Assembly Of The Tool - Ingersoll-Rand 2161P Series Instructions Manual

Assembly of the Tool

1. Wipe a thin film of the recommended grease on the
inside of the Hammer Case Bushing (36) and insert the
assembled impact mechanism into the Hammer Case
(35).
2. Secure the Hammer Case and impact mechanism by
the anvil (square drive) end in leather–coverd or
copper–covered vise jaws. See Dwg. TPD1922.
MAINTENANCE SECTION
(Dwg. TPD1922)
15
3. Install a new Hammer Case Gasket (34) on the
Hammer Case making sure that the holes in the gasket
align with the holes in the Hammer Case.
When installing optional Hanger Kit, place Gasket
(34) on the Housing.
4. Wipe a small amount of the recommended grease on
the flat side of the Hammer Frame Washer (30) and
place it on the splined face of the Hammer Frame (31)
with the hub end of the washer pointing up.
When installing optional Hanger Kit, place
additional washer provided between the Hammer
Frame and Hammer Frame Washer.
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 (13) 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 the Housing.
7. Place a Motor Clamp Washer (19) 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 (14) over the back of the Housing
making sure that the Reverse Valve Lever (16) 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 using a No. 27
TorxR drive wrench or bit, tighten to 10–12 ft–lbs
(13–16 Nm) torque.