Ingersoll-Rand 7RL Series Setup guide

16584054
Edition 1
May 2006
Air Angle Wrench
7RL Series
Maintenance Information
Save These Instructions

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WARNING
Always wear eye protection when operating or performing maintenance on this tool.
Always disconnect 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).
Cushion Clutch
Adequate lubrication is very important for satisfactory clutch
life. use Ingersoll Rand No. 67 grease.
5LN2C-AH580 Adjustable Cushion Clutch
After each 50,000 cycles or every 100 hoursof operation,
whichever occurs first, lubricate the Cushion Clutch as
follows:
1. Rotate the Adjustment Hole Cover to expose the
adjusting hole.
2. Insert the Clutch Sprag Key into the adjusting hole and
into one of the holes in the Clutch Adjusting Nut to keep
the Nut from turning.
3. Using a wrench on the output end of the Angle Head, turn
the wrench counterclockwise until the Clutch Adjusting
Nut is loose or until the clicking sound stops.
4. Grasp the flats of the Gear Case and using a wrench,
unscrew the Coupling Nut.
5. Remove the Clutch Housing and Angle Housing from the
Gear Case.
6. Grasp the Clutch Shaft Support and pull the entire Clutch
Assembly from the Housing.
7. Remove the Clutch Driver and Clutch Shaft Support from
the Clutch. Work a small amount of the recommended
grease between the Clutch Ball Spacer and Front Clutch
Jaw and three strokes of grease (1.0cc) around the
Clutch Balls of the jaw. Work a small amount of the
recommended grease between the two front clutch spring
seats and around the Spring Seat Bearing. This should
be done every 50,000 cycles or 100 hours whichever
occurs first.
7L3C-A580 Adjustable Cushion Clutch
After each 50,000 cycles or every 100 hours ofoperation,
whichever comes first, lubricate the Cushion Clutch as
follows:
WARNING
Disconnect the air supply hose at the tool before
performing any maintenance.
1. Rotate the Adjusting Hole Cover to expose the adjusting
hole.
2. Insert a 1/4” Allen Wrench into the Bit Holder or using a
wrench on the output end of the Angle Head, rotate the
Bit Holder until the hole in the Clutch Adjusting Nut is
aligned with the slot in the Clutch Housing.
3. Insert the Clutch Adjusting Key into the hole in the Clutch
Adjusting Nut and while holding the Nut against rotation,
rotate the Bit Holder counterclockwise until there is no
compression on the Clutch Spring.
4. Grasp the flats on the Clutch Housing in a vise, making
certain not to distort the Housing.
NOTICE
The Clutch Housing has a left-hand thread.
5. Using an adjustable wrench, grasp the flats on the Gear
Case and unscrew the entire power unit from the Clutch
Housing.
WARNING
Do not get your fingers between the clutch components.
6. Withdraw the assembled clutch from the Clutch Housing
and work some Ingersoll Rand No. 67 Grease around
the Clutch Jaw Bearing Balls, Clutch Release Balls,
Spring Seat Bearing and between the AdjustingNut Lock
and Clutch Adjusting Nut. To grease the Clutch Release
Balls, index the Clutch Jaw until the Spring Seat lifts.
Changing the Clutch Spring
5LN2C-AH580 Clutch
1. Carefully grasp the flats of the Coupling Nut in leather-
covered or copper-covered vise jaws. Angle Attachment
facing downward.
NOTICE
This is a left-hand thread.
2. Using a wrench on the flats of the Gear Case, loosen the
Gear Case from the Coupling Nut. Remove the tool from
the vise.
3. Unscrew the Coupling Nut and remove the Clutch
Housing from the Gear Case.
4. Grasp the Clutch Shaft Assembly and pull the Assembly
out of the Clutch Housing.
5. Grasp the spline of the Clutch Shaft Support in leather-
covered or copper-covered vise jaws with the Clutch
Adjusting Nut upward and the Clutch Driver against the
top of the vise of the vise jaws.
NOTICE
This is a left-hand thread.
6. Using a Wrench on the flats of the Clutch Adjusting Nut,
loosen and remove the Nut.
CAUTION
There are twenty-four Clutch Balls located between the
Clutch Driver and the Clutch Spring Seat nearest the
Clutch Driver. Failure to remove the remaining
components carefully may result in the Balls falling out
of position and becoming lost.
7. With the assembly in the vise and while applying slight
downward pressure to the Clutch Spring Seat nearest the
Clutch Driver, remove the Adjusting Nut Lock, first Clutch
Spring Seat, Spring Seat Bearing, second Clutch Spring
Seat and the Clutch Spring from the Clutch Shaft.

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8. Thoroughly grease the Bearing and Adjusting Nut Lock
and, in the order named, slide the following over the
Clutch Shaft: the new Clutch Spring, a Clutch Spring Seat
and the Adjusting Nut Lock, indented side trailing.
NOTICE
This is a left-handed thread.
9. Start the Clutch Adjusting Nut, detent side first, onto the
Clutch Shaft and run it finger tight against the
compression of the Spring. With a wrench, tighten the Nut
an additional one or two turns.
10. Remove the assembly Clutch from the vise.
11. Install the Clutch Shaft Assembly into the Clutch Housing
with the splined end of the Clutch Shaft Support trailing.
12. Install the Clutch Housing Assembly into the Gear Case
Assembly matching the spline of the Clutch Housing with
that of the Gear Case.
13. Thread the Coupling Nut onto the Gear Case, hand tight.
Grasp the flats of the Gear Case in copper-covered vise
jaws and using a wrench on the flats of the Coupling Nut,
tighten it to 25ft-lb. (34 N-m) torque.
14. Adjust the Clutch as directed in the Clutch Adjustment
Section in Product Information Manuals Form 80167497
or Form 80227531.
7L3C-A580 Clutch
1. Carefully grasp the flats of the Clutch Housing in copper-
covered or leather-covered vise jaws, Angle Head facing
downward.
NOTICE
This is a left-hand thread.
2. Using a wrench on the flats of the Gear Case, loosen the
Gear Case from the Clutch Housing. Remove the tool
from the vise.
3. Unscrew and remove the Clutch Housing from the Gear
Case.
4. Grasp the Clutch Driver and pull the assembly out of the
Clutch Housing.
5. Carefully grasp the Front Clutch Jaw in leather-covered
or copper-covered vise jaws with the Clutch Adjusting Nut
upward.
NOTICE
This is left-hand thread.
6. Using a wrench on the flats of the Clutch Adjusting Nut,
loosen and remove the Nut.
7. With the assembly in the vise and while applying slight
downward pressure to the Clutch Ball Seat, remove the
Adjusting Nut Lock, Spring Seat Bearing, Clutch Spring
Seat and the Clutch Spring from the Clutch Driver.
8. Thoroughly grease the Bearing and Adjusting Nut Lock,
and, in the order named, slide the following over the
Clutch Driver: the new Clutch Spring, the Clutch Spring
Seat, the Spring Seat Bearing and the Adjusting Nut
Lock, indented side trailing.
NOTICE
This is a left-hand thread.
9. Start the Clutch Adjusting Nut, detent side first, onto the
Clutch Driver and run it finger tight against the
compression of the Spring. With a wrench, tighten the Nut
an additional one or two turns.
10. Remove the assembled Clutch from the vise.
11. Install the Clutch Driver Assembly into the Clutch
Housing with the splined end of the Clutch Diver trailing.
NOTICE
This is a left-hand thread.
12. Thread the assembled clutch onto the Gear Case.
Tighten the Clutch Housing between 2 to 5 ft.-lb. (2.7 to
6.8 Nm) torque.
13. Adjust the Clutch as directed in the Clutch Adjustment
section in Product Information Manuals Form 80167497
or Form 80227531.
Lubrication
Each time a Series 7RL Angle Wrench is disassembled for
maintenance, repair or replacement of parts, lubricate the
tool as follows:
1. Inject a few drops of Ingersoll Rand No. 10 Oil into each
vane slot in the Rotor bore before inserting the Vanes.
2. Moisten all O-rings with O-ring lubricant.
3. Work approximately 1.5 cc of Ingersoll Rand No. 28
Grease into the Rear Rotor Bearing (2), Front Rotor
Bearing (31) and Spindle Bearing (49).
4. Work approximately 3 cc to 6 cc of Ingersoll Rand No.
28 Grease into the gear train. Grease the Planet Gear
Bearings (38) or (43), the teeth on the Planet Gear
Bearings (37) or (42), the gear teeth inside the Gear
Case (46) and the planet gear shafts on the Spindle (34)
and Gear Head (41).
5. Work approximately 0.5 cc of Ingersoll Rand No. 67
Grease into the Lower Spindle Bearing (214) of the Angle
head.
6. Work approximately 0.5 cc to 1 cc of Ingersoll Rand No.
67 Grease into the Upper Spindle Bearing (204), Bevel
Pinion Bearing (206) and Bevel Pinion Thrust Bearing
(212).
7. Apply a light coat of Ingersoll Rand No. 67 Grease to the
Bevel Gear (205), Bevel Pinion (205) and bevel pinion
spline.
Disassembly
General instruction
1. Do not disassemble the tool any further than necessary
to replace or repair damaged parts.
2. Whenever grasping a tool or part in a vise, always use
leather-covered or copper-covered vise jaws to protect
the surface of the part and help prevent distortion. This is
particularly true of threaded members and housings.
3. Do not remove any part which is a press fit in or on a
subassembly unless the removal of that part is necessary
for repairs or replacement.
4. Do not disassemble the tool unless you have a complete
set of new gaskets and O-rings for replacement.
5. Do not press any needle bearing from a part unless you
have a new needle bearing on hand for installation.
Needle bearings are always damaged during the removal
process.
Disassembly of the Angle Attachment
1. Carefully grasp the flats of the Coupling Nut (225) in
leather-covered or copper-covered vise jaws so that the
Angle Attachment (201) is facing downward.

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NOTICE
This is a left-hand thread.
2. Using a wrench on the flats of the Gear Case (46), loosen
the Gear Case from the Coupling Nut. Remove the tool
from the vise. Unscrew and remove the Coupling Nut
from the Gear Case.
3. Carefully grasp the Angle Attachment in leather-covered
or copper-covered vise jaws so that the Spindle (219 or
220) is facing upward.
NOTICE
This is a left-hand thread.
4. Using the Housing Cap Wrench (51), unscrew and
remove the Spindle Bearing Cap (223). Withdraw the
Spindle from the Angle Attachment.
5. Inspect the Lower Spindle Bearing (214) for looseness or
roughness. If either of these conditions exists, replace the
bearing as follows:
a.Grasp the output end of the Spindle in copper-
covered vise jaws.
b.Unscrew or unstrap the Bevel Gear Retainer (215)
and lift off the Bevel Gear (205).
c.Press the Spindle from the Lower Spindle Bearing.
NOTICE
Do not remove the Upper Spindle Bearing unless you
have a new Bearing ready to install. This type of bearing
is always damaged during the removal process.
6. If the Upper Spindle Bearing (203) appears rough or
loose, press it from the Angle Housing (201).
7. For 5L2C6 Angle Attachment, remove the Bearing
Retainer (213) and slide off the Bevel Pinion Thrust
Bearing (212).
For 7L3D6 Angle Attachment, remove the Bearing Seat
Retainer (208). Slide off the Rear Thrust Bearing Seat
(207), Bevel Pinion Thrust Bearing (212) and Front
Thrust Bearing Seat (209).
8. For 5L2C6 Angle Attachments, use snap ring pliers to
remove the Bearing Spacer Retainer (211). Remove the
Pinion Bearing Spacer (210).
For 7L3D6 Angle Attachment, use a screwdriver to
remove Bearing Spacer Retainer (211) and remove Bevel
Pinion Bearing Spacer (216).
NOTICE
Do not remove the pinion shaft and Bevel Pinion Bearing
(206) unless you have a new bearing on hand.
9. Grasp the spline of the pinion shaft in leather-covered or
copper-covered vise jaws and while gently tapping the
rear face of the Angle Attachment with a soft hammer,
pull the Bevel Pinion and Bearing (206) from the Angle
Attachment.
After the Angle Attachment is disassembled, check all
parts for damage or wear.
NOTICE
If the gear teeth on either the Bevel Gear (205) or Bevel
Pinion (205) are worn or chipped, replace both parts.
These are matched set and must be replaced with a
matched set.
Disassembly of the Clutch
1. Carefully grasp the flats of the Coupling Nut (67) in
leather-covered or copper-covered vise jaws, Clutch
Housing (51) facing downward.
NOTICE
This is a left-hand thread.
2. Using a wrench on the flats of the Gear Case (46), loosen
the Gear Case from the Coupling Nut. Remove the tool
from the vise.
3. Unscrew the Coupling Nut and remove the Clutch
Housing from the Gear Case.
4. Grasp the Clutch Shaft Assembly and pull the Assembly
out of the Clutch Housing.
CAUTION
When the Clutch Adjusting Nut (60) is loosened enough
to relieve the spring pressure, hold the assembly over a
container to catch the twenty-four Clutch Balls (56) that
will be free to drop out and might otherwise be lost.
NOTICE
This is a left-hand thread.
5. Working over a workbench, unscrew and remove the
Clutch Adjusting Nut.
6. Remove the Adjusting Nut Lock (61), Clutch Spring Seat
(58), Spring Seat Bearing (59) and another Clutch Spring
Seat (58).
7. Slide the Clutch Spring (63), the third Clutch Spring Seat
(58) and Clutch Ball Spacer (57) off the Clutch Shaft (54).
8. Remove the Front Clutch Jaw (55).
9. Remove the Clutch Driver Retainer (66) and slide the
Clutch Driver (65) from the Clutch Shaft Support (64).
NOTICE
This is a slip fit.
10. Using needle nose pliers or a wire hook, remove the
Clutch Engaging Spring (62).
Disassembly of the Gearing
1. Using a pin punch and hammer, drive out the Throttle
Lever Pin (5) to release the Throttle Lever (4).
2. Grasp the flats of the Motor Housing in leather-covered or
copper-covered vise jaws, Gear Case facing upward,
being careful not to distort the Motor Housing.
NOTICE
This is a right-hand thread.
3. Using a wrench on, the flats of the Gear Case, loosen,
but do not remove the Gear Case.
CAUTION
Be certain to hold the tool over a workbench so that you
will not lose any parts.
4. Remove the tool from the vise and, while holding the tool
horizontally, carefully unscrew the Gear Case by hand
and pull it away from the Motor Housing.
5. For M or N ratio, the Rotor Pinion (39) and Rotor Pinion
Spacer (40) may come out with the Spindle, or they may
have remained with the Rotor (26) when the Gear Case
was removed. Remove the Rotor Pinion and Rotor Pinion
Spacer.

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6. For K or L ratio, remove the Spindle Planet Gears (37).
Position the Gear Case vertically in an arbor press,
planet gear end down. Using a 7/16" (11 mm) diameter
brass rod against the outer rim of the Spindle, press the
Spindle from the Gear Case.
For M or N ratio, remove the Gear Head Planet Gears
(42), Gear Head (41), Gear Head Spacer (44) and
Spindle Planet Gears (37). Position the Gear Case
vertically in an arbor press, planet gear end down. Using
a 7/16" (11 mm) diameter brass rod against the outer rim
of Spindle, press the Spindle from the Gear Case.
7. Using snap ring pliers, remove the Spindle Bearing
Retainer (50).
8. Tap the externally threaded end of the Gear Case on a
workbench to remove the Grease Shield (48) and Spindle
Bearing (49).
9. Remove the Seal (36), Seal Support (35) and Seal
Retaining Washer (34A) from the Spindle.
Disassembly of the Motor and Throttle
1. Remove the Rotor Bearing Housing (33) from the Motor
Housing (1).
2. Grasp the splined end of the Rotor (26) and pull the
assembled motor from the Motor Housing.
3. Remove the Rear End Plate Gasket (24) from the Motor
Housing.
CAUTION
Make certain the Rear End Plate Retainer (25) does not
fly when it is slipped off the hub of the Rotor.
4. Using a pair of external snap ring pliers with just the tip of
the pliers inserted between the ends of the Rear End
Plate Retainer, spread the Retainer enough to remove it
from the groove in the hub of the Rotor.
5. Remove the Rear End Plate (23), Cylinder (28) and
Vanes (27).
6. Check the Front Rotor Bearing (31) for damage or
roughness. If replacement is necessary, support the
Front End Plate (29) between the two blocks of wood on
the table of an arbor press. Press the Rotor from the
Front Rotor Bearing.
7. Do not remove the Rear Rotor Bearing (2) unless you
have a new bearing on hand for replacement. The old
bearing will be damaged during the removal process. To
remove the Rear Rotor Bearing, refer to step 14 below.
8. Grasp the flats of the MotorHousing in leather-covered or
copper-covered vise jaws, inlet facing upward.
9. Using a wrench on the flats, unscrew and remove the
Inlet Bushing (16).
10. Remove the Throttle Valve Spring (6) and Air Strainer
Screen (17).
11. Remove the Exhaust Deflector(13), Inlet Bushing Spacer
(15), Exhaust Silencer (12), Muffler Element (14),
Exhaust Deflector Seal (11) and Silencer Seal Ring (10).
12. Lift out the Throttle Valve (8) and the Throttle Valve
Plunger (9).
13. If removal of the Throttle Valve Seat (7) is necessary, use
a wire hook to pull the Throttle Valve Seat from the Motor
Housing.
14. If removal of the Rear Rotor Bearing is necessary, thread
No. 10-24 thread cap screw through the Bearing and into
the Rear Rotor Bearing Nut (3) to jack the Bearing form
the bearing recess.
Disassembly of the Reverse Valve
1. Using a 3/32" Allen Wrench, remove the Retainer
Setscrew (21).
2. Remove the Lock Pin Retainer (19).
NOTICE
Be careful not to lose the Reverse Valve Spring (22)
when removing the Reverse Valve (18).
3. While holding the Motor Housing horizontally with the
throttle plunger hole downward, tap the top side of the
Housing with a plastic hammer to dislodge the Reverse
Valve Lock Pin (20) allowing the Reverse Valve to be
withdrawn from the Housing.
Assembly
General Instructions
1. Always press on the inner ring of a ball-type bearing
when installing the bearing on a shaft.
2. Always press on the outer ring of a ball-type bearing
when pressing the bearing into a bearing recess.
3. Whenever grasping a tool or part in a vise, always use
leather-covered or copper-covered vise jaws. Take extra
care with threaded parts and housings.
4. Always clean every part and wipe every part with a thin
film of the recommended oil before installation.
5. 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 not be cleaned. Work
grease into every open bearing before installation.
6. Apply a film of O-ring lubricant to all O-rings before
installation.
7. Unless otherwise noted, always press on the stamped
end of a needle bearing when installing the needle
bearing in a recess. Using the bearing inserting tool
similar to the one shown in Dwg. TPD786. (Dwg. TPD786)
Assembly of the Motor and Throttle
1. If the Rear Rotor Bearing (2) was removed, install a new
one as follows:
a.Install the Rotor Bearing Ejecting Nut (3) in the
hexagon recess in the bore of the Motor Housing.
b.Using a bearing inserting tool that has a pilot
extending into the Bearing and a shoulder that
contacts the outer radius of the bearing shell, press
Needle Bearing Inserting Tool

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new Rear Rotor Bearing (2) into the Motor Housing
until it is about 0.010" to 0.020" (0.25 mm to 0.50
mm) below flush. Inject 0.5 cc of grease into the
Bearing.
2. Carefully grasp the flats of the Motor Housing in a
copper-covered vise jaws, inlet end facing upward.
3. If the Throttle Valve Seat (7) was removed, use a flat
faced rod 1/2” (11 mm) in diameter by 3" (75 mm) long to
push the Throttle Valve Seat into the Motor Housing until
it seats.
4. Install the Throttle Valve Plunger (9) until the hole in the
Plunger aligns dead center with the hole in the Throttle
Valve Seat.
5. Using needle nose pliers to hold the short-stem end of
the Throttle Valve (8), install the Valve, long-stem end
through the hole in the Throttle Valve Seat and the
Throttle Plunger.
6. Install the Muffler Element (14) by wrapping it horseshoe
fashion around the inside of the Exhaust Deflector (13)
covering all exhaust holes.
7. Snap the Exhaust Silencer (12) into the large open end of
the Exhaust Deflector.
8. Install the Exhaust Deflector Seal (11) into the groove on
the front end of the Exhaust Deflector.
9. Install the Silencer Seal Ring (10) over the hub of the
Motor Housing and flush with the base of the hub.
10. Install the Exhaust Deflector over the hub of the Motor
Housing, aligning the wide tab on the Exhaust Deflector
with the throttle plunger hole in the Motor Housing.
NOTICE
Tabs on the Exhaust Deflector match notches in the
Motor Housing. Do not force the Exhaust Deflector in
place.
11. Insert the Air Strainer Screen (17) closed end first, inside
the external threaded end of the Inlet Bushing (16).
12. Insert the Throttle Valve Spring (6) large coil end first, into
the Inlet Bushing, making sure it contacts the Air Strainer
Screen.
13. Install the Inlet Bushing Spacer (15) in the large hole in
the Exhaust Deflector.
14. Thread the Inlet Bushing into the Motor Housing making
certain the Throttle Valve Spring encircles the short-stem
end of the Throttle Valve. Tighten the Inlet Bushing to a
minimum of 25 ft.-lb. (33.9 Nm) torque.
15. Note that the throttle lever pin hole in the Exhaust
Deflector is larger at one end than the other. Install the
Throttle Lever (4), pressing the Throttle Lever Pin (5) into
the large end of the pin hole.
16. Slide the Front End Plate (29), flat side first, over the
splined end of the Rotor (26).
17. Using a sleeve that contacts only the inner ring of the
Front Rotor Bearing (31), press the Front Rotor Bearing
onto the splined hub of the Rotor until it seats against the
Front End Plate. Inject 0.5 cc of grease into the bearing.
18. The clearance between the Front End Plate and the
Rotor is critical. While holding the Front End Plate, gently
tap the splined end of the Rotor until you can insert a
0.001" feeler gauge or shim between the face of the
Rotor and End Plate.
19. Grasp the splined end of the Rotor in copper-covered
vise jaws so that the short hub of the Rotor is upward.
20. Wipe each Vane (27) with a film of Ingersoll Rand No.
10 Oil and place a Vane in each slot in the Rotor.
21. Place the Cylinder (28) down over the Rotor and against
the Front End Plate so that the tapered section on the rim
faces the Front End Plate.
22. Place the Rear End Plate (23), flat side first, over the
short hub of the Rotor.
CAUTION
Make certain the End Plate Retainer (25) does not fly as
you slip it on the hub of the Rotor:
23. Install the End Plate Retainer in the groove on the rotor
hub.
24. Position the Rear End Plate Gasket (24) into the bottom
of the motor housing bore so that dowel hole and air inlet
port in the Gasket align with the dowel hole and air inlet in
the housing bore face.
25. Using an assembly dowel 3/32" in diameter by 10" long
(2.3 mm x 254 mm), align the dowel groove in the Front
End Plate, Cylinder and Rear End Plate. Place the
assembly rod in the aligned grooves so that about 3" (75
mm) of the rod extends beyond the Rear End Plate.
Insert the extension into the dowel hole at the bottom of
the housing bore, and slide the motor into the Motor
Housing until it seats.
26. Withdraw the assembly dowel and insert the Cylinder
Dowel (30) until the Cylinder Dowel is lightly below the
surface of the Front End Plate.
27. Place the two Bearing Spring Washers (32) inside the
Rotor Bearing Housing (33).
28. Slide the Rotor Bearing Housing into the Motor Housing
and over the Front Rotor Bearing until it seats.
Assembly of the Reverse Valve
1. Install the Reverse Valve Lock Pin (20) into the hole in the
side of the Reverse Valve (18).
2. Slip the Reverse Valve Spring (22) into the end of the
Reverse Valve opposite the reverse valve knob.
3. Hold the Motor Housing (1) horizontally with the Throttle
Lever on top. Insert the Reverse Valve and Spring in the
reverse valve bushing, so that the Reverse Valve Lock
Pin is on top. Rotate the Reverse Valve one-half turn
(180°) to allow the Lock Pin to drop into the slot in the
wall of the Bushing. Release the Reverse Valve and
install the Lock Pin Retainer (19) and Retainer Setscrew
(21). Tighten Retainer Setscrew to 20 in-lb (27 Nm).
NOTICE
The Setscrew must not protrude from the Reverse valve.
4. Operate the Reverse Valve to make sure it functions
smoothly.
Assembly of the Gearing
1. Install the Grease Shield (48) into the front end of the
Gear Case (46) until it seats in the recess.
2. Slip the Spindle Bearing (49) into the Gear Case until it
seats and is flush against the Grease Shield.
3. Using snap ring pliers, install the Spindle Bearing
Retainer (50) in the groove in front of the Spindle Bearing.
4. If the Spindle Planet Gear Bearings (38) were removed,
press in new Spindle Planet Gear Bearings using a
bearing inserting tool similar to the one in the Dwg.
TPD786 that has a pilot and thatcontacts the outer radius
of the bearing. Press against the stamped end of the
Bearing.
For M ratio, press the new Spindle Planet Gear Bearings
into the Spindle Planet Gear to a depth of 0.02" to 0.03"
(0.50 mm to 0.75 mm) from the face of the Spindle Planet
Gear.
5. For L ratio, proceed as follows:
a.While supporting the inner race of the Spindle
Bearing in an arbor press, external threads of the
Gear Case facing downward, press the spindle into
the Spindle Bearing until the shoulder of the Spindle
is seated against the Bearing.
b.Place a Spindle Planet Gear (37) on each gear shaft
of the Spindle.

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c.Work 3 cc to 6 cc of the recommended grease into
the gear train.
For M or N ratio, proceed as follows:
a.While supporting the inner race of the Spindle
Bearing in an arbor press, external threads of the
Gear Case facing downward, press the Spindle into
the Spindle Bearing until the shoulder of the Spindle
is seated against the bearing.
b.Place a Spindle Planet Gear on each gear shaft of
the Spindle.
c.Work 3 cc to 6 cc of the recommended grease into
the gear train.
d.If the Gear Head Planet Gear Bearings (43) were
removed, press in new Gear Head Planet Gear
Bearings using a bearing inserting tool similar to that
one in Dwg. TPD786 that has a pilot and that
contacts the outer radius of the Bearing. Press
against the stamped end of the Bearing.
e.Install the Gear Head Spacer (44) into the Gear
Case flush against the face of the Spindle Planet
Gears.
f.Install the assembled Gear Head (41) into the Gear
Case, entering the spline of the Gear Head into
mesh with the Spindle Planet Gears.
6. Insert the Bearing Housing Spacer (33B) into the Gear
Case.
7. For M or N ratio, place the Rotor Pinion Spacer (40) and
Rotor Pinion (39) over the splined end of the Rotor.
NOTICE
This is a right-hand thread.
8. Thread the assembled Gear Case into the Motor Housing
and tighten to 40 ft.-lb (54 Nm) torque.
NOTICE
Run the motor at free speed on low air pressure while
tightening the Gear Case. Listen while tightening to
make sure there is no scoring.
Assembly of the Cushion Clutch
1. Install the Clutch Driver (65), flat side first,onto the spline
end of the Clutch Shaft Support (64) and retain with the
Clutch Driver Retainer (66). Set the Clutch Driver
Assembly aside.
2. Slide the Front Clutch Jaw (55), jaw end first, over the
end of the Clutch Shaft (54) and along the splines to the
groove at the opposite end.
3. Coat the grooved end with the recommended grease and
insert 13 Clutch Balls (56) (9/64" diameter) between the
Jaw and into the groove of the Clutch Shaft. Pull the
Clutch Jaw down to lock the Bearings into the groove of
the Shaft.
4. While holding the Clutch Jaw firmly on the Clutch Balls,
insert the Clutch Driver Assembly, spline end trailing, into
the bore of the Clutch Shaft.
NOTICE
Make certain the jaws of the Clutch Driver engage the
Front Clutch Jaw.
5. Carefully grasp the spline of the Clutch Shaft Support in
leather-covered or copper-covered vise jaws so that the
spline end of the Clutch Shaft faces upward.
6. Lightly coat the face of the Front Clutch Jaw with the
recommended grease.
7. Slide the Clutch Ball Spacer (57) over the splined end of
the Clutch Shaft, aligning the holes in the Spacer with the
holes in the Clutch Jaw. Put some grease in the holes in
the Spacer.
8. Insert a Clutch Ball (56) 9/64" diameter) into each of the
eleven holes in the Spacer, and, in the order named,
slide the following over the Clutch Shaft: one Clutch
Spring Seat (58), the Spring Seat Bearing (59), the third
Clutch Spring Seat (58) and the Adjusting Nut Lock (61),
indented side trailing. Thoroughly grease the Clutch
Balls, Bearing and Adjusting Nut Lock.
9. Start the Clutch Adjusting Nut (60), detent side first, onto
the Clutch Shaft and run it finger right against the
compression of the Spring.
NOTICE
This is a left-hand thread.
10. Remove the assembled Clutch from the vise.
11. Install the Clutch Shaft Assembly into the Clutch Housing
(51) with the splined end of the Clutch Shaft Support
trailing.
12. Install the Clutch Housing Assembly into the Gear Case
Assembly matching the spline of the Clutch Housing with
that of the Gear Case (46).
13. Thread the Coupling Nut (67) onto the Gear Case, hand
tight. Grasp the flats of the Gear Case in leather-covered
or copper-covered vise jaws and using a wrench on the
flats of the Coupling Nut, tighten it to 25 ft.-lb (34 Nm)
torque.
Assembly of the Angle attachment
1. Lubricate the Bevel Pinion (205) with 0.5 cc of the
recommended grease and insert it, gear end first, into the
long bore of the Angle Attachment (201).
2. Lubricate the Bevel Pinion (206) with a light coat of the
recommended grease and insert it, unstamped end first,
into the bore of the Angle Attachment and onto the bevel
pinion shaft.
3. For 5L2C6 Angle Attachment, press the Bevel Pinion
Bearing, stamped face outward, using the PinionBearing
Spacer (210).
NOTICE
The outward face of the Spacer must be flush with the
internal groove in the Angle Housing.
Using snap ring pliers, install the Bearing Spacer
Retainer (211).
For the 7L3D6 Angle Attachment, use the Bearing
Inserting
tool (227) and press the Bevel Pinion Bearing so the
stamped face is a maximum of 1.35" (34.40 mm) but not
less that 1.34" (34.14 mm) below the end of the face of
the Angle Head. Install the Bevel Pinion Bearing Spacer
(216) and install the Bearing Spacer Retainer (211).
4. For 5L2C6 Angle Attachment, lubricate the Bevel
Pinion Thrust Bearing (212) with 0.5 cc to 1 cc of the
recommended grease. Install the Bearing over the
splined end of the Bevel Pinion and retain it with the
Bearing Retainer (213).
For 7L3D6 Angle Attachment, lubricate the Bevel
Pinion Thrust Bearing (212) with 0.5 cc of the
recommended grease. Install in order named the Front
Thrust Bearing Seat (209), Bevel Pinion Thrust Bearing,
and Rear Thrust Bearing Seat (207) over the splined end
of the Bevel Pinion and retain with the Bearing Seat
Retainer (208).
5. If the Lower Spindle Bearing (214) has been removed,
work 0.5 cc to 1 cc of the recommended grease into the
bearing. Use a sleeve that will contact only the inner ring
of the Bearing and press the Lower Spindle Bearing,
sealed side first, onto the Spindle (219 or 220).

EN-7 16584054_ed1
EN
6. Lubricate the Bevel Pinion Gear (205) with 0.5 cc to 1 cc
of the recommended grease and slide the Bevel Gear
onto the Spindle.
7. Apply a thin coat of thread locking compound to the
threads of the Bevel Gear Retainer and tighten it on the
Spindle to 10 ft.-lb (13.5 Nm) torque.
For 7L3D6 Angle Attachment, snap Bevel Gear
Retainer in place on Spindle to retain Bevel Gear on
Spindle.
8. Lubricate a new Upper Spindle Bearing (204) with 0.5 cc
to 1 cc of the recommended grease. Press the closed
end of the Upper Spindle Bearing entering the Bearing
into the small bore opposite the threaded end of the
Angle Housing (201) to the dimension shown in Drawing
TPD680.
For 7L3D6 Angle Attachment, press Angle Housing
Cap (203) flat and flush with surface of Angle Housing.
9. Lubricate the Spindle Upper Bearing, Bevel Gear and
Lower Spindle Bearing with 0.5 cc to 1 cc of the
recommended grease and install the Spindle into the
Angle Attachment.
(Dwg. TPD680)
10. Clean the threads on the Angle Attachment and the
Spindle Bearing Cap (223), and apply a thin coat of
thread locking compound to the threads.
11. Install the Spindle Bearing Cap.
For 5L2C6, tighten to 15 ft-lb (20.0 Nm) torque.
For 7L3D6, tighten to 25 ft-lb (34.0 Nm) torque.
12. Slide the Coupling Nut (225), threaded end trailing, over
the splined end of the Angle Attachment.
13. Apply the Coupling Nut Retainer (224) to the external
groove on the splined end of the Angle Attachment.
14. For 5L2C6 Angle Attachment, engage the spline on the
Bevel Pinion with the matching spline in the Clutch Shaft
(54) and thread the Coupling Nut onto the Clutch
Attachment. Tighten the Coupling Nut to aminimum of 25
ft.-lb (34 Nm) torque. Make certain the output end of the
Spindle is on the same side of the tool as the Throttle
Lever (4).
15. For 7L3D6 Angle Attachment, engage the spline on the
Bevel Pinion with the matching spline in the Spindle (34)
and thread the Coupling Nut onto the Gear Case (46).
Tighten the Coupling Nut to a minimum of 25 ft.-lb
(34 Nm) torque. Make certain the output end of the
Spindle is on the same side of the tool as the Throttle
Lever.
Troubleshooting Guide
Minimum Dimension “A”
Angle Attachment in mm
5L2C6 1.21 30.75
7L3D6 .72 18.25
Maximum Dimension “A”
5L2C6 1.37 31.25
7L3D6 .73 18.50
Trouble Probable Cause Solution
Low power or low
free speed Low air pressure Check the air line pressure at the inlet. The pressure must not exceed 90 psig (6.2 bar/620 kPa) at the inlet.
Plugged Inlet Bushing Screen or Air
Strainer Screen Clean the Screen in a clean, suitable, cleaning solution. if it cannot be cleaned, replace it.
Worn or broken Vanes Replace the complete set of Vanes.
Loose Rotor Bearing Retaining Nut Tighten the Nut.
Worn or broken Cylinder Replace the Cylinder if it is worn or broken or if the bore is
scored or wavy.
Scoring of End Plates Replace End Plates if they are scored.
Improper lubrication or dirt build-up in
the motor. Lubricate the Wrench as instructed in LUBRICATION. If lubrication does not result in satisfactory operation,
disassemble the motor inspect and clean all parts.
Clogged Muffler Clean the Muffler Element in a clean, suitable, cleaning
solution. If it cannot be cleaned replace it.
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 for about 30 seconds.
Immediately, pour 3 cc of oil in the air inlet and operate the
tool for 30 seconds to lubricate all cleaned parts.
Scoring Improper assembly Make certain that all motor or Cylinder parts are properly
aligned prior to clamping the motor assembly.

16584054_ed1 EN-8
EN
Related Documentation
For additional information refer to:
Product Safety Information Manual Form 04585006.
Product Information Manuals Form 80167497 or Form 80227531.
Product Parts List Manual Form 16574047.
Manuals can be downloaded from www.irtools.com.
Gear Case gets
hot Excessive grease Clean and inspect the Gear Case gearing parts and lubricate as instructed in LUBRICATION.
Worn or damaged parts Clean and inspect the Gear Case and gearing. Replace worn
or broken components.
Angle Attachment
gets hot Excessive grease Clean and inspect the Angle attachment and gearing parts. Lubricate as instructed in Lubrication.
Inadequate grease Inject 0.5 to 1.5 cc of grease into the Grease Fitting.
Worn or damaged parts Clean and inspect the Angle Attachment and gearing. If the
Bevel Gear and/or Bevel Pinion is worn or broken, replace
both parts as they are a matched set.
Inconsistent
disengagement of
Clutch Attachment
Improper lubrication Lubricate the Attachment in accordance with the instructions
in Lubrication.
Worn or damaged part Replace the worn or damaged parts.
Worn Clutch Spring (using a Heavy
Spring on a light torque application) Install a light Clutch Spring in place of the Heavy Spring.
Motor stalls Improper adjustment of Attachment or
incorrect gearing ratio for the
application.
Check the adjustment of the Attachment and review the Tool
performance compared to torque requirements.
Motor shuts off
before peak torque
is reached
Improper adjustment of Attachment or
incorrect gearing ratio for the
application.
Check the adjustment of the Attachment and review the Tool
performance compared to torque requirements.
Trouble Probable Cause Solution

Notes

Notes

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