Ingersoll-Rand 2135TI Instructions For Use Manual

04579249

Form P7604

Edition 3

May, 2003

INSTRUCTIONS FOR MODELS

2135Ti, 2135Ti-2, 2135QTi, 2135QTi-2 AND 2135PTi

ULTRA DUTY AUTOMOTIVE IMPACT WRENCHES

The 2135Ti and 2135QTi series of Impact Wrenches are designed for use in general auto-

motive repair, tire service and heavy duty fleet applications.

Model 2135PTi Impact Wrench is designed for use in light assembly work and machinery

maintenance.

IMPORTANT SAFETY INFORMATION ENCLOSED - SAVE THESE INSTRUCTIONS

READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING THIS PRODUCT

IT IS YOUR RESPONSIBILITY TO MAKE THIS SAFETY INFORMATION

AVAILABLE TO OTHERS THAT WILL OPERATE THIS PRODUCT

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY

PLACING TOOL IN SERVICE

• Always install, operate, inspect and maintain this product

in accordance with all applicable standards and regula-

tions (local, state, country, federal, etc.).

• Always use clean, dry air at 90 psig (6.2 bar/620 kPa)

maximum air pressure at the inlet. Higher pressure may

result in hazardous situations including excessive speed,

rupture, or incorrect output torque or force.

• Be sure all hoses and fittings are the correct size and are

tightly secured. See Dwg. TPD905-2 for a typical piping

arrangement.

• Ensure an accessible emergency shut off valve has been

installed in the air supply line, and make others aware of

its location.

• Do not use damaged, frayed or deteriorated air hoses and

fittings.

• Keep clear of whipping air hoses. Shut off the compressed

air before approaching a whipping hose.

• Always turn off the air supply, bleed the air pressure and

disconnect the air supply hose before installing, removing

or adjusting any accessory on this tool, or before perform-

ing any maintenance on this tool or any accessory.

• Do not lubricate tools with flammable or volatile liquids

such as kerosene, diesel or jet fuel. Use only recommended

lubricants.

• Use only proper cleaning solvents to clean parts. Use only

cleaning solvents which meet current safety and health

standards. Use cleaning solvents in a well ventilated area.

• Keep work area clean, uncluttered, ventilated and illumi-

nated.

• Do not remove any labels. Replace any damaged label.

USING THE TOOL

• Always wear eye protection when operating or perform-

ing maintenance on this tool.

• Always wear hearing protection when operating this tool.

• Always use Personal Protective Equipment appropriate to

the tool used and material worked. This may include dust

mask or other breathing apparatus, safety glasses, ear

plugs, gloves, apron, safety shoes, hard hat and other

equipment.

• When wearing gloves always be sure that the gloves will

not prevent the throttle mechanism from being released.

• Prevent exposure and breathing of harmful dust and par-

ticles created by power tool use.

Some dust created by power sanding, sawing, grind-

ing, drilling, and other construction activities con-

tains chemicals known to cause cancer, birth defects

or other reproductive harm. Some examples of these

chemicals are:

- lead from lead based paints,

- crystalline silica from bricks and cement and

other masonry products, and

- arsenic and chromium from chemically treated

lumber.

Your risk from these exposures varies, depending on

how often you do this type of work. To reduce your

exposure to these chemicals: work in a well ventilated

area, and work with approved safety equipment, such

as those dust masks that are specially designed to fil-

ter out microscopic particles.

• Keep others a safe distance from your work area, or

ensure they use appropriate Personal Protective Equip-

ment.

• This tool is not designed for working in explosive environ-

ments, including those caused by fumes and dust, or near

flammable materials.

• This tool is not insulated against electric shock.

• Be aware of buried, hidden or other hazards in your work

environment. Do not contact or damage cords, conduits,

pipes or hoses that may contain electrical wires, explosive

gases or harmful liquids.

• Keep hands, loose clothing, long hair and jewelry away

from working end of tool.

• Power tools can vibrate in use. Vibration, repetitive

motions or uncomfortable positions may be harmful to

your hands and arms. Stop using any tool if discomfort,

tingling feeling or pain occurs. Seek medical advice before

resuming use.

• Keep body stance balanced and firm. Do not overreach

when operating this tool. Anticipate and be alert for sud-

den changes in motion, reaction torques, or forces during

start up and operation.

• Tool and/or accessories may briefly continue their motion

after throttle is released.

• To avoid accidental starting - ensure tool is in “off” posi-

tion before applying air pressure, avoid throttle when car-

rying, and release throttle with loss of air.

• Ensure work pieces are secure. Use clamps or vises to hold

work piece whenever possible.

• Do not carry or drag the tool by the hose.

• Do not use power tools when tired, or under the influence

of medication, drugs, or alcohol.

• Never use a damaged or malfunctioning tool or accessory.

• Do not modify the tool, safety devices, or accessories.

• Do not use this tool for purposes other than those recom-

mended.

• Use accessories recommended by Ingersoll-Rand.

• Note the position of the reversing mechanism before oper-

ating the tool so as to be aware of the direction of rotation

when operating the throttle.

• Use only impact sockets and accessories. Do not use hand

(chrome) sockets or accessories.

Refer All Communications to the Nearest

Ingersoll-Rand Office or Distributor.

Printed in U.S.A.

GB

2

Using the Tool (Continued)

• Impact Wrenches are not torque wrenches. Connections

requiring specific torque must be checked with a torque

meter after fitting with an impact wrench.

• Periodically check the drive end of the tool to make cer-

tain that the socket retainer functions correctly, and that

sockets and drive ends are not excessively worn which

may allow the socket to come off when rotating.

The use of other than genuine Ingersoll-Rand replacement parts may result in safety hazards, decreased tool

performance, and increased maintenance, and may invalidate all warranties.

Repairs should be made only by authorized trained personnel. Consult your nearest Ingersoll-Rand Authorized

Servicenter.

WARNING SYMBOL IDENTIFICATION

USING THE POWER MANAGEMENT SYSTEM

Impact Wrenches are not torque wrenches. Connections

requiring specific torque must be checked with a torque

meter after fitting with an impact wrench.

(Dwg. TP2081)

The 2135Ti series of Impact Wrenches incorporates a Power

Management System that allows the operator to select four

power output settings. These settings range from minimum

power output through maximum power output in the clock-

wise direction only.

The Air Wrench will always operate

at maximum power output in the counterclockwise direction,

no matter what power output level is selected. The four

power setting indicators of increasing size on the rear of

the housing indicate increasing power output levels, are for

reference only and DO NOT denote a specific power output.

The smallest power setting indicator designates minimum

power output, the two middle power setting indicators

denote medium power outputs and the largest power setting

indicator denotes maximum power output. The power output

can be further reduced in clockwise or counterclockwise by

using the variable throttle. Air supply systems which do not

deliver adequate air pressure can affect power output at all

settings.

WARNING

Always wear eye protection

when operating or performing

maintenance on this tool.

WARNING

Read this manual before

operating tool.

WARNING

Always wear hearing

protection when operating

this tool.

POWER MANAGEMENT SYSTEM

POWER SETTING INDICATORS

MAXIMUMMINIMUM

POWER

REGULATOR

3

LUBRICATION

Ingersoll-Rand No. 10 Oil

Ingersoll-Rand No. 115-1LB for routine external lubrica-

tion of the impact mechanism through the Hammer Case

Grease Fitting.

Use Ingersoll-Rand No. 105-1LB when disassembling and

assembling the impact mechanism.

Always use an air line lubricator with these tools. We rec-

ommend the following Filter-Regulator-Lubricator (FRL)

Unit:

Inside USA use FRL Unit # C18-03-FKG0-28

Outside USA use FRL Unit # C18-C3-FKG0

INSTALLATION

(Dwg. TPD905-2)

AIR & HOSE CONNECTIONS

(Dwg. TP2082)

F

L

R

Main Line(s) Inner Ø

to be 3X Size of

Air Tool's Inlet Ø

T

o Air

S

ystem

T

o Air

T

ool

Lubricator

Emergency

S

hut-Off

V

alve

Regulator

Filter

Compressor

FRL

Drain Regularly

Branch Line(s) Inner Ø

to be 2X Size of

Air Tool's Inlet Ø

AIR SUPPLY (FROM COMPRESSOR)

3/8" COUPLER

OR LARGER

(I-R PART NO. MSCF33)

3/8" COUPLER

OR LARGER

(I-R PART NO. MSCF33)

I-R PART NO. MSPM32 (MALE THREAD)

I-R PART NO. MSPF32 (FEMALE THREAD)

I-R PART NO. MSPM32 (MALE THREAD)

3/8" AIR HOSE

W/ 1/4" NPT FITTINGS

4

SPECIFICATIONS

■ Tested in accordance with PNEUROP PN8NTC1.2

♦ Tested in accordance with CAGI/ANSI S12.41

• Tested in accordance with ISO8662

(Dwg. TP2083)

SAVE THESE INSTRUCTIONS. DO NOT DESTROY.

When the life of the tool has expired, it is recommended that the tool be disassembled,

degreased and parts be separated by material so that they can be recycled.

Model Handle Drive

Impacts

per min.

Recommended

Torque Range

I.D. Type inches bpm

Forward

ft•lb (N•m)

Reverse

ft•lb (N•m)

2135Ti

pistol grip

1/2”

1,250

50-550 [600 Max.]

(68-746 [813 Max.] )

650 [700 Max.]

(881 [949 Max.] )

2135Ti-2 1/2” Extended

2135QTi 1/2”

2135QTi-2 1/2” Extended

2135PTi 1/2”

Model

■Impacting

Sound Level dB(A)

♦ Free Speed

Sound Level dB(A)

• Vibration

Level

I.D. Pressure Power Pressure Power m/s

2

2135Ti

99.6 112.6 101.2 114.2

5.3

2135Ti-2

2135QTi

97.2 110.2 86.0 96.0

2135QTi-2

2135PTi 99.6 112.6 101.2 114.2

SOURCE/DATE CODE

LOCATION

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16

LUBRIFICAZIONE

Ingersoll-Rand No. 10 Olio

Ingersoll-Rand Nr. 115-1LB per lubrificazione esterna di

routine del meccanismo dell'attrezzo ad impulsi attraverso

l'ingrassatore posto sulla cassa del martello.

Usare Ingersoll-Rand No. 105-1LB quando si smonta e si

monta il meccanismo ad impulsi.

Con questi attrezzi usare sempre un lubrificatore di linea. Si

raccomanda l'uso del seguente gruppo filtro-regolatore-lub-

rificatore (FRL):

All'interno degli Stati Uniti utilizzare FRL N. C18-03-

FKG0-28

Fuori degli Stati Uniti utilizzare FRL N. C18-C3-FKG0

INSTALLAZIONE

(Dis. TPD905-2)

COLLEGAMENTO ARIA E FLESSIBILE

(Dis. TP2082)

F

L

R

TUBAZIONE PRINCIPALE,

3 VOLTELA DIMENSIONE

DELL'ENTRATA ARIA

DELL'UTENSILE

LUBRIFICATORE

VALVOLA DI

INTERCETTAZIONE

DI EMERGENZA

REGOLATORE

FILTRO

COMPRESSORE

FRL

SVUOTARE

REGOLARMENTE

DIRAMAZIONE, 2 VOLTE

LA DIMENSIONE

DELL'ENTRATA ARIA

DELL'UTENSILE

ALL'UTENSILE

PNEUMATICO

ALL'IMPIANTO

PNEUMATICO

ALIMENTAZIONE ARIA (DAL COMPRESSORE)

RACCORDO DI 3/8"

O MAGGIORE

(I-R PARTE NR. MSCF33)

RACCORDO DI 3/8"

O MAGGIORE

(I-R PARTE NR. MSCF33)

I-R PARTE NR. MSPM32 (MASCHIO)

I-R PART NR. MSPF32 (FEMMINA)

I-R PARTE NR. MSPM32 (MASCHIO)

FLESSIBILE ARIA DI 3/8"

CON ACCESSORI NPT DI 1/4"

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20

LUBRICACIÓN

Ingersoll-Rand Nº 10 Aceite

Ingersoll-Rand Nº 115-1LB para lubricación externa

periódica del mecanismo impulsor a través del engrasador

de la carcasa de mazas.

Utilice Ingersoll-Rand Nº 105-1LB al montar y desmontar

el mecanismo de impacto.

Recomendamos utilizar el siguiente conjunto de filtro-regu-

lador-lubricador (FRL):

En EE.UU. utilizar FRL nº C18-03-FKG0-28

Fuera de EE.UU. utilizar FRL nº C18-C3-FKG0

MONTAJE

(Esq. TPD905-2)

AIRE Y MANGUERA ADMISIÓN

(Esq. TP2082)

F

L

R

TUBERÍAS PRINCIPALES

3 VECES EL TAMAÑO

DE ENTRADA DE

HERRAMIENTA NEUMÁTICA

LUBRICADOR

VÁLVULA DE

CORTE DE

EMERGENCIA

REGULADOR

FILTRO

COMPRESOR

FRL

PURGAR

PERIÓDICAMENTE

TUBERÍA DE RAMAL 2 VECES

EL TAMAÑO DE ENTRADA

DE HERRAMIENTA NEUMÁTICA

A LA HERRA-

MIENTA

NEUMÁTICA

AL SISTEMA

NEUMÁTICO

AIRE COMPRIMIDO

ACOPLAMIENTO DE

3/8 PULG. O MÁS GRANDE

(N_ PIEZA I-R MSCF33)

ACOPLAMIENTO DE

3/8 PULG. O MÁS GRANDE

(N_ PIEZA I-R MSCF33)

N_ PIEZA I-R MSPM32 (MACHO)

N_ PIEZA I-R MSPF32 (HEMBRA)

N_ PIEZA I-R MSPM32

MANGUERA DE AIRE DE

3/8 PULG. CON RACORES

DE 1/4 PULG. NPT

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24

DE SMERING

Ingersoll-Rand Nr. 10 Olie

Gebruik Ingersoll-Rand Nr. 115-1LB voor routine uit-

wendige smering van het slagmechanisme aan te brengen

via de Smeernippel op het Hamerhuis.

Gebruik Ingersoll-Rand Nr. 105-1LB wanneer het slag-

mechanisme wordt gedemonteerd en gemonteerd.

Always use an air line lubricator with these tools. We rec-

ommend the following Filter-Regulator-Lubricator (FRL)

Unit:

Gebruik binnen VS FRS #C18-03-FKG0-28

Gebruik buiten VS FRS #C18-C3-FKG0

MONTAGE

(Tekening TPD905-2)

SLANG EN LUCHT AANSLUITING

(Tekening TP2082)

F

S

R

HOOFDLEIDINGEN

3 MAAL AFMETINGVAN

INLAATVOOR DRUKLUCHT-

GEREEDSCHAP

SMEERINRICHTING

NOODAF-

SLUITVENTIEL

REGELAAR

FILTER

COMPRESSOR

FRS

REGELMATIG

AFTAPPEN

AFTAKKENDE LEIDING

2 MAAL AFMETING VAN

INLAAT VOOR DRUKLUCHT-

GEREEDSCHAP

NAAR

DRUKLUCHT-

GEREED-

SCHAP

NAAR

LUCHTSYSTEEM

LUCHTTOEVOER (VAN COMPRESSOR)

3/8" KOPPELING OF

GROTER

(I-R ONDERDEEL

NR. MSCF33)

3/8" KOPPELING OF

GROTER (I-R ONDERDEEL

NR. MSCF33)

I-R PART NO. MSPM32 (UITWENDIGE DRAAD)

I-R PART NO. MSPF32 (INWENDIGE DRAAD)

I-R ONDERDEEL NR. MSPM32

3/8" LUCHTSLANG

MET 1/4" NPT FITTINGEN

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26

MAINTENANCE INSTRUCTIONS

(Dwg. TP2060)

27

PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING

*

Housing Assy (2135Ti and 2135Ti-2)

2135-A40 * Kit Grease

-----

Housing Assy (2135QTi and 2135QTi-2) 2135QTi-A40 * Hammer Frame Assy Kit

2135-K703

Housing Assy (2135PTi) 2135PTi-A40 15 Hammer Frame

-----

1 Housing ----- 15A Hammer Pin (2)

-----

1A Exhaust Deflector ----- * Kit Grease

-----

3 Nameplate ----- * Anvil Assy (2135Ti and 2135QTi)

231B-A626

4 Information Label ----- * Anvil Assy (2135Ti-2 and 2135QTi-2)

231B-A414

5 Warning Label ----- Anvil Assy (2135PTi)

231B-A726

23 Gasket ----- 16 Anvil

-----

24 Reverse Valve ----- 17 Socket Retainer Spring or O-Ring

-----

24A

O-Ring, Reverse Valve (top) ----- 18 Socket Retainer

-----

24B

O-Ring, Reverse Valve (bottom)

----- + 17 O-Ring, Anvil (2135Ti and 2135QTi)

R1A-159

29 Button Kit -----

Socket Retainer Spring (2135PTi)

5UHD-718

2 Screw, Hammer Case (4 required) 2135-638 +

18

Retaining Clip (2135Ti and 2135QTi)

231-425A

3 Nameplate (2135Ti and 2135Ti-2) 2135-301 Socket Retainer (2135PTi)

804-716

Nameplate (2135PTi) 2135PTi-301

19

Bushing, Hammer Case

2135-941

Nameplate (2135QTi) 2135QTi-301

*

Hammer Case Assy

2135-D727

4 Information Label 2135-300 19 Bushing, Hammer Case

-----

5 Warning Label WARNING-2-99 20 Hammer Case

-----

* Power Regulator Assy 2135-D249 21 Grease Fitting

-----

6 Power Regulator -----

21

Grease Fitting

D0F9-879

6A O-Ring, Power Regulator ----- +

*

Trigger Assy

2135-D93

7 Retaining Ring 2131-6 22 Trigger

-----

8 Ball Bearing (2 required) 2131-97 22A O-Ring, Trigger

-----

9 Cylinder 2131-3A +

23

Gasket

2131-283

10 Rotor 2135-53

*

Reverse Valve Assy

2131-A329

+ 11 Vane Pack (set of 7) 2135-42A-7 24 Reverse Valve

-----

12 End Plate 2131-11 24A O-Ring, Reverse Valve (top)

-----

+ 13 Hammer Case Gasket 2135-36 24B O-Ring, Reverse Valve (bottom)

-----

* Hammer Kit (2135Ti and 2135QTi) 2135-THK1

26

Inlet Bushing Assy (incl. 27, 28)

2135-D565

* Hammer Kit (2135Ti-2 and 2135QTi-2) 2135-2-THK1

27

Inlet Clip

2131-57

Hammer Kit (2135PTi) 2135PTi-THK1

28

Inlet Parts Kit

2131-K303

13 Hammer Case Gasket ----- 28A Washer

-----

14 Hammer (2) ----- 28B O-Ring, Seal

-----

15A Hammer Pin (2) ----- 28C Valve

-----

16 Anvil Assy ----- 28D Spring

-----

* Not Illustrated

+ To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of each part indicated by a (+) for every four tools

in service.

28

PART NUMBER FOR ORDERING PART NUMBER FOR ORDERING

28E

Seat

----- 22A O-Ring, Trigger

-----

28F Support ----- 23 Gasket

-----

28G Retainer ----- 24A O-Ring, Reverse Valve (top)

-----

29 Button Kit 2135-K75 24B O-Ring, Reverse Valve (bottom)

-----

29A Forward Button ----- 28 Inlet Parts Kit

-----

29B Reverse Button -----

* Tune-Up Kit 2135-TK1 * Inlet Clip Removal Tool

2131-322

6A O-Ring, Power Regulator -----

*

“Pump-n-Grease” (Grease & Gun Kit)

500C

7 Retaining Ring ----- + * Air Care Kit (grease gun, grease, oil)

115-LBK1

8 Ball Bearing (2) ----- * Grease (replacement tube for -LBK1)

115-4T

11 Vane Pack (set of 7) ----- * Air Tool Oil (4 oz. Bottle)

10Z4

13 Hammer Case Gasket ----- * Grease (1 lb can)

105-1LB

17 O-Ring ----- * Grease (8 lb can)

105-8LB

18 Retaining Clip ----- * Kit Grease

105-6GR

* Not Illustrated

+ To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of each part indicated by a (+) for every four tools

in service.

29

MAINTENANCE SECTION

TROUBLESHOOTING GUIDE

Trouble Probable Cause Solution

Low power Dry Motor Daily, inject 3 cc of Ingersoll-Rand No. 10 Oil

into the inlet and run the tool to lubricate the

motor.

Inadequate air supply Install proper air supply and connection. Refer

to Dwg. TPD905-2 and Dwg. TPD2082 on

Page 3.

Dirty Inlet bushing Screen Using a clean, suitable, cleaning solution in a

well ventilated area, clean the Inlet Bushing

Screen.

Worn or broken Vanes Replace a complete set of Vanes

Worn or broken Cylinder and/or

scored End Plates

Examine Cylinder. Check outside and ends for

wear or damage and inside for scored or wavy

bore.

Replace Cylinder if any of these conditions exist.

Replace End Plates if they are scored.

Dirty motor parts. Disassemble the Tool and clean in a clean, suit-

able, cleaning solution in a well ventilated area.

Assemble the Tool and inject 3 cc of the recom-

mended oil into Inlet and run Tool to

lubricate internal parts.

Dirty Exhaust Element

(2135QTi only)

Clean Exhaust Element with non-flammable

aerosol cleaner.

Damaged Reverse Valve Replace Reverse Valve.

Motor will not run Incorrect assembly of motor Disassemble motor and replace worn or broken

parts and reassemble.

Insufficient lubricant in impact

mechanism.

Lubricate impact mechanism through Hammer

Case Grease Fitting using the recommended

grease.

Tool will not impact Broken or worn impact mecha-

nism parts

Remove Hammer Case Assembly and examine

impact mechanism parts. Replace any worn or

broken parts.

Impact mechanism not

assembled correctly.

Reassemble Impact Mechanism.

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Service Centers

Centres d’entretien

Ingersoll-Rand Niederlassungen

Centri di Assistenza

Centros de Servicio

Service Centra

Ingersoll-Rand Company

510 Hester Drive

White House

TN 37188

USA

Tel: (615) 672 0321

Fax: (615) 672 0601

Ingersoll-Rand Sales Company Limited

Chorley New Road

Horwich, Bolton

Lancashire BL6 6JN

England - UK

Tel: (44) 204 880890

Fax: (44) 204 880388

Ingersoll-Rand Equipements de Production

111 Avenuè Roger Salengro

BP 59

F-59450 Sin Le Noble

France

Tel: (33) 27 93 0808

Fax: (33) 27 93 0800

Ingersoll-Rand GmbH

Gewerbealle 17

45478 Mülheim/Ruhr

Germany

Tel: (49) 208 9940

Fax: (49) 208 9994445

Ingersoll-Rand Italiana SpA

Casella Postale 1232

20100 Milano

Italy

Tel: (39) 2 950561

Fax: (39) 2 95380169

Ingersoll-Rand

Camino de Rejas 1, 2-18 B1S

28820 Coslada

Spain

Tel: (34) 1 669 5850

Fax: (34) 1 669 6054

Ingersoll-Rand Nederfand

Produktieweg 10

2382 PB Zoeterwoude

Netherlands

Tel: (31) 71 45220

Fax: (31) 71 218671

Ingersoll-Rand Company SA

PO Box 3720

Alrode 1451

South Africa

Tel: (27) 11 864 3930

Fax: (27) 11 864 3954

Ingersoll-Rand

Scandinavian Operations

Kastruplundgade 221

DK-2770 Kastrup

Denmark

Tel: (45) 32 526092

Fax: (45) 32 529092

Ingersoll-Rand SA

The Alpha Building

Route des Arsenaux 9

CH-1700 Fribourg

Switzerland

Tel: (41) 37 205111

Fax: (41) 37 222932

Ingersoll-Rand Company

Presnensky Val

19, Moscow, Russia 123557

Tel: (7) 095-933-03-24

Fax: (7) 095-737-01-48

Ingersoll-Rand Company

16 Pietro

Ul Stawki 2

PL-00193 Warsaw

Poland

Tel: (48) 2 635 7245

Fax: (48) 2 635 7332

0503

Ingersoll-Rand 2135TI Instructions For Use Manual

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