W2109 & W2110 SERIES IMPACTS
Contents
1. Smoking Tobacco Cold Temperatures Certain Drugs Keep wrists as straight as possible Avoid highly repetitive movements of hands and wrists and continuous vibration exposure Work gloves with vibration reducing liners and wrist supports are available from some manufacturers of industrial work gloves These gloves are designed to reduce and moderate the effects of extended vibration exposure and repetitive wrist trauma Since they vary widely in design material vibration reduction and wrist support qualities it is recommended that the glove manufacturer be consulted for gloves designed for your specific application WARNING Proper fit of gloves is important Improperly fitted gloves may restrict blood flow to the fingers and can substantially reduce grip strength Also note that various tool wraps are available from a number of different manufacturers Like gloves these wraps are also intended to reduce and moderate the effects of extended vibration exposure They vary widely in design material thick ness vibration reduction effectiveness and durability so con sideration must be given to choosing the proper wrap for the specific application This information is a compilation of general safety practices obtained from various sources available at the date of produc tion However our company does not represent that every acceptable safety practice is offered herein or that abnormal or unusual circumstances may not war2. from operating if the throttle is accidently engaged Never use the air hose for supporting lifting or lowering the tool Use a safety line or cable on the tool when working in elevated areas Tools with exposed throttles should not be used where obstruc tions can hold the throttle in the on position An impact wrench operating in reverse will move backwards as a nut is removed and can trap an operator s hand making it difficultto release an outside trigger Inside trigger or pistol grip tools are advised for close quarter operation Outside Trigger Pistol Grip Rev A Rev Ten x DO NOT USE OK Only use sockets designed for use with impact wrenches Never use a hand tool socket on an impact wrench Hand tool sockets can break resulting in a hazard from flying pieces Inspect Sockets retainers and drives regularly for wear or damage and replace as necessary Worn sockets reduce power cause drive wear and increase the chance for breakage and should not be used Impact wrenches equipped with the spline drive have an integral socket retainer pin which may be depressed by a screwdriver or similar tool when installing or removing a socket Tools with square drives 3 4 and larger use an aor ring and pin for socket retention Retainers either pin or integral should be properly engaged to prevent dropping sockets into lower working levels Always use socket retainer components recommended by the socket manufacturer Nev
3. 6 and torque to 20 ft lbs 27Nm minimum After complete assembly of the tool 1 1 4 fluid ounces 40ml of 30W oil should be added to the 30W oil fill hole SAFETY CHECK Alltools should be tested after repair or replacement of parts to assure that they are functioning properly DRAWINGS AND PARTS LISTS OPTIONAL PARTS 865021 865007 PARTS LIST OPTIONAL PARTS PART NO NAME OF PART 865007 Spacer 1 865021 Suspension Bracket 1 PA i 7 2 ER E N A SIL LAN 1 ERA A 7 LAGER SON aNd EN Co Jon 1viu3S 6017 dm 1300W 992419 SLLZIV 600198 c9ceoc 619698 8898 62698 82690 9598 216098 446499 L62198 112698 69 992699 8 9 600698 000699 889 LOC hoe 612698 662698 262698 20t698 22698 x bl 698 16698 vay Fi dx 7 1 MM X KAS See f Nez GET Z 5 gt ea afin Q N pou m ge 056199 196298 606198 Bs 062698 692698 282698 122198 0 698 160798 154619 L11998 PIET ER i RG PS ES AZ Ve SE DAN VIETA L KLAN TI ST A IT oa 5 KAKASZ S STRESS Sl 4 086438 A 18269 11069 LAE NEPI X P SANS dp a A E TL 62698 142698 8 2698 962698 r 6017 S6z698 0112 8 6012 262698 109698 Lovie 867698 861721 203282 Pistol Grip Models Only 869289 869511 869279 867980 1 SQ DR ANVIL gt
4. 69297 869298 619751 869275 863097 PARTS LIST MOTOR UNIT PART NO NAME OF PART PART NO NAME OF PART 619751 O ring 2 13 16 X 3 869294 2110 Cylinder 863097 Rotor Bearing 869295 2109 Cylinder 864117 Alignment Pin 869297 2109 Bearing Plate 869275 Rotor Shaft Seal 869298 2110 Bearing Plate 869280 Rotor Blade 869299 Rotor 869281 Motor Clamp Seal 867998 203282 J Outside Trigger 869271 865006 Inside Trigger 869270 832125 ALIGN WITH CYL SLOT 867801 864387 844303 844320 Di 843656 A 869269 lt 619016 Ss dem Q 864973 Ay 869268 867977 0900 867974 844301 869286 Outside Trigger Oniy 864975 PARTS LIST SPADE HANDLES AND MOTOR HOUSING PART NO NAME OF PART PART NO NAME OF PART 867977 Throttle Valve Seal 867998 nside Trigger 869000 Outside Trigger 869004 Muffler Plate 869009 Trigger Stop Pin 869266 Motor Housing incl 863637 869004 869268 869269 869268 Retainer Screw 869269 Wear Plate 869270 nside Trigger Handle incl 864975 869271 Outside Trigger Handle incl 864975 869276 Reversing Valve 869283 nlet Bushing 869286 Throttle Pin 869293 Gasket 203282 Washer 619016 Retainer Ring 832125 Trigger Pin 842656 Inlet Screen 844301 O ring 1 8 X 1 4 844303 O ring 3 16 X 5 16 844312 O ring 5 8 X 13 16 844320 O ring 1 1 16 X 1 5 16 863637 Wear Plate Pin 864387 10W Oil Fill Plug 864973 Throttle Valve Sprin
5. A 8 O a 69278 Length A 1 869301 N i 869508 3 Ext urma ass 1 xt b 4 1 a 869011 x 869292 x M N x N a 6 1 5 8 SPLINE DRIVE ANVIL Ria Incl Anvil 4 Socket Retainer Parts 869302 861775 861805 869532 6 Ea 861806 j 869012 203282 Washer 869277 Cam Roller Shaft 842290 Support Handle 869278 Cam Roller 861721 Anvil Housing incl 869273 869289 869511 869279 Timing Pin 861775 5 1 5 8 Std Spline Drive Anvil incl 867949 867950 869282 Hammer Spring 867951 869302 869288 Housing Bolt 861805 5 1 5 8 3 Ext Spline Drive Anvil incl 867949 869289 Anvil Housing Seal 867950 867951 869531 869290 Anvil Pin 861806 5 1 5 8 6 Ext Spline Drive Anvil incl 867949 869292 Cam Shaft 867950 867951 869532 869296 Cam 865022 Support Handle Bracket 869301 1 Sq Dr Anvil Std 867949 Socket Retainer Spring 869302 5 1 5 8 Spline Drive Anvil Std 867950 Socket Retainer Plunger 869303 Hammer 867951 Socket Retainer Pin 869508 1 Sq Dr Anvil 3 Ext 867980 Shock Absorber 869509 1 Sq Dr Anvil 6 Ext 869011 Butt Plate 869511 Retainer Ring 869012 Insulator 869531 5 1 5 8 Spline Drive Anvil 3 Ext 869273 Anvil Bushing 869532 5 1 5 8 Spline Drive Anvil 6 Ext 869274 Spring Clip B69281 863097 869275 Model No Part No 2109 869297 2110 869298 Model No Part No 869295 869294 Model No Part No 869280 8
6. bute to the sound level experienced by the operator Proper hearing conservation measures including annual audiograms and training in the use and fit of hearing protection devices may be necessary For additional information on hearing protection refer to Federal OSHA Regulations 29 CFR Section 1910 95 Occupational Noise Exposure and American National Stan dards Institute ANSI S12 6 Hearing Protectors Gloves and other protective clothing should be worn as required unless they create a greater hazard Do not wear loose fitting clothing or clothing that may restrict movement become entangled or in any way interfere with the safe operation of the impact Cleco impact wrenches are designed to operate on 90 psig 6 2 bar maximum air pressure If the tool is properly sized and applied higher air pressure is unnecessary Excessive air pressure increases the loads and stresses on the tool paris sockets and fasteners and may result in breakage Installation of a filter regulator lubricator in the air supply line ahead of the tool is highly recommended Before the tool is connected to the air supply check the throttle for proper operation i e throttle moves freely and returns to closed position Being careful not endanger adjacent person nel clear air hose of accumulated dust and moisture Before removing a tool from service or changing sockets make sure the air line is shut off and drained of air This will prevent the tool
7. can be ordered as a subassembly using the part number listed below 861808 e COOPER Tools CooperTools 670 Industrial Drive Lexington SC 29072 Phone 803 359 1200 Fax 803 359 2013 www cooperindustries com
8. d be stored in a clean and dry environment GENERAL ALL MODELS Disconnect the tool from the air supply and unscrew and remove the four 4 nuts No 865006 then remove the handle assembly gasket No 869293 and the motor clamp seal No 869281 from the rear of the motor unit Drive the four 4 housing bolts No 869288 outthe front of the motor unit Removing the anvil housing No 861721 will allow the complete impacting mechanism to slip out the front of the motor unit The impact wrench is now separated into four 4 basic assemblies See the following paragraphs for commplete disassembly instructions on these assemblies ANVIL HOUSING For better performance it is recommended that the anvil housing seal No 869289 be replaced during each repair The seal may be removed by prying it out with a screwdriver after removing retainer ring No 869511 Shouldthe anvil housing bushing No 869273 need replac ing the housing seal will have to be removed as outlined above Press the housing bushing out the rear of the housing using a suitable bushing driver IMPACT MECHANISM Clampthe hammer No 869303 horizontally in a softjawed vise and drive the anvil away from the hammer using a soft hammer This will allow the anvil pin No 869290 spring clip No 869274 hammer spring No 869282 to be re moved from the front of the cam shaft No 869292 Remove the hammer from the vise and slip the cam shaft and related component
9. e All tools and hoses should be installed by trained compe tent personnel Hoses and fittings should be inspected regularly for worn or damaged areas and replaced if neces sary LUBRICATION An automatic in line filter lubricator is recommended as it increases tool fif e and keeps the tool in sustained opera tion The in line lubricator should be regularly checked and filled with agood grade of 1 OW machine oil Proper adjustment of the in line lubricator is performed by placing a sheet of paper next to the exhaust ports and holding the throttle open approximately 30 seconds The lubricator is properly set when a light stain of oil collects on the paper Excessive amounts of oil should be avoided In the event an in line lubricator is not used the oil reservoir in the handle should be utilized The oil reservoir marked 30W oil should not require attention until thetool istorn down for inspection purposes however if the tool is on the application for an unduly long period of time the plug should be removed and the reservoir checked for the presence of oil If oil is required approxi mately 1 1 4 fluid ounces 40ml of 30W oil should be added to the oil reservoir MAINTINANCE DISASSEMBLY STORAGE Inthe event that it becomes necessary to store the tool for an extended period of time overnight weekend etc it should receive a generous amount of lubrication atthat time and again when returned to service The tool shoul
10. er substitute wire nails or welding rods for retaining pins because they are dangerous if thrown from the tool at free speed or if the protruding nail or wire is accidently grasped by the operator A WARNING Repetitive work motions and or vibration may cause injury to hands and arms Use minimum hand grip force consistent with proper control and safe operation Keep body and hands warm and dry Avoid anything that inhibits blood circulation Avoid continuous vibration exposure Keep wrists straight Avoid repeated bending of wrists and hands Some individuals may be susceptible to disorders of the hands and arms when performing tasks consisting of highly repetitive motions and or exposure to extended vibration Cumulative trauma disorders such as carpal tunnel syndrome and tendoni tis may be caused or aggravated by repetitious forceful exer tions of the hands and arms Vibration may contribute to a condition called Raynaud s Syndrome These disorders de velop gradually over periods of weeks months and years It is eee SafetyRecommendations presently unknown to what extent exposure to vibrations or repetitive motions may contribute to the disorders Hereditary factors vasculatory or circulatory problems exposure to cold and dampness diet smoking and work practices are thought to contribute to the conditions Tool operators should be aware of the following warning signs and symptoms so that a problem can be addr
11. essed before it becomes a debilitating injury Any user suffering prolonged symptoms of tingling numbness blanching of fingers clumsi ness or weakened grip nocturnal pain in the hand or any other disorder of the shoulders arms wrists or fingers is advised to consult a physician If itis determined that the symptoms are job related or aggravated by movements and postures dictated by the job design it may be necessary for the employer to take steps to prevent further occurrences These steps might in clude but are not limited to repositioning the workpiece or redesigning the workstation reassigning workers to other jobs rotating jobs changing work pace and or changing the type of tool used so as to minimize stress on the operator Some tasks may require more than one type of tool to obtain the optimum operator tool task relationship BAD POSTURE We 7 fe 6 7 d GOOD POSTURE Tasks should be performed in such a manner that the wrists are maintained in a neutral position which is not flexed hyperextended or turned side to side Stressful postures should be avoided Select a tool appropriate for the job and work location The following suggestions will help reduce or moderate the effects of repetitive work motions and or extended vibration exposure Use a minimum hand grip force consistent with proper control and safe operation Keep body and hands warm and dry Avoid anything that inhibits blood circulation
12. g 864975 Throttle Pin Bushing 865006 Nut 867801 30W Oil Fill Plug 867974 Throttle Valve i N i ii dA Ad 2A ck c c mm ck dimmi Denotes parts not included in subassemblies listed below The complete spade handle can be ordered as a subassembly using the part numbers listed below Outside Trigger 861723 Inside Trigger 861724 ALIGN WITH CYL SLOT SA 869285 617288 uU P N 5 844312 412775 aie a N 864972 a c 27 I 9 y 869291 844310 EP 2 Sf 863009 863072 N 867977 E N 867974 843590 869287 N 832211 844303 864387 d PARTS LIST PISTOL GRIP MOTOR HOUSING PART NO NAME OF PART PART NO NAME OF PART 412775 Air Screen 865006 Nut 617288 Air Screen Retainer Ring 867801 Oil Fill Plug 30W 832211 Throttle Pin Bushing 867974 Throttle Valve 842320 Pin 867977 Throttle Valve Seal 843590 Oiler Bushing 869265 Backcap incl 867801 844303 O ring 3 16 X 5 16 869285 Reversing Valve 844310 O ring 1 2 X 11 16 869287 Throttle Rod 844312 O ring 5 8 X 13 16 869291 Muffler 847688 Muffler Screw 869526 Gasket 863009 O ring 3 4 X 7 8 869618 Motor Housing incl 832211 843590 863072 Throttle Valve Spring 869619 Trigger 864387 Oiler Plug 10W 864972 Inlet Bushing EA mk EE mk mE mA mb ck dx Denotes parts not included in subassemblies listed below The complete pistol grip motor housing
13. on the roller shaft and slip the butt plate No 86901 1 insulator No 869012 and shock absorber No 867980 onto the rear of the cam shaft Hold the cam shaft vertically on the work bench with the shock absorber down and tap the end of the cam shaft with a soft mallet to seat the cam shaft in the shock absorber Slipthe camshaft and related components through the cam and hammer assembly Install the hammer spring No 869282 spring clip No 869274 and anvil pin No 869290 onto the front of the cam shaft and hammer assembly Rotate the spring clip to accept the anvil pin and then install the anvil on top of the assembly be sure the slot in the anvil lines up with the anvil pin and drive the anvil down until the spring clip engages the recess in the anvil To install the socket retainer pin No 867951 in the spline drive anvil insert socket retainer spring No 867949 and Socket retainer plunger No 867950 into the anvil and then drive the socket retainer pin radially into the plunger ANVIL HOUSING When replacing the anvil housing seal No 869289 the housing bore should be cleaned with a solvent and then coated with PERMATEX Aviation Form A Gasket No 3H and then be allowedto air dry atleast four 4 minutes before of the cam shaft Hold the cam shaft vertically on the work bench with the shock absorber down and tap the end of the cam shaft with a soft mallet to seat the cam shaft in the shock absorber Slipthe cam
14. pe Operation amp Service Manual COOPER Tools 823035 2 01 Cleco W2109 amp W2110 SERIES IMPACTS Impact Wrench Optional Equipment 6E 6 Extended Spindle 3E 3 Extended Spindle Output Drive 8 1 Handle P Pistol Grip T Inside Trigger Outside Trigger Spline Drive No 5 Spline Tool Size 2109 2110 Tool Generation Concept B Second NORTH AMERICA EUROPE CooperTools Cooper Power Tools GmbH amp Co P O Box 1410 Postfach 30 Lexington SC 29071 D 73461 Westhausen SafetyRecommendations For your safety and the safety of others read and understand the safety recommendations before operating an impact wrench Always wear protective equipment and clothing A WARNING Impact resistant eye protection must be worn while operating or working near this tool For additional information on eye protection refer to Federal OSHA Regulations 29 CFR Section 1910 133 Eye and Face Protection and ANSI Z87 1 Occupational and Educational Eye and Face Protection This standard is available from the Ameri can National Standards Institute Inc 11 West 42nd Street New York NY 10036 A CAUTION Personal hearing protection is recommended when operating or working near this tool Hearing protection is recommended in high noise areas above 85 dBA Close proximity of additional tools reflective surfaces process noises and resonant structures can substantially con tri
15. rant or require additional procedures Your work may require additional specific safety procedures Follow these procedures as required by your company Warnings The warnings found on these tools are an essential part of the product Warnings should be checked periodically for ligibility Replace warnings when missing or when the information can no longer be read Replacements can be ordered as any spare part 869976 For more information see the latest edition of ANSI B186 1 Safety Code for Portable Air Tools available from the American National Standards Institute Inc 11 West 42nd Street New York NY 10036 These operating instructions and service manual should accompany tool if it is subsequently sold or ownership is changed GENERAL INFORMATION AIR SUPPLY Thetool isdesigned to operate on 90 psig 6 2 bar airpressure measured at the tool air inlet with the tool running using a 1 2 12 7mm hose up to 8 2 4m in length An automatic in line filter lubricator is highly recommended to supply the tool with cleanlubricated air This will keepthe tool in sus tained operation and increase its service life The air hose should be cleared of accumulated dirt and moisture then one 1 teaspoon 5ml of 1 OW machine oil should be poured into the tool s air inlet before connection the hose to the tool IMPORTANT If a puick disconnect coupling is used with thetool itshould be separated from the tool by a whip hos
16. s out of the rear of the cam No 869296 Remove the shock absorber No 867980 slight press fit from the rear of the cam shaft This will allow the insulator No 869012 butt plate No 86901 1 cam roller No 869278 and cam roller shaft No 869277 to be removed from the cam shaft Slip the cam No 869296 out of the rear of the hammer being careful not to lose the timing pin No 869279 NOTE Onthe spline drive anvils should any of the socket retainer parts need replacing a 5 32 4mm hole should be drilled in the socket retainer plunger No 867950 as shown in Figure 3 Insert a pin punch in the drilled hole and lightly tap the punch under the socket retainer pin No 867951 Pry on the punch to pop the pin out of its pocket in the plunger 5 32 DRILL Figure 3 MOTOR UNIT Remove the motor unit from the rear of the housing and disassemble for inspection of parts HANDLE ASSEMBLIES For inspection of the throttle valve seal No 867977 un screw the inlet bushing This will allow the removal of the complete throttling mechanism Ifthe throttle pin bushing should need replacing tap the I D of the bushing with a 114 20 6m thread tap Insert a 1 4 20 6mm bolt of the appropriate length and clamp the bolt in the vise Drive the handle away from the vise using a soft mallet MAINTENANCE REASSEMBLY CLEANING AND INSPECTION All oar s should be cleaned in a solvent and inspected for wear or darnage If rotor blades mea
17. sary Cleanthe threads in the handle arid on the inlet bushing and apply Locktite No 271 to the threads Torque the bushing to 80 ft Ibs 109Nm minimum MOTOR UNIT During assembly of the bearing plates the rotor shaft seals No 869275 should be pressed into the bearing plates with their lips facing outward visible after assembly Pressing on the OUter race install the rotor bearings No 863097 into the bearing plate Lubricate both the bearings arid seals with 30W oil and install the rotor No 869299 with the end stamped i rear into one of the bearing plate assemblies both bearing plates are identical Insert the six 6 rotor blades into the blade slots and place the cylinder on the assembly with the airinletholes down Assemble the other bearing plate onthe front of the rotor and install 0 ring No 619751 on this bearing plate Lubricate this C ring and the two 2 0 rings No 844312 in the motor bore Place the motor unit on flat surface front end up and slide the motor housing down overthe motor unit with the alignment pin No 864117 in place IMPACT MECHANISM All parts should receive a thin coating of 30W oil before assembly Insert the timing pin No 869279 into the recess located on the small O D of the cam No 869296 and then install the cam and pin into the rear of the hamr ner No 869303 Installthe cam roller shaft No 869277 inthe cam shaft No 869292 Put the cam roller No 869278
18. shaftandrelated components through the cam and hammer assembly Install the hammer spring No 869282 spring clip No 869274 andanvil pin No 869290 onto the front of the cam shaft and hammer assembly Rotate the spring clip to accept the anvil pin and then install the anvil on top of the assembly be sure the slotin the anvil lines up with the anvil pin and drive the anvil down until the spring clip engages the recess in the anvil To install the socket retainer pin No 867951 in the spline drive anvil insert socket retainer spring No 867949 and socket retainer plunger No 867950 into the anvil andthen drive the socket retainer pin radially into the plunger ANVIL HOUSING When replacing the anvil housing seal No 869289 the housing bore should be cleaned with a solvent and then coated with PERMATEX Aviation Form A Gasket No 3H and then be allowedto air dry atleast four 4 minutes before pressing inthe seal Press the sealin with its lip toward the bore of the housing Lip should not be visible after assembly GENERAL ALL MODELS Coatthe impact mechanism with 30W oil and insert into the rotor Lubricate the anvil housing seal bushing and front bearing plate C ring with 30W oil and install the anvil housing Install the dead handle housing bolts motor clamp seal gasket and handle or back cap depending on model NOTE Upper cut out on the gasket aligns with the cylinder slot Install the four 4 nuts No 86500
19. sure less than 11 32 8 73mr n on either end they should be replaced Rotor bearings should be replaced if they feel rough after cleaning orshow excessive looseness Rotor shaft seals No 869275 should be replaced if they are badly worn or are no longer flexible HANDLE ASSEMBLIES A Spade Handles VVInen installing the trigger use a pin slightly smaller Ihan the hole in the handle to loCate the trigger when driving the trigger pin No 832125 into the handle If the throttle pin bushing No 864975 was removed the new bushing should be pressed in to a depth of 1 5 8 4 1 28mm from the bottom face of the handle Inspect the throttle valve seal No 867977 for wear or deterioration If replacement is necessary he new seal should be pushed cupped face first on the throttle valve No 867974 from the taPered end The inlet bUshing No 869283 should be torqued to 150 ft lbs 204Nm rninimurn B Pistol Grip Handle It the throttle pin bushing No 832211 was removed the new bushing ShOLM be pressed in to a depth of 1 151 16 49 2 1 mr n from the bottom face of the handle and the D of the bushing sized to 1880 1887 dia 4 775mm 4 793mm after installation Inspect the throttle valve seal No 867977 for wear or deterioration If replacement is necessary the new seal should be pushed cupped face first on the throttle valve No 867974 from the tapered end Inspect the C ring No 863009 and replace if neces
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