Air TEc MASTER 35 MA20 A001 User manual

NEW MASTER 35®
from MA20 A001
PETROL/GASOLINE IMPACT WRENCH
Couper Street, Glasgow G4 0DL United Kingdom
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New Master 35 Petrol/Gasoline Impact Wrench
Copyright Airtec International Ltd©". All Rights Reserved.
No reproduction of whole or part of this Manual is allowed without
written Permission of Copyright.
Airtec International Limited, Couper Street, Glasgow G4 0DL, U.K.
New Edition June 2020
DECLARATION OF CONFORMITY
To whom it may concern:
We Airtec International Ltd Couper Street GLASGOW G4 0DL United Kingdom
Declare that we are solely responsible for the supply/manufacture of the
Master 35® Petrol/Gasoline Impact Wrench
1” Square Drive powered by special Emak Engine
Serial No. MA ………..
Detailed information on weight, noise, vibration etc. is contained in this Operation Manual to
which this declaration relates and is in conformity with the relevant standards of the undernoted
European Union.
2006/42/EC Machinery Directive
In addition to the above Laws the Wrench meets the manufacturing standard UNI EN12100
relating to the principles of good Engineering practice and design.
GLASGOW A. KILPATRICK
(Place and date of issue) (Name and signature of authorised Person)
Directors : A. Bissoli (Italy) A. Kilpatrick Co. Sec. : A. Kilpatrick Registered in Scotland 135384

New Master 35 Petrol/Gasoline Impact Wrench
Copyright Airtec International Ltd©". All Rights Reserved.
No reproduction of whole or part of this Manual is allowed without
written Permission of Copyright.
Airtec International Limited, Couper Street, Glasgow G4 0DL, U.K.
New Edition June 2020
MASTER 35®
PETROL/GASOLINEIMPACTWRENCH
MAINTENANCE MANUAL
CONTENTS
DESCRIPTION PAGE NUMBER
Uses & Technical Information 1
Safety Precautions 2
Operating Controls –Illustrations 3
Operating Controls –Instructions for use 4
Start/Stop Operation 5
Basic Workshop Safety Rules 6
Routine Service 7
Motor - Repairs 8
Motor Parts - Exploded Diagram Drawings and Parts Lists 9-13
Impact Unit - Repairs 14
Impact Unit & Gearbox –Exploded Diagram Drawings & Parts Lists 15-17
Troubleshooting Advice 18
General Information 18
Workshop Tools 19
Accessories 20

New Master 35 Petrol/Gasoline Impact Wrench
The Master Impact Wrench is ideal for removing/fitting Chairscrews (Lag Screws) and Fishplates (Joint
Bars) where track possession is not possible, if there are access difficulties or if other sources of power e.g.
Air Compressors, Generators or Power Packs are not available. The Master can drill holes in Wooden
Sleepers (Ties) using our Safety Quick Release Attachment which allows the fitting/removal of Auger Bits in
seconds.
If there is track possession it can be fitted to one of our Braked Tool Carriers which then makes it easier for
the operator to use in both a vertical and horizontal position. The Tool Carrier carries the weight not the
operator.
Most Screwed Fasteners can be removed/fitted in under three seconds
1. BOLT CAPACITY
16 to 32mm - (5/8" to 11/4") diameter
2. DIMENSIONS
Length 600mm (23 5/8”)
Height 284mm (11")
Width 452mm (17 ¾”)
3. ENGINE-Twostroke/cycleSpecialAirtecEMAK065
63.4 c.c. complying with EUR5 and EPA3
Standards
Maximum free speed 9,500 rpm
Power 4.70 HP 3.5 kW
Fuel Tank capacity 0.8 Litres (1.20 pints)
Fuel Mixture ratios
Petrol/Gasoline Unleaded minimum 89 Octane,
Gasohol with less than 10% Ethanol or E10 fuel
with two stroke oil
MIX RATIO MLS.PER OZS. PER
OIL LITRE US GAL
Mineral 25:1 40 3
Synthetic 50:1 20 11/2
DO NOT use 2 stroke Outboard Motor Oil
4. GEARBOX
Fill with 0.25 Litre (1/2 pint) of Gazpromneft
Reductor CLP68, Mobil Gerar 626, Carter EP68,
Merpoa 68, Valvoline 80-90W or an equivalent non
synthetic 68 viscosity Gear Oil to half way up sight
glass with Wrench in the horizontal position. Change
Oil every twelve months.
5. IGNITION –DIGITAL
Spark Plug Champion RCJ-4 or equivalent.
Gap should be 0.5mm
6. IMPACT MECHANISM
Fill with 130 grammes (41/2 oz) of Molybdenum
Disulphate Grease, Castrol MS3, Klubern
N12MF, Valvoline NLG 1 # 2 or equivalent Grade
2 quality.
7. NOISE
Operation levels based on ISO3744
Acoustic Pressure (LpA) 101.7 dBA
Power (LWA) 114.8 dBA
Always wear ear protection
8. SQUARE DRIVE
Standard 1" (25.4mm)
9. TORQUE RANGE
(500 –2,500Nm) or (350 to 1850 ft/lbs)
approximately
It is possible to generate higher torques under
special conditions. The Master will loosen any
screwed fastener previously tightened by any
other Petrol/Gas Driven Impact Wrench.
10. VIBRATION EXPOSURE
Vibration exposure is more important than vibration
e.g. a low vibration machine which takes a long time
to perform a task generates higher vibration
exposure than a higher vibration machine which
performs a task much more quickly.
The following data is based on practical on
track testing carried out in the UK in February 2020.
Fishplates/Joint Bar Nuts 43mm (1 11/16”) Square – 2.25 seconds
AV
LV
Vibration
Trigger
Time
Minutes
No of
Fasteners
Trigger
Time
Minutes
No of
Fasteners
Tightening
12.28m/s2
20
533
80
2133
Loosening
11.05m/s2
25
667
98
2613
Chairscrews/Lagscrews 38.6mm (1 1/8”) Square –2.5 seconds
AV
LV
Vibration
Trigger
Time
Minutes
No of
Fastener
s
Trigger
Time
Minutes
No of
Fasteners
Tightening
11.90m/s2
21
504
85
2040
Loosening
14.72m/s2
14
336
55
1320
The actual figures achieved can vary depending on
operator technique and condition of Wrench,
fastener, track and Socket.
11.WEIGHT
17.9 Kgs (39 ½ lbs)
USES
TECHNICAL INFORMATION –NEW VERSION from Serial No. MA20 A001
1

New Master 35 Petrol/Gasoline Impact Wrench
BEFORE using the Impact Wrench read these safety instructions CAREFULLY and ensure you fully
UNDERSTAND them. DO NOT allow untrained personnel to use the Wrench.
1. Wear suitable PROTECTIVE CLOTHING, safety
boots, goggles, gloves and ear protection
according to Company rules, working
conditions or Government/State Legislation.
2. The effect of vibration exposure can be
REDUCED by following a number of simple
rules :-
a) Always wear protective gloves and keep
hands warm and dry.
b) Ensure Wrench is properly maintained.
c) Do not use worn Sockets and ensure
Wrench Anvil is replaced when worn.
Use of our NO GO GAUGE allows quick
and easy checks on Socket Square
Drive and Anvil wear.
d) Share the workload whenever possible.
3. FILL the fuel tank carefully BEFORE starting the
Wrench in a well ventilated area and avoid
spillage. Use the Fuel Funnel provided or a
Safety Fuel Can. DO NOT fill or add oil while the
Motor is running. Allow machine to cool before
re-fueling, DO NOT over fill, allow for
fuel expansion. Keep well away from naked
flames or equipment which generates sparks
e.g Rail Saw or Rail Grinder. Do not leave the
mixture in the fuel tank for any prolonged
period of time.
4. The exhaust is fitted with a Catalytic
Converter to reduce emission levels to meet
EUR5 and EPA 3 Standards.
It will become HOT during and
after use.
Please AVOID direct contact.
5. Know where the controls are and how to
use them and be able to STOP the Wrench
quickly in an emergency.
6. Do Not Operate in confined spaces because of
the danger of Carbon Monoxide being present.
7. Remove FUEL FILLER CAP CAREFULLY as
pressure can build up in the tank. This is very
important in warm weather, if the Wrench has
been left in an exposed area or after
prolonged periods of use.
8. Do not wear hanging jewellery, a tie or
loose or torn clothing.
9. Take up a FIRM footing and maintain a balanced
body position
10.Check pull cord is not frayed or worn.
11.Use only IMPACT QUALITY Sockets and
Accessories
HAND Sockets must NEVER be used
12.Use Rubber Rings and Steel Pins or other
suitable retaining devices to retain the
Socket or Accessory onto the Square Drive.
DO NOT use twigs, wire, nails or plastic
straps.
13.Set the GEAR CONTROL in NEUTRAL before
starting.
14.Check the Wrench for damage regularly.
Ensure fasteners are tight at all times.
A poorly maintained Wrench will be inefficient
and produce extra noise and vibration
15.Switch OFF ENGINE BEFORE transporting
the Wrench to another location.
16.Take CARE when LIFTING or carrying the
Wrench - weight with fuel and excluding
accessory approximately 18.5Kgs (40 ¾ lbs)
17.The engine has a break in period of 5 to 8
hours. During this time the engine may emit
some smoke.
SAFETY PRECAUTIONS
SAFETY IS EVERYONE’S RESPONSIBILITY
THINK, ACT, BE SAFE
2

1. Control Switch (Choke/Run/Stop) 7. Socket Square Drive - Anvil
2. De-Compression Button 8. Oil Filler Plug with Sightglass
3. Recoil Starter Handle 9. Fuel Filler Cap
4. Throttle Trigger 10. Location of Serial Number Label
5. Trigger Lock 11. Air Filter Cover Clips
6. Gear Lever
OPERATING CONTROLS - ILLUSTRATIONS
2
10
8
7
6
3
11
9
1
4
5
3

New Master 35 Petrol/Gasoline Impact Wrench
O
OPERATING CONTROLS - Instructions for use (See Page 3 for locations)
1. CONTROL SWITCH
Settings
STOP
RUN
CHOKE
2. DE-COMPRESSION BUTTON
To assist in easy
starting. Push in
before starting.
Comes out
Automatically when
Motor Starts.
DO NOT use when Engine is warm
3. RECOIL STARTER HANDLE
Always allow the Starter Cord to return
to its position under control and DO NOT
allow it to fly back.
4. THROTTLE TRIGGER
Depress Safety Lock 5 and squeeze Trigger
to increase Motor speed
5. TRIGGER LOCK
This is to prevent accidental acceleration
6. GEAR LEVER
This has three positions: marked N, F and
R
N - Neutral
F - Clockwise Rotation
R - Anti-clockwise Rotation
To engage turn fully 90° from the Neutral
position.
The gears are stationary when the Motor
is idling at tickover speed. Select the gear
required. If it will not engage, gently
squeeze the throttle trigger so the gear
parts move slightly.
7. SOCKET SQUARE DRIVE
Standard 1” Square Drive. The Accessory is
secured to the Square Drive by a Rubber
Ring and a 5mm dia Bright Steel Pin or other
suitable retaining device. If the Pin breaks or
bends examine both Accessory and Square
Drive for possible wear.
Worn Accessories damage the
Square Drive. A worn Square
Drive damages Accessories and
both create extra vibration.
Replace when worn.
Use our Master 35 No Go Gauge to check if
Anvil and Sockets are worn and need to be
replaced.
8. OIL FILLER PLUG
Use for filling, draining and indicating
Gearbox oil level.
9. FUEL FILLER CAP
Remove carefully when refilling the Fuel
Tank.
10. LOCATION OF SERIAL NUMBER
LABEL
First Serial Number for New Master 35
Impact Wrench MA20 A001
11. AIR FILTER COVER CLIPS
4

New Master 35 Petrol/Gasoline Impact Wrench
START/STOP OPERATION
1. FUEL MIXTURE
Mix = 1:25 Mineral oil
Mix = 1:50 Synthetic oil
with Unleaded Petrol/
Gasoline minimum
89 Octane, Gasohol with
less than 10% Ethanol or E10 fuel
Mix Oil and Petrol/Gasoline thoroughly in a
separate Safety container before filling the
tank. Only fill in a well ventilated area and
away from equipment which generate sparks
e.g. Rail Saws and Grinders.
REMEMBER: Using too much Oil will oil
up the Spark Plug and too little causes
extra wear leading to Engine damage.
2. PREPARATION FOR START-UP
Check oil level in the gear box is correct
and all nuts and screws are tight. Fill the
fuel tank with the correct mixture. Check
starter cord is not worn and Anvil for wear
using our No Go Gauge.
3. STARTING THE WRENCH
1Place Wrench on a SOLID base and take a
comfortable stance.
2Slide Accessory onto Square Drive and
secure with a Steel Pin and Rubber Ring or
appropriate retaining device.
3Set Gear Lever (6) to NEUTRAL (N).
4Push in De-Compression
Button (2) to make
starting easier.
5Set Control Switch (1)
to Choke
6Place heel of boot on
the extended Handle
base or Roll Bar and
pull to activate Choke
and engine firing cycle.
7After engine fires set
Control Switch to RUN
and pull Recoil Starter
again. The engine should
start with one or two pulls.
8Repeat step 3
A few pulls are sufficient
to start the engine.
If the engine “dies”,
please repeat steps
2, 3, 4 and 5.
The De-Compression
Button (2) automatically
goes off when the engine
fires.
9When the engine is
running pull the trigger to
achieve the engine idling.
Note : If the engine is warm it is only necessary
to engage the Choke for a few seconds.
DO NOT use the De-Compression Button
again
4. OPERATING THE WRENCH
Always follow the "SAFETY PRECAUTIONS"
shown on Page 2.
Position Wrench and Socket over fastener to
be tightened/loosened and keep all three in
a straight line.
Select the gear by moving gear lever (6) fully
90oto position F or R.
5. STOPPING THE WRENCH
Release throttle trigger and let Motor return
to idle. Set Gear lever to Neutral position and
turn off Motor by moving Control Switch to the
STOP position.
6. RE-FUELLING
ALWAYS open the Fuel Filler Cap carefully
to release any pressure which may have
built up.
Never re-fuel when the Engine is running
or in a confined space.
Do not smoke or attempt to refill in an area
where there may be sparks from other
machines.
Avoid spillage.
Cold fuel expands in a hot tank. Do not
attempt to fill fuel tank if it is hot.
7. TUNING
The Carburettor is Factory set to meet
International Emission level regulations with
Screws locked to permit only a half turn
movement.
Do not force them further or the plastic cap
locks will break.
Emission levels could then be exceeded.
Tuning should only be attempted by a
trained and competent person i.e. Plant
Fitter
5

New Master 35 Petrol/Gasoline Impact Wrench
Only qualified trained Fitters should attempt to service or repair this machine.
Your personal safety and those of your fellow workers is your responsibility.
Please observe all local and national regulations on safety. The undernoted list should be used as
a guide.
1. Do not run or test any Two Stroke powered Machine in a Workshop or confined space.
This can lead to a build up of poisonous gases and it generates unnecessary noise.
2. Empty fuel from the tank in a safe area before starting work on any Engine.
3. If the Wrench has not been used for some time empty and clean the fuel tank.
4. Under no circumstances smoke in a Workshop area.
5. Keep work areas clean and free from old oil, fuel and dirty rags which could ignite.
6. Do not leave fuel in open containers.
7. Use safety cans for the storage of fuel and do not keep more than the permitted legal
quantity in any one place.
8. After repair, test the Wrench using clean properly mixed fuel and do so in a well ventilated
area.
BASIC WORKSHOP SAFETY RULES GUIDE
SAFETY IS EVERYONE’S RESPONSIBILITY
THINK, ACT, BE SAFE
6

New Master 35 Petrol/Gasoline Impact Wrench
7
.
ROUTINE SERVICE (See Exploded Diagram Drawings on Pages 9 to 13 and 15 to 17)
1. REPLACING SPARK PLUG 4003.5010
Lift two Cover Clips and lift off Filter Cover
4003.3010. Pull off Spark Plug Cover. Unscrew
Spark Plug and replace with Champion RCJ4 or
equivalent making sure the gap is set at 0.5mm
(0.02”).
2. REPLACING AIR FILTER 4003.3080
Remove the Filter
Cover by lifting the
Filter Cover Clips.
Loosen the two air filter
screws and remove it
Clean with a suitable
degreaser, rinse with
water and blast dry with
compressed air.
Renew the filter if
heavily clogged or
damaged.
3. REPLACING FUEL FILTER 4003.1075
With the Wrench in a
vertical position open
Fuel Cap 4003.6020
cautiously to release
any build-up of
pressure in the Fuel
Tank. Pull out Fuel
Filter and replace if
dirty.
4. REPLACINGSTARTERROPE4003.0340
Remove four Screws 4003.2070 holding
Starter Assembly 4003.2190 and Screws
2300.0520 off muffler guard and remove
Starter Assembly. Hold Pulley 4003.2130 with
thumb, cut old cord and allow Pulley to turn
slowly back until no tension is left in Recoil
Spring 4003.2150. Remove Centre Screw
4003.0690 and Washer 4003.0700 and slowly
lift off Pulley. Fit new Rope through Pulley and
tie a knot. Feed other end of Rope through
Starter Assembly 4003.2190 and into Starter
Handle 4003.2180 and again tie a knot. Locate
Pulley in Recoil Spring and replace Centre
Screw 4003.0690 and Washer 4003.0700.
Locate Rope in the notch on outside of pulley,
turn clockwise two complete
turns then release. Repeat
until the Starter Handle
returns to the Housing locating
hole - Approximately six
complete turns when pulled
out. Re-attach starter
assembly.
5. REPLACE GEAR BOX OIL
Remove three Screws 2300.0512 in Gear
Selector 2870.1000 and remove from
Gear Box. Empty out old oil. Fill
gearbox with 0.25 litres (1/2 pint) of
Gazpromneft Reductor CLP68, Mobil Gerar
626, Carter EP68, Merpoa 68, Valvoline 80-
90W or an equivalent non synthetic 68
viscosity Gear Oil. Re-fit Selector and fit
screws using a suitable fastener locking fluid.
6. GREASING HAMMER AND ANVIL
Remove three nuts 2310 2061, four Screws
2300.0851 and Nose Casing 035301.
Clean out old grease and replace with 130
grammes (41/2 ozs) of new Molybdenum
Disulphate Grease Grade 2 Ensure this is
pumped into holes on the side of Hammer
Casing 2590.1000 and onto all eight
striking faces.
Use of the correct quality grease will extend
the life of both Anvil and Hammer.
7. ENGINE
Clean Starter Housing and Cylinder Fins at
regular intervals. Use either a brush or
compressed air.
Dirt build up on the cylinder will generate
overheating which could then reduce engine
performance.
8. CARRYING AND THROTTLE HANDLE
Replace Rubber Mounts when they are
ineffective or worn out.
9. ROUTINE MAINTENANCEINSTRUCTIONS
It is recommended a record of
inspections and maintenance is kept
and each Wrench is given a routine
maintenance check every three months.
This will reduce maintenance costs,
improve efficiency and extend its useful life.
Fix a label showing next Service date
DAILY Check all Bolts, Screws and Nuts for
tightness and gearbox oil level.
WEEKLY Clean Air Filter and Fuel Filter. If
necessary use a suitable Solvent.
MONTHLY Clean Spark Plug and
check gap is 0.5 m
THREE MONTHS As above plus following:-
Clean internal Hammer and Anvil
faces thoroughly and replace Grease.
SIX MONTHS Change Fuel Filter and check
condition of Air Filter and Spark Plug
ANNUALLY Replace Gear Box Oil
Use only GENUINE MASTER SPARE PARTS
This will cost less than using non original Spare
Parts which generally don’t last as long.
Use of non-original parts reduces Wrench life
cancels Warranty and affects Product
Liability cover.
7

New Master 35 Petrol/Gasoline Impact Wrench
MOTOR –REPAIRS (See Exploded Diagram Drawings on Pages 9 to 13
Please Note :
The Spring in the Cassette
Case is tensioned.
Always handle with care
1.REMOVINGTOPCOVER4003.3006
Remove Muffler Guard 2650.1670 by loosening
four Screws 2300.0520. Lift Top Cover clips to
remove Air Filter Cover 4003 3010. Loosen three
Screws 4003.2070 and lift Top Cover. Pay
attention to pull Spark Plug wire aside, noting
position for reconnecting it.
2. REPLACING STARTER RECOILSPRING
4003.2150
Follow procedure for replacing Starter Rope - See
4 on Page 7. With the Pulley separated from Starter
Housing, remove two Screws 4003.0096.
Remove old Spring Cassette and replace with new
one. Refit screws.
When refitting Starter Housing pull Starter Cord
to ensure it operates before tightening Screws.
3.REMOVINGEXHAUSTGUARD2650.1670 and
MUFFLER ASSEMBLY 4003.5270
Remove four Screws 2300.0520 holding
Exhaust Guard and lift off. Unfasten two
Screws 4003.2060 on inside of Exhaust Box
and remove it and Gasket 4003.5033 from
Motor. When re-assembling tighten screws
to 10 Nm (7 3/8 ft/lbs. Warm Muffler by running
Engine and tighten screws again. This ensures
the Muffler is held on securely.
4. MUFFLER ASSEMBLY
The muffler is fitted with a catalytic converter to
comply with international emission regulations.
DO NOT modify or remove it
WARNING
a) DO NOT use the impact wrench if the muffler is
damaged or missing.
This could cause a fire hazard or damage the operators
hearing.
b) The catalytic muffler gets very HOT
during use, when idling and remains hot after use. A
damaged muffler must be replaced. If it becomes
clogged regularly this suggests it is no longer efficient
and should be replaced.
5. CARBURETTOR ADJUSTMENT
Before adjusting the Carburettor clean the
Starter Cover and Air Filter. Fuel and warm
up Engine. This special Engine is designed
and Manufactured to comply with (EU)
2016/1628 (EU) 2017/654 and (EU) 2017/656
Regulations.
The Carburettor is designed to allow limited
adjustment of Screws L and H by one half turn
which is factory set and should not be changed
by the user. Idle Screw T is adjusted to provide
a safety margin between idle running and clutch
engagement. If the Anvil turns during idling, lower
the idle speed by turning Screw T out until the
Anvil stops.
5. Continued
If engine cuts out turn idle screw in and repeat
process.
Screw L should be adjusted so
engine responds to quick
acceleration and good idle
operation.
Screw H is adjusted so engine
produces maximum power.
The main reason for having to make
adjustments on a new Wrench is to allow for
climatic conditions and working at high altitudes.
WARNING : Don’t try to force the screws
outside the present range
6. REMOVING CARBURETTOR 4003.3220
Remove top cover as per section 1, then
remove two side Screws 2300.0520 from Exhaust
Guard, two Manifold Screws 4003.3090 and
disconnect Pipes 4003.3310 & 4003.6140 from
Carburettor making sure to note re-connecting
positions. Lift and disconnect Throttle Cable
4003.6030 and remove Carburettor.
7. DISMANTLING MOTOR FROM IMPACT UNIT
Remove Carrying Handle 2800.4650 and
2626.5010 complete by removing two nuts
2310.2061, two screws 4003.2050, fixing screw
2580 0814 and four Screws 2300.0635 holding
Clutch Support Flange 2600.0460 to the Engine
and pull apart.
8.REMOVINGFLYWHEEL 4003.2090
Fit Piston Stop Tool 4000.0307 into Cylinder and
remove Flywheel Nut 4003.0040. Open Flywheel
Ratchet Assembly 4003.1187. Using Puller
4000.0308 remove Flywheel.
9. REMOVING CYLINDER AND PISTON
After completing Sections (1) (3) and (6) remove
four Screws 4003.5030 and lift away Cylinder.
Using Fine Nose Pliers remove Retaining Clip
4003.0140 and Gudgeon Pin 4003.0800.
10. REMOVE CRANKCASE from FUELTANK
After completing sections (1) (3) (6) and (7)
remove four screws 4003.6050 and Tank by
pulling the Trigger Handle gently backwards.
11. REMOVING CRANKSHAFT
Use Piston Stop Tool and remove Clutch
4003.1110.
After completing sections (8),
(9) and (10) remove seven screws 4003 3230 and
split Crankcase. When rebuilding use new Gasket
Kit 4003.3190 and two Crankcase Oil Seals
4003.0210.
8

New Master 35 Petrol/Gasoline Impact Wrench
MASTER MOTOR PARTS LIST - CARBURETTOR
Ref No
Qty
Part No.
Description
1
2
4003.4010
Spring
2
1
4003.4020
Min. Adjustment Screw
3
2
4003.4030
Cap
4
1
4003.4040
Repair Kit
5
1
4003.3220
Carburettor
6
1
4003.4050
Max Adjusting Screw
9

New Master 35 Petrol/Gasoline Impact Wrench
MASTER MOTOR PARTS LIST –CYLINDER & PISTON
Ref No
Qty
Part No.
Description
1
1
4003.5010
Spark Plug
2
4
4000.0885
Washer
3
4
4003.5030
Screw
4
1
4003.5042
DecompressionButton
(4003.1073)
5
1
4003.5050
Housing
6
1
4003.0390
Spring Ring
7
1
4003.0830
Gasket
8
2
4001.4320
Seal
9
2
4000.0378
Bearing
10
1
4003.5100
Motor Shaft
11
1
4003.0580
Bearing
12
1
4003.0600
Clutch Washer
14
1
4003.1110
Clutch Complete
Ref No
Qty
Part No.
Description
15
1
4003.3190
Gasket Kit
17
1
4003.0050
Spring
22
2
4003.5170
Piston Ring
23
2
4003.0140
Spring Clip 72.01198
24
1
4003.0800
Gudgeon Pin
25
1
4003.5200
Piston Kit
26
1
4003.5210
CompleteCylinder
27
2
4003.2060
Screw
28
1
4003.5230
Gasket
29
4
4003.5240
Screw
30
1
4003.5250
Deflector
31
1
4003.5260
Seal
32
1
4003.5270
Complete Muffler
33
1
4003.5033
Seal
10
9

New Master 35 Petrol/Gasoline Impact Wrench
MASTER MOTOR PARTS LIST –FUEL TANK
Ref
No
Qty
Part No.
Description
1
1
4003.0470
‘O’ Ring
2
1
4003.6020
Fuel Filler Cap
3
1
4003.6030
Throttle Cable
4
4
4003.6040
Antivibration Bush
5
4
4003.6050
Screw
6
2
4003.0870
Rubber Mount
7
1
4003.6070
Cam
8
1
4003.6080
Throttle Lever
9
1
4003.6090
Spring
10
1
4003.6100
Lever
11
1
4003.6110
Cover
12
3
4003.6120
Screw
13
1
4003.6130
Fuel Tank Complete
14
1
4003.6140
Tube
15
1
1708.0070
Fastening Clip
16
1
4003.1075
Fuel Filter
19
1
4003.0460
Vent Tube
21
1
4003.6150
Cover
22
3
4003.2050
Screw
23
2
4003.6160
Spacer
11

New Master 35 Petrol/Gasoline Impact Wrench
Ref
No
Qty
Part No.
Description
1
2
4003.2010
Screw
2
2
4003.0100
Washer
3
1
4003.2030
Spring
4
1
4003.2110
Coil (was 4003.2040)
5
1
4003.0040
Nut
6
1
4003.0670
Washer
7
1
50.00361
Washer
8
1
4003.0440
Flywheel Ratchet Assembly
9
1
4003.2090
Flywheel Kit
10
1
4003.2100
Flange
11
1
4003.0690
Screw
12
1
4003.0700
Washer
13
1
4003.2130
Starter Pulley
14
4
4003.0096
Screw
15
1
4003.2150
Starter Spring
16
1
4003.2160
Washer
17
1
4003.0340
Starter Rope
18
1
4003.2180
Starter Handle
19
1
4003.2190
Starter Assembly
20
4
4003.2070
Screw
21
1
4003.2210
Plug
22
1
4003.2220
Cover
MASTER MOTOR PARTS LIST –STARTER ASSEMBLY
12

New Master 35 Petrol/Gasoline Impact Wrench
MASTER MOTOR PARTS LIST –TOP COVER & CRANKCASE
Ref No
Qty
Part No.
Description
1
1
4003.3010
Filter Cover
2
2
4003.3020
Clip
3
2
4003.2070
Screw
4
1
4003.3040
Deflector
5
1
4003.3050
Spacer
6
1
4003.3006
Cover
7
1
4003.3070
Guide
8
1
4003.3080
Air Filter
9
2
4003.3090
Screw
10
1
4003.3100
Filter Support
11
2
4003.3120
Bush
13
1
4003.3130
Ground Cable
14
1
4003.3140
Cable
15
1
4003.3150
Ring
16
1
181.00118
Fuel Filter Cap
Ref No
Qty
Part No.
Description
17
1
4003.3170
Crankcase
18
1
4003.3180
Gasket
20
1
4003.3190
Gasket Kit
22
1
4003.3200
Screw
23
1
4003.3210
Cable Entry
24
1
4003.3220
Carburettor
26
7
4003.3230
Screw
36
1
4003.3240
Stop Lever
37
1
4003.3250
Screw
38
1
4003.3260
Screw
39
1
4003.3270
Spring
40
1
4003.3280
Seal
41
1
4003.3290
Support
42
4
4003.3300
Antivibration Mount
43
1
4003.3310
Vent tube
45
1
4003.3320
Protection
13

New Master 35 Petrol/Gasoline Impact Wrench
1. REMOVING CLUTCH SUPPORT FLANGE
2600.0460
After completing section 10 Motor Repairs Page
8 remove Gear Selector 035304 and empty oil
from Gearbox 035105. Remove six Screws
4003.0635 holding Clutch Support Flange to
Gearbox and pull apart. Always use a suitable
thread lock when rebuilding.
2. REMOVINGCLUTCH4003.1110
Remove Spark Plug 4003.5010 and fit Piston Stop
Tool 4000.0307. Turn Clutch in clockwise
direction and remove. If replacing fit a new
clutch washer 4003.0600
Assemble in reverse order.
3. REPLACING SEAL 2342.4370 & BEARINGS
2332.0200 IN CLUTCH SUPPORT FLANGE
2600.0460
Remove Circlip 2321.0200 and using a Soft
Face Mallet tap out Clutch Ring 2690.7300.
Remove Circlip 2322.0420 and from the
opposite side push out Bearings 2332.0200.
Remove Oil Seal 2342.4370 and replace if
necessary. Assemble in reverse order.
4. DISMANTLING GEARBOX 035105
Remove Ring Flange 035561 and check Bearings
2332.0351 and 2332.0300 and replace Oil
Seal 2343.0520. Remove Cluster Gear Shaft
2690.6000 and check for damage. Note
position of Gear Cluster 035104 before
removal for rebuild purposes.
Remove Circlip 2321.0160 and lift off Drive
Gear 2640.7300 then remove Circlip 135516
and from the opposite side tap Drive Gear Shaft
035119 using a Flat Punch and remove with
Bearing 2331.0170. Check for wear and damage.
Remove Satellite Gear 035551 by tapping inwards
and then remove it and the Gear Cluster. Check
both for wear or damage. Assemble in reverse
order.
When rebuilding the Gearbox always fit new Seals
and Gaskets. Use Gasket Kit 2890.1065
Please Note:
The Satellite Gear has a chamfered edge
which MUST be re-fitted in the same way as
before.
5. DISMANTLING COMPLETE HAMMER 035309
Place complete Hammer Assembly length
ways in a vice with one hole uppermost.
Carefully tighten vice until Steel Ball
2360.1032 drops out of the lower hole - a short
blast of air will assist this operation. Loosen vice
and turn Hammer over to opposite hole and
repeat previous instruction to allow second
ball to be removed and loosen vice
again. Hammer Assembly 035302 can now
be separated. Remove Shaft 035567, Spring
035566 and Bearing 2334.0210 and
inspect for wear and damage.
Re-grease as per Routine Service
item 6 on Page 7 and assemble in
reverse order.
Inspect Anvil 035572 and Hammer 035302
striking faces for wear or damage. These
are critical areas which will affect the
Wrenches performance and vibration. Refit
Hammer and Anvil to Gearbox and replace
Nose Casing 035301 with new Gasket
035562.
6. ANVIL 035572
The Square Drive is 1” (25.4mm). If this
wears by 1mm (1/32”) or more replace it
immediately.
The wear can be checked using our No Go
Gauge.
A worn Anvil reduces speed of
operation, increases vibration,
damages Sockets and Accessories
and the Wrench
IMPACT UNIT –REPAIRS See Exploded Diagram Drawings on Pages 15 to 17
14

New Master 35 Petrol/Gasoline Impact Wrench
Ref No
Qty
Part No.
Description
1
1
2870.0610
Impact Assembly
3
1
2650.1670
Exhaust Guard (2650.1660)
4
1
2800.4653
Compl.AntiVibrationHandle
4.1
1
2620.5200
Handle
4.2
1
035129
Side Support
4.3
4
54.00227
Rubber Mount
4.4
2
4000.3290
Cap
4.5
2
54.00563
Cap
4.6
2
2580.0085
Screw
4.8
2
2310.2061
Locknut
4.9
2
2400.1050
Lock Washer
5
1
2650.1050
FuelTank Protection Plate
6
1
2810.1072
Engine Complete
IMPACT UNIT, GEARBOX AND CARRYING HANDLE
Ref No
Qty
Part No.
Description
8
3
4003.2050
Screw
9
1
2700.0200
Retention
10
1
2580.0050
Fixing Screw
11
1
2310.2061
Locknut
12
1
2580.0814
Screw
13
4
2300.0520
Screw
14
2
2300.0635
Screw
15
4
2400.7060
Lock Washer
16
4
2400.2080
Flat Washer
17
1
2626.5010
Roll Bar only
18
2
2310.2081
Lock Nut
19
2
2400.8080
Lockwasher
20
4
2400.1050
Lockwasher
21
1
Serial Number Label
15

New Master 35 Petrol/Gasoline Impact Wrench
IMPACT UNIT AND GEARBOX –DETAILED
16

New Master 35 Petrol/Gasoline Impact Wrench
Ref
No
Qty
Part No.
Description
1
1
035560
Flange Gasket
2
1
035562
Gasket
3
1
2500.2065
Gasket
4
1
035115
Flange Gasket
5
3
2300.0851
Screw
6
1
2300.0856
Screw
7
3
2310.2081
Locknut
8
5
2400.8080
Lock Washer
9
6
2300.0635
Screw
10
7
2400.7060
Lock Washer
11
1
2600.0460
Clutch Flange
12
1
2342.4370
Seal Ring 24x37x7
13
2
2332.0200
Bearing
14
1
2690.7300
Clutch Ring
15
1
2322.0420
Stop Ring 42
16
1
2321.0200
Stop Ring 20
17
4
2540.7090
Plug
18
1
035105
Gearbox
19
1
035106
Bronze Bush
20
1
035119
Gear
21
1
2331.0170
Bearing
22
1
135516
Circlip
23
1
2640.7300
Drive Gear
24
1
2321.0160
Circlip
25
1
2331.0200
Bearing
26
1
035104
Gear Cluster
27
1
035103
Bush
28
1
2690.6000
Cluster Gear Shaft
29
1
035548
Bronze Bush
30
1
035551
Gear with Bush
31
1
035548
Satellite Gear Bush
32
1
035549
Satellite Pin
33
1
2580.0090
Gear Lever
34
1
035112
Gear Selector
35
1
135114
O Ring
36
1
2360.0397
Ball
Ref
No
Qty
Part No.
Description
37
1
035523
Spring
38
1
035111
Gear Lever Flange
39
1
035107
Reverse Lever
40
1
035554
Pin
41
1
135110
Ring
42
1
2300.0620
Screw
44
1
035561
Ring Flange
45
1
2343.0520
Ring Seal
46
1
2332.0351
Bearing
47
1
2332.0300
Bearing
50
1
035568
Hammer Casing
51
1
035538
Cam
52
4
035537
Steel Plug (4)
53
2
135533
Seeger Ring
54
1
035536
Steel Ring
55
1
035565
Catch
56
1
035586
Stop Bush
57
1
035585
Guide Bush
58
1
2334.0210
Bearing
59
1
035566
Spring
60
1
035567
Central Shaft
61
2
2360.1032
Ball 13/32"
62
1
035572
Anvil
64
1
033005
Nose Casing Bush
65
1
135542
‘O’ Ring
67
1
135153
Foot Rest
68
3
2400.7050
Lock Washer
69
3
2300.0510
Screw M5x12
72
1
135520
Oil Plug
100
1
2890.1065
Set of Gaskets
1,2,3,4,12,45,65
101
1
035309
Impact Assembly
102
1
035302
Hammer Assembly
103
1
035304
Gear Selector Assembly
104
1
035301
Nose Casing and Bush
IMPACT UNIT AND GEARBOX –DETAILED
17