45481785
Edition 1
March 2007
Air Impact Wrench
2131 Series
Maintenance Information
Save These Instructions
1. Secure the Inlet Bushing in a vise. Press in both tabs of the Inlet
Retainer Clip (27) and pull upward on the Housing (19). This
will allow the Inlet Bushing to come free from the Handle of the
Housing. Refer to Dwg. TPD1326.
2. Pull the Trigger (28) from the front of the Housing and remove
the Trigger O-ring (2A).
NOTICE
To prevent damage to the Cylinder, do not tap or strike Cylinder on
a hard or metallic surface when removing the Rotor Bearings (3).
To remove the Front Rotor Bearing, hold the Front End Plate with
Front Rotor Bearing down and tap the Front End Plate on a flat,
nonmetallic surface such as a work bench. This will loosen the Front
Rotor Bearing so that it will drop out of the Front End Plate. Refer to
Dwg. TPD1323.
SLOT FOR TAB
(BOTH SIDES)
FRONT END PLATE
TAB ON INLET
RETAINER CLIP
(BOTH SIDES)
FRONT ROTOR BEARING
BENCH WITH NONMETALLIC SURFACE
(Dwg. TPD1323)
(Dwg. TPD1326)
4. Remove the Rear Rotor Bearing Retainer (6) from the rear of
the Rotor (5). The Rotor can now be removed from the Cylinder.
Remove the Vanes (4) from the Rotor if they need to be replaced.
3. With the Inlet Bushing still in the vise, remove the Tilt Valve Seat
Retainer (1G) and Tilt Valve Seat Support (1F). Use a hooked tool
with no sharp edges to remove the Tilt Valve Seat (1E) from the
Inlet Bushing. Refer to Dwg. TPD1327.
CYLINDER
HOOKED TOOL
REAR ROTOR BEARING
TILT VALVE STEM
BENCH WITH NONMETALLIC SURFACE
(Dwg. TPD1324)
5. To remove the Rear Rotor Bearing, hold the Cylinder with the Rear
Rotor Bearing down and tap the Cylinder on a flat, nonmetallic
surface such as a work bench. This will loosen the Rear Rotor
Bearing so that it will drop out of the Cylinder. Refer to Dwg.
TPD1324.
6. Working from the rear of the Housing, push out the Motor Gasket (7).
(Dwg. TPD1327)
NOTICE
4. Remove the Tilt Valve (1D) and Tilt Valve Spring (1C) if damaged.
5. Remove the Inlet Bushing Seal (1B) and Inlet Retainer Clip (27) if
damaged. Remove Washer (1A).
When removing the Motor Gasket, do not use a screwdriver or
any other sharp object which could damage the Gasket and/or
Housing.
NOTICE
Disassembly of the Throttle Mechanism
Do not remove the Inlet Bushing Screen (20A) from the Inlet
Bushing unless it is damaged. Clean the Inlet Bushing Screen by
using a suitable cleaning solution in a well ventilated area.
NOTICE
For ease of disassembly, we recommend using the Inlet Clip
Removal Tool (36). See Dwg. TPD1681.
Disassembly of the Reverse Valve Mechanism
NOTICE
The Reverse Valve Assembly cannot be removed without first
removing the Forward and Reverse Buttons (4A) and (4B).
Therefore, it is important that the procedure below be followed
exactly.
LEFT-HAND BUTTON
TRIGGER
1. Notice the notches on either side of the partition. These notches
indicate the correct location for insertion of a thin-bladed
screwdriver used for removing the Forward and Reverse Buttons.
Insert the screwdriver between the partition and the Button
which is fully extended. Gently pry against the Button to
disengage the detent so that the Button can be removed. After
the Button is removed, reach inside the Housing and rotate the
Reverse Valve to extend the remaining Button. Repeat the above
procedure for the remaining Button. Refer to Dwg. TPD1328.
INLET BUSHING
ASSEMBLY
INLET CLIP
REMOVAL TOOL
(Dwg. TPD1681)
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REMOVAL OF
FORWARD/
REVERSE
BUTTONS
REVERSE
VALVE
(Dwg. TPD1328)
2. Insert thumb into the front of the Housing and push down on the
Reverse Valve so that it can be removed through the bottom of
the handle. Refer to Dwg. TPD1329.
(Dwg. TPD1329)
NOTICE
Do not try to remove the Reverse Valve by pushing upward. It
can only be removed by pushing it downward and out of the
bottom of the handle. If the Reverse Valve does not come free,
tap the bottom of the handle lightly with a rubber hammer until
it drops out.
3. Remove the Top Reverse Valve O-ring (3A) and the Bottom
Reverse Valve O-ring (3B) from the Reverse Valve.
Assembly
General Instructions
1. Whenever grasping a tool or part in a vise, always use leather-
covered vise jaws to protect the surface of the part and help
prevent distortion. This is particularly true of threaded members
and housings.
NOTICE
Always use leather-covered vise jaws when clamping the handle
in a vise. Leather will conform to the shape of the handle and
allow the tool to be held securely. To prevent damage to the
exhaust diffuser, never clamp only the bottom of the handle.
EARS
2. Always clean every part and wipe every part with a thin film of oil
before installation.
(Dwg. TPD1330)
NOTICE
Use a wooden dowel to push the Reverse Valve up through
the handle until the top of the Reverse Valve is flush with or
slightly above the bottom of the motor bore in the Housing
(19). Refer to Dwg. TPD1331.
Do not remove grease from the impact mechanism or Hammer
Case (15). If the impact mechanism has not been disassembled,
inject Ingersoll Rand No. 115-1LB Grease through the Hammer
Case Grease Fitting (17).
When disassembling and assembling the impact mechanism,
remove all grease from the impact mechanism and Hammer Case
and lubricate the impact mechanism and Hammer Case Bushing
(16) with Ingersoll Rand No. 105-1LB Grease or Ingersoll Rand
No. 105-8LB Grease.
3. Apply a film of o-ring lubricant to all O-rings before final
assembly.
DOWEL
Assembly of the Reverse Valve Mechanism
1. Install the Bottom Reverse Valve O-ring (3B) (color-coded blue)
and the Top Reverse Valve bring (3A) on the Reverse Valve (30).
2. Insert the Reverse Valve in the bottom of the handle making sure
that two ears on the Reverse Valve are facing downward. Refer to
Dwg. TPD1330.
(Dwg. TPD1331)
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NOTICE
If the Reverse Valve is pushed up too far and becomes wedged,
it will have to be pushed back down through the handle and
re-inserted from the bottom of the handle. The Reverse Valve
cannot be removed by pushing it up through the handle and
into the motor bore. If the Reverse Valve must be removed and
re-installed, make sure that the Top and Bottom Reverse Valve
O-rings have not been rolled off and are in their proper positions
on the Reverse Valve.
REAR OF
HOUSING
REVERSE
VALVE
3. When the Reverse Valve has been installed, rotate the Reverse
Valve so that the tab on the Reverse Valve is at the rear of the
Housing. Refer to Dwg. TPD1332.
REVERSE
BUTTON
TAB
FRONT OF
HOUSING
(Dwg. TPD1334)
NOTICE
REVERSE
VALVE
If the Forward/Reverse Buttons will not install easily, move the
Reverse Valve slightly higher in the handle to provide better
alignment with the Buttons.
7. After the Forward/Reverse Buttons have been installed, remove
the Trigger before proceeding with installation of the throttle
mechanism.
APPROX. 1/32”
(Dwg. TPD1332)
Assembly of Throttle Mechanism
1. Using an Inlet Bushing Screen Installation Tool, install the Inlet
Bushing Screen (20A), screened end first, in the bottom (hex end)
of the Inlet Bushing (20). Insert the rounded end of the tool in the
cone formed by the screen and tap the end of the tool to secure
the rim of the screen in the Bushing. Refer to Dwg. TPD1473.
NOTICE
If the orientation of the Reverse Valve is not correct (tab facing
the rear of the Housing), the Trigger (28) and the Forward and
Reverse Buttons (4A) and (4B) cannot be installed.
4. Install the Trigger O-ring (2A) on the Trigger. Insert the Trigger
Assembly in the front of the Housing.
Inlet Bushing Screen Installation Tool
5. Rotate the Reverse Valve in either direction until an ear comes up
against the Trigger.
6. Look through the Housing from the rear. If the tab on the Reverse
Valve has been rotated to the left, install the right Button in the
Housing. When one Button has been installed, push the Button
in. This will rotate the’Reverse Valve so that the other Button can
be installed. Refer to Dwg. TPD1333.
0
(Dwg. TPD1473)
2. Install the Washer (1A), Inlet Retainer Clip (27), Inlet Bushing Seal
(1B), Tilt Valve Spring (1C), Tilt Valve (1D) Tilt Valve Seat (1E) and
Tilt Valve Seat Support (1F).
REAR OF
HOUSING
REVERSE
VALVE
WARNING
The Tilt Valve Seat Retainer (1G) must be properly installed in the
groove in the Inlet Bushing (20). To check for correct installation
of the Retainer, insert a pin into one of the holes in the Retainer
and rotate the Retainer. A correctly installed Retainer will
rotate freely but with some resistance in the groove of the Inlet
Bushing. An incorrectly installed Retainer will pop out of the
Inlet Bushing when the Retainer is rotated.
TAB
FORWARD
BUTTON
(Dwg. TPD1333)
If the tab on the reverse Valve has been rotated to the right,
install the left Button. Refer to Dwg. TPD1334.
WARNING
Do not use compressed air to check installation of the Tilt Valve
Seat Retainer or Inlet Bushing Screen unless the entire Inlet
Bushing Assembly is installed in the tool with the Hammer Case
installed and properly secured to the Motor Housing. Failure to
do so could result in injury.
Install the Tilt Valve Seat Retainer.
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Assembly of the Impact Mechanism
NOTICE
When re-installing the Inlet Bushing Assembly (20), pull the
Trigger (28) outward and make sure that the Reverse Button (4B)
is depressed before snapping the Inlet Bushing Assembly back
into the Housing.
3. Install the Inlet Bushing Assembly by pushing it into the hole in
the Housing until you see and hear the tabs on Inlet Retainer Clip
snap into place through the slots in Housing handle.
TOP HAMMER
HALF-ROUND
NOTCH ON RIGHT
NOTICE
The Reverse Button (left) (4B) must be pushed in before the
Trigger can be installed. Otherwise, the Trigger will be damaged
during installation.
4. Install the Trigger by pushing it into the handle until a click is
heard indicating that it is properly engaged.
BOTTOM HAMMER
HALF-ROUND
INSTALLATION
OF MOTOR
GASKET
NOTCH ON LEFT
(Dwg. TPD1535)
1. Coat the Hammers (14) with a light film of No. Ingersoll Rand
105-1LB Grease or Ingersoll Rand No. 105-8LB Grease.
2. Heavily coat the jaws of the Anvil (8) with Ingersoll Rand No.
105-1LB Grease or Ingersoll Rand No. 105-8LB Grease.
3. Replace the Hammers in the Hammer Frame (12) exactly as they
were when you marked them prior to disassembly.
NOTICE
If you are installing new Hammers or want to change the location
of the existing Hammers to utilize both impacting surfaces, slide
the Hammers in the Hammer Frame so that the half-round notch
on one Hammer is located on one side of the Frame and the
half-round notch on the other Hammer is located on the other
side of the Frame.
(Dwg. TPD1336)
Assembly of the Motor
NOTICE
When disassembling, assembling or pulling the Motor, we
recommend replacement of the Motor Gasket (7).
4. Replace the Hammer Pins (13).
5. Examine the base of the Anvil (8) and note its contour. While
looking down through the Hammer Frame, swing the top
Hammer to its full extreme one way or another until you can
match the contour of the Anvil. Enter the Anvil into the Hammer
Frame and through the first Hammer. Swing the bottom Hammer
in the opposite direction from the top Hammer and maneuver
the Anvil slightly until it drops into the bottom Hammer. Refer to
Dwg. TPD1535.
1. Install the Motor Gasket in the Housing making sure that the
grooves in the tab of the Motor Gasket fit around ridge in the
Housing. Refer to Dwg. TPD1336.
2. Install the Rear Rotor Bearing (3) into the rear of the Cylinder (1).
3. Install the Rotor in the Cylinder and secure with the Rear Rotor
Bearing Retainer (6).
4. Install Vanes (4) in the slots in the Rotor (5).
5. Install the Front Rotor Bearing (3) into the Front End Plate (2).
Install the Front End Plate on the Cylinder by pressing on the
inner race of the front Rotor Bearing until the Bearing is seated on
the Rotor Shaft.
6. Install the Power Management Dial Seal (5A) on the Power
Management Dial (35) and install the Dial in the end of the
Cylinder.
Assembly of the Air Wrench
1. Position the Motor Housing (19) in leather-covered vise jaws with
the splined shaft of the Rotor in a horizontal position.
2. Place the assembled impact mechanism down onto the splined
hub of the Rotor.
3. Position the Hammer Case Gasket (18) against the face of the
Motor Housing.
7. Clean the Silencer (6A) using a suitable cleaning solution in a
well-ventilated area. Position the Silencer over the top of the
Cylinder and insert the Motor Assembly into the Housing (19),
Power Management Dial end first.
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FRONT OF
HOUSING
NOTICE
Be sure that the flat on the bottom of the Hammer Case Gasket is
installed in the corresponding flat in the Housing. If the Hammer
Case Gasket is not installed correctly, the Air Wrench will not
function properly.
GASKET
Refer to Dwg. TPD1335-1.
4. Apply a thin film of Ingersoll Rand No. 105-1LB Grease or
Ingersoll Rand 105-8LB Grease on inside surface of the Hammer
Case Bushing (16), and place the Hammer Case (15) down over
the Anvil and against the Motor Housing.
FLATS
(Dwg. TPD1335-1)
5. Install the Hammer Case Screws (11) and tighten them to 25 in-lb
(2.8 Nm) torque.
Troubleshooting Guide
Trouble
Probable Cause
Dry Motor
Solution
Daily, inject 3 cc of Ingersoll Rand No. 50 Oil into the inlet and run the tool to
lubricate the motor.
Install proper air supply and connection. Refer to Dwg. 04581666 on Page 2 of Air
Impact Wrench Product Information Manual Form 04584686.
Inadequate air supply
Using a clean, suitable, cleaning solution in a well ventilated area, clean the Inlet
Bushing Screen.
Dirty Inlet Bushing Screen
Worn or broken Vanes
Replace a complete set of Vanes.
Low power
Examine Cylinder. Check outside and ends for wear or damage and inside for
scored or wavy bore. Replace Cylinder if any of these conditions exist. Replace
End Plates if they are scored.
Worn or broken Cylinder
and/or scored End Plates
Disassemble the Tool and clean in a clean, suitable, cleaning solution in a well
ventilated area. Assemble the Tool and inject 3 cc of the recommended oil into
Inlet and run Tool to lubricate internal parts.
Dirty motor parts
Replace Reverse Valve. Refer to Assembly of the Reverse Valve Mechanism.
Refer to “Assembly of the Reverse Valve Mechanism”.
Damaged Reverse Valve
Disassemble motor and replace worn or broken parts and reassemble. Refer to
Assembly of the Motor.
Incorrect assembly of motor
Motor will not run
Tool will not impact
Insufficient lubricant in impact
mechanism
Lubricate impact mechanism through Hammer Case Grease Fitting using the
recommended grease.
Broken or worn impact
mechanism parts
Remove Hammer Case Assembly and examine impact
mechanism parts. Replace any worn or broken parts.
Impact mechanism not
assembled correctly
Refer to Assembly of the Impact Mechanism.
Related Documentation
For additional information refer to:
Air Impact Wrench Product Safety Information Manual Form 04580916.
Air Impact Wrench Product Information Manual Form 04584686.
Air Impact Wrench Parts List Manual Form 04584025.
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