GATOR ESP710 Battery Stud Punch

Transcription

1 INSTRUCTION MANUAL GATOR ESP710 Battery Stud Punch Serial Code AKJ Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Register this product at Greenlee Textron Inc. IM 1503 REV 9 9/10

2 Table of Contents Description... 2 Purpose... 2 Important Safety Information Identification... 5 Specifications... 6 Operation... 6 Maintenance... 7 Troubleshooting and Service... 8 Disassembly/Reassembly Exploded Views Parts List Safety Safety is essential in the use and maintenance of Greenlee tools and equipment. This manual and any markings on the tool provide information for avoiding hazards and unsafe practices related to the use of this tool. Observe all of the safety information provided. Purpose This instruction manual is intended to familiarize operators and maintenance personnel with the safe operation, troubleshooting and repair procedures for the Gator ESP710 Battery-powered Stud Punch. Keep this manual available to all personnel. Replacement manuals are available upon request at no charge at Description Do not discard this product or throw away! For recycling information, go to The ESP710 Battery-powered Stud Punch is a hand-held, self-contained tool intended to punch a 1.34" diameter hole in metal studs up to 16 gauge thick. All specifications are nominal and may change as design improvements occur. Greenlee Textron Inc. shall not be liable for damages resulting from misapplication or misuse of its products. AVIA is a registered trademark of Avia International. Mobil is a registered trademark of Mobil Oil Corporation. NUTO is a registered trademark of Exxon Corporation. Tellus is a registered trademark of Shell Oil Company. KEEP THIS MANUAL Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

3 IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard. Electric shock hazard: This tool is not insulated. When using this unit on or near energized electrical lines, use proper personal protective equipment. Failure to observe this warning could result in severe injury or death. Immediate hazards which, if not avoided, WILL result in severe injury or death. Hazards which, if not avoided, COULD result in severe injury or death. Skin injection hazard: Do not use hands to check for leaks. Depressurize the hydraulic system before servicing. Oil under pressure easily punctures skin causing serious injury, gangrene, or death. If you are injured by escaping oil, seek medical attention immediately. Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage. Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Failure to observe this warning could result in severe injury or death. Do not use solvents or flammable liquids to clean the tool. Solvents or flammable liquids could ignite and cause serious injury or property damage. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

4 IMPORTANT SAFETY INFORMATION Inspect tool before use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby personnel. Failure to observe this warning could result in severe injury or death. Pinch points: Remove battery before changing dies, adapters, or jaws. Keep hands away from the tool head when punching. Failure to observe these warnings could result in severe injury or death. Do not dispose of batteries in a fire. They will vent vapors and may explode. Failure to observe this warning could result in injury from inhalation of vapors or burns from flying debris. Wear eye protection when using this tool. Failure to wear eye protection could result in serious eye injury from flying debris or hydraulic oil. Do not operate tool without dies. Damage to the ram or C-head may result. This tool is not designed for continuous use. After 30 to 40 cycles, allow the tool to cool for 15 minutes. Do not place the tool in a vise. This tool is designed for hand-held operation. Protect the tool from rain and moisture. Water will damage the tool and battery. Use this tool for the manufacturer s intended purpose only. Failure to observe these precautions may result in injury or property damage. Do not allow anything to contact the battery terminals. Do not immerse the batteries in liquid. Liquid may create a short circuit and damage the battery. If batteries are immersed, contact your service center for proper handling. Do not place the battery into a pocket, tool pouch, or tool box with conductive objects. Conductive objects may create a short circuit and damage the battery. Do not place a battery on moist ground or grass. Moisture may create a short circuit and damage the battery. Do not store the battery at more than 60 C (140 F). Damage to the battery can result. Do not use another manufacturer s charger. Other manufacturers chargers may overcharge and damage the battery. Do not attempt to open the battery. It contains no user-serviceable parts. Failure to observe these precautions may result in injury or property damage. Do not perform any service or maintenance other than as described in this manual. Injury or damage to the tool may result. Failure to observe this precaution may result in injury and property damage. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

5 Identification Housing 5. Battery Load Display 2. Retract Button 6. C-Head 3. Battery 7. Punch 4. Trigger Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

6 Specifications Weight (with battery) kg (9.0 lb) Overall Length cm (14-1/2") Width cm (4") Height cm (12") Motor...Direction-Current Permanent Field Motor Motor Voltage...12 VDC Charging Voltage V Charging Time... 1 Hour Punching Time seconds Punching Performance... approximately 175/charge Hydraulic Oil... 1 pint (50 ml) Shell Tellus T 15 Sound Level db (A) at 1 meter Vibration...< 2.5 m/s 2 Operation Charging the Battery Read the instructions supplied with the charger for explanation of proper use. Battery Condition Battery Load Display Momentary illumination at beginning of cycle Flickering at point of maximum punching force Flickering during entire punching cycle Constant when operating without a load Battery condition Normal or operating charge level Normal or operating charge level Low charge level Low charge level Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

7 Maintenance Each Operating Day Before use: 1. Inspect the punch and die for defects, such as cracks, gouges or chips. 2. Inspect the tool for damage or leaks. If damage is detected, return the tool to an authorized Greenlee service center for inspection. Skin injection hazard: Do not use hands to check for leaks. Depressurize the hydraulic system before servicing. Oil under pressure easily punctures skin causing serious injury, gangrene, or death. If you are injured by escaping oil, seek medical attention immediately. After Use: 1. Wipe clean and dry all exposed surfaces. Note: Use a slightly damp cloth and a mild detergent to clean the cutter body. Solvents can damage the cutter body and may ignite. Monthly 1. Thoroughly clean all surfaces. 2. Check the oil level. 3. Oil the bolt joints. Annually or After 10,000 Cycles 1. Change the hydraulic oil. 2. Return the tool to an authorized Greenlee service center for inspection. General Store the tool in the carrying case when it is not in use. Checking the Oil Level 1. Remove the two screws holding the tank housing cover. 2. Remove the tank housing cover. 2. Point the head towards the ground and remove the oil plug. Refill reservoir if necessary. 3. Replace the oil plug and tank housing cover. Recommended Hydraulic Oils AVIA HVI 15 Shell Tellus T 15 Mobil DTE 11M NUTO H 15 Do not use solvents or flammable liquids to clean the tool. Solvents or flammable liquids could ignite and cause serious injury or property damage. 2. Place tool in the carrying case. Store in a cool, dry place. 3. Fully discharged batteries should be recharged so that they are ready for use. (See battery charger instructions.) Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

8 Troubleshooting Before you begin 1. Make sure that the battery is charged. Recheck the battery after several minutes to make sure the battery is holding its charge. 2. Use a NONFLAMMABLE contact cleaner or pencil eraser to clean the electrical contacts on the battery and tool. 3. Reinstall battery and check the tool again. Problem Probable Cause Probable Remedy Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool. of tool. Tool battery contacts damaged. Reform contacts. Tool components worn or damaged. Return tool to an authorized Greenlee service center. Dies stop during operation. Oil level is low. Check oil level. Refill reservoir. Air in hydraulic system. Pull trigger and hold retract button simultaneously. Hold for approximately 10 seconds. Battery load display flashes Battery charge low. Charge or replace battery. constantly. Tool loses oil. Damaged internal seal. Return tool to an authorized Greenlee service center. Oil plug not installed properly. Refill reservoir and replace plug. Service Should your battery-powered tool require service, return it to an authorized Greenlee service center. Customer Center and Field Service: 800/ Fax (24-hour) Customer Center: 800/ or 815/ Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

9 Disassembly (see Exploded Views) 1. Remove battery. 2. Loosen two screws (111). 3. Unscrew and remove C-head assembly. 4. Remove piston assembly. Replace the piston O-ring (118) and piston backup ring (119). Note: There is spring tension on the piston assembly. Use arbor press to compress springs prior to removing retraining ring (105). 5. Unscrew two tank cover screws (203) and remove tank cover (207). 6. Remove the hydraulic reservoir plug (76) and drain hydraulic fluid. 7. Reinstall plug. 8. Remove the remaining housing screws (201 and 203). 9. Remove right housing half (208). 10. Remove trigger cover (205). 11. Lift pump/motor assembly and circuit card from left housing half (209). Lift LED (213) from its housing. 12. Slide a plastic bag over the circuit card and electronic subassemblies. Tape the bag shut to protect the subassemblies from hydraulic oil and other contamination. 13. Unscrew shoulder bolt (15) and remove release lever (18). 14. Remove screws (94) and separate the gear housing/ motor subassembly from pump housing. 15. Use a hooked tool to remove the reservoir O-ring (80). Gently slide it over the reservoir. 16. Remove the reservoir (74). 17. Remove pump piston (47). Replace the O-ring (46). 18. Remove screw plug (41), washer (42), pump piston (45), valve stem (44), and spring (43). Replace sealing washer (42). 19. Use a piece of tape to mark the side of the relief (11) that is facing up. (This is a reference point for reassembly.) Remove unloading valve by unscrewing the pressure relief (11). 20. Remove feeder tube subassembly by unscrewing filter adapter (78). Replace the oil filter (77). Remove metal chips from magnet (82). 21. Remove threaded bushing (72) and replace O-ring (73). Motor/Gearbox/Bearing Disassembly 22. Remove tamper-proof paper seal (89). 23. Remove two screws (87). Remove end cap (92). 24. Apply pressure evenly at three points around the ball bearing (86) and gently pry the bearing up to remove it. 25. Remove eccentric (93), grooved ball bearing (91), and snap ring (90) subassembly from shaft. 26. Remove four screws (88). Remove mounting block (95) from gear housing (96). 27. Use a snap-ring removal tool to remove the snap ring (90). 28. Unscrew four bolts (not numbered) from the gearbox (96). Separate gear housing from spacer (not numbered). Unscrew two Fillister head screws (99) to separate spacer from motor (85). Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

10 Reassembly Motor/Gearbox/Bearing Reassembly 1. Install two Fillister head screws (99) into spacer (not numbered) and motor (85). Tighten screws. 2. Install four screws (not numbered) into gearbox (96). Tighten screws. 3. Install four screws (88) into mounting block (95) and gearbox (96). Tighten screws. 4. Replace grooved ball bearing (91) and snap ring (90) subassembly. 5. Replace eccentric (93). Use a fiber mallet to tap eccentric onto shaft. Replace ball bearing (86). 6. Align end cap (92). Use a fiber mallet to tap cover until it is flush on mounting block (95). Install two screws (87). 7. Align gear housing/motor subassembly so that the pump piston (47) extends through the mounting block (95) and makes contact with the grooved bearing (91). Locate and start the screws (94) through the mounting block and into the pump housing. Tighten the screws. Pump Subassembly 8. Insert pump piston (47) into pump housing. 9. Insert seal (4) and unloading valve assembly into pump housing. Grasp needle valve subassembly by the pressure relief (11) and twist it several turns clockwise. Stop when the mark or piece of tape is facing up. 10. Assemble pump piston (45), valve stem (44), spring (43) and screw plug (41). Be sure to replace sealing washer (42). Torque screw plug (41) to 75 ft-lb. 11. Install release lever (19) so that the forked end engages the unloading valve subassembly between the pressure relief (11) and the support ring (12). Install screw (15) and washer (17). 12. Insert threaded bushing (79) and filter adapter subassembly (77, 78 and 82). Screw in until snug. 13. Install reservoir (74). Slip the O-ring (80) over the reservoir. Using a hooked tool, carefully slip the O-ring over the lip of the pump housing. 14. Insert the plug (76) into the reservoir. Misc. Components Reassembly 15. Remove the protective plastic bag from the electronics subassembly. Insert the LED into the LED bushing (213). 16. Lay the gear housing/motor subassembly into the left half of the housing. Insert the circuit board into the circuit board slot, so that the wires and chip face in the direction of the trigger. 17. Lay the wires into case. Be sure that the wires will not be pinched. 18. Guide the wires for the battery clip so that battery wires lay on top of the electronics box; install the battery clip so the red wire is upward. 19. Install the trigger cover (205). Depress and release the trigger to be sure that it operates freely. 20. Locate the right housing half (208) on top of the left housing half (209). Check for pinched wires. 21. Install the housing screws (201 and 203). Note: Handle screw (201) must engage the nut (202). 22. Install the piston assembly. 23. Replace the front head assembly. Twist the cutting head base until it stops; back off 3/4 of a turn and tighten the screws (111). Be sure that the head assembly rotates freely approximately Clamp the head assembly into a vise with the reservoir plug facing upward. Remove the plug (76) and fill the reservoir with hydraulic oil. 25. Install the battery. 26. Squeeze the trigger while depressing the release lever for seconds. Fill the reservoir with hydraulic oil. Replace the plug (76). 27. Replace the tank cover (207) and tank cover screws (203). Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

11 Exploded Views Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

12 Exploded Views (cont d) Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

13 Exploded Views (cont d) Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

14 Parts List Key Part No. Description Qty Relief valve assembly (includes items 2 14) 2 Plunger Seal Valve seat Needle valve O-ring Spring Pressure relief Support ring Retaining ring O-ring, needle valve Retraction lever assembly (includes items 15 17) 15 Screw, flat head M4 x Release lever Compression spring Motor accessories (includes items 21 23) 21 Spacer Capacitor Ground strap O-ring Backup ring Piston cup Piston pump assembly (includes items 41 47) 41 Screw plug Sealing washer Spring Valve stem Pump piston O-ring Pump piston Pump housing, reservoir assembly (includes items 70 83) t 70 Ring tie...1 t 71 Cable tie Threaded bushing...1 t 74 Hydraulic reservoir Ring...1 t 76 Reservoir plug Filter Threaded bushing...1 t 80 O-ring Attachment ring Pump housing...1 Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

15 Parts List (cont d) Key Part No. Description Qty Motor assembly (includes items 85 99) o Motor and pinion...1 m 86 Ball bearing...1 m 87 Screw, flat head M3 x m 88 Screw, flat head M3 x m 89 Seal...1 m 90 Retaining ring...1 m 91 Grooved ball bearing...1 m 92 End cap...1 m 93 Eccentric...1 m 94 Screw, pan head...2 m 95 Mounting block...1 o 96 Gearbox (includes 100)...1 o 98 Flange...1 o 99 Screw Screw, gear box C-Head unit (includes items ) Retaining ring Punch Die Screw Stripper C-head Screw, M4 x Piston Bushing Spring Sleeve O-ring Compression spring End cap Screw Screw Switch Battery contacts Wire (not shown) Wire (not shown)...1 Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

16 Parts List (cont d) Key Part No. Description Qty Housing unit (green) (includes items ) Screw Nut Screw Switch cover (black) Trigger guard Reservoir cover Housing, right side Housing, left side Decal, identification Decal, warning Bushing LED Circuit board, programmed Decal, pinch hazard Case w/inserts V Battery V Charger 110V AC V Charger 220V AC V Charger 12V DC Seal kit (includes 4, 9, 13-14, 30-31, 42, 46, 70-71, 78, 80, 116) Decal Kit (includes , 215) o Motor and Gearbox Assembly (includes 85, 96, 98-99) t Reservoir Kit (includes 70-71, 74, 76, 80) Eccentric Bearing Kit (includes 86, 90-91, 93) m Eccentric Kit (includes 86-95) Piston and Spring Kit (includes 105, ) USA Fax: Fax: Canada Fax: International Fax: Boeing Drive Rockford, IL USA An ISO 9001 Company Greenlee Textron Inc. is a subsidiary of Textron Inc. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA