Ingersoll-Rand QP1P Series Setup guide

16575219
Edition 4
October 2013
Save These Instructions
Air Screwdrivers
QP1P, QP1S and QP1T Series
Maintenance Information

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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).
Clutch Spring Selection Chart
Tool Free Speed (rpm) Torque Range (Soft Draw)
Light Clutch Spring (Orange) Medium Clutch Spring (Red) Heavy Clutch Spring (Green)
“All Series QP Pistol
Grip Screwdrivers”
2800 1.7 to 9.7 in-lbs. ---- ----
(0.19 to 1.1 Nm) ---- ----
2000 1.7 to 9.7 in-lbs. 7.9 to 22.1 in-lbs. ----
(0.19 to 1.1 Nm) (0.89 to 2.50 Nm) ----
1500 1.7 to 9.7 in-lbs. 7.9 to 27.3 in-lbs. ----
(0.19 to 1.1 Nm) (0.89 to 3.08 Nm) ----
1000 1.7 to 9.7 in-lbs. 7.9 to 27.3 in-lbs. 13.3 to 40.0 in-lbs.
(0.19 to 1.1 Nm) (0.89 to 3.08 Nm) (1.50 to 4.52 Nm)
500 1.7 to 9.7 in-lbs. 7.9 to 28.3 in-lbs. 13.3 to 47.8 in-lbs.
(0.19 to 1.1 Nm) (0.89 to 3.20 Nm) (1.50 to 5.40 Nm)
250 1.7 to 9.7 in-lbs. 7.9 to 28.3 in-lbs. 13.3 to 47.8 in-lbs.
(0.19 to 1.1 Nm) (0.89 to 3.20 Nm) (1.50 to 5.40 Nm)
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Lubrication
Each time a Series QP Screwdriver is disassembled for maintenance
and repair or replacement of parts, lubricate the tool as follows:
1. Coat all exposed gears with Ingersoll Rand No. 67 Grease and
work some of the Grease into the gearing of the
Spindle Assembly (51).
2. Work approximately 6 to 8 cc of Ingersoll Rand No. 28 Grease
into the ball pockets, jaws, adjusting nut lock and shaft threads of
the clutch mechanism.
3. Use Ingersoll Rand No. 10 Oil to lubricate the motor. Inject
approximately 1 to 2 cc of oil into the air inlet before attaching
the air hose to the tool.
Changing Inlet Location
Series QP1P, QP1S and QP1T Screwdrivers with the Top Inlet feature
are shipped from the factory with the air connection attached to the
bottom of the handle. To use the Top Inlet connection on these tools,
proceed as follows:
1. Shut o the air supply and disconnect the air supply hose, if the
tool is in use.
2. Using a 3/16” hex. wrench, unscrew and remove the Inlet Plug
Assembly (15) from the top of the Housing (1).
3. Using a 3/4” wrench on the ats of the Inlet Bushing Assembly
(27), unscrew and remove the Assembly.
4. Transfer the Wave Washer (25) and Inlet Bushing Bezel (26) from
the threads of the Inlet Bushing to the threads of the Inlet Plug.
Make certain the Washer is against the Grip End Cap (23) and the
smaller end of the Bezel is against the Inlet Plug Seal (16).
5. Thread the assembled Inlet Plug into the bottom of the Handle
and tighten it between 15 and 20 ft-fbs. (20 and 27 Nm) torque.
6. Thread the Inlet Bushing with Inlet Bushing Seal (28) into the top of the
Handle and tighten it between 15 and 20 ft-lbs. (20 and 27 Nm) torque.
7. Connect the air supply hose to the Inlet Bushing and turn on the
air supply.
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 vice jaws to protect the surface of
the part and help prevent distortion. This is particularly true of
threaded members and housings.
3. 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.
4. Do not disassemble the tool unless you have a complete set of
gaskets and O-Rings for replacement.
Disassembly of the Tool
Each Series QP Screwdriver is made using four modules or units
including a motor housing unit, a motor unit, a clutch with bit holder
unit and a combined gearing and spindle unit.
The tool can be disassembled for repairs to each individual unit
without disturbing the other units. To separate the modules, proceed
as follows:
NOTICE
The thread in the following step is a left-hand thread. Rotate the
Bit Finder clockwise to remove it.
1. For models with Bit Finder Bit Holders, unscrew and remove
the Non-Rotating Bit Finder (110).
For models with Quick Release Bit Holders, use a thin blade
screwdriver to spiral the Retaining Ring (109) out of the groove in
the end of the Bit Holder (102). Being careful not to loose the Bit
Retaining Ball (103), slide the Spring Seat (108), Retaining Sleeve
Spring (107) and the Bit Retaining Sleeve (106) o the Bit Holder.
2. Lightly grasp the ats of the Gear Case (52) in copper-covered or
leather-covered vise jaws with the Clutch Housing (100) upward.

16575219_ed4 3
NOTICE
The thread in the following step is a left-hand thread. Rotate the
Clutch Housing clockwise to remove it.
3. Using a strap wrench, loosen the Clutch Housing from the Gear
Case and remove the assembled tool from the vise jaws. While
holding the assembly over a non-damaging container or surface,
nish unscrewing the Clutch Housing from the Gear Case.
Remove the Clutch Return Spring (60 or 79), the Clutch Input
Driver (61 or 80), the Push Rod (44), and the Clutch Assembly or
Clutch Shaft (95), from the Housing.
4. Push on the output end of the Bit Holder (102) to remove it from
the Clutch Housing.
5. For Models with Trigger Start, slide the Shuto Spacer (105) and
Wave Washer (105A) o the Bit Holder.
6. If the Clutch Housing Bearing (101) must be replaced, press it
from the Clutch Housing.
7. Lightly grasp the ats of the Gear Case in copper-covered or
leather-covered vise jaws with the handle upward and rotate
the assembled handle to loosen the assembly from the Gear
Case. Remove the assembly from the vise jaws and separate the
components.
8. Remove the Motor Clamp Washer (43) and Motor Seal (42) from
the Motor Housing (1).
9. Tap the motor end of the Housing on a wooden block to remove
the assembled motor from the Housing.
Disassembly of the Adjustable Shuto Clutch
1. Using a thin blade screwdriver, pry the Clutch Adjusting
Nut Stop (78) o the end of the Clutch Shaft (66).
2. Insert the tip of a #1 Phillips Head Screwdriver into the
adjustment opening between the Clutch Adjusting Nut (77) and
the Clutch Adjusting Nut Washer (76). Rotate the screwdriver
clockwise to thread the Adjustment Nut o the Clutch Shaft.
NOTICE
In the following step, the Clutch Cam Balls will be free to fall from
the assembly when the Cam Ball Seat is moved. Make certain the
Balls fall into a non-damaging container.
3. Holding the assembly over a small pasteboard box, slide the
Adjusting Nut Washer, the Thrust Bearing (75), the Spring Seat
(74), the Clutch Spring (73) and the Cam Ball Seat (72) o the
Clutch Shaft. Allow the three Clutch Cam Balls (70) to fall into the
pasteboard box.
4. The Clutch Cam Ball Driver (69) has a cross hole that is larger on one
side than the other. Insert a 1/16” drill shank or piece of wire into the
smaller hole and gently push the Clutch Driver Retaining Pin (71)
out of the larger hole and out of the Driver and the Clutch Shaft.
NOTICE
In the following step, the Clutch Balls will be free to fall from the
assembly when the Cam Jaw is moved along the Clutch Shaft.
Make certain the Balls fall into a non-damaging container.
5. Holding the assembly over a small pasteboard box, and using
care to drop the twelve Clutch Balls (67) into the box, slide the
Clutch Cam Ball Driver and Cam Jaw (68) o the Clutch Shaft. If
grease held some of the Balls inside the jaw cavity, remove them.
6. With the large end of the Clutch Shaft downward, depress the
Automatic Shuto Pin (64) with varying amounts of nger
pressure while tapping the large end edge of the Clutch Shaft
on a piece of wood until the Automatic Shuto Plunger (62)
protrudes slightly from the end of the Shaft. Grasp the Plunger
and carefully pull it out of the Clutch Shaft.
7. Remove the Automatic Shuto Pin and Automatic Shuto Pin
Spring (65) from the Clutch Shaft. The Pin Spring should remain
in the pin recess when the Pin is removed. To separate the Spring
from the Pin, gently rotate the Spring while pulling it from the
recess to avoid elongating the Spring.
8. Using a hooked tool, reach into the opening in the end of the
Clutch Shaft and carefully pull the Automatic Shuto Plunger
Return Spring (63) out of the Shaft without elongating the Spring.
Disassembly of the Adjustable Cushion Clutch
1. Using a thin blade screwdriver, pry the Clutch Adjusting
Nut Stop (94) o the end of the Clutch Shaft (82).
2. Insert the tip of a #1 Phillips Head Screwdriver into the
adjustment opening between the Clutch Adjusting Nut (93) and
the Clutch Adjusting Nut Washer (92). Rotate the screwdriver
clockwise to thread the Adjustment Nut o the Clutch Shaft.
NOTICE
In the following step, the Clutch Cam Balls will be free to fall from
the assembly when the Cam Ball Seat is moved. Make certain the
Balls fall into a non-damaging container.
3. Holding the assembly over a small pasteboard box, slide the
Adjusting Nut Washer, the Thrust Bearing (91), the
Spring Seat (90), the Clutch Spring (89) and the Cam Ball Seat (88)
o the Clutch Shaft. Allow the eleven Clutch Cam Balls (86) to fall
into the pasteboard box.
4. The Clutch Cam Ball Driver (85) has a cross hole that is larger on
one side than the other. Insert a 1/16” drill shank or piece of
wire into the smaller hole and gently push the Clutch Driver
Retaining Pin (87) out of the larger hole and out of the Driver
and the Clutch Shaft.
NOTICE
In the following step, the Clutch Balls will be free to fall from the
assembly when the Cam Jaw is moved along the Clutch Shaft.
Make certain the Balls fall into a non-damaging container.
5. Holding the assembly over a small pasteboard box, and using
care to drop the twelve Clutch Balls (83) into the box, slide the
Clutch Cam Ball Driver and Cam Jaw (84) o the Clutch Shaft. If
grease held some of the Balls inside the jaw cavity, remove them.
Disassembly of the Gearing
1. For Models having a Clutch, use snap ring pliers to remove the
Gear Retainer (45) from the motor end of the Gear Case (52) and
remove the Gear Head Spacer (46) as well.
2. For 250, 500 and 1000 rpm Models, lightly rap the motor end of
the Gear Case on a wooden workbench top to remove the three
Planet Gears (48), the Planet Gear Head Assembly (47) and the
Planet Gear Head Spacer (50).
For 1500 and 2000 rpm Models, lightly rap the motor end of
the Gear Case on a wooden workbench top to remove the three
Planet Gears (48), the Gear Head Pinion (49), the Planet Gear
Head Assembly (47) and the Planet Gear Head Spacer (50).
3. Using snap ring pliers, remove the Spindle Bearing
Retaining Ring (55).
4. Stand the Gear Case on the table of an arbor press with the
output spindle upward. Using a rod that neatly ts inside the
internal hex. of the Spindle (51), press the Spindle Assembly out
of the Spindle Bearing (53).
CAUTION
Do not remove the Bearing in the following step unless you have
a new replacement available for installation. The Bearing will be
damaged by the removal process.
5. Invert the Gear Case on the table of an arbor press so that the
end face having four notches makes contact with the table. Using
a rod against the inner race of the Spindle Bearing, press the
Bearing from the Gear Case.
6. If the Spindle Bearing Seat (54) must be replaced, use a small, thin
blade screwdriver to spiral it out of the groove in the Gear Case.

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Disassembly of the Motor
1. Using snap ring pliers, remove the Rear End Plate Assembly
Retainer (33) from the shaft of the Rotor (37).
2. Pull the Rear End Plate Face Plate (32) and Rear End Plate
Assembly (31) o the hub of the Rotor.
3. Lift the Cylinder (34) from the Rotor.
4. Remove the Vanes (38) from the Rotor.
5. Support the Front End Plate Assembly (39), as near the rotor body
as possible, on the table of an arbor press and press the Rotor
from the Front Rotor Bearing (41). Remove the Bearing from the
Front End Plate.
Disassembly of the Housing
1. Use a wrench to unscrew and remove the Inlet Bushing
Assembly (27) from the Motor Housing Assembly (1). Remove the
Inlet Bushing Bezel (26) and the Wave Washer (25).
2. Pull the Housing Grip (21) o the Motor Housing.
3. Pull or carefully pry the Grip End Cap (23) o the inlet end of the
Grip and remove the two End Cap Muer Elements (24).
4. Pull the Grip Muer Element (22) out of the inlet end of the Grip
and the two Housing Muer Elements (20) out of the trigger end
of the Grip.
5. For Top Inlet Models, use a 3/16”hex. wrench to unscrew and
remove the Inlet Plug Assembly (15).
6. Using a 1/4” hex. wrench, unscrew and remove the Rear Housing
Cap Assembly (9).
7. For Models with Trigger Start or Trigger Permit, remove the
Throttle Valve Spring (19) and the Throttle Valve (18) from the
rear of the Housing.
For Models with Automatic Shuto, remove the Automatic
Shuto Valve (30) from the rear of the Housing.
8. For Models with Trigger Start or Trigger Permit, if the Throttle
Valve Seat (17) must be replaced, insert a hooked tool through
the central opening of the Seat and pull it from the Motor
Housing.
9. Use a #2 Phillips Head Screwdriver, to unscrew and remove the
Reverse Lever Screw (8) and lift the Reverse Lever (7) out of the
Motor Housing.
10. Insert a 5/16” wooden dowel between 6 and 8 inches long, into
the Rear Housing Cap opening and push the Reverse Valve Front
O-Ring (6B), Reverse Valve Assembly (5) and Wave Washer (6A)
out the motor end of the Housing.
11. Use a hooked tool to pull the Housing O-Ring (4) out of the
Motor Housing.
12. For Push-to-Start Models, use a 1/16” pin punch to drift the two
Trigger Retaining Pins (13) out of the Motor Housing and pull the
Trigger Assembly (11) out of the Housing.
For all other Models, use a 1/16”pin punch to drift the Trigger
Retaining Pin (13) out of the Motor Housing and pull the Trigger
Assembly (11) out of the Housing.
13. For Models having a memory chip, if the chip must be replaced,
pry the Memory Chip Holder Assembly (14) out of the Motor
Housing in the area above the trigger location.
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 to protect the surface of
the part and help prevent distortion. This is particularly true of
threaded members and housings.
4. Except for bearings, always clean every part and wipe every part
with a thin lm of oil before installation.
5. Apply O-Ring lubricant to all O-Rings before nal assembly.
6. Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a clean, suitable cleaning solution
and dry with a clean cloth. Sealed or shielded bearings should
never be cleaned. Work grease into every open bearing before
installation.
Assembly of the Housing
1. For Models having a memory chip, if the Memory Chip Holder
Assembly (14) is being replaced, insert the memory chip into the
Holder with the contact ends leading. Position the Assembly at
the slot in the exterior wall of the Motor Housing (1) above the
trigger hole with the exposed contacts away from the Housing
and pointing toward the spindle end of the tool. Press the
Assembly into the slot.
2. Lubricate a new Trigger Shaft O-Ring (12) and install it in the
groove on the shaft of the Trigger Assembly (11).
3. For Push-to-Start Models, insert the shaft of the Trigger
Assembly into the hole in the Motor Housing (1) until the at
on the shaft is aligned with the two holes in the Housing for the
Trigger Retaining Pins (13). Tap the two pins into the Housing to
capture the Trigger Assembly.
For all other Models, insert the shaft of the Trigger Assembly
into the hole in the Motor Housing (1) until the at on the shaft
is aligned with the hole in the Housing for the Trigger Retaining
Pin (13). Tap the pin into the Housing to capture the Trigger
Assembly.
4. Lubricate the Housing O-Ring (4) with O-Ring lubricant and install
it at the bottom of the cylinder bore in the Motor Housing.
5. Inspect the face on the hub of the Reverse Valve Assembly (5)
for nicks or damage. Replace the Assembly if damage is evident.
Examine the Reverse Valve Seals (6) & (6B) for nicks or cuts and
replace the Seals if damaged.
6. Lubricate the Reverse Valve Seals (6) & (6B) with O-Ring lubricant.
Insert O-Ring (6B) over front end of Reverse Valve Assembly (5).
Insert Reverse Valve Assembly (5), small seal end and
Wave Washer (6A), and load into the cylinder bore of the
Motor Housing. Push the Assembly toward the bottom of the
cylinder and seat in its proper location making sure all Seals
are correctly positioned.
7. Rotate the Valve inside the Housing until the threaded hole in
the side of the Valve for the Reverse Lever Screw (8) is centered
radially in the slot in the top of the Housing for the
Reverse Lever (7).
8. Install the Reverse Lever in the slot and use a #2 Phillips Head
Screwdriver to secure the Lever to the Valve with the Reverse
Lever Screw.
9. Install the Throttle Valve Seat (17) in the bottom of the housing
cap opening. Use a rod with a at end and no sharp edges to
push the Seat at at the bottom face of the opening.
10. For Models with Automatic Shuto, install the Automatic Shuto
Valve (30), large end trailing, through the center of the Valve Seat.
11. Install the Throttle Valve (18), at face leading, in the opening
against the Valve Seat. Place the Throttle Valve Spring (19), small
end leading, into the Housing against the Valve. Encircle the hub
on the Valve with the Spring opening.
12. Examine the Rear Housing Cap Seal (10) for nicks or cuts. If
damaged, carefully install a new Seal over the threads of the
Rear Housing Cap Assembly (9).
13. Using a 1/4” hex. wrench, thread the Assembly into the rear of the
Motor Housing. Tighten the Assembly between 15 and 20 ft-lbs.
(20 and 27 Nm) torque.
14. For Top Inlet Models, examine the Inlet Plug Seal (16) for nicks or
cuts. If damaged, carefully install a new Seal over the threads of
the Inlet Plug Assembly (15).
15. For Top Inlet Models, use a 3/16”hex. wrench to thread the
Assembly into the top of the Motor Housing. Tighten the
Assembly between 15 and 20 ft-lbs. (20 and 27 Nm) torque.
16. Lay a Housing Muer Element (20) on each side of the handle
rib and use a non-pointed probe to fully push the end of each
Element into the recess near the body of the Housing.

16575219_ed4 5
17. Install the Housing Grip (21) over the Elements and onto the inlet
end of the Motor Housing. Make certain the Grip is fully seated
against the Housing and the Trigger Assembly works freely.
18. Fold the Grip Muer Element (22) in half and then fold each half
equally again and insert it into the bottom of the Grip.
19. Stack the two End Cap Muer Elements (24) inside the Grip and
push the Grip End Cap (23) onto the inlet end of the Grip.
20. If the Inlet Screen (29) required replacement, use a wooden
dowel to carefully push a new one into the Inlet Bushing (27).
21. If the Inlet Bushing Seal (28) is nicked or damaged, carefully
install a new one over the threads of the Inlet Bushing.
22. Install the Inlet Bushing Bezel (26), small end leading, followed
by the Wave Washer (25) onto the threads of the Inlet Bushing
against the Seal.
23. Thread the assembled Inlet Bushing through the Grip End Cap
into the handle of the Motor Housing and tighten the Bushing
between 15 and 20 ft-lbs. (20 and 27 Nm) torque.
Assembly of the Motor
1. Place the Front End Plate (39) on the splined shaft of the
Rotor (37) with the bearing recess away from the rotor body.
2. Place the Front Rotor Bearing (41) onto the shaft and using a
sleeve or piece of tubing that contacts the inner race of the
Bearing, press the Bearing onto the shaft until the Front End Plate
nearly contacts the rotor body.
NOTICE
In the following step, the measurement must be made at the end
corner of the large rotor body.
3. The clearance between the Front End Plate and Rotor is critical.
While pressing down with your nger on the outer edge of the Front
End Plate on the bearing side, insert a 0.004” (0.1 mm) feeler gauge
between the face of the rotor body and the face of the End Plate at
a point that is 180 degrees from where the pressure is applied. Refer
to Dwg. TPA1740. To increase the gap, support the End Plate and
lightly tap the rotor shaft with a plastic hammer; to decrease the
gap, press the Bearing farther onto the rotor shaft.
Measurement of Front End Plate Clearance
Pressure
Feeler
Gauge
(Dwg. TPA1740)
4. Wipe each Vane (38) with a light lm of Ingersoll Rand No.10 Oil
and place a Vane in each slot in the Rotor.
5. One end of the Cylinder Assembly (34) has a notch that breaks
the outer wall and end face of the Cylinder. With that end trailing,
install the Cylinder Assembly over the Rotor and Vanes against
the Front End Plate. Make certain the Cylinder Front Alignment
Pin (36) enters the hole in the Front End Plate.
6. Install the Rear End Plate Assembly (31), at face leading, on the
rear hub of the Rotor. Make certain the Cylinder Rear Alignment
Pin (35) enters the hole in the Rear End Plate.
7. Examine the Rear End Plate Face Plate (32) for scratches. If it is
scratched, replace it. If it is not, slide it onto the rear hub of the
Rotor and onto the Cylinder Rear Alignment Pin against the Rear
End Plate. Some pressure may be required to t the hole in the
Plate onto the Alignment Pin.
8. Using snap ring pliers, install the Rear End Plate Assembly
Retainer (33) in the annular groove on the rear rotor hub to
secure the assembly in position.
9. Set the assembled motor aside.
Assembly of the Gearing
1. Using a small screwdriver, work the Spindle Bearing Seat (54)
into the internal groove nearest the notched end of the
Gear Case (52).
2. Stand the Gear Case, notched end upward, on the table of an
arbor press. Using a piece of tubing that contacts the outer race
of the Spindle Bearing (53), press a new Bearing into the Gear
Case against the Seat.
3. Lubricate the gears in the Spindle Assembly (51) with
Ingersoll Rand No. 67 Grease.
4. Invert the Gear Case and using another piece of tubing
that supports the inner race of the Bearing and clears the output
end of the Spindle Assembly, press the Spindle Assembly into the
Bearing from the motor end of the Gear Case.
5. Using snap ring pliers, install the Spindle Bearing Retainer (55) in
the external groove near the driver end of the spindle.
6. For all Clutch Models, lightly lubricate the Planet Gear Head
Spacer (50) with Ingersoll Rand No. 67 Grease and install it in the
Gear Case against the Spindle Assembly.
7. For all Clutch Models, lubricate the shafts of the Planet Gear
Head Assembly (47) with Ingersoll Rand No. 67 Grease and
install the Gear Head in the Gear Case meshing the spline on the
shaft with the gear teeth in the Spindle Assembly.
8. For 250, 500 and 1000 rpm Models, lubricate the
Planet Gears (48) with Ingersoll Rand No. 67 Grease and
install them on the shafts of the Planet Gear Frame Assembly.
For 1500 and 2000 rpm Models, lubricate the Planet Gears (48)
and Gear Head Pinion (49) with Ingersoll Rand No. 67 Grease and
install the Planet Gears on the shafts of the Planet Gear Frame
Assembly. Insert the Gear Head Pinion in the center of the Planet
Gears making certain the teeth mesh.
9. For all Clutch Models, install the Gear Head Spacer (46) against
the Gears and secure the assembly by using snap ring pliers to
install the Gear Retainer (45) in the internal groove at the motor
end of the Gear Case.
Assembly of the Adjustable Cushion Clutch
1. Insert the small end of the Clutch Shaft (82) into the end of the
Cam Jaw (84) having the large opening and slide the Shaft about
half way into the Jaw.
2. Drop the twelve Clutch Balls (83) into the Cam Jaw forming a ring
around the Clutch Shaft.
3. Lay a bead of Ingersoll Rand No. 28 Grease, approximately
2 to 3 cc, on top of the Clutch Balls and then bring the Clutch
Shaft and Cam Jaw together capturing the Balls between them.
4. While holding the Shaft and Jaw together, slide the Clutch Cam
Ball Driver (85), large end leading, onto the Clutch Shaft until it is
against the Cam Jaw.
5. Rotate the Driver to align the large hole through one wall of
the Driver with the comparable size opening of the cross hole
through the Clutch Shaft. Push the Clutch Cam Ball Driver
Retaining Pin (87) into the hole to lock the Driver in position on
the Clutch Shaft.
6. Apply a coating of Ingersoll Rand No. 28 Grease to each of the
eleven Clutch Cam Balls (86).
7. Holding the assembled Clutch Shaft with the Clutch Cam Ball
Driver upward, insert a lubricated Ball into each of the eleven ball
pockets in the Driver.
8. Slide the Cam Ball Seat (88), large end leading, onto the Shaft
against the Balls. Follow with the Clutch Spring (89),
Spring Seat (90), Thrust Bearing (91) and the Clutch Adjusting
Nut Washer (92) with the smooth face leading.
9. Thread the Clutch Adjusting Nut (93), smooth face trailing, onto
the Clutch Shaft.

6 16575219_ed4
10. Insert the tip of a #1 Phillips Head Screwdriver into the
adjustment opening between the Clutch Adjusting Nut and
the Clutch Adjusting Nut Washer. Rotate the screwdriver
counterclockwise and thread the Adjustment Nut onto the
Clutch Shaft until the external groove for the Clutch Adjusting
Nut Stop (94) is visible.
11. Install the Nut Stop in the groove.
Assembly of the Adjustable Shuto Clutch
1. Hold the Clutch Shaft (66) in your hand with the large end
upward.
2. Insert the Automatic Shuto Plunger Return Spring (63) into the
central opening in the large end of the Clutch Shaft. Use a 1/8”
dowel to push the Spring below the cross hole for the Automatic
Shuto Pin (64).
3. Insert the Automatic Shuto Pin Spring (65) in the end hole of
the Automatic Shuto Pin opposite the pointed end. Rotate the
Spring a little to keep it in the hole.
4. Drip one or two drops of Ingersoll Rand No. 10 Oil into the
central hole with the Plunger Return Spring.
5. Position the Shuto Pin, Spring leading, in the cross hole on the
large end of the Clutch Shaft with the hole in the Shuto Pin
aligned with the central hole containing the Return Spring.
6. Push on the pointed end of the Shuto Pin to depress the
Spring while inserting the Automatic Shuto Plunger (62) into
the central opening with the Return Spring. The smaller center
portion of the Shuto Plunger will allow the Shuto Pin to spring
outward and capture the components within the Clutch Shaft
when properly positioned.
7. Insert the small end of the Clutch Shaft into the end of the
Cam Jaw (68) having the large opening and slide the Shaft
about half way into the Jaw.
8. Drop the twelve Clutch Balls (67) into the Cam Jaw forming a
ring around the Clutch Shaft.
9. Lay a bead of Ingersoll Rand No. 28 Grease, approximately
2 to 3 cc, on top of the Clutch Balls and then bring the Clutch
Shaft and Cam Jaw together capturing the Balls between them.
10. While holding the Shaft and Jaw together, slide the Clutch Cam
Ball Driver (69), large end leading, onto the Clutch Shaft until it is
against the Cam Jaw.
11. Rotate the Driver to align the large hole through one wall of
the Driver with the comparable size opening of the cross hole
through the Clutch Shaft. Push the Clutch Cam Ball Driver
Retaining Pin (71) into the hole to lock the Driver in position on
the Clutch Shaft.
12. Apply a coating of Ingersoll Rand No. 28 Grease to each of the
three Clutch Cam Balls (70).
13. Holding the assembled Clutch Shaft with the Clutch Cam Ball
Driver upward, insert a lubricated Ball into each of the three ball
slots in the Driver.
14. Slide the Cam Ball Seat (72), large end leading, onto the Shaft
against the Balls. Follow with the Clutch Spring (73),
Spring Seat (74), Thrust Bearing (75) and the Clutch Adjusting
Nut Washer (76) with the smooth face leading.
15. Thread the Clutch Adjusting Nut (77), smooth face trailing, onto
the Clutch Shaft.
16. Insert the tip of a #1 Phillips Head Screwdriver into the
adjustment opening between the Clutch Adjusting Nut and
the Clutch Adjusting Nut Washer. Rotate the screwdriver
counterclockwise and thread the Adjustment Nut onto the
Clutch Shaft until the external groove for the Clutch Adjusting
Nut Stop (78) is visible.
17. Install the Nut Stop in the groove.
Assembly of the Tool
1. Grasp the spline of the Rotor (37) in the assembled motor and
after aligning the End Plate Alignment Pin (40) with the internal
notch in the motor end of the housing bore, insert the assembled
motor into the Motor Housing (1). Make certain the motor is far
enough into the Housing to have the undercut below the internal
housing thread visible.
2. Lubricate the Motor Seal (42) with O-Ring lubricant and install
it around the Front End Plate (39) and into the undercut in the
Housing.
3. Align the tab of the Motor Clamp Washer (43) with the internal
notch in the Housing and install it over the rotor hub and End Plate
Alignment Pin against the Motor Seal. Make certain the Pin enters
the hole in the Washer and the Washer is at against the Seal.
4. Apply some Ingersoll Rand No. 67 Grease to the spline on the
rotor shaft.
5. Thread the assembled Gear Case (52), output spindle trailing, into
the Motor Housing and using a 1-1/16” wrench, tighten the joint
between 15 and 20 ft-lbs. (20 and 27 Nm) torque.
6. Grasp the ats on the Gear Case lightly in leather-covered or
copper-covered vise jaws with the Spindle Assembly (51) upward.
7. For Automatic Shuto Models, insert the Push Rod (44) into the
center of the Spindle Assembly. Only a small portion of the Rod
should be visible when it has correctly entered the assembled
gearing and motor.
8. For all Clutch Models, place the narrow end of the Clutch Return
Spring (60 or 79) in the Gear Case against the inner race of the
Spindle Bearing (53).
9. For all Direct Drive Models, insert the Clutch Shaft (95) into the
hex. recess of the Spindle Assembly until the Shaft Stop Pin (95A)
contacts the Spindle. If the Shaft Stop Pin does not protrude
equally from both sides of the Clutch Shaft, adjust it or replace it.
For all Clutch Models, place the hex. drive end of the Clutch Input
Driver (61 or 80) on the Spring and compress the Spring until the
hex. on the Driver enters the hex. recess in the Spindle Assembly.
While holding the Driver in position, engage the raised bar on the
face of the Driver with the jaw of the Cam Jaw (68 or 84).
10. If the Clutch Housing Bearing (101) was removed, stand the
Clutch Housing (100) on the table of an arbor press with the gear
case end upward.
11. Using a Needle Bearing Inserting Tool as shown in Dwg. TPD786
with a 0.030” (0.76 mm) thick washer that clears the inner bore
and outer edge of the Bearing inserted between the Bearing
and stop surface on the tool, press the Bearing into the Clutch
Housing. The trailing end of the Bearing must be between 0.025”
and 0.035” (0.63 and 0.89 mm) below the face of the bore into
which the Bearing is being pressed.
Needle Bearing Inserting Tool
Shoulder to
regulate depth Pilot to t I.D. of bearing.
Length of pilot to be
approximately 1/8'' less
than length of bearing
15°
(Dwg. TPD786)
12. For Trigger Start Models, slide the Wave Washer (105A) followed
by the Shuto Spacer (105) onto the hub of the Bit Holder (102)
and insert the Bit Holder into the large end of the Clutch Housing
and push the output end through the Clutch Housing Bearing.
For Trigger Permit Models, insert the Bit Holder (102) into
the large end of the Clutch Housing and push the output end
through the Clutch Housing Bearing.

16575219_ed4 7
NOTICE
The following step has threads with a left-hand thread. Rotate
the components counterclockwise to tighten them.
13. Install the assembled Clutch Housing over the clutch components
and thread it into the Gear Case. Using a strap wrench, tighten
the joint between 15 and 20 ft-lbs. (20 and 27 Nm) torque.
14. For Quick Release Bit Holder Models, place the Bit Retaining
Ball (103) in the hole through the wall of the Bit Holder and
slide the Bit Retaining Sleeve (106) large end trailing, onto the
Bit Holder. Slide the Retaining Sleeve Spring (107) and Spring
Seat (108) onto the Bit Holder and secure the components by
installing the Retaining Ring (109) in the external groove at the
output end of the Bit Holder.
For Bit Finder Models, place the Bit Retaining Ball (103) in
the hole through the wall of the Bit Holder and spread the Bit
Retaining Spring (104) enough to slide it onto the Bit Holder and
secure the Ball in position.
NOTICE
The following step has threads with a left-hand thread. Rotate
the components counterclockwise to tighten them.
15. For Bit Finder Models, thread the Non-Rotating Bit Finder (110)
onto the Clutch Housing and hand-tighten it between 2 and 6
ft-lbs. (3 and 8 Nm) torque.
16. Remove the tool from the vise jaws.
Testing the Tool
Before placing the tool back in service, test the tool in a run down
application to determine if adjustments are necessary to satisfactorily
perform the operation. Since four interrelated adjustments can aect
tool performance, only experience, along with trial and error, can
dictate which adjustment or combination of adjustments will provide
the desired results.
The Clutch Spring (73 or 89), the clutch adjustment procedure,
the length of the Push Rod (44) and the length of the Shuto
Valve (30) can individually or collectively have an eect on torque
and/or speed. Always try to make adjustments before replacing or
attempting to modify components.
If adjustments are unable to provide the desired torque, it may be
necessary to install a lighter or heavier Clutch Spring.
If the tool ratchets when operated but fails to shuto, it may be
necessary to shorten the Push Rod. Only shorten the Push Rod in
small increments. Increments between 0.005”and 0.010”
(0.13 and 0.25 mm) are recommended.
If the tool stalls and does not shuto, runs slower than normal or has
low power, the Shuto Valve may require lengthening. To lengthen
the Shuto Valve, grasp the stem between two pieces of rubber or
other non-slip, non-marring material and rotate the molded nut
counterclockwise. Rotating the nut one half revolution will lengthen
the Valve approximately 0.009”(0.23 mm). Should the stem of the
Valve become bent, marred, nicked or damaged in any way
during the adjustment process, replace it.
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 Inlet Bushing Screen Clean the Inlet Bushing Screen using a clean, suitable cleaning
solution. If the Screen cannot be cleaned, replace it.
Worn or broken Vanes Replace a complete set of Vanes.
Worn or broken Cylinder Replace the Cylinder if it is cracked or if the bore appears wavy
or scored.
Shuto Valve too short Lengthen the Shuto Valve. Refer to Testing the Tool on page 7.
Motor won’t run Motor Clamp Washer binding Remove the Gear Case make certain the Washer is at and the
Motor Seal is properly positioned.
Gears binding Clean and inspect all gearing. Replace any worn or damaged
gearing.
Push Rod worn Install a new Push Rod.
Gear Case gets hot Excessive grease Clean and inspect 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
the Adjustable Clutch Improper lubrication Remove the Adjustable Clutch mechanism and examine the 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 ratchets
Improper Clutch adjustment or improper
tool ratio for application
Check Clutch Adjustment and review tool performance vs.
requirements.
Low pressure at the inlet Check the air supply. For top performance, the air pressure must
be 90 psig (6.2 bar/620 kPa) at the inlet.
Insucient grease Lubricate the Clutch as instructed.
Tool ratchets before shuto Push Rod too long Shorten the push Rod. Refer to Testing the Tool on page 7.
Tool stalls without shutting o Shuto Valve too short Lengthen the Shuto Valve. Refer to Testing the Tool on page 7.
Tool runs slower than normal Shuto Valve too short Lengthen the Shuto Valve. Refer to Testing the Tool on page 7.
Related Documentation
For additional information refer to:
Product Safety Information Manual Form 04585006.
Product Information Manual Form 80165939.
Parts List Manual Form 16574527.
Manuals can be downloaded from ingersollrandproducts.com

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