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Disassembly of the Motor
1. Grasp the Motor Retainer (35) and remove it from the Motor
Housing (1).
2. Remove the Rear Hammer Frame Washer (41) and the Motor
Clamp Washers (34) from the front of the Motor.
The End Plate Dowel (30) will fall free when the Front End
Plate (29) clears the Housing. Do not lose the Dowel.
3. Grasping the splined end of the Rotor (31), carefully lift the
assembled motor from the Motor Housing.
4. Remove the Rear End Plate Gasket (26).
5. Remove the Motor Housing from the vise.
6. Slide the Front End Plate (29) with the Front Rotor Bearing (32)
from the Rotor.
7. Remove the Cylinder Dowel (33), Cylinder (27) and Vanes (28)
from the Rotor.
8. Using snap ring pliers, remove the Rear Rotor Bearing
Retainer (23) and slide the Rear End Plate (25) with the Rear Rotor
Bearing (24) from the Rotor.
9. If the Front or Rear Rotor Bearing requires replacement, press it
from the End Plate.
Disassembly of the Throttle Mechanism
1.
Unscrew the Air Inlet Bushing (9) and remove the Air Strainer
Screen (8), Throttle Valve Spring (7),
2.
Throttle Valve Assembly (5) and Throttle Valve Plunger (4).
3.
If the Throttle Valve Seat (6) needs replacement, insert a hooked
tool through the center of the Valve Seat. Catch the backside of
the Seat with the hook and pull the Seat from the Housing.
4.
Unscrew the four Exhaust Deflector Screws (15) and remove the
Exhaust Deflector (13) Exhaust Deflector Gasket (14) and the
Exhaust Silencer/Exhaust Baffle (12, 11) combination.
Model 2920B9
Dissasembly of the Angle Attachment
1. Slide the Connector Retaining Sleeve (116) toward the square
drive anvil and pull the Angle Housing Assembly (102) off the
tool.
Assembly
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 and housings.
4. Always clean every part and wipe every part with a thin film of
the recommended oil before installation.
5. Apply a film of O-ring lubricant to all O-rings before final
assembly.
Assembly of the Throttle Mechanism
1. Sandwich the Exhaust Baffle (11) between the two Exhaust
Silencers (12) and install them in the rectangular opening in the
bottom of the Motor Housing (1).
2. Install the Exhaust Deflector Gasket (14) on the rim of the
opening.
3. Place the Exhaust Deflector (13) over the Gasket and after
applying a thread locking compound to the four Exhaust
Deflector Screws (15), secure the Deflector with the Screws.
Tighten each Screw to 20 to 25 in-lb (2 to 3 Nm) torque.
4. Apply a thin coat of O–ring lubricant to the Throttle Valve Face (6).
Using a dowel, seat the Valve securely and without damage.
5. Install the Throttle Valve on the small end of the Throttle Valve
Plunger (4) and insert the Plunger and Valve, Plunger first, into
the air inlet chamber of the housing.
04584264_ed3
NOTICE
Be careful not to lose the three Connector Retaining
Balls (119) as they are free to fall out when the Connector
Retaining Sleeve is removed.
2. Grasp the Angle Housing Assembly in leather-covered or copper-
covered vise jaws, bevel pinion end facing upward. Slide the
Connector Retaining Sleeve (116) toward the square drive anvil
and remove the Connector Retaining Sleeve Stop (118) from the
Angle Housing Connector (114).
3. Working over a workbench, carefully slide the Connector
Retaining Sleeve off the Angle Housing Connector.
4. Slide the Retaining Sleeve Spring (117) off the Angle Housing
Connector.
5. Using a thin blade screwdriver, pry the two Connector Lock Pins
(115) from the Housing.
6. Using a spanner wrench in one of connector lock pin holes,
unscrew and remove the Angle Housing Connector (114).
7. Pull the Bevel Pinion Driver (109) off the Bevel Pinion Assembly
(104).
8. Slide the Bevel Pinion Assembly, four Bevel Pinion Clamp Washers
(110), Bevel Pinion Bearing (107) and Bevel Pinion Spacer (108)
from the Angle Housing Assembly. Remove the Angle Housing
from the vise.
9. Grasp the Angle Housing in leather-covered or copper-covered
vise jaws, Bevel Gear (111) facing upward.
10. Using snap ring pliers, remove the Bevel Gear Bearing Retainer (113).
11. Slide the Bevel Gear Bearing (107), Bevel Gear, and Bevel Gear
Spindle (112) from the Angle Housing. Remove the Angle
Housing from the vise.
Further disassembly of the Model 2920B9 Impactool is identical
to Model 2920B.
6. Put the small end of the Throttle Valve Spring (7) over the trailing
end of the Throttle Valve. Place the Air Strainer Screen (8) so
that it sits within the coils of the Spring and install the Air Inlet
Bushing (9). Tighten the Inlet Bushing to 50 to 60 ft–lb (68 to 81
Nm) torque.
Assembly of the Motor
1. Using a sleeve that will contact only the outer ring of the bearing.
press the Front Rotor Bearing (32) into the Front End Plate (29)
and the Rear Rotor Bearing (24) into the Rear End Plate (25).
2. Slip the Front End Plate and Bearing over the splined hub of the
Rotor (31).
3. Grasp the splined end of the Rotor in leather-covered or copper-
covered vise jaws with the Rotor in a vertical position.
4. Dampen each Vane (28) with light oil and insert a Vane into each
vane slot in the Rotor.
5. Set the Cylinder (27) over the Rotor and onto the Front End Plate.
6. Slide the Rear End Plate and Bearing onto the Rotor hub and
against the Cylinder.
7. Using snap ring pliers, install the Rear Rotor Bearing Retainer (23)
in the groove on the rotor hub.
8. Align the dowel hole in both End Plates with the one through
the Cylinder, and insert a guide rod 3/16" x 8" (4.7 mm x 203 mm)
through the holes. Allow the rod to protrude about 3–1/2" (89
mm) from the Rear End Plate.
9. While holding the assembled motor intact, remove it from the
vise.
NOTICE
NOTICE
3
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