04584348
Edition 2
April 2006
Air Impact Wrench
2925Ti Series
Maintenance Information
Save These Instructions
3. Hold the Hammer Frame firmly and, without disturbing
the Hammers, gently lift the Anvil, simultaneously rotating
it clockwise about 1/8 of a turn, from Hammer Frame.
4. With Anvil removed, lift out the two Hammer Pins.
2. Remove the Backcap, Motor Clamp Washer (21) and
Backcap Gasket from the Housing and set them aside on
a clean bench. Discard the Backcap Gasket and replace
it with a new one when assembling the tool.
3. Lift the Housing from the Hammer Case. Place one hand
over the rear of the Housing and turn the Housing over so
that the assembled motor can slide and be guide out of
the Housing.
4. Place the assembled motor on a clean bench with the
rotor spline facing upward.
5. Remove the Front End Plate (29) and Cylinder (27).
6. Remove the Rotor (25) from Rear End Plate (23).
7. Remove the Vanes from the Rotor.
NOTICE
The twin Hammers are now free to slide from the
Hammer Frame. Be careful not to drop them.
Disassembly of the Reverse Valve
1. Remove the four Backcap Bolts (14)
2. Lift the Backcap off of the rear of the Housing.
3. Discard the Backcap Gasket (15) and replace it with a
new one when assembling the tool.
4. Use a hooked tool to remove the Reverse Valve (32) from
the reverse valve bushing. Set the Reverse Valve aside
on a clean bench.
8. Inspect all motor parts including the Front Rotor
Bearing (30) and Rear Rotor Bearing (22) and replace all
worn or damaged parts.
Disassembly of the Throttle Mechanism
5. Remove and discard the Reverse Valve O-ring (31).
Replace it with a new one when assembling Reverse Valve.
6. Use a flat, thin blade screwdriver to remove the Reverse
Lever Retaining Ring (19) and Reverse Lever Spring (20)
from the Reverse Lever (18).
1. Unscrew and remove the Air Inlet Bushing (18).
2. Remove the Screen (7), Throttle Valve Spring (6) and
Throttle Valve (5).
3. If the Throttle Valve Seat (2) requires replacement, insert
a hooked tool through the center of the Valve Seat.
Catching the backside of the Seat with the hook, pull the
Seat from the Housing.
4. Withdraw the Trigger Assembly (3) from Housing.
5. Remove the Retaining Ring (11), Exhaust Deflector (12)
and Muffler Element (10) from the Housing.
7. Remove the Reverse Lever from the Backcap.
Disassembly of the Motor
1. Remove the four Backcap Bolts.
Assembly
4. As an alternate assembly procedure, drop the Throttle
Valve, long stem first, into the inlet passage. If the throttle
Valve does not sit squarely on the Throttle valve Seat,
shake the Handle until it seats.
5. Install the Throttle Valve Spring (6), small end first, with
the inside diameter of the small first coil around the hub
of the Throttle Valve.
6. Coat the Inlet Bushing O-ring (9) with O-ring lubricant and
install it on the Inlet Bushing (8).
7. Screw the Inlet bushing into the Housing until snug and
tighten to 50-55 ft. lbs. (68-75 Nm) torque.
General Instructions
1. Always press on the inner ring of a ball-type bearing
when installing the bearing on a shaft.
2. Always press on the outer ring of a ball-type bearing
when pressing the bearing into a bearing recess.
3. Whenever grasping a tool or part in a vise, always use
leather-covered or copper-covered vise jaws. Take extra
care with threaded parts or housings.
4. Always clean every part and wipe every part with a thin
film of oil before installation.
5. Apply a film of O-ring lubricant to all O-rings before final
assembly.
6. Check every bearing for roughness. Sealed or shielded
bearings should never be cleaned. Work grease
thoroughly into every open bearing before installation.
8. Wipe the stem of the Trigger Assembly (3) with light
grease and insert the stem of the Trigger into the trigger
bore in the Housing until it snaps into place on the
Throttle Valve.
Assembly of the Motor
Assembly of the Throttle Mechanism
1. Pack the Front Rotor Bearing (30) and Rear Rotor
Bearing (22) with the recommended grease. Install the
Front Rotor Bearing in the Front End Plate (29) and the ar
Rotor Bearing in the Rear End Plate (23).
2. Slide the assembled Rear End Plate and Rear Rotor
Bearing on the hub of the Rotor (25).
3. Set the assembled Rear End Plate and Rotor on a clean
surface with the spline of the Rotor pointing upward.
4. Insert the Vanes (26) in the vane slots on the Rotor.
5. Install the Front and Rear Cylinder Dowels (28) in the
Cylinder (27).
1. Install a new Throttle Valve Seat (2) by pushing it into
position in the Housing (1) with a 13/16” dowel.
2. Insert the short end of the stem of the Throttle Valve (5)
into the jaws of an expanding-type mechanical pencil.
Allow the jaws to retract around stem to secure it.
3. Install the Throttle Valve on the Valve Seat.
See Dwg. TPD1919.
6. Slide the Cylinder over the Rotor and Vanes making sure
that the Rear Cylinder Dowel enters the notch in the
outside diameter of the Rear End Plate.
For Series 2925RBP1Ti and 2925RBP3Ti: Assemble
Cylinder with exhaust ports to LEFT of top dead center
(11 o’clock position). See Dwg. TPD1921.
(Dwg. TPD1919)
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ALIGN REVERSE VALVE
TIMING MARK WITH
MARK ON REVERSE
VALVE BUSHING LO-
CATED IN HOUSING
REVERSE LEVER IN
FORWARD POSITION
(Dwg. TPD1913)
(Dwg. TPD1921)
NOTICE
NOTICE
The Reverse Valve must be installed and indexed with
the bushing as directed in Step 2 and Dwg. TPD1913.
Failure to do so will cause improper operation of the
Reverse Valve.
If more power is needed for forward operation than for
reverse operation, install the Cylinder with exhaust ports
to the RIGHT of top dead center (1 o’clock position).
7. Install the assembled Front End Plate and Bearing over
the front, splined end of the Rotor making sure that the
front Cylinder Dowel fits into the notch in the outside
diameter of the Front End Plate.
8. Grasp the Housing with one hand and set it upside down
on its top. With the other hand, carefully guide the motor
assembly into the Housing, making sure that the side of
the motor assembly containing the Cylinder Dowels is
oriented to the top of the Housing. Install Locating Pin (24)
into Housing and End Plate. See Dwg. TPD1920-1.
3. Insert the Reverse Lever (18) through the rear of the
Backcap (16).
4. Slide the Reverse Lever Spring (20) over the shaft of the
Reverse Lever and secure the Spring and Reverse Lever
by installing the Reverse Lever Snap Ring (19) in the
groove in the shaft of the Reverse Lever. Rotate the
Reverse Lever so that it is pointing to the symbol for
FORWARD (clockwise) operation. See Dwg. TPD1913.
Assembly of the Impact Mechanism
NOTICE
To ensure proper Reverse Valve operation, the Reverse
Lever must stay in this position when installing the
Backcap and Reverse Valve.
TOP HAMMER HALF–ROUND
NOTCH ON RIGHT
TOP HAMMER
WIDE BEVEL UP
(Dwg. TPD1920-1)
Assembly of the Reverse Valve
1. Coat a new Reverse Valve O-ring (31) with O-ring
lubricant and install it in the groove on the Reverse
Valve (32).
2. Install the Reverse Valve in the reverse valve bushing
with the slotted end trailing, making sure that the index
mark on the Reverse Valve is aligned with the index mark
on the Bushing. See Dwg. TPD1913.
BOTTOM HAMMER
HALF–ROUND
NOTCH ON LEFT
BOTTOM HAMMER
WIDE BEVEL DOWN
(Dwg. TPD652)
1. Coat the Hammers (35) with a light film of
Ingersoll Rand No. 170 Grease.
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2. Replace the Hammers in the Hammer Frame (34) exactly
as they were when you marked them prior to
disassembly.
Assembly of the Tool
1. Wipe a thin film of the recommended grease on the inside
of the Hammer Case Bushing (38) and insert the
assembled impact mechanism into Hammer Case (39).
2. Secure the Hammer Case and impact mechanism by the
anvil (square drive) end in leather-covered or copper-
covered vise jaws. See Dwg. TPD1918.
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. These Hammers must be installed with the
wide bevels facing the web of the Hammer Frame as
illustrated.
3. Replace the Hammer Pins (36).
4. Examine the base of the Anvil (40, 42 or 48) 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.
Assembly of the Square Drive Anvil and Spline
Drive Anvil
1. Place the Hammer Frame Washer (33), hub side first,
over the hub of the Rotor and against the Front Rotor
Bearing.
(Dwg. TPD1918)
2. Set the assembled impact mechanism down over the
splined hub of the Rotor. If the impact mechanism was
disassembled, refer to Assembly of Impact Mechanism.
3. Position the new Hammer Case Gasket (37) on Housing.
4. Work approximately 12 to 15 cc of Ingersoll Rand
No. 170 Grease into the impact mechanism.
5. Smear a thin film of Ingersoll Rand No. 170 Grease on
the inside surface of the Hammer Case Bushing (38) and
place the Hammer Case (39) down over the Anvil and
against the Motor Retainer.
3. Install a new Hammer Case Gasket (37) on the Hammer
Case making sure that the holes in the gasket align with
the holes in the Hammer Case.
NOTICE
When installing optional Hanger Kit, place Gasket on the
Hammer Case followed by the Hanger.
6. Install the Backcap Bolts and tighten them to 10 to 12 ft-lb
(13 to 16 Nm) torque.
7. Remove the Impactool from the vise and inject 2 to 4 cc
of Ingersoll Rand No. 170 Grease into the Grease
Fitting (17).
4. Wipe a small amount of the recommended grease on the
flat side of the Hammer Frame Washer (33) and place it
on the splined face of the Hammer Frame (34) with the
hub end of the washer pointing up.
NOTICE
Assembly of the Quick-Change Anvil
When installing optional Hanger Kit, place additional
washer provided between the Hammer Frame and
Hammer Frame Washer.
1. Place the Hammer Frame Washer (33), hub side first,
over the hub of the Rotor and against the Front Rotor
Bearing.
2. Set the assembled impact mechanism down over the
splined hub of the Rotor. If the impact mechanism was
disassembled, refer to Assembly of Impact Mechanism.
3. Position the new Hammer Case Gasket (37) on Housing.
4. Work approximately 12 to 15 cc of Ingersoll Rand
No. 170 Grease into the impact mechanism.
5. Smear a thin film of Ingersoll Rand No. 170 Grease on
the inside surface of the Hammer Case Bushing (38) and
place the Hammer Case (39) down over the Anvil and
against the Motor Retainer.
6. Install the Backcap Bolts (14) and tighten them to
10 to 12 ft-lb (13 to 16 Nm) torque.
7. Reinstall the rear Thrust Ring Lock (44) on the Quick
Change Anvil.
8. Place a dab of grease into the hole in the Quick Change
Anvil (42) to temporarily hold the Retaining Ball (47).
9. Slide the Retaining Sleeve (43), Retaining
Sleeve Spring (46), Thrust Ring (45), and front Thrust
Ring Lock (44) onto the Anvil.
10. Remove the Impactool from the vise and inject 2 to 4 cc
of Ingersoll Rand No. 170 Grease into the Grease
Fitting (17).
5. Set the fully assembled Motor Housing over the opening
in the Hammer Case. Insert the spline drive of the Rotor
into the splined hole of the impact mechanism. Make sure
of the wide section of the Hammer Case is just above the
Trigger.
6. Place a new Backcap Gasket (15) over the rear of the
Housing making sure that the holes in the Gasket align
with the holes in the Housing and that the profile of the
Gaskets matches the profile of Housing.
7. Place a Motor Clamp Washer (21) over the rear of the
motor with the convex side up and matching the large
outside diameter of the Rear End Plate.
8. Place the Backcap (16) over the back of the Housing
making sure that the Reverse Valve Lever (18) is in the
full-forward (clockwise) position with the lugs in the Lever
engaging the slots in the Reverse Valve. Make sure that
the index mark on the Reverse Valve lines up with the
index mark on the reverse valve bushing.
9. Install the four Backcap Bolts and tighten to 10-12 ft-lbs
(13-16 Nm) torque.
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Troubleshooting Guide
Trouble
Probable Cause
Solution
Dirty Inlet Bushing or Air Strainer
Screen and/or Exhaust Silencer
Using a suitable cleaning solution, in a well ventilated area, clean Air
Strainer Screen, Inlet Bushing and Exhaust Silencer.
Worn or broken Vanes
Replace the complete set of Vanes.
Low power
Worn or broken Cylinder and/or
scored End Plates
Examine the Cylinder and replace it if it is worn or broken or if the bore is
scored or wavy. Replace the End Plates if they are scored.
Disassemble tool and clean all parts with a suitable cleaning solution, in a
well-ventilated area. Reassemble tool as instructed in this manual.
Dirty motor parts.
Improper positioning of the
Reverse Valve Lever or Reverse
Valve
Make certain that the Reverse Valve Lever is in the reverse position or one
of the three forward positions. If the tool has been disassembled, refer to
Dwg. TPD1913 for proper Reverse Valve and Reverse Lever orientation.
Motor will
not run
Disassemble the motor, replace worn or broken parts and reassemble as
instructed.
Incorrect assembly of the motor.
Insufficient lubricant in the impact
mechanism
Remove the Hammer Case Assembly and lubricate the impact
mechanism.
Tool will
not impact
Broken or worn impact
mechanism parts
Remove the Hammer Case and examine the 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:
Safety Information Manual 04580916.
Product Information Manuals 16573206.
Parts List Manuals 04584561.
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Notes
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