2 04584058_ed2
Disassembly
General Instructions
1. Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
2. Whenever grasping a tool or part in a vise, always use
leathercovered 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.
3. Do not remove any part which is a press fit in or on a
subassembly unless the removal of that part is necessary for
repairs or replacement.
4. Do not disassemble the tool unless you have a complete set of
new gaskets and O-Rings for replacement.
Disassembly of the Impact Wrench
1. Clamp the handle of the impact wrench in a vise with leather-
covered jaws with the square drive positioned horizontally.
NOTICE
Avoid excessive clamping pressure which can damage the
Housing and can cause difficulty when removing the parts.
2. Unscrew and remove the four Hammer Case Screws (12).
3. While lightly tapping on the end of the Anvil (9) with a plastic
hammer, lift off the Hammer Case (16) and Hammer Case Gasket
(19).
NOTICE
The Front End Plate (2) might come off during the removal of the
Hammer Case. Make sure that it does not drop on the floor or
strike a hard or metallic surface since it might be damaged.
4. Grasp the Hammer Frame (13) and carefully lift off the entire
impact mechanism, making certain not to drop the two Hammer
Pins (14).
Disassembly of the Impact Mechanism
1. Set the mechanism, driver end up, on the workbench.
NOTICE
Note the twin hammers within the Hammer Frame. These are
identical, but must be placed in the Hammer Frame in a certain
relationship. Using a felt-tipped pen, mark the top “
T
↑
“ hammer
and the bottom hammer “
B
↑
” with the arrows pointing upward.
Mark both Hammers on the same end.
2. With the mechanism sitting upright on the workbench, slowly
rotate the Anvil in a clockwise direction until it comes up solid.
NOTICE
If you continue to rotate the Anvil, it will cam the Hammers out
of engagement. Don’t do this; merely rotate the Anvil until it
comes up solid.
3. Hold the Hammer Frame firmly and without disturbing the
hammers, gently lift the Anvil while simultaneously rotating it
clockwise about 1/8 of a turn, from the Hammer Frame.
4. With the Anvil removed, lift out the two Hammer Pins.
NOTICE
The twin hammers are now free to slide from the Hammer Frame.
Be careful do not to drop them.
Disassembly of the Motor
NOTICE
When pulling, disassembling or assembling the motor, we
recommend replacement of the Motor Gasket (8).
1. Remove the Motor Assembly from the Housing (20) by pushing
on Power Management Dial (42) from the back of the Housing.
See Dwg. TPD1322.
Power
Management
Dial
Power
Management
Dial
(Dwg. TPD1322)
NOTICE
If the Motor Assembly cannot be removed from the Housing by
pushing, tap the Power Management Dial lightly until the Motor
Assembly is free.
2. Remove the Power Management Dial from the rear of the
Cylinder (1). Remove the Power Management Dial Seal (43) if it
needs to be replaced.
3. Remove the Front End Plate (2) from the Cylinder by tapping the
splined end of the Rotor (6) with a plastic hammer. If the Front
End Plate does not come loose, secure a center punch in a vise
with the point angled downward and outward from the vise.
Grasp the Cylinder and Front End Plate in one hand and position
the hole in the end of the Rotor against the punch.
NOTICE
Be careful not to drop the Cylinder since it can be damaged by
hitting a hard surface.
Using the other hand, tap the punch with a hammer while pressing
the Rotor against the punch. After a few taps, the Front End Plate will
slide off of the Cylinder.
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) and (4).
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. See Dwg.
TPD1323.
Front End Plate
Front Rotor Bearing
Bench With Non-Metallic Surface
(Dwg. TPD1323)