotorBearing.Usingaflat facepunchonthe
innerring,taptheBearingoutof theEndPlate.
ChecktheRearRotorBearing(42)for damageor
roughness.If replacementisnecessary,useaflat face
punchontheinnerring andtaptheBearingoutof the
EndPlate.
Disassembly of the Pistol Grip Motor Housing
For Models 4RA and 4RT
1.
2.
3.
4.
5.
6.
7.
8.
18
Usinga l/16” Allen Wrench,unscrewandremovethe
ReverseValveScrew(11).RemovetheReverseValve
Switch(9).
Lightly graspthehandleof theMotor Housing(1)in
copper-coveredvisejaws sothattheInletBushing
(27)isupward.UnscrewtheInletBushing.
RemovetheMuffler Assembly(30),Muffler Element
(34),InletScreen(29),ThrottleValveSpring(23),
ThrottleValve(21)andTriggerAssembly(15and
16).
ToremovetheThrottleValveSeat(25),insertawire
hookthroughthecentralholeof theSeatandhooking
theundersideof theThrottleValveSeatSupport(26),
pull theSeatandSupportoutof thehandle.
Only removethe Throttle Valve Seatwhen
replacing it or when the Trigger Bushing (2) must
be replaced.
Usingawrenchontheflatsof theHousingBackCap
(35),unscrewandtheBackCapfromtheHousing.
The Back Cap is under spring tension. Remove it
carefully to prevent parts from becoming lost.
For 4RT Models, removethePushrodThrottleValve
Spring(22),PushThrottleValveAssembly(20).
If thePushrodSeal(24)mustbereplaced,make
certainanewSealisavailableatassemblybecauseit
maybedamagedduringremoval.TheSealmaybe
removedby usingawire enteringthemotorendof the
ReverseValvetopry theSealouttheBackCapendof
theValve.
RemovetheReverseValveSpring(5)andReverse
Valve(4)fromtheHousing.

MAINTENANCE SECTION
9. If theTriggerBushingmustbereplaced,proceedas
follows:
a. Removeall Sealsandcomponentsfromthe
MotorHousing.
b. CarefullygrasptheMotorHousingin copper-
coveredvisejaws with theTriggerBushing
upward.
c. Usingatorch,applyheattotheMotorHousing
aroundtheBushing.
Apply enough heat to warm the Housing but
not enough heat to distort it.
d. Threada 12-28tapintotheBushingandpull the
Bushingoutof theHousingwith thetap.
Disassembly of the Lever Throttle Motor Housing
1.
2.
3.
4.
For 4RL Models, usingapin punchandhammer,
drivetheThrottleLeverPin(14)outof theMuffler
Assembly(32)andremovetheThrottleLever(13).
Usinga3/32”Allen Wrench,unscrewandremovethe
RetainerSetscrew(8)fromtheReverseValve(4).
RemovetheLockPinRetainer(7).
Hold theMotorHousing(1)horizontallywith the
throttleplungerholddownward.while applyinglight
inwardpressuretotheReverseValve,tapthetopside
of theHousingwith aplastichammertodislodgethe
ReverseValveLock Pin(6).
5.
WithdrawtheReverseValvefromtheHousing.
Becareful not to losethe ReverseValve Spring (5)
when removing the ReverseValve.
6.
7.
8.
Beingcarefulnotto distorttheHousing,graspthe
flatsontheMotorHousingin copper-coveredvise
jaws with theinletupward.
Usingawrenchontheflats,unscrewandremovethe
InletBushing(27).
For 4RL Models, removetheAir Strainer(29),
ThrottleValveSpring(23),MufflerAssembly(32),
InletBushingSpacer(28),ExhaustDeflectorSeal
(37).SilencerSealRing(38)andMufflerElement
(34).
For 4RP Models, removetheAir Strainer(29),
PnshrodThrottleValveSpring(22),Muffler
Assembly(32),InletBushingSpacer(28),Exhaust
For Models 4RL and 4RP
9.
10.
11.
DeflectorSeal(37),SilencerSealRing(38)and
MufflerElement(34).
For 4RL Models, lift theThrottle Valve (21) outof
theHousingandremovetheThrottlePlunger
Assembly(18).
For 4RPModels, lift the PushThrottleValve
Assembly(20)outof theHousing.
For 4RL Models, to removetheThrottleValveSeat
(25), insertawire hookthroughthecentralholeof the
Sealandhookingtheundersideof theThrottleValve
SeatSupport(26),pull theSeatandSupportoutof the
MotorHousing.
Only remove the Throttle Valve Seatwhen
replacing it or when the Throttle Plunger Bushing
(3) must bereplaced.
For 4RL Models, toremovetheThrottlePlunger
Bushing,proceedasfollows:
a. Removeall Sealsandcomponentsfromthe
MotorHousing.
b. CarefullygrasptheMotorHousingin copper
coveredvisejaws with theThrottlePlunger
Bushingupward.
c. Usingatorch,applyheattotheMotor Housing
aroundtheBushing.
Apply enough heat to warm the Housing, but
not enough heat to distort it.
d. Threada 10-32tapintotheBushingandpull the
Bushingoutof theHousingwith thetap.
ASSEMBLY
General Instructions
1. Alwayspressonthe inner ring of aball-type bearing
wheninstallingthebearingonashaft.
2. Alwayspressonthe outer ring of aball-typebearing
wheninstallingthehearingin abearingrecess.
3. Whenevergraspingatoolorpartin avise,alwaysuse
leather-coveredor copper-coveredvisejawsto
protectthesurfaceof thepartandhelpprevent
distortion.Thisisparticularlytrueof threaded
members.
4. Alwayscleaneverypartandwipeeverypartwith a
thinfilm of oil beforeinstallation.
5. ApplyO-ring lubricanttoeachO-ring before
assembly.
19

MAINTENANCE SECTION
6. Checkeverybearingfor roughness,If anopenbearing
mustbecleaned,washit thoroughlyin aclean,
suitable,cleaningsolutionanddrywith acleancloth.
Sealedor shielded bearings should never he
cleaned. Workgreasethoroughlyintoeveryopen
bearingbeforeinstallation.
Assembly of the Lever Throttle Motor Housing
1.
2.
3.
4.
5.
6.
7.
*
For Models 4RL and 4RP
For 4RL Models, if theThrottlePlungerBushing(3)
wasremoved,proceedasfollows:
a.
b.
C.
d.
e.
InsertthenewThrottlePlungerBushingintothe
MotorHousing(1)toadepthapproximately
one-halfthelengthof theBushing.
PutafewdropsofLoclite®* No. 601sealantin
thecounterboresurroundingtheoutsidediameter
of theBushing.
RotatetheBushingapproximately180°tomake
certainthesealantmakescompletecontact
aroundtheoutsideof theBushing.
PushtheBushinginto theHousinguntilit
bottomsagainsttheshoulderinsidetheHousing.
Allow thesealanttocurefor eighthoursatroom
temperature.
CarefullygrasptheflatsontheMotorHousing(I) in
copper-coveredvisejaws,inletendracingupward.
For 4RL Models, if theThrottleValveSeat(25)and
ThrottleValveSeatSupport(26)wereremoved,usea
flat-tied rod l/2” (12.7mm)in diameterby3”
(76mm)longtopushtheSeatSupportintotheMotor
Housinguntil it seats.Usethesamerodtopushthe
SeatintotheHousinguntil it seatsagainsttheSeat
support.
For 4RL Models, installtheThrottlePlungerSeal
(19)in thegrooveof theThrottlePlunger(18).Insert
theThrottlePlungerintothePlungerBushingand
rotatethePlungeruntil theholein thePlungeraligns
deadcenterwith theholein theThrottleValveSeat.
For 4RL Models, usingneedlenoseplierstoholdthe
short-stemendof theThrottleValve(21),installthe
Valveinsertingthelong-stemend,throughtheholein
theThrottleValveSeatandThrottlePlunger.
For 4RPModels, install the PushThrottleValve
Assembly(20),largeendfirst,in thecentralopening
attheinletendof theMotor Housing.
InserttheC-shapedMuffler Element(32A)intothe
MufflerAssembly(32)makingcertainit coversall
exhaustholes.
AfterholdingtheMuffler Element(33)lengthwise,
RegisteredtrademarkofLoctiteCorp.
8.
9.
10.
12.
13.
14.
15.
16.
17.
18.
and with thefoldtrailing,installtheElementby
wrappingit horseshoefashionaroundtheinsideof the
MufflerAssemblyagainsttheC-shapedMuffler
Element.
InstalltheExhaustDeflectorSeal(37)in thegroove
onthefrontendof theMuffler Assembly.
InstalltheMufflerElement(34)overthehubatthe
rearof theMotorHousingandwork theElementinto
theHousing.
InstalltheMuffler Assemblyoverthehubof the
MotorHousing,aligningthewidetabontheMuffler
with thethrottleplungerholein theMotorHousing.
Tabson the Muffler match notches on the Motor
Housing. Do not force the Muffler Assembly into
place.
InserttheAir StrainerScreen(29),closedendfirst,
insidetheexternalthreadedendof theInletBushing
(27).
InserttheValveSpring(22or23),largecoilendfirst,
intotheInletBushingmakingsureit contactstheAir
StrainerScreen.
InstalltheInletBushingSpacer(28)in thelargehole
in theMufflerAssembly.
ThreadtheInletBushinginto theMotor Housing,
makingcertaintheValveSpringencirclesthestemof
theThrottleValve.TightentheInlet Bushingtoa
minimum26ft-lbs (35Nm) torque.TheInlet
BushingmustsecurelyclamptheMuffler Assembly.
InserttheReverseValveLock Pin (6) intotheholein
thesideof theReverseValve(4).
SliptheReverseValveSpring(5) into theendof the
ReverseValveoppositethereversevalveknob.
HoldingtheReverseValvewith theLock Pinupward,
aligntheL-shapedslotinsidethereversevalve
bushingwith theLock Pin.SlidetheReverseValve
intothebushinguntil theReverseValveSpringis
slightlycompressed.RotatetheassembledHousing
andValveone-halfturn(180°)andtaptheHousing
oppositetheLock Pinwith aplastichammeruntil the
Lock PindropsintotheL-shapedslot.Slowlyrelease
theReverseValve.
If the ReverseValve comesout of the Housing, the
Lock Pin did not enter the L-shaped slot. Repeat
the procedure until the Valve remains in the
Housing.
20