Ingersoll-Rand 5 series Setup guide

16575268
Edition 2
June 2009
Save These Instructions
Air Screwdrivers
5 Series
Maintenance Information

2 16575268_ed2
WARNING
Always wear eye protection when operating or performing maintenance on this tool.
Always turn o 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).
# Improved Disengaging Plunger and Spring
The Adjustable Clutch Attachments have been revised to incorporate a new style Disengaging Plunger (222) and Plunger Spring (223). The new
style parts in combination can be used to replace the old style. Parts are easily identied by the following descriptions.
Part Old Style New Style
Spring Length- 2”(50 mm) Coils- 20 Diameter of end
coils smaller than others
Length- 1-5/16”(33 mm) Coils- 15 Diameter end of
coils larger than others
Plunger Overall Length- 1-3/8”(35 mm) Overall Length - 2-5/16”(59 mm)
Note that the position of the new style parts is transposed in comparison with the old. When assembling, insert the small diameter section of
the Plunger through the bore of the Spring, then insert the Plunger, large end rst, into the bore of the Bit Holder (208).
Lubrication
Each time the Series 5 Screwdrivers are disassembled for
maintenance, repair or replacement of parts, lubricate the tool as
follows:
Squirt a few drops of oil into each vane slot in the Rotor (101) after
entering the Vanes (105) in the slots.
Work enough of Ingersoll Rand grease No. 28 into the Front
Rotor Bearing (108) and Spindle Bearing ( 122) to coat the balls
of the races; also heavily coat the hub on the rear of the Rotor
and place as much grease as will adhere to it on the end of the
hub before installing the motor assembly in the Motor Housing
(1 or 51).
1.
2.
Apply a coat of Ingersoll Rand grease No. 28 to the Planet Gears
(116 and 123), the shafts on which they rotate, the bearing
surfaces on the Spindle (118) and Gear Head (115) and the teeth
of the Ring
Gear (112). Do not pack the gear chamber; excess grease will
cause loss of power and heating.
Apply Ingersoll Rand grease No. 67 to the Clutch Jaws and for
Adjustable Clutch Attachments coat the Clutch Balls (210) and
Spring Seat Bearing (212A). Coat the bearing surface on the
Disengaging Plunger (222 or 403) when entering it in the Bit
Holder.
3.
4.
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.
1.
2.
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.
3.
4.
Operation
Periodically, unscrew the Inlet Bushing (18 or 71) from the Motor
Housing (1 or 51). Wash the Bushing in a clean, suitable, cleaning
solution to clean the Screen (19 or 72). Replace the Screen if it is
damaged. Do not omit the Screen. Without the Screen, a large piece
of foreign material could enter and jam the Throttle Valve in the
open position. Tighten the Bushing between 25 to 30 ft-lb (33.9 to
40.7 Nm) torque. The Inlet Bushing must securely clamp the Exhaust
Deector (21) or Muer Assembly (66).
Withdraw the Exhaust Deector (21) or Muer Assembly (66) from
the Housing. Wash the Muer Element (23) or Muer Assembly in a
clean, suitable, cleaning solution.
Disassembly of the Tool
To service these Screwdrivers, you will need Waldes Truarc®* Pliers
No. 22, a sti steel rod 3/32”(2.3 mm) diameter approximately 10”
(254 mm) long, and a small probe, preferably with a hooked tip, in
addition to the tools ordinarily found in a mechanic’s tool box.
* Registered trademark of Waldes Truarc Company
Disassemble a Screwdriver only as far as required for inspection and
replacement of worn or damaged parts. A single Clutch Coupling
Nut (124) retains the motor and gearing within the Motor Housing as
well as connecting the Attachment. However the adjustable clutch
assembly of No. 5C1 or 5C3 Attachment can be removed or installed
without removing the Coupling Nut. This is important because the
proper squeeze on the motor is dependent on the correct tightness
of the Coupling Nut. Thus being able to remove the clutch assembly
without disturbing the Coupling Nut simplies servicing the
Adjustable Clutch Unit.
Disassembly of the Quick-Change Retainer
Using snap ring pliers, remove the Sleeve Spring Retainer (221A,
308 or 412). Using a small probe, work the rst coil of the Retaining
Sleeve Spring (221, 307 or 411) out of the groove in the Bit Holder
(208, 303 or 407), and rotate the Spring on the Holder to work it free.
Use care to avoid distorting the Spring. The Retaining Ball (217, 304
or 408) will drop from the Holder when the Retaining Sleeve (219,
306 or 410) is removed.
For No. 5C1 Attachment, remove the Bit Holder Stop (216) with
Waldes Truarc No. 22 Pliers.

16575268_ed2 3
D1 Direct Drive Attachment
With quick - change Bit Holder
306
305
303
304
124
307
308
(Dwg. TPB6801-1)
Disassembly of the Adjustable Clutch
Rotate the Adjusting Hole Cover (203) to expose the adjusting
hole in the Clutch Housing (201).
Clamp the ats on the Nose-piece (204) in a vise as shown. Do not
tighten the vise enough to distort the Nose-piece.
Enter the pin on the No. MR-453 Spanner Wrench in the adjusting
hole and rotate the Clutch Housing (and Tool) clockwise when
facing the rear of the Tool (this is a left-hand thread).
(Dwg. TPD579)
NOTICE
Be sure the pin on the Spanner Wrench is fully engaged with the
Clutch Housing, otherwise the housing wall may be distorted or
otherwise damaged.
When the Adjusting Nut (214) is positioned for very low torque, it
may interfere with full engagement of the Spanner Wrench, in which
case simply move the Nut as for a higher torque until the interference
is eliminated.
C1 Adjustable Clutch Attachment
with quick - change Bit Holder
206
207
223
222
210
208
209
210
211
124
221
224
201
216214
219
204
203
202215
213
212
221A
212A
217
(Dwg. TPB606-2)
1.
2.
3.
Non-rotating
Finder
C3 Adjustable Clutch
Attachment for
Non-Rotating nder
for Flat Bits
124
220
214
213
212A
206
208A
210
211 209
210
222
208
207
223
208 B
202
203
205
212
212
215
216
204
201
(Dwg. TPB607-1)
4. Remove the Bit Holder Stop (216) from the Bit Holder (208).
5. Clamp a 1/4” hex steel (an Allen Key is ne) horizontally in a vise
and slide the Bit Holder onto it.
NOTICE
When the Nut is loosened enough to relieve the Spring pressure,
hold the assembly over a container to catch the twenty-four
Clutch Balls (210) that will be free to drop out and might
otherwise be lost.
6. Insert a rod into one of the radial holes in the Adjusting Nut (214)
or place a wrench on the ats and rotate the Nut clockwise to
remove it from the Holder.
Pistol grip handle
series 5RA Screwdrivers
65
51
53
52
57
56
55
63
60
59
58
64 58B
58C
58A
70 66 71
72
(Dwg. TPB615-2)
Disassembly of the Throttle
For Pistol Grip Models
A leaking throttle is usually caused by a worn or damaged Throttle
Valve Face (56), and can be corrected by replacing this small O-ring
as follows: With a small pin punch, remove the Throttle Retaining
Pin (65) from the Motor Housing (51), and withdraw the throttle
mechanism. Carefully work the new Face over the end of the
Valve (55) and into the groove. Align the notch in the Throttle Valve
Bushing (61) or Reverse Valve Bushing (60) with the hole for the
Retaining Pin and slide the throttle mechanism into position. Install
the Retaining Pin.

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For Lever Throttle Models
A leaking throttle is usually caused by a worn or damaged Throttle
Valve Seat (12) and can be corrected by replacing this small washer
type part. Unscrew the Retainer Screw (14) and withdraw the throttle
mechanism from the Motor Housing (1).
NOTICE
Before proceeding, place an index mark on Valve Body and knob
to assure their same relative position when reassembling. It is
possible to change orientation 180° in which case performance
will be adversely aected. Using a small pin punch, push the
Valve Knob Retainer (9) from the Knob (7) and separate the Knob
from the Throttle Valve Body (S), freeing the Spring (11) and
ball type Throttle Valve (10). Withdraw the Seat and install the
new one. Insert the Valve and Spring into the Valve Body, join
the Body to the Knob and install the Retainer. Make certain the
Retainer is installed ush with the outside of the Throttle Valve
Body.
Spindle and Planet
Gears J, K, L Ratios”
122
123
114
119
121
113 112
118
120
(Dwg. TPC398-2)
Gear Head, Spindle and
Planets Gears “N” Ratio
122
121
119
118
123
117
115
114
113 112
116
120
(Dwg. TPC399-1)
Disassembly of the Attachment, Gearing and Motor
Lightly clamp the Tool, front end up, in copper-covered vise jaws.
For Pistol Grip Models, clamp the vise on the handle; for Lever
Throttle Models, clamp the vise over the throttle area. In either
case apply only enough pressure to keep the Housing from
turning. Loosen the Coupling Nut (124) with a wrench applied to
the ats on the Nut.
For No. 5C1, 5C3 or SP1 Attachment, remove the Clutch Driver
Retainer (207 or 405) from the groove and slip the Driver (206 or
401) from the Spindle (118).
For Screwdrivers with No. 5P1 Attachment, the Clutch Driver (401)
and Front Jaw (406) are released by removal of the Jaw
Retainer (402) and Driver Retainer (405).
Grasp the end of the Spindle and pull straight forward. If the
gearing and motor cannot be removed with the ngers, protect
the Housing thread by running on the Coupling Nut, then bump
the open face on the workbench to jar the parts loose.
The Spindle Bearing (122) is a moderate press t on the Spindle (1,
18) and should not be removed unless replacement is necessary.
All other parts of the gear train are free tting and will slide apart
with ease.
WARNING
Wear eye protection when prying the Retainer from the rotor
hub. It is tempered steel and may y when free.
5. All parts of the motor assembly are free tting and will slide apart,
except the Rear End Plate (102) which must remain on the
Rotor (101) until the End Plate Retainer (103) is removed.
1.
2.
3.
4.
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 Quick-Change Retainer
This is a direct reversal of the disassembly procedure. When installing
the Spring, slide it large end rst onto the Holder and rotate it while
applying pressure with the ngers until the end coil snaps into the
groove. Apply a thin lm of Ingersoll Rand grease No. 67 to the Bit
Holder and Bit Holder Stop during assembly.
Assembly of the Adjustable Clutch
Slide the Front Clutch Jaw (209), jaw end rst, over the hexagon
recess end of the Bit Holder (208) and move it along over the
splines to the groove in the Holder.
Coat the grooved end with grease and insert thirteen Clutch
Balls (210) between the Jaw and Holder.
Stand the Holder, front end up, on the workbench and slide the
Clutch Ball Spacer (211) over it.
Enter a Clutch Ball (210) into each of the eleven holes in the
Spacer, and in the order named, slide the following over the
Holder: one Clutch Spring Seat (212), the Spring Seat
Bearing (212A), the second Clutch Spring Seat, the Clutch
Spring (213) and the Adjusting Nut Lock (215).
1.
2.
3.
4.

16575268_ed2 5
Start the Adjusting Nut (214), indented side rst, onto the Holder
and run it nger tight against the compression of the Spring.
Install the Bit Holder Stop (216) in the groove.
Assembly of the Attachment, Gearing and Motor
109
107
110
105 102
103 111
101
104
106
108
(Dwg. TPC400)
Slip the Rear End Plate (102) on the rear hub of the Rotor (101)
and install the Retainer (103) in the groove.
Hold the Rotor vertically and clamp the short hub in leather-
covered or copper-covered vise jaws.
Insert a Vane (105) in each slot.
Place the Cylinder (104), front end up, over the Rotor and onto
the Rear End Plate. To determine which end of the Cylinder is the
front end, hold the Cylinder horizontally, facing one end. Position
the external groove for the Dowel (110) at the top as shown in
the motor illustration. If the air ports through the cylinder wall
are in the bottom right quadrant, you are facing the front of the
Cylinder. When assembling the motor, be sure to properly install
the Cylinder. The motor will not operate properly if the Cylinder
is inverted.
Slip the Front End Plate (106) over the rotor shaft. Press the Front
Rotor Bearing (108) into the Bearing Housing (107), and slide the
Bearing, followed by the Retaining Washer (109), onto the shaft.
Obtain a sti steel rod 3/32”(2.3 mm) diameter and approximately
10” (254 mm) long to use as an assembly dowel.
Align the dowel groove in the Rear End Plate (102), Cylinder (104)
and Front End Plate (106) with the dowel hole through the Rotor
Bearing Housing (107) and insert the rod.
Enter the Rear End Plate Gasket (111) into the Motor Housing (1
or 51), positioning the Gasket smoothly on the back bore so that
the dowel notch in the Gasket aligns with the dowel hole in the
Housing.
Enter the end of the assembly dowel in the dowel hole and slide
the motor assembly into the Housing. This is a sliding t and if
proper alignment is maintained, the assembly will enter under
only slight nger pressure. Do not drive, or otherwise force the
motor into position.
Replace the assembly dowel with the Cylinder Dowel (110). Make
sure the Cylinder Dowel is entered into and remains in the dowel
hole in the Housing. When in proper position, approximately 3/32”
(2.3 mm) of the Dowel protrudes from the face of the Bearing
Housing. If it is not in the hole, it will protrude approximately
7/32” (5.5 mm).
Work the Seal Support (119), large end rst, over the spindle shaft
and against the gear frame face. Follow with the Seal (120) and
the Grease Shield (121).
Install the Spindle Bearing (122), sealed side rst, over the spindle
shaft. Firmly support the Spindle (118) and press, do not drive,
the Bearing into position using an arbor that will contact only the
inner ring of the Bearing.
Slide the Ring Gear (112) into the Motor Housing (1 or 51), making
sure the Cylinder Dowel (110) enters one of the notches in the
end of the gear.
For N or J ratio, slide the Rotor Pinion Spacer (113) followed by
the Rotor Pinion (114) onto the spline shaft on the Rotor (101).
5.
6.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
For N ratio, slide a Gear Head Planet Gear (116) (13 teeth) onto
each of the three gear shafts on the Gear Head (115). Enter the
assembly into the Ring Gear (112) and slide it into engagement
with the Rotor Pinion. Slip the Bearing Retainer Washer (117) over
the spline on the Gear Head.
For all ratios, slide a Spindle Planet Gear (123) onto each of the
three gear shafts on the Spindle (118) and slide the assembly
into the Ring Gear and into engagement with the Rotor Pinion
or Gear Head.
NOTICE
In N ratio, a Gear Head Planet Gear (116) has 13 teeth and a
Spindle Planet Gear (123) has 14 teeth. Do not mix, mismatch
or switch locations with these small gears when reassembling
a Tool.
17. For Screwdrivers with No. 5C1, 5C3 or 5P1 Attachment, slide
the Clutch Driver (206 or 401) onto the Spindle (118) and install
the Retainer (207 or 402) in the groove.
For Screwdrivers with No. 5P1, Attachment, slide the Front
Jaw (406) onto the Bit Holder (407) and install the Front Jaw
Retainer (405) on the Bit Holder.
18. For Screwdrivers with 5C1 or 5C3 Attachments, slip the
Disengaging Plunger (222) and Plunger Spring (223) into the Bit
Holder (208) making sure the Plunger slides freely.
For Screwdrivers with 5P1 Attachments, slip the Plunger
Spring (404) and Disengaging Plunger (403) into the Bit
Holder (407) making sure the Plunger slides freely.
19. For Screwdrivers with 5C1 or 5C3 Attachments, enter the
opposite end of the Spring into the spindle bore while entering
the end of the Clutch Housing (201) into the Motor Housing
(1 or 51).
For Screwdrivers with 5P1 Attachments, enter the opposite
end of the Plunger into the spindle bore while entering the end
of the Clutch Plunger (409) into the Motor Housing (1 or 51).
For Screwdrivers with 5D1 Attachments, slide the Bit Holder
(303) onto the Spindle (118) while entering the end of the Clutch
Housing (305) into the Motor Housing (1 or 51).
20. Using a wrench, snug the Coupling Nut onto the Motor Housing.
Bump the back of the Motor Housing to seat the internal parts as
the Coupling Nut is tightened.
21. When the Coupling Nut is snug, connect an air supply line to
the Inlet Bushing (18 or 71) and check performance. If the Tool
does not function properly, loosen the Nut and realign the
components. If the Tool does function properly, tighten the Nut
to a minimum of 25 ft-lb (33 Nm) torque.
15.
16.

6 16575268_ed2
Piped-away Exhaust
A Piped-Away Exhaust Kit is available for Lever Throttle Models. To install it, slip the spring-type clamp over the length of lightweight exible
exhaust hose, then slide the exhaust hose over the hose whip and onto the rear of the Exhaust Deector as shown in the illustration. Apply
the clamp to the part of the hose over the annular groove in the Deector. This is easily accomplished by standing the Tool upright on a solid
support and starting with the bottom coil, work around the clamp with downward pressure until it is in position.
Piped – Away Exhaust for Series 5L and 5RL
(Dwg. TPD569-1)
Dead Handle
A Dead Handle (30) is oered for N ratio Tools. Its use provides the operator ample leverage to easily resist the torque reaction of this gear ratio.
It is particularly desirable on Lever Throttle Models and is almost an essential on Tools with No. 5D1 Direct Drive Attachment that are used on
applications that require near full torque of the Tool.
Two Dead Handle Adapters (32) are required for attaching the Handle which is retained by a single Pinch Bolt (31). This arrangement allows 360°
positioning and rapid, easy adjustment of the radial position.
For ”N” Ratio
only
Lever Throttle Handle
31
30
32
15
16
25
17
24
23 22
21
20
18 19
26
13
14
3
2
1
7
86
5
6
11
10
12
9
(Dwg. TPB616-1)

16575268_ed2 7
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 or Screen 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 Replaced 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 of the recommended oil in the air
inlet and operate the tools for 30 seconds to
lubricate all the cleaned parts.
Gear Case gets hot Excessive grease Clean and inspect the Gear Case and
gearing parts and lubricate as instructed.
Worn or damaged parts Clean and inspect the Gear Case and
gearing. Replace worn or broken
components.
Inconsistent disengagement of Adjustable
Clutch
Improper lubrication Remove Adjustable Clutch mechanism and
check. Lubricate as instructed.
Worn or damaged parts Remove Adjustable Clutch and examine
parts. Replace worn or broken parts.
Wrong clutch Spring (using Heavy Clutch
Spring on light application)
Change to Medium or Light Clutch Spring.
Motor stalls before Adjustable Clutch
ratchets
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 80167273 and 80167281.
Parts Information Manual 16574576.
Manuals can be downloaded from www.ingersollrandproducts.com.

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