Ingersoll-Rand ES45T, ES50TC, ES50T User Manual

45527801

May 2007

Electric Screwdrivers

ES45T, ES50T and ES50TC

Maintenance Information

Edition 1

Save These Instructions

2 45527801_ed1

WARNING

Always wear eye protection when operating or performing maintenance on this tool.

NOTICE

GREEN

BLUE

RED

MOTOR

FORWARD/REVERSE SWITCH

(VIEWED FROM REAR)

RED

BLACK

332

POWER CORD

BRAKE SWITCH

TRIGGER SWITCH

WHITE

YELLOW

Wiring diagrams for ES45T, ES50T and ES50TC Electric Screwdrivers

BRAKE SWITCH

SWITCH PLATE SCREW

Models ES45T, ES50T and ES50TC Electric Screwdrivers

.014 ± .002

“ON” POINT (SWITCH “CLICKS”)

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).

Clutch Spring Selection Chart

Part Number Torque Range

ES50T-43 1 0.3 to 2.6 in-lb (0.04 to 0.30 N m) ES50T-462 1.2 to 6.5 in-lb (.I4 to .74 N m)

Part Number Torque Range

ES50T-431 0.5 to 3.0 in-lb (0.06 to 0.34 N m) ES50T-462 2.0 to 9.0 in-lb (0.23 to 1.02 N m)

Model ES45

Model ES50T and ES50TC

Disassembly

For Models ES45T and ES5OT, unscrew and remove the

1. Coupling (55). This is a left-hand thread; turn clockwise to remove. For Model ES5OTC, unscrew and remove the Nose Collar (61). Using a Phillips Screwdriver, remove the three Housing Screws (2).

2. This is a left-hand thread; turn clockwise to remove. Carefully separate the right side of the Housing from the left side

3. of the Housing.

The Model ES5OTC Screwdriver housing is assembled using a liquid gasket as a sealing material. Carefully pry the housing sections apart using a thin, at piece of metal. Do not use heat or chemical solutions to seperate the two halves.

4. Lifting the spindle end of the assembly slightly, carefully pull the

Gear Case (37) and assembled clutch away from the Motor.

5. Trigger Switch (8) replacement

Lift the Trigger Switch out of its recess in the left side of the

Housing (1) and unsolder the connections. Solder the leads to a new Trigger Switch and reposition the

Switch in the Housing. (Refer to the wiring diagram below).

6. Reverse Switch (9) replacement

The Reverse Switch is tted into the left side of the Housing.

Remove the Switch by depressing the locking tab of the switch mount from the rear with a at blade Screwdriver and pushing the Switch out of the Housing. Unsolder the wiring to the Switch and install a new Switch.

(Refer to the wiring diagram below).

(Dwg. TPD1114)

7. Brake Switch (15) replacement Remove the two Screws (16) holding the Brake Switch.

Unsolder the wiring to the Brake Switch and install a new

Switch. (Refer to the wiring diagram above). Position the Brake Switch and install the two Screws to secure

it to the Shuto Switch Plate (10). After installing the Brake Switch, loosen the Switch Plate

Screw (11) that holds the Switch Plate in the Housing. Move the Switch Plate toward the Motor and tighten the

Screw when the Switch is pushed .014 + or -.002 beyond the “ON” point (point that the Switch clicks). Placing a .014” shim on the arm of the Switch and moving the Switch until it clicks is a simple method of setting the Brake Switch gap.

(Dwg. TPD1113)

8. Brush Assembly (24) replacement Unsolder the brush lead.

Lift the brush spring end upward and over the corner of the

phenolic tab. Remove the brush. Solder the brush lead onto a new brush, install the brush and

reposition the brush spring. (d) Repeat steps (a), (b) and (c) for the remaining brush.

9. Power Cord Assembly (6) replacement Unsolder the wires to the Trigger Switch (S), Brake Switch (15)

and the green and yellow wires of the Power Cord where the leads from the Reverse Switch (9) are spliced. Install a new Power Cord Assembly and solder the wires to the

Trigger Switch, Brake Switch and two leads from the Reverse Switch as shown in the wiring diagram on page 12.

* Trademark of Permabond International.

10. Motor Assembly replacement

NOTE HOLE LOCATION

BLUE

RED

NOTICE

(Dwg. TPD1052)

Unsolder the two motor leads. Note the location of the red

and blue leads to the hole in the side of the motor. Solder the motor leads to a new motor as illustrated above.

Carefully check the Reverse Switch (9) to make sure that the

motor runs in the correct rotation as indicated on the Switch. If the motor does not run in the correct rotation, reverse the leads.

Model ES5OTC has a Shield Plate (20) separating the motor from the switches. When installing the assembled motor, make certain Perma-Lok GasketMaker* HH190 liquid gasket material forms a seal around the edge of the Plate and also at the opening in the Plate for the motor leads.

11. Pushrod replacement Remove the Gear Case (37) from the Motor Assembly.

Pull the Pushrod (35) out of the motor and replace it with a

new one. Pull the Pushrod (46) out of the Gear Case. Lightly coat a new

Pushrod with Ingersoll Rand No. 67 Grease and insert it into the Gear Case. After replacing both Pushrods, adjust the timing of the Switch

Plate (10) as described in Step 7(e).

12. Gear replacement Pull the Gear Case (37) away from the Motor Assembly.

The joint between the Gear Case and Clutch Housing (53) is a

left-hand thread. Using one wrench on the gear case ats and another on the ats of the Clutch Housing, turn the Housing clockwise to separate the two parts. Remove the Cam (43), two Cam Pins (44), Thrust Washer (42),

Spindle Assembly (40) and Gear Head Assembly (38) from the clutch end of the Gear Case. Inspect the Gear Head Planet Gears (39), Spindle Planet

Gears (41) and the gear teeth in the Gear Case for chipped or broken teeth. Apply a small amount of Ingersoll Rand No. 67 Grease to the Gears, Gear Case and Cam. Insert the Gear Head Assembly, Planet Gears rst, into the

clutch end of the Gear Case. Make certain the Planet Gears mesh with the gear case spline. Insert the Spindle Assembly, gear end leading, into the Gear

Case. Make certain the Spindle Planet Gears mesh with the pinion of the Gear Head. Install the Thrust Washer, Cam, Cam Pins and Collar into the Gear Case. The joint connecting the Gear Case to the Clutch Housing is a

left-hand thread. Thread the Housing onto the Gear Case in a counterclockwise direction and tighten the joint to 21 ft-lb (28.5 Nm) torque.

13. Place the assembled motor, gearing and clutch unit in the left

side of the Housing.

14. For Models ES45T and ES5OT, place the right side of the

Housing against the left side and install the three Housing Screws.

For Model ES5OTC, place a bead of Perma-Lok GasketMaker*

HH190 around the edge of Shield Plate and the mating edges of the Housing. Place the right side of the Housing against the left side and install the three Housing Screws.

15. For Models ES45T and ES5OT, thread the Coupling (55) onto the

Gear Case and tighten it with a wrench. For Model ES5OTC, thread the Nose Collar (61) onto the Gear Case and tighten it with a wrench.

Troubleshooting Guide

Trouble Probable Cause Solution

Is there power to the tool?

Does the Trigger Switch click when the Trigger is depressed?

Does the Trigger Switch turn on power to the Motor?

Can the bit be turned by hand when the tool

Screwdriver fails to rotate (reverse or forward)

is unplugged?

Does the tool operate properly when bumped and jiggled?

Defective Power Cord Assembly (6). Replace the Power Cord

1. Assembly if necessary. No power from the Controller. Repair or replace (see Controller

2. Service Manual).

Defective Trigger Switch (8). Replace the Trigger Switch.

Trigger pad worn. Replace the Trigger (17).

Planetary gearing defective. Replace the Planet Gears (39 or

41), Spindle Assembly (40) and Gear Head Assembly (38).

2. Clutch defective. Repair or replace the clutch.

Defective power cord. Replace the Power Cord Assembly (6).

1. Forward/Reverse Switch defective. Replace the Forward/

2. Reverse Switch (9). Defective solder connection.

3. Check all solder connections; resolder where necessary. Defective Armature. Replace the Motor Assembly.

4. Brush contact defective. Replace the Brush Assembly.

Worn or defective Brushes. Replace the Brush Assemblies (24).

Does brush wear appear normal?

Does motor appear to be in good condition?

45527801_ed1 3

1. Defective Commutator. Replace the Armature (31).

Carbon buildup or dirt on Armature (31).

1. Clean the Armature using a good electrical contact cleaner

2. and blow dry.

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