Cleco WP2049 Series Installation and operating instructions

1
Operation & Service Manual
823033 2/01
WP2049 & WP2050 SERIES IMPACTS
2049
2050
Tool Size:
W
Pistol Grip
Impact Wrench:
P
Handle:
-- XXXXSPX
Ring Retainer
Quick Change
R
Q
Output Drive:
6
53/4" 5/8"
NORTH AMERICA EUROPE
CooperTools
P.O. Box 1410
Lexington, SC 29071
Cooper PowerTools GmbH & Co.
Postfach 30
D-73461 Westhausen

2
SafetyRecommendations
nel, clear air hose of accumulated dust and moisture. Before
removing a tool from service or changing sockets, make sure
theairlineisshutoffanddrainedofair.Thiswillpreventthetool
from operating if the throttle is accidently engaged.
Never use the air hose for supporting, lifting, or lowering the
tool. Use a safety line or cable on the tool when working in
elevated areas.
Tools with exposed throttles should not be used where ob-
structions can hold the throttle in the “on” position. An impact
wrench operating in reverse will move backwards as a nut is
removed and can trap an operator's hand, making it difficult to
release an outside trigger. Inside trigger or pistol grip tools are
advised for close quarter operation.
Only use sockets designed for use with impact wrenches.
Never use a hand tool socket on an impact wrench. Hand tool
sockets can break, resulting in a hazard from flying pieces.
Inspect sockets, retainers, and drives regularly for wear or
damage, and replace as necessary. Worn sockets reduce
power,causedrivewear,andincreasethechanceforbreakage
and should not be used.
Some individuals may be susceptible to disorders of the hands
and arms when performing tasks consisting of highly repetitive
motions and/or exposure to extended vibration. Cumulative
trauma disorders such as carpal tunnel syndrome and ten-
donitis may be caused or aggravated by repetitious, forceful
exertions of the hands and arms. Vibration may contribute to a
condition called Raynaud's Syndrome. These disorders de-
velop gradually over periods of weeks, months, and years. It is
presently unknown to what extent exposure to vibrations or
repetitive motions may contribute to the disorders. Hereditary
factors, vascular or circulatory problems, exposure to cold and
dampness, diet, smoking and work practices are thought to
contribute to the conditions.
For your safety and the safety of others, read and understand
the safety recommendations before operating an impact
wrench.
Always wear protective equipment and clothing.
For additional information on eye protection, refer to Federal
OSHA Regulations, 29 CFR, Section 1910.133, Eye and Face
Protection,andANSIZ87.1,OccupationalandEducationalEye
and Face Protection. This standard is available from the
American National Standards Institute, Inc., 11 West 42nd
Street, New York, NY 10036.
Hearing protection is recommended in high noise areas
(above 85 dBA). Close proximity of additional tools, reflective
surfaces, process noises, and resonant structures can sub-
stantially contribute to the sound level experienced by the
operator. Proper hearing conservation measures, including
annual audiograms and training in the use and fit of hearing
protection devices may be necessary. For additional informa-
tion on hearing protection, refer to Federal OSHA Regulations,
29 CFR, Section 1910.95, Occupational Noise Exposure, and
American National Standards Institute, ANSI S12.6, Hearing
Protectors.
•Gloves and other protective clothing should be worn as
required, unless they create a greater hazard.
•Do not wear loose fitting clothing, or clothing that may
restrict movement, become entangled or in any way
interfere with the safe operation of the impact.
Clecoimpact wrenches aredesigned to operateon 90 psig(6.2
bar) maximum air pressure. If the tool is properly sized and
applied, higher air pressure is unnecessary. Excessive air
pressure increases the loads and stresses on the tool parts,
sockets, and fasteners and may result in breakage. Installation
of a filter-regulator-lubricator in the air supply line ahead of the
tool is highly recommended.
Before the tool is connected to the air supply, check the throttle
for proper operation (i.e., throttle moves freely and returns to
closed position). Being careful not endanger adjacent person-
WARNING!
Impact resistant eye protection
must be worn while operating
or working near this tool.
Repetitive work motions and/or vibration
may cause injury to hands and arms.
Use minimum hand grip force consistent
with proper control and safe operation.
Keep body and hands warm and dry.
Avoid anything that inhibits blood circulation.
Avoid continuous vibration exposure.
Keep wrists straight.
WARNING
!
Avoid repeated bending of wrists and hands.
CAUTION!
Personal hearing protection is
recommended when operating
or working near this tool.

3
SafetyRecommendations
the glove manufacturer be consulted for gloves designed for
your specific application. WARNING! Proper fit of gloves is
important.Improperlyfittedglovesmayrestrictbloodflowto
the fingers and can substantially reduce grip strength.
Also note that various tool wraps are available from a number
of different manufacturers. Like gloves, these wraps are also
intended to reduce and moderate the effects of extended
vibration exposure. They vary widely in design, material, thick-
ness, vibration reduction, effectiveness, and durability, so
considerationmustbegiventochoosing theproperwrapforthe
specific application.
This information is a compilation of general safety practices
obtained from various sources available at the date of produc-
tion. However, our company does not represent that every
acceptable safety practice is offered herein, or that abnormal
or unusual circumstances may not warrant or require addi-
tional procedures. Your work may require additional specific
safety procedures. Follow these procedures as required by
your company.
Warnings
The warnings found on these tools are an essential part of the
product. Warnings should be checked periodically for legibility.
Replace warnings when missing or when the information can
no longer be read. Replacements can be ordered as any spare
part.
869976
Formoreinformation,seethelatest editionofANSI B186.1,
SafetyCodeforPortableAirTools,availablefromtheAmeri-
can National Standards Institute, Inc., 11 West 42nd Street,
New York, NY 10036.
These operating instructions and service manual should
accompany tool if it is subsequently sold or ownership is
changed.
Tool operators should be aware of the following warning signs
and symptoms so that a problem can be addressed before it
becomes a debilitating injury. Any user suffering prolonged
symptoms of tingling, numbness, blanching of fingers, clum-
siness or weakened grip, nocturnal pain in the hand, or any
other disorder of the shoulders, arms, wrists, or fingers is
advised to consult a physician. If it is determined that the
symptoms are job related or aggravated by movements and
postures dictated by the job design, it may be necessary for the
employer to take steps to prevent further occurrences. These
steps might include, but are not limited to, repositioning the
workpiece or redesigning the workstation, reassigning work-
ers to other jobs, rotating jobs, changing work pace, and/or
changing the type of tool used so as to minimize stress on the
operator. Some tasks may require more than one type of tool
to obtain the optimum operator/tool/task relationship.
• Tasks should be performed in such a manner that the
wrists are maintained in a neutral position, which is not
flexed, hyperextended, or turned side to side.
• Stressfulposturesshouldbeavoided. Selectatool ap-
propriate for the job and work location.
The following suggestions will help reduce or moderate the
effects of repetitive work motions and/or extended vibration
exposure.
•Use a minimum hand grip force consistent with proper
control and safe operation
•Keep body and hands warm and dry
•Avoid anything that inhibits blood circulation
—Smoking Tobacco
—Cold Temperatures
—Certain Drugs
•Keep wrists as straight as possible
•Avoid highly repetitive movements of hands and wrists,
and continuous vibration exposure
Work gloves with vibration reducing liners and wrist supports
are available from some manufacturers of industrial work
gloves.These gloves aredesigned to reduce andmoderate the
effects of extended vibration exposure and repetitive wrist
trauma. Since they vary widely in design, material, vibration
reduction, and wrist support qualities, it is recommended that
BAD POSTURE
GOOD POSTURE
OVER
CAUTION!
Personal hearing protection is recommended when operating or working near this tool.
WARNING!
Impact resistant eye protection must be worn while operating or working near this tool.
Read Operating Instructions carefully. Follow the Safety Recommendations for your safety and the safety of others. Hearing protection is recommended in high noise areas (above 85 dBA). Close proximity of other tools, reflective surfaces, process noises, and resonant structures can substantially contribute to the sound level experienced by the user.
WARNING
!
Repetitive work motions and/or vibration can cause injury to hands and arms. Use minimum hand grip force consistent with proper control and safe operation. Keep body and hands warm and dry. Avoid anything that inhibits blood circulation. Avoid continuous vibration exposure. Keep wrists straight.
Avoid repeated bending of wrists and hands.
Do not remove this tag until the operator of this tool has read these safety precautions.

4
REASSEMBLY
All parts should be cleaned in a solvent and inspected for
wear or damage. If rotor blades measure less than 5/16"
(7.9mm) on either end, they should be replaced. Rotor
bearingsshouldbe replacediftheyshowexcessiveloose-
ness. Rotor shaft seals and the anvil seal should be
replaced if they are badly worn or no longer flexible.
Clean the bearing plates and anvil housing with a solvent
andcoat thesealbores with"PERMATEX"Aviation Form-
a-gasket #3H. Allow to air dry at least four (4) minutes
beforepressingintheseals.Presstherotorshaftsealsinto
the bearing plates with their "lips" facing outward (visible
afterassembly).Press the anvil seal into the anvil housing
withits"lips"towardtherearofthehousing("lip"notvisible
after assembly).
All impact mechanism and motor parts should receive a
thin coating of 30W oil before reassembly. Insert the cam
timing pin into the recess located on the small O.D. of the
cam and then install the cam and pin into the rear of the
hammer. Install the cam roller shaft in the cam shaft. Put
the cam roller on the roller shaft and slip the butt plate,
insulator, and shock absorber onto the rear of the cam
shaft.Hold the cam shaft vertically onthe work bench with
theshock absorber down and tap the end of the cam shaft
with a soft mallet to seat the cam shaft in the shock
absorber.
Slip the cam shaft and related components through the
cam and hammer assembly. Install the hammer spring,
springclip,andanvilpinontothefrontofthecamshaftand
hammer assembly. Rotate the spring clip to accept the
anvil pin and then install the anvil on top of the assembly
(be sure the slot in the anvil lines up with the anvil pin) and
drivetheanvildownuntilthespringclipengagestherecess
in the anvil.
During the assembly of the motor unit, the rear of the rotor
canbeidentifiedbythe"O"-ring,No.869715,and the "O"-
ringgroovelocatedinthel.D.oftherotorbore.Thecylinder
port "O"-rings can be coated with grease to retain them
during assembly of the motor unit.
During reassembly of the complete tool, 3/8 fluid ounces
(12ml) of 30W oil should be placed in the anvil housing.
Install the anvil housing on the tool with the straight flange
down (i.e., toward the trigger). Before installing the rear
cap,1/4fluidounce(8ml)of30Woilshouldbeaddedtothe
rear cavity of the rotor.
All tools should be tested after repair or replacement or
parts to ensure that they are functioning properly.
OPERATING INSTRUCTIONS
OPERATION
The WP-2049 and WP-2050 Impact Wrench is designed to
operate on 90 psig (6.2 bar). The minimum hose size is
3/8" (10mm).
LUBRICATION
An automatic in-line filter-lubricator is recommended as it
increasestoollifeandkeepsthetoolinsustainedoperation.
Thein-line lubricator should be regularly checked and filled
withagoodgradeof10Wmachineoil.Properadjustmentof
thein-linelubricatorisperformedbyplacingasheetofpaper
next to the exhaust ports and holding the throttle open
approximately 30 seconds. The lubricator is properly set
when a light stain of oil collects on the paper. Excessive
amounts of oil should be avoided. In the event an in-line
lubricator is not used, the oil reservoir in the handle should
be utilized.
The oil reservoir marked "30W Oil" should not require
attention until the tool is torn down for inspection purposes.
However, if the tool is on the application for an unduly long
periodoftime,theplugshouldberemovedandthereservoir
checked for the presence of oil. If oil is required, approxi-
mately1/2fluid ounce (16ml) of 30Woilshouldbeadded to
the oil reservoir.
STORAGE
In the event that it becomes necessary to store the tool for
an extended period of time (overnight, weekend, etc.), it
shouldreceiveagenerousamountoflubricationatthattime
and again when returned to service. The tool should be
stored in a clean and dry environment.
SERVICE INSTRUCTIONS
DISASSEMBLY
Loosen and remove the four (4), housing bolts. This will
allow the anvil housing and impact mechanism to be re-
moved from the front of the motor housing. The motor unit
may now be slipped out the rear of the motor housing.
Clampthehammer,No.869325,horizontallyinasoft-jawed
viseanddrive the anvil awayfromthehammer,using a soft
hammer. This will allow the anvil pin, No. 867437, spring
clip,No.869336,andthehammerspring,No.869345,tobe
removed from the front of the cam shaft, No. 869322. This
will allow the cam shaft and related components to be
removed from the rear of the hammer.
Slip the two (2) bearing plates off the rotor and remove the
cylinder and six (6) rotor blades.
Unscrewing the air inlet bushing will allow the throttle valve
to be removed for inspection of the throttle valve seal.
Remove the air inlet screen for cleaning and inspection.

5
PARTNO.
203997
203998
842455
843924
844077
861736
864710
864711
864712
865019
867437
869322
869325
869326
869329
869330
869331
NAMEOFPART
RetainerRingAnvil(incl.203998)
Ring Retainer Kit (incl. "O"-ring & Ring)
Lock Washer
SocketHeadCap Screw
5/16" Steel Ball ("Q" Model)
AnvilHousing(incl.869340,
869344,869404)
LockPinRetainerSleeve
Socket Lock Pin
Lock Pin Spring
CamRoller
AnvilTimingPin
CamShaft
Hammer
Cam
ShockAbsorber
Insulator
Butt Plate
PARTNO.
869335
869336
869338
869339
869340
869344
869345
869346
869347
869351
869353
869354
869355
869356
869404
NAMEOFPART
Hanger(ExtraEquipment)
SpringClip
CamTimingPin
CamRollerShaft
AnvilHousingSeal
AnvilBushing
HammerSpring
3/4" Sq. Dr. Anvil
5/8" Sq. Dr. Anvil (incl. 864710,
864711,864712)
"Q"ModelAnvil (5/8" internalhex)
ReleaseCollar("Q"Model)
ReleaseCollarSpring("Q"Model)
ReleaseCollarRetainer("Q"Model)
ReleaseCollarWasher("Q"Model)
RetainerRing
The "Q" Model anvil may be purchased as a complete subassembly using part no. 861858.
QTY.
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PARTS LIST —IMPACT MECHANISM

6
PART NO.
832117
843434
863399
863627
869321
869323
869324
869332
NAMEOF PART
AlignmentPin
30W Oil Fill Plug
"O"- Ring 7/16" x 9/16"
RotorBearing
Rotor (incl. 869715)
Bearing Plate (WP-2049 Requires
oneOnly)
BackCap Gasket
MotorClampSeal
PART NO.
869341
869343
869348
869352
869715
869741
869742
882311
NAME OF PART
Rotor Shaft Seal
Rotor Blade
Cylinder (WP-2050)
Rear Cap
"O"-Ring 15/16" x 1-1/16"
Rear Bearing Plate (WP-2049)
Cylinder (WP-2049)
"O"-Ring 1-15/16" x 2-1/8"
QTY.
1
1
2
2
1
2
1
1
QTY.
2
6
1
1
1
1
1
1
PARTS LIST —MOTOR UNIT

7
PART NO.
412775
619016
813449
833471
843571
844892
863072
869320
NAME OF PART
Screen
RetianerRing
O-ring 5/16" X 1/2"
InletBushing
OilerValve
10W Oil Fill Plug
ThrottleValveSpring
Motor Housing ( incl. 843571)
PART NO.
869328
869337
869342
869349
869350
869712
NAME OF PART
ReversingValve
Muffler
Trigger (incl. 869712)
Air Screen Sleeve
ThrottleValve
O-ring 5/64" X 13/64"
QTY.
2
1
1
1
1
1
1
1
QTY.
1
1
1
1
1
1
PARTS LIST —MOTOR HOUSING
The complete motor housing can be purchased as a complete subassembly using part no. 861737

8
CooperTools
670 Industrial Drive
Lexington, SC 29072
Phone: [phone]
Fax: [phone]
www.cooperindustries.com