Ingersol Rand 500PS3 Setup guide

47109533

Edition 1

September 2010

Save These Instructions

Air Impulse Wrench (Twin Blade)

Model 500PS3, 700PS3 and 900PS4

Maintenance Information

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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 Manual when applicable (see under Related

Documentation for form numbers).

Changing The Mechanism Fluid

To change the Mechanism Fluid in the Impulse Mechanism, proceed

as follows:

1. Using a hex wrench, remove the three Hammer Case Cap Screws

and Lock Washers. Lift the Hammer Case o the Motor Housing

over the Drive Shaft. Remove the Hammer Case Gasket.

2. Lift the assembled mechanism o the Rotor.

3. Using a 2.5 mm hex wrench, unscrew and remove the Oil Plug.

Remove the Oil Plug Seal and Oil Plug Seal Support.

4. Using either the 1.5 mm or the 2 mm hex wrench furnished

with the tool, rotate the Adjustment Screw without paint in the

wrench hole, counterclockwise until it stops.

5. With the oil plug opening downward over a container, rotate the

Drive Shaft to purge the uid from the mechanism.

6. Using the syringe and uid from the Fluid Replacement Kit (Part

No. EQ106S–K400), ll the mechanism with the uid furnished

in the Kit until the uid overows the ll hole. Model 500PS3 will

require 9 cc of uid; Model 700PS3, 12 cc and

Model 900PS4, 17 cc.

(Refer to Dwg. TPD1265)

NOTICE

Do Not Substitute Any Other Fluid.

Failure to use the impulse mechanism uid provided could

damage the tool, increase maintenance and decrease

performance. Use only clean uid in these tools.

(Dwg. TPD1265)

7. Submerge the mechanism in a reservoir containing mechanism

uid, and using a wrench, rotate the Drive Shaft clockwise and

counterclockwise to purge any remaining air from the system.

8. Remove the mechanism from the uid and rotate the Adjustment

Screw clockwise until it stops.

9. Thread the Oil Plug with the Oil Plug Seal and Seal Support into

the mechanism until it is snug.

10. Wipe the outside of the mechanism dry and clean and remove

the Oil Chamber Plug. Using the syringe, withdraw 0.55 cc of uid

from 500PS3 models, 0.65 cc of uid from 700PS3 models and

0.90 cc from 900PS4 models.

11. Install the Oil Chamber Plug and tighten it between 20 and 25

in–lb (2.3 and 2.8 Nm) torque.

12. Position a new Hammer Case Gasket on the Motor Housing and

install the assembled mechanism on the rotor shaft.

13. Place the Hammer Case Cover over the Drive Shaft against the

Housing and Gasket. Install the three Hammer Case Cap Screws

and Lock Washers. Tighten each Screw between 45 an 50 in–lb

(5.1 and 5.6 Nm) torque.

14. Test the tool for torque at maximum, minimum and mid–range

torque settings. If the tool does not perform satisfactorily, repeat

the rell procedure and pay particular attention to removing

unwanted air from the uid system. Refer to the section

TORQUE ADJUSTMENT for specic adjustment procedures.

15. If the torque is satisfactory but the tool fails to shut–o, only

then, is it necessary to adjust the shut–o mechanism.

If it should become necessary, proceed as follows:

Remove the Adjusting Hole Plug from the Hammer Case.

Using a pointed probe, pick the paint out of the wrench

opening in the Adjustment Screw that is 180 degrees away

from the Torque Adjustment Screw.

Rotate the Screw counterclockwise not more than ten

degrees.

Permanently mark the Screw for future identication and then

retest the tool. Adjustments to the shuto mechanism should

only be made in ve to ten degree increments.

NOTICE

Before operating the tool, mark the shuto Adjustment Screw

with a permanent marker or paint so that it can be distinguished

for future adjustments.

47109533_ed1 3

Disassembly

General Instructions

1. Do not disassemble the tool any further than necessary to replace

or repair damaged parts.

2. When 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 t in or on an assembly

unless the removal of that part is necessary for repairs or

replacement.

Disassembly of the Impulse Mechanism

1. Use a hooked wire to pull the Retaining Pin Spring (68) out of the

end of the Drive Shaft (66) and remove the

Socket Retaining Pin (67).

2. Using a hex wrench, remove the three Hammer Case Cap Screws

(85) and Lock Washers (86). Lift the Hammer Case (82) o the

Motor Housing (1) over the Drive Shaft. Remove the Hammer

Case Gasket (80).

3. Lift the assembled mechanism o the Rotor (42).

4. Grasp the ats of the Housing (47) in vise jaws with the output

end of the Drive Shaft downward.

5. Insert the pins of the Spanner Plug from the No. 700A–99 Tool Kit

into two holes in the Housing Cap (49). Using a wrench on the

plug, unscrew and remove the Housing Cap from the Housing.

(Refer to Dwg. TPD1267).

Spanner Plug Clockwise To Loosen

(Dwg. TPD1267)

6. Stand the Disassembly Arbor from the Tool Kit, large end

downward, on a workbench or the table of an arbor press. Insert

the output end of the Drive Shaft into the central opening and

either tap the Housing downward o the components or use the

Pressing Sleeve in the Kit to press the Housing downward o the

components.

(Refer to Dwg. TPD1268)

Pressing Sleeve Tap Edge Lightly With Brass

Hammer Or Use Pressing

Sleeve From Tool Kit

Disassembly Arbor

From Tool Kit

Housing

(Dwg. TPD1268)

NOTICE

In the following step, do not remove or turn the Shut–o

Adjustment Screw (73) located in the Front Liner Cover (72). It is

the Screw with the paint in the wrench opening.

7. Disassemble the components of the mechanism in the sequence

shown in Drawing TPA1480 on Page X.

Disassembly of the Motor

1. Grasp the Motor Housing (1) in vise jaws with the Backcap (23)

upward.

2. Using a hex wrench, remove the three Backcap Screws (36) and

Lock Washers (37).

3. Lifting straight upward, remove the Backcap and assembled

shut–o mechanism from the Motor Housing and also the

Backcap Gasket (35). Set the assembled Backcap aside.

4. Remove the Housing from the vise jaws and insert a rod into the

central opening in the output end of the rotor shaft.

5. While holding the motor end of the Housing above a piece of

cardboard on the workbench, lightly tap the rod to remove the

Rear End Plate Assembly (38), Rotor (42) and Vanes (43).

6. On the table of an arbor press, support the Rear End Plate with

blocks as close to the Rotor as possible and press the Rotor out of

the Rear End Plate and Rear Rotor Bearing (39).

NOTICE

In the following two steps, do not enlarge or damage the shaft

hole in the End Plate.

7. To remove the Rear Rotor Bearing from the Rear End Plate, use a

small drift or pin punch through the central opening of the Rear

End Plate to tap the Bearing out of the End Plate.

(Refer to Dwg. TPD1271)

(Dwg. TPD1271)

8. Using a longer drift punch through the Cylinder (41), tap the

Front Rotor Bearing (45) out of the Front End Plate Assembly (44)

in the same manner.

9. The Cylinder and Front End Plate are a shrink t in the Motor

Housing and parts that can be damaged during the heating

process must be removed before heating the Housing.

10. Press the Reverse Lever Retaining Pin (21) out of the Reverse

Lever (19) and pull the lever o the shaft of the ReverseValve (15).

11. Using snap ring pliers, remove the Reverse Valve Retainer (18).

12. Grasp the shaft of the ReverseValve with pliers, and pull the

Reverse Valve, Reverse Valve Detent Ball (17) and Detent Spring

(16) out of the Reverse Valve Bushing (14). Be careful not to lose

the Ball and Spring.

4 47109533_ed1

General Instructions

1. When 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.

2. Always press on the inner ring of a ball–type bearing when

installing the bearing on a shaft.

3. Always press on the outer ring of a ball–type bearing when

pressing the bearing into a bearing recess.

4. Except for bearings and mechanism parts, always clean every part

and wipe every part with a thin lm of oil before installation.

5. Wipe a thin lm of mechanism uid on all internal mechanism

components before installing them in the mechanism.

6. Apply a lm of O–ring lubricant to every O–ring before

installation.

Assembly of the Motor

1. If the shut–o mechanism was disassembled, install the Control

Shaft Seal (34) into the groove on the Control Shaft (33).

2. Insert the Control Shaft Spring (32) into the central opening

at the large end of the Control Bushing (29) and insert the

assembled Shaft, Seal end leading, into the opening. The end of

the Shaft must be encircled by the Spring and the long groove

must align with the three crossholes for the

Control Bushing Balls (31).

3. Coat the Control Bushing Balls with Ingersoll Rand No.28 Grease

and insert them into the crosshole openings.

4. Install the Control Valve Seal (28) on the ControlValve (27) and

place the Control Plate (26), large open end leading, over the

shaft of the Control Bushing.

5. Install the Backcap Front Spring (25) and the Control Valve

Assembly, seal end leading, over the shaft of the Control Bushing.

Install the Control Bushing Seal in annular groove around the

bushing shaft.

6. Fit the Backcap Rear Spring (24) against the Control Valve and

thread the entire assembly, spring end leading, into the Backcap

(23). Using a spanner wrench, tighten the Control Bushing in the

Backcap.

7. Using an arbor press and a piece of tubing that contacts the outer

ring of the bearings, press the Front Rotor Bearing (45) into the

Front End Plate (44) and the Rear Rotor Bearing (39) into the Rear

End Plate (38).

(Refer to Dwg. TPD1274)

8. Stand the Rotor (42) on the table of an arbor press. It should be

upright on a at metal plate having a clearance hole for the shaft.

The shaft with the hex must be upward.

End Plate

Tubing

Bearing

(Dwg. TPD1274)

9. Place a 0.001”(0.025 mm) shim on the upward surface of the large

portion of the rotor body. Using a piece of tubing that contacts

the inner ring of the bearing, press the Front Rotor Bearing and

Front End Plate, End Plate leading, onto the shaft of the Rotor

until the End Plate contacts the shim. Remove the shim.

(Refer to Dwg. TPD1275)

Pressing Plug

Front Rotor

Bearing

Rotor

Plate With Rotor

Shaft Clearance

Front End Plate

0.001” (0.025 mm)

Shim Space

(Dwg. TPD1275)

10. Coat each Vane (43) with a thin lm of oil and insert a Vane into

each of the rotor vane slots with the straight edge of the Vane

outward.

11. Install the Cylinder (41) over the Vanes and Rotor making certain

the End Plate Alignment Dowel (46) enters the notch in the end

face of the Cylinder.

12. Stand the assembly on an arbor press table so that the rotor shaft

on the front end plate end contacts the table. Press the Rear End

Plate Assembly, bearing end trailing, onto the rotor shaft against

the Cylinder. Make certain the End Plate Alignment Dowel (40)

enters the notch in the end face of the Cylinder.

13. Stand the assembly on a table with the Front End Plate Assembly

upward.

13. Using a pin punch, tap the Throttle Retaining Pin (13) out of the

Handle.

14. Grasp the Trigger (11) and pull the assembled throttle out of the

Motor Housing.

15. Using a pin punch and without damaging the Trigger, remove the

Trigger Pin (12).

16. Slide the Throttle Bushing Assembly (4) o the shaft of the

Throttle Rod Assembly (8).

17. Using a thin blade screwdriver, remove theValve Retaining Ring

(10) and slide the Throttle Valve Assembly (6) o the shaft of the

Throttle Valve Rod.

18. Using an adjustable wrench, unscrew and remove the Inlet

Bushing (2) and Exhaust Deector Assembly (22).

19. Insert a threaded rod through the Cylinder and Front End Plate

and install a nut and washer on the end plate end of the rod.

Position the Rear End Plate on the threaded rod against the

Cylinder and clamp the End Plates and Cylinder snug with

another nut and washer. Do not tighten the assembly excessively.

CAUTION

In the following step, take all precautions necessary to prevent

being burned by handling warm or hot parts.

20. Using a heat induction coil or an oven, heat the assembly and

Housing until it is warm enough to pull the assembly out the rear

of the Motor Housing. Do not apply enough heat to distort the

Housing.

21. To disassemble the shut–o mechanism, grasp the Backcap in

copper–covered vise jaws with the Control Shaft Assembly (33)

upward.

22. Using a spanner wrench, unscrew the Control Bushing Assembly

(29) and carefully separate the components. Be doubly careful

not to lose the three Control Bushing Balls (31) from the shaft of

the Control Bushing.

Assembly

47109533_ed1 5

CAUTION

In the following step, take all precautions necessary to prevent

being burned by handling warm or hot parts.

14. Using an induction coil or oven, heat the Motor Housing (1)

until the motor opening is large enough to be placed over the

Cylinder. At that time, install the Housing over the Cylinder and

Front End Plate making sure the radial End Plate Alignment Pin in

the Rear End Plate enters the notch in the Motor Housing.

15. Allow the assembly to cool and install the Backcap Gasket (35)

and the assembled Backcap (23).

16. Secure the Backcap to the Housing by installing the three

Backcap Mounting Screws (36) and Lock Washers (37). Tighten

each Screw between 45 and 50 in–lb (5.1 and 5.6 Nm) torque.

17. Install the Exhaust Deector (22) in the bottom of the handle of

the Motor Housing and tighten it between 20 and 25 ft–lb (27

and 34 Nm) torque.

18. Thread the Inlet Bushing (2) into the bottom of the handle of the

Motor Housing (1) and tighten it between 30 and 35 ft–lb (40 and

47 Nm) torque.

19. Install theThrottle Rod Seal (9) in the groove on the large hub of

the Throttle Rod (8).

20. Install theThrottle Valve Seal (7) in the groove on the large hub of

the Throttle Valve (6).

21. Slide the Throttle Valve, Valve Seal end rst, onto the Throttle

Valve Rod.

22. Secure the ThrottleValve Assembly by installing the Valve

Retaining Ring (10) in the small groove on theThrottle Valve Rod.

23. Install the threeThrottle Bushing Seals (5) in the grooves on the

Throttle Bushing (4).

24. Slide the Throttle Bushing Assembly onto the shaft of theThrottle

Valve Rod and position the Trigger (11) on the same shaft. Install

the Trigger Pin (12).

25. Insert the assembled Trigger into the Housing. Make certain

the widest end of the Trigger is nearest the motor bore and

the narrowest portion of the Throttle Valve aligns with hole for

the Throttle Retaining Pin (13). Install the Pin making certain it

captures the Throttle Valve and secures the assembled Trigger.

26. Align the detent hole in the Reverse Valve (15) with the hole

inside the Reverse Valve Bushing (14) and slide the Valve into the

Bushing until almost reaching the detent hole. Insert the Reverse

Valve Detent Spring (16) and Reverse Valve Detent Ball (17) into

the hole and while compressing the Spring with the Ball, slide the

Valve completely into the Bushing.

27. Using snap ring pliers, install the Reverse Valve Retainer (18).

28. Slide the Reverse Lever (19) onto the Reverse Valve, making

certain the Reverse Lever Alignment Pin (21) enters the notch

on the face of the Reverse Valve Bushing. Secure the Lever to the

Valve by inserting the Reverse Lever Retaining Pin (20).

Assembly of the Impulse Mechanism

1. Insert the long shaft of the Piston Stop (58) into the central

opening of the O–ring Installer furnished with the Tool Kit (Part

No. 700A–99). Place the Piston Stop Seal (59) on the tapered end

of the Installer and roll the Seal up the taper and into the groove

on the large body of the Piston Stop. Install the Check Valve Front

Seal (61) and Check Valve Rear Seal (62) on the Check Valve (60).

2. When looking inside the central opening of the Liner Assembly

(55), the internal wall has three holes on one side which do not

extend through the wall. The opening on the end face of that wall

is for the Torque Valve Piston (57). Install theTorque Valve Piston,

large end trailing, into that opening.

3. Insert the Piston Spring (64) into hole in the end face of the

opposite wall. Insert the Check Valve Piston (63), large end

trailing, and the Check Valve Ball (65) into the same opening.

4. Thread the Threaded Tee Wrench furnished with the Tool Kit into

the end of the Check Valve Assembly and using the Wrench to

hold the Assembly, insert the Assembly into the opening against

the Ball.

5. Unscrew the Wrench and screw it into the Piston Stop Assembly

and using the Wrench to hold the Assembly, insert the Assembly

into the opening against the Piston. Mark this opening with a felt

marker to indicate that it contains the Torque Valve Piston.

6. Install the Sensor Seal Back–up O–ring (54) followed by the

Sensor Seal (53) on one end of the Sensor (62) and insert the

assembly, Seal end leading, into the central opening of the Rear

Liner Cover (50). Make certain the assembly slides freely in the

opening.

7. Install the Rear Liner Cover Seal (51) in the annular groove on the

face of the Rear Liner Cover.

8. Install the two Front Liner Cover Piston Seals (78) in the openings

on the face of the Front Liner Cover (71).

9. Install the Seal Back–Up Ring (77) followed by the Drive Shaft

O–ring (76) in the central opening in the face of the Front Liner

Cover.

10. Insert the short round hub of the Drive Shaft (66) into the central

opening of the Rear Liner Cover.

11. Insert a Blade (69) into one slot in the Drive Shaft. Install the Blade

Springs (70) through the Drive Shaft and into the holes in the

Blade. Place the remaining Blade on the Springs making certain

the Springs enter the holes in that Blade.

12. Using nger pressure, compress the Springs with the Blades

until the outer edges of the Blades are ush with the drive shaft

surface. Capture the Blades in this position by installing the

Liner Assembly, piston stop end trailing, over the Drive Shaft and

against the Rear Liner Cover.

NOTICE

This installation can be accomplished more easily by aligning the

compressed Blades with the webs at the narrowest portion of the

opening. Keeping the Blades on the web allows them to slide the

length of the Liner without interference.

13. Insert the hex end of the Rear Liner Cover into the Disassembly

Arbor from the Tool Kit and stand it on a workbench with the

Drive Shaft upward.

14. Install the Front Liner Cover Assembly over the Drive Shaft and

against the Liner. Make certain the Torque Adjustment Screw

(72) aligns with the proper piston stop opening that was marked

during assembly.

15. Install the two Liner Cover Seals (48) in the grooves inside the

Liner Housing (47) near the end with the external wrench ats.

16. Place the Liner Housing, Seal end trailing, over the assembled

Liner. Make certain the notch in the trailing end face of the

Housing aligns with the Oil Plug (73) in the Front Liner Cover.

Use the Pressing Sleeve from the Tool Kit to press the Housing

over the Seals and into position. Do not Damage the Seals during

installation.

17. Grasp the ats of the Liner Housing in vise jaws and using the

Spanner Plug furnished with the Tool Kit and a torque wrench,

install the Housing Cap, castellated end leading. This is a

left–hand thread; rotate the wrench counterclockwise to tighten

the Cap.Tighten the Cap on models 500PS3 and 700PS3 between

9.4 and 10.7 ft–lb (12.7 and 14.5 Nm) torque and on model

900PS4 between 10.7 and 12.1 ft–lb (12.7 and 16.4 Nm) torque.

18. Make certain the Drive Shaft rotates freely and then ll the

mechanism with uid and reassemble the tool as instructed in

the section, CHANGING THE MECHANISM FLUID.

6 47109533_ed1

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