W2119 & W2120 SERIES IMPACTS
Contents
1. Figure 4 GENERAL ALL MODELS Coat the hammer and rotor splines with 30W oil and insert the impact mechanism into the front of the rotor Lubricate the anvil housing seal and bushing with 30W oil andinstall on the unit being sure the contour of the anvil housing matches that of the motor housing The anvil and hammer lugs should be in line with the recess in the make up lip located in the anvil housing Install the dead handle bracket No 867990 on the left side of the tool and insert the four 4 housing bolts Tap the bolts with a hammer until the anvil housing seats against the motor housing Clarnp the tool vertically ina vise and install the gasket Insert 0 ring No 847981 into the reversing valve bore and install the reversing valve No 869008 Apply a thin coat of grease to the motor clamp seal No 869001 and place it into the handle recess Put the handle on the tool and install the four 4 nuts No 865006 Torque these nuts to 20 ft lbs minimum Lay the tool on its right side and remove the 30W oil fill plug No 867801 Fill the reservoir with a good grade of 30W oil up to the level of the fill indicator pin located in the reservoir approximately 1 1 1 4 fluid Ounces Place a couple of teaspoons of 10W machine oil in the air inlet bushing before attaching the air hose to ensure imme diate lubrication of all motor parts SAFETY CHECK Alltools should be tested after repair or replacement of parts to assure that2. 861863 gi COOPER Tools CooperTools 670 Industrial Drive Lexington SC 29072 Phone 803 359 1200 Fax 803 359 2013 www cooperindustries com
3. air supply and unscrew and remove the four 4 nuts No 865006 then remove the handle assembly reversing valve No 869008 gasket and the motor clamp seal No 869001 from the rear of the motor unit Drive the four 4 housing bolts No 869066 outthe front of the motor unit Removingthe anvil housing No 861605 will allow the complete impacting mechanism to slip out the front of the motor unit The anvil housing may need to be rotated to clear the anvil and hammer lugs 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 867993 be replaced during each repair The seal may beremoved by prying it out with a screwdriver Shouldthe anvil housing bushing No 861602 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 bushing driver 2 3 16 in diameter IMPACT MECHANISM Clamp the hammer No 867969 horizontally in a softjawed vise and drive the anvil away from the hammer using a soft hammer This will allow the anvil pin No 867994 spring clip No 867964 and hammer spring No 867984 to be removed from the front of the cam shaft No 867973 Remove the hammer from the vise and slip the cam shaft and related components out of the rear of the cam No 867
4. 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 difficult to release an outside trigger Inside trigger or pistol grip tools are advised for close quarter operation Outside Trigger Pistol Grip Rev Rev Ten D GW 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 Never substitute wire nails or welding rods for retaining pins because they are dangerous if
5. 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 warrant or require additional procedures Your work may require additional specific safety
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7. 12 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 malletto seat the cam shaftin the shock absorber Slip the cam shaft and related components through the cam and hammer assembly Install the hammer spring No 867984 spring clip No 867964 and anvil pin No 867994 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 If the anvil housing bushing No 861602 is replaced it should be pressed in as shown in Fig 4 When replacing the anvil housing sea No 867993 the housing bore should be cleaned with a solvent and then coated with PERMATEX Aviation Form A Gasket No 3H and then be allowed to air dry at least four 4 minutes before pressing in the seal Press the seal in with its lip toward the bore of the housing Lip should not be visible after assem bly p lt PRESS ON THIS O D ONLY SN gt
8. 991 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 869011 cam roller No 869278 andcamroller shaft No867979 to be removed from the cam shaft Slip the cam No 867991 out of the rear of the hammer being careful not to lose the timing pin No 867966 NOTE On the spline drive anvils should any of the socket retainer parts need replacing a 5 32 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 Figure 3 MOTOR UNIT Set the front of the housing No 869744 on a cylinder 4 112 I D x 5 long and using a suitable driver 2 1 8 O D drive the rotor out of the rear rotor bearing No 867995 This will remove the front bearing plate No 867985 six 6 rotor blades No 867975 and rotor from the housing Invert the housing on the fixture and use the rotor to drive the rear bearing plate assembly from the housing The cylinder should not be removed from the housing unless replace mentis necessary If cylinder replacementis necessary a 4 5 32 O D bushing driver with a suitable relief for the alignment key No 867981 should be used to press the cylinder out of the housing Remove the rotor bearings No 867
9. 995 from the bearing plates for inspection For better performance it is recom mended that the rotor shaft seals No 867996 be replaced during each repair NOTE UNLESS THE 0 RINGS NO 844309 LOCATED ON THE O D OF THE BEARING PLATE ARE SEVERELY DAMAGED THEY SHOULD NOT BE REMOVED IF RE PLACEMENT ISNECESSARY REPLACEMENT 0 RINGS SHOULD BE INSTALLED WITH AFAST CURE CONTACT ADHESIVE LOCTITE 404 For cleaning and inspection of the three 3 muffler plates No 869004 unscrew the retainer screw No 883695 HANDLE ASSEMBLIES Both the inside and outside trigger handle assemblies are disassembled using the same procedure Unscrewing the air inlet bushing No 864972 will allow the O ring No 863008 air inlet screen No 843656 throttle valve spring No 864973 throttle valve No 867974 throttle valve seal No 867977 and throttle valve pin No 867982 to be removed from the handle If the throttle pin bushing No 864975 should need replac ing tap the I D of the bushing with a 114 20 thread tap Insert a 114 20 bolt of the appropriate length and clamp the bolt in the vise Drive the handle away from the vise using a soft mallet Ifthe trigger should need replacing only the trigger pin solid pin No 832125 need be removed MAINTENANCE REASSEMBLY CLEANING AND INSPECTION All parts should be cleaned in a solvent and inspected for wear or damage If rotor blades measure less than 7116 on either end th
10. GOOPER Tools 823036 Operation amp Service Manual Cleco W2119 amp W2120 SERIES IMPACTS NORTH AME CooperTools Ww xix xxxx x Impact Wrench Handle Output Drive 12 11 2 S Spline Drive No 5 Spline T Inside Trigger Outside Trigger Tool Size 2119 2120 RICA EUROPE Cooper Power Tools GmbH amp Co P O Box 1410 Postfach 30 Lexington SC 29071 D 73461 Westhausen 2 01 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 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 tribute to the sound level experienced by the operator Proper hearing conservation measures incl
11. bearing s outer race Lubricate both the seals and rotor bearings with 30W oil before assembly into the motor unit Inspect the O ring No 863096 and replace if necessary This O ring is used only on the front bearing plate both bearing plates are identical Ifthe cylinder was removed the new cylinder with alignment key No 867981 in place should be pressedinfromthe rear of the motor housing to a depth 5 8 from the rear face of the housing Lubricate the O rings on the O D of the rear bearing plate assembly and press the assembly into the housing When installing either bearing plate assembly be sure the O rings line up with the air ports in the housing Invert the housing and install the rotor with the end stamped REAR into the rear rotor bearing No 867995 Insert the six 6 rotor blades No 867975 then lubricate the O rings on the front bearing plate assembly and press the assembly into the housing NOTE Be sure 0 ring No 863096 is in place on the front bearing plate IMPACT MECHANISM All parts should receive a thin coating of 30W oil before assembly Insertthe timing pin No 867966 into the recess located on the small O D of the cam No 867991 and then install the cam and pin into the rear of the hammer No 867969 Installthe cam roller shaft No 867979 in the cam shaft No 867973 Put the cam roller No 867978 on the roller shaft and slip the butt plate No 86901 1 insulator No 8690
12. er W 2120 867975 Rotor Blade 867981 Alignment Key 867985 Bearing Plate incl 844309 867995 Rotor Bearing 867996 Rotor Shaft Seal 869001 Motor Clamp Seal 869004 Muffler Plate 869596 Rotor 869635 Cylinder W 2119 869744 Housing incl 863637 865004 869004 883695 883695 Retainer Screw ONES E 869000 867998 864972 J 203282 865006 863009 843656 869743 gt 869740 Soo E 864973 86780 St i l W 86 7977 p aa A PS 864387 A 867974 D i S P 867 382 844303 l L 864975 47981 869008 PARTS LIST HANDLES PART NO NAME OF PART PART NO NAME OF PART 203282 Washer 832125 Trigger Pin 843656 Air Inlet Screen 844303 O ring 3 16 X 5 16 847981 O ring 1 3 8 X 1 1 2 863009 O ring 3 4 X 7 8 864387 10W Oil Fill Plug 864972 Air Inlet Bushing 864973 Throttle Valve Spring 864975 Throttle Valve Pin Bushing 865006 Nut 867801 30W Oil Fill Plug 867974 throttle Valve 867977 Throttle Valve Seal 867982 Throttle Valve Pin 567998 Inside Trigger 867999 Gasket 869000 Outside Trigger 869008 Reversing Valve 869009 Trigger Stop Pin 869740 Inside Trigger Handle incl 864975 869743 Outside Trigger Handle incl 864975 nnn N Denotes parts not included in subassemblies listed below The complete handle can be ordered as a subassembly using the part numbers listed below Outside Trigger 861867 Inside Trigger
13. ey should be replaced Rotor bearings should be replaced if they feel rough after cleaning or show exces sive looseness HANDLE ASSEMBLY Wheninstailing the trigger use a pin slightly smaller than the hole in the handle to locate the trigger when driving the trigger pin No 832125 into the handle If the throttle valve bushing No 864975 was removed the new bushing should be pressed into a depth of 1 15 16 plus or minus 1 64 from the bottom face of the handle 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 O ring No 863009 and replace if necessary Clean the threads on the air inlet bushing No 864972 and apply LOCKTITE No 271 to the threads Now install the throttle valve pin No 867982 and throttle valve assembly into the handle Place the inlet air screen No 843656 arid throttle valve spring No 864973 in the air inlet bushing and screw the bushing into the handle The bushing should be torqued to 80 It lbs minimum MOTOR UNIT Insertthe three 3 muffler plates No 869004 and install the retaining screw No 883695 During reassembly of the bearing plates No 867985 the rotor shaft seals No 867996 should be installed with their lips facing out visible after installation When installing the rotor bearings No 867995 press on the
14. ling 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 Coen fe 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 Smoking Tobacco Cold Temperatures Certain Drugs Keep wrists as straight as
15. 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 Thetoolisdesignedtooperate 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 hose All tools and hoses should be installed by trained compe tent personnel Hoses and fi
16. 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 addressed before it becomes a debilitating injury Any user suffering prolonged symptoms of ting
17. ttings 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 a good 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 STORAGE In the event that it becomes necessary to store the tool for an extended period of time overnight weekend etc it shouldreceive a generous amountof lubrication atthat time and again when returned to service The tool should be stored in a clean and dry environment MAINTINANCE DISASSEMBLY GENERAL ALL MODELS Disconnect the tool from the
18. uding 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 parts 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 from operating if the throttle is accidently engaged Never use the air hose for supporting
19. ueH o6zzre 646 98 786498 381 JOH we J8UitU H 816498 696 98 weg Buugeg 1010 166 98 966 98 18881 apisuj 10108 866498 963698 867976 867987 867983 ANVIL HOUSING BUSHING ASSEMBLY 842290 867984 869010 867980 i 867994 869012 aN i 869011 D 3 E 867978 y don i 8679 ze i E E Sd 867950 PARTS LIST IMPACT MECHANISM PART NO NAME OF PART PART NO NAME OF PART 842290 Support Handle 867984 Hammer Spring 861602 Anvil Housing Bushing incl 867976 867983 867987 867987 Thrust Bearing 867988 867988 Thrust Race 861605 Anvil Housing incl 861602 867993 867990 Support Handle Bracket 867949 Socket Retainer Spring 867991 Cam 867950 Socket Retainer Plunger 867993 Anvil Housing Seal 867951 Socket Retainer Pin 867994 Anvil Pin 867964 Spring Clip 869010 1 1 2 Sq Dr Anvil 867966 Timing Pin 869011 Butt Plate 867969 Hammer 869012 Insulator 867970 5 1 5 8 Spline Drive Anvil 869066 Housing Bolt 867973 Cam Shaft 867976 Thrust Race 867978 Cam Roller 867979 Cam Roller Shaft 867980 Shock Absorber 867983 Cushion Eech a a a E al a lk M lt 1 a 869596 S 4 M N N 863096 K gt 869001 Ps 867995 867981 W 2119 869635 W 2120 867971 LEE yc P e 8 Ges zi i be 1 Itc 883695 869004 PARTS LIST MOTOR UNIT PART NO NAME OF PART PART NO NAME OF PART 863096 O ring 3 1 4 X 3 1 2 863637 Wear Plate Pin 865004 Wear Plate 867971 Cylind
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