MODEL DT-10-H3-O 3/4 TIE DRILL OPERATION AND MAINTENANCE MANUAL

Transcription

1 MODEL DT-10-H3-O 3/4 TIE DRILL OPERATION AND MAINTENANCE MANUAL 1

2 Warranty: PortaCo, Inc. warrants, to the original purchaser all products manufactured by it to be free from defects, in material and workmanship under normal operation conditions and proper application, for a period of one year from the date of shipment of such products or for a period of 500 hours of operation by the original purchaser, whichever occurs first. The term original purchaser as used herein, means the person or firm who first purchases the product for his own use and not for resale. Our obligation on this warranty shall be limited to the repair or exchange of warranted products, at our option F.O.B. our factory. The above warranty does not cover conditions over which we have no control, including, without limitation, foreign materials in the oil systems, pressure in excess of recommended maximum, products damaged or subjected to accident, abuse or misuse after shipment from out factory, nor to products altered or repaired by anyone other than authorized personnel. No products shell be returned without prior written authorization from PortaCo, Inc. There will be no acceptance of any charges of labor and/or parts incidental to the removal and remounting of products repaired or replaced under this warranty. PortaCo, Inc. will in no event be liable for any special or consequential damage whatsoever. Copyright: PortaCo. Inc. reserves all rights to the design, manufacturer and patents for all products. (Rev. 5/5/90) 2

3 TABLE OF CONTENTS 1.0 Introduction 1.1 General Information 1.2 Features 1.3 Options 1.4 Safety Summary 1.5 General Safety Precautions 1.6 Warning and Caution Statements 1.7 Training Requirements 2.0 Installation Instructions 2.1 Unpacking Instructions 2.2 Tool Preparations 2.3 Testing 2.4 Hose Requirements 2.5 Hydraulic Fluid Recommendations 2.6 Tool Connecting Procedures 2.7 Work Area Safety Precautions 3.0 Operating Instructions 3.1 Description of Tool 3.2 Accessories and Kits Descriptions 3.3 Controls and Graphics 3.4 Connecting Hoses 3.5 Tool Operation 3.6 Disconnecting Hoses 3.7 Cold Weather Operation 3.8 Storage Preparation 4.0 Maintenance Instructions 4.1 Assembly View and Parts List 4.2 Graphic Set Complete 4.3 Tool Maintenance 4.4 Trouble Shooting 4.5 Technical Specification List of drill bits.pg 27 3

4 1.0 INTRODUCTION 1.1 General Information This manual presents installation, operation, and maintenance information for PortaCo s model DT-10-H3-O 3/4 Tie Drill. The tie drill is designed to drill into ties from a standing position. This tool will help eliminate the use of other methods that increase the likely hood of injury. When properly used this tool will help reduce back strain and also reduce operator fatigue. PortaCo, Inc. reserves the right to make changes at anytime without notice and without incurring any obligation. The manifold features a push button to reverse the direction of rotation. (Figure 1.2A, arrow D) The drill has a 7/16 hex quick chuck for mounting a verity of drill bits. A grease zerk allows lubrication of the internal impact components without disassembling the tool. (Figure 1.2A, arrow E) B D A 1.2 Features Features of the DT-10-H3-O ¾ Tie Drill are as follows: Length Width Height (LESS DRILL BIT) Weight (LESS DRILL BIT) 4.50 in/11.4 cm in/54 cm in/45.7 cm 24.6 lbs/10.8 kg C E The Tie Drill is operated from a T style handle. On the T style handle is a trigger that is used to operate the driver (Figure 1.2A, arrow A). A trigger lock prevents accidental operation of the tool. (Figure 1.2A, arrow B) Hose whips move the hydraulic couplers away for operator s hands making the tool easy to handle. (Figure 1.2A, arrow C) Figure 1.2A 1.3 Options The H OOK Tie Drill Depth Gauge mounts to the tool with two bolts. The Depth Gauge allows the operator to limit the drilling depth by loosening a knob and adjusting the length of the stop. (Figure 1.3A) 4

5 should develop additional precautions relating to the specific work area and local safety regulations. 1.5 General Safety Precautions The PortaCo Inc. tools are designed to provide safe and dependable service if operated according to the instructions provided in this manual. Read and understand this manual and any stickers attached to the power unit before operating. Failure to do so could result in personal injury or equipment damage. Check the rules and regulations at your location. The rules may include an employer s work safety program. Regulations may identify hazards such as working around utility supply lines or hazardous slopes. Read and understand any manuals for additional or optional equipment, which maybe shipped with the tool. Figure 1.3A PortaCo, Inc stocks a large variety of drill bits to meet customer needs. 1.4 Safety Summary Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hoses. These safety precautions are given for your safety. Review them carefully before operating the tool and before performing maintenance or repairs. Supervising personnel 1.6 Warning and Caution Statements Warning and Caution statements have been strategically placed throughout the text prior to operating or maintenance procedures, practices, or conditions considered essential for the protection of personnel, equipment, and property. WARNING: HIGHLIGHTS A, ESSENTIAL OPERATING, OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION STATEMENT, ETC WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN INJURY TO, 5

6 OR DEATH OF, PERSONNEL OR LONG TERM HEALTH HAZARDS. CAUTION: HIGHLIGHTS AN ESSENTIAL OPERATING OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION STATEMENT, ECT. WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO, OR DESTRUCTION OF, EQUIPMENT OR LOSS OF MISSION EFFECTIVENESS. 1.7 Training Requirements Operator training for the lag driver should consist of information found in this manual. In addition the operator must receive instructions, both verbally and through demonstrations for applications in which the tool is going to be used. The new operator must start in an area without bystanders and use the tool until able to fully operate the tool under the conditions for the work area. 2.0 INSTALLATION INSTRUCTIONS 2.1 Unpacking Instructions Upon receiving your Tie Drill promptly remove it from the shipping container. Always keep top side of container up. Inspect unit for damage which may have incurred during shipping and report it to carrier for claim. 2.2 Tool Preparations The Tie Drill is read for use after unpacking and no special preparation is required. If the tool is used in cold weather, preheat the hydraulic fluid by running power source at low engine speed. Fluid temperature should be at or above 50 F/10 C (400-ssu/82 centistroke) before use, when using recommended fluids. Using too thick of fluid may result in tool damage. 2.3 Testing WARNING: NEVER STICK FOREIGN OBJECTS, FINGERS, OR OTHER EXTRMIIES INTO MOVING MECHANISMS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY LEAD TO SEVERE PERSONAL INJURY OR TOOL DAMAGE. Before operating the Tie Drill it is important to inspect the trigger linkage mechanism for obstructions. Make sure all kits and components are securely mounted and tight. Remove the drill bit from the drill chuck, if one is installed. Follow all safety precautions when inspecting tool. Connect the tool to the power source follow the procedures in section 2.6 of this manual. Hold the drill by the handles so the working end is suspended off the ground. -When the trigger is drawn the handle, the drill chuck should rotate. 6

7 -Release the trigger and allow the tool to stop rotating. Press the button to reverse the rotation and check that the tool rotates in both directions. CAUTION: WHEN OPERATING THE TIE DRILL DO NOT CHANGE ROTATION WITH THE DRILL BIT ROTATING. ALLOW THE DRILL BIT TO COMPLETELY STOP ROTATING BEFORE PUSHING THE BUTTON. BE SURE TO FOLLOW ALL SAFETY GUIDELINES. 2.4 Hose Requirements It is not often necessary or advisable to use long hoses. All hoses must have an oil resistant inner surface and an abrasion resistant outer surface. Each hose must have male pipe ends for most application. Longer hoses can be used when necessary, but can affect the operation of the engine due to resistance in the hose. If small diameter or long hoses are used, or if restrictive fittings are connected to the supply and return ports, the pressure required to push the fluid through the system and back to the tank will be higher. This will reduce tool power. *Important Oil should always flow from the male coupler through the female coupler. NOTE: The pressure increase in uncoupled hoses left in the sun may make them difficult to connect. When possible after use, connect the free ends of the operating hoses together. HOSE TYPES Hydraulic hose types authorized for use by PortaCo, Inc. is as follows: 1. Labeled and certified nonconductive 2. Wire braided (conductive) 3. Fabric braided (not certified or labeled non-conductive) Hose 1: Listed above is the only hose authorized for use near electrical conductors. Hoses 2 and 3: Listed above are conductive and must never be used near electrical conductors. HOSE PRESSURE RATING The rated working pressure of the hydraulic hose must be at least 175 bar (2500 psi). 7

8 HYDRAULIC HOSE RECOMMENDATION Table 2.4 FLOW PER CIRCUIT LENGTH EACH HOSE USE INSIDE DIAMETER SAE SPEC HOSE (WIRE DRAID) SAE SPEC HOSE (FIBER BRAID) GPM LPM FEET METERS INCH MM 5 to 8 19 to 30 To 50 To 15 Both ½ 13 SAE 100R R7-8 5 to 8 19 to to 30 Both 5/8 16 SAE 100R2-10 SAE 100R to 8 19 to to 90 Pressure Return 5/8 ¾ SAE 100R2-10 SAE 100R1-12 SAE 100R8-10 SAE 100R to to 45 To 50 To 15 Both 5/8 16 SAE 100R2-10 SAE 100R to to to 30 Pressure Return 5/8 ¾ SAE 100R2-10 SAE 100R3-12 SAE 100R8-10 SAE 100R to to to 60 Pressure Return ¾ SAE 100R2-12 SAE 100R1-16 SAE 100R8-12 SAE 100R Hydraulic Fluid Recommendation The following fluids work well over a wide temperature range at startup, allow moisture to settle out, and resist biological growth likely in cool operating Hydraulic circuits. These fluids are Recommended by PortaCo Inc. Other That meets or exceeds the specifications of these fluids may also be used. Type Hydraulic fluid Chevron Clarity AW Exxon Univis J 32 Mobil D.T.E. 13 M Gulf Harmony AW-HVI Shell Tellus T 32 Texaco Rando HDZ 32 Union Unax AW-WR-32 Amsoil AWH Sunvis Low Pour H/032-product code Hydraulic fluid requirements: a) Viscosity (fluid Thickness) USA METRIC 50 F 4450 SSU Max 10 C 95 Centistokes 100 F SSU 38 C C.S. 140 F 85 SSU Min. 60 C 16.5 C.S, Min. Pour Point- 10 F/-23 C Minimum (for cold startup) Viscosity Index (ASTM D 2220) 140 Minimum Demulsibility (ASTM D-1401) 30 Minutes Maximum Flash Point (ASTM D-92) 340 F/171 C Minimum Rust Inhibition (ASTM D-665 A & B) Pass Oxidation (ASTM D943) 1000 Hours Minimum Pump Wear Test (ASTM D2882) 60 mg Maximum 2.6 Tool Connecting Procedures Stop the engine before connecting the tool and, or hoses to the off power unit, and when switching hoses or tools. Turn the hydraulic on/off valve to the off position before starting the engine. Make sure all hose are connected for correct flow direction to and from the tool being used. When routing hose in the work area, position them where personnel will not be at risk of tripping over them where vehicles can run over the hoses. Do not lay hose over sharp objects. WARNING: PRESSURIZED FLUID ESCAPING FROM A DAMAGED HOSE CAN PENETRATE THE SKIN AND BE INJECTED IN THE BODY CAUSING INJURY OR DEATH. CAUTION: DO NOT PULL ON HOSES TO DRAG POWER UNIT OR TOOL. 8

9 2.7 Work Area Safety Precautions - Never operate the tool when you are tired, angry, emotionally disturbed, or under the influence of alcohol, drugs, medications, or anything that could affect your vision, alertness, coordination or judgement. - Establish a training program for all operators to ensure safe operation. - Do no operate the tool unless thoroughly trained or under the supervision of an instructor. - Do not allow others to be near the tool when starting it or while operating. Keep bystanders and animals out of the work area. - Always wear safety goggles, ear, leg, and head protection devices, safety footwear, and snug fitting clothes. - Do not operate the tool near energized transmission lines. - Do not overreach. Maintain proper footing and balance at all times. - Always hold the tool with both hands, using a firm grip when activating and operating. - Be sure to keep hands and other body parts clear and free from all moving parts. - Always connect hydraulic hoses to the tool before activating the hydraulic circuit on your power unit. Check that hydraulic couplers are secure before activating the circuit. - Keep handles clean and dry. - Disconnect tool from hydraulic source before inspection or cleaning. - Only a properly trained person should perform any maintenance, service, and or repairs to a tool. - During start up of the tool, do not rest tool on any surface. - Make sure the tool s attachment was stopped turning before setting down tool. - At the work site, never carry the tool with the attachment rotating. - Always use attachements that meet the minimum requirements of the tool. - Never operate a tool that is damaged, improperly adjusted, or not completely and securely assembled. - Do not operate the tool until you have a clear work area and a secure balance. - Never carry or pick this tool up by the hydraulic hose. 9

10 SAFETY REGULATION Enter below any local or other safety regulations required for the operator to follow. Make sure the operator and maintenance personnel have knowledge of these regulations. 3.0 Operating Instructions 3.1 Description of Tool PortaCo s model DT-10-H3-O Tie Drill is designed to drill holes in wood railroad ties from a standing position. The drill reduces the risk to maintenance workers by eliminating the use of other methods which increase the likely hood of injury. When properly used it also reduces operator fatigue. The driver is equipped with a spool which reverses the drive direction. (Figure 3.1A arrow C) Insulated handles reduce vibration and operator fatigue. (Figure 3.1A arrow D) A grease zerk allows lubrication of the internal impact components without disassembling the tool. (Figure 3.1A arrow E) The Tie Drill requires a flow of 10 GPM (40 LPM) at 2000 PSI (138 Bar) for best performance. Use this tool on an open center hydraulic system only with a maximum pressure of 2150 PSI (148.3 BAR). D B C A The Tie Drill uses a 7/16 hex quick chuck to retain the drill bit. Only drill bits with a 7/16 hexagon shank are to be used with this drive system.(figure 3.1A Arrow F) F E PortaCo Inc s Tie Drill is operated from a T style handle. The handle features a trigger (Figure 3.1A arrow A) and trigger locking mechanism. (Figure 3.1A arrow B) Figure 3.1A PortaCo recommends the G-18D55-53W, a versatile power unit that can meet the needs for most hydraulic 10

11 tools used by the rail road industry. This power unit is capable of powering two tools simultaneously at 5 GPM (20 LPM) or one tool a 10 GPM (40 LPM) all the flows are at 138 BAR (2000 PSI). The maximum pressure of the hydraulic system is limited to BAR (2150 PSI). The power source provided the required flow and pressure to operated HTMA type I LPM (4-6 GPM) and type RR LPM (9-10.5) tools. All of which, are OPEN-CENTER tools required an operating pressure of 138 BAR (2000 PSI). A 3.2 Accessories and Kits Descriptions PortaCo, Inc. stocks a variety of drill bits to meet the customer s needs. B The tool can be fitted with a depth gauge, H OOK. (Figure 3.2A&B) The depth gauge attaches with two bolts at the impact head of the tool. If ordered with the Depth Gauge Kit, the kit is installed at the factory. The depth of the hole is set by loosening a clamping knob (Figure 3.2A Arrow A), adjusting the stop (Figure 3.2A Arrow B) to the desired position and then tightening the knob to lock it in position. Figure 3.2A Figure 3.2B 11

12 3.3 Controls and Graphics The following decals are placed on the tool to aid in its operation and maintenance. The operator should locate and understand them before using this power tool. On the impact head there is a CAUTION decal that specifies that the Tie Drill is rated for a flow of 10 GPM/40 LPM and pressure of 2000 PSI/150 BAR do not exceed these flow / pressure ratings. Also on the decal is a few written warnings improper use may cause severe injury, read and understand operators manual before operating tool, keep all guards in place, during operation always wear gloves, safe clothing and footwear, and during operation always wear approved safety protection for ears, eyes, and head. (Figure 3.3A) (Figure 3.3D arrow A) protected and kept legible. The serial number is needed when ordering replacement parts. (Figure 3.3B) (Figure 3.3D arrow B) Figure 3.3B On the impact head there is a CAUTION decal that specifies to only use accessories which meet the requirements of the tool s rating. The decal also states the following: Do not exceed the tool s max. flow or pressure. Use on open-center system only. Correctly connect hoses to tool in and out ports. Improper handling, use, or maintenance of tool could result in a leak, burst, or other tool failure. Contact at a leak or burst can cause oil injection into the body. Failure to observe these precautions can result in serious personal injury. Read and understand the instructions in the operator s manual before using this tool. (Figure 3.3C) (Figure 3.3D arrow C) Figure 3.3A On the main body of the tool is a serial # decal. This decal has the serial number as well as the model number of the unit. Each unit has its own unique serial number. It is important to keep this decal Figure 3.3C 12

13 A B CAUTION: DO NOT PULL ON HOSES TO DRAG POWER UNIT. NOTE: When possible, connect the free ends of uncoupled hoses to prevent build up in the hoses. The sun can also increase pressure in the hoses and make connecting them difficult. 3.5 Tool Operation Position the drill bit in the location the hole is required. C Figure 3.3D 3.4 Connecting Hoses Wipe quick couplers with a clean lint free cloth before connecting them. 1. Connect hoses from power source to the tool. It is recommended that you connect the return hoses first and disconnect last to minimize or avoid trapping pressure within the tool. 2. When connecting the quick couplers, the flow should run from male coupler to the female coupler. The female coupler on the tool is the inlet. Quick couplers are marked with a flow direction arrow. WARNING: PRESSURIZED FLUID ESCAPING FROM A DAMAGED HOSE CAN PENETRATE THE SKIN AND BE INJECTED IN THE BODY CAUSING INJURY OR DEATH. Shift the spool to the direction of rotation desired. When holding the tool with the trigger in the right hand, pushing the spool towards the operator rotates the socket in the clockwise direction IN. Pushing the spool away from the operator rotates the socket counter clockwise OUT. (Figure 3.5A) Figure 3.5A CLOCKWISE COUNTER CLOSKWISE Caution: Do not shift the spool while the tool is operating, 13

14 damage to internal components may occur. Hold the tool securely with both hands, press the trigger lock down, and pull the trigger. To stop the drill, release the trigger. When the bit passes through the tie, continue to hold the trigger in the on position and carefully pull the dill up until the bit clears the hole. Release the trigger to stop rotation of the attachment. Running the tool while lifting it out of the hole will clean the hole. If using the depth stop, drill into the tie until the depth stop contacts the surface of the tie. Continue to hold the trigger in the on position and carefully pull the dill up until the bit clears the hole. Release the trigger to stop rotation of the attachment. Running the tool while lifting it out of the hole will clean the hole. If the drill bit binds in the hole and the tool can not be pulled out of the hole, release the trigger to stop the bits rotation. Change the rotation of the tool to OUT and pull the trigger while pulling the tool out of the hole. Push the rotation spool back to the IN position before going to the next hole. Move on the next hole to be drilled. 3.6 Disconnecting Hoses: 1. Stop the hydraulic power source. 3. Allow system and hydraulic fluid to cool. 4. Disconnect the supply (pressure) hose to the power source (pressure port) from the tool ( IN port). 5. Disconnect the return (tank) hose to the hydraulic power source (return port) from the tool ( OUT port). 6. To prevent contamination, always install dust caps over the hydraulic ports of the tool when disconnected. WARNING: IF INJURY RESULTS FROM ESCAPING HYDRAULIC FLUID, SEEK IMMEDIATE MEDICAL ATTENTION. SERIOUS BODILY INJURY MAY OCCUR IF PROPER MEDICAL ATTENTION IS NOT ADMINISTERED IMMEDIATELY. WARNING: DO NOT ATTEMPT TO LOCATE HYDRAULIC LEAKS BY FEELING AROUND HOSES AND FITTING WITH HANDS. PIN- HOLE LEAKS CAN PENETRATE THE SKIN. 3.7 Cold Weather Operation Hydraulic fluids are thicker in cold weather; therefore, run the engine at low idle lone enough to bring the fluid temperature up to minimum of 10 C/50 F or until the top of the hydraulic tank feels warm, before operating tool. 2. Depressurize the system 14

15 3.8 Storage Preparation Remove any installed drill bit or attachment. Cover male and female hose whips. Store in the upright position. Secure tool to prevent it from being knocked over. Store the Lag Driver on a smooth level surface or hung on a wall. The tool should be stored in a cool, dry environment which is not subjected to rapid temperature changes. 15

16 4.0 Maintenance Instructions CAUTION: USE ONLY GENUINE PORTACO INC. PARTS OR EQUIVALENT. THE USE OF REPACEMENT PARTS WHICH ARE NOT OF EQUIVALENT QUALITY MAY DAMAGE THE HYDRAULIC TOOL. 4.1 Assembly View and Parts List DT-10-H3-O Serial No. ITEM P/N DESCRIPTION QTY OSP NUT 1/4nc NYLOCK OOP LOCK WASHER ¼ OOP WASHER ¼ FLAT OOP FITTING 1/8 PLUG ALLEN OOP PLUG ¼ ALLEN OOP PLUT 3/8 ALLEN OOP BOLT 5/16nc X 1 SHCS OOP BOLT 1/4nc X 1-3/ OOP BOLT ¼nc X OOP VALVE FLOW OOD ORIFICE OOP PLUG 1/16 NPT ALLEN OOP BOLT 5/16 X 1-3/ OOP COUPLER HYD FEMALE OOP COUPLER HYD MALE OOP BOLT ¼ nc X ½ SHCS OOP BEARING OOD ORIFICE OOP WASHER LOCK 3/ OOP LINK VALVE # OOP SNAP RING ½ OOP BACK-UP OOP QUAD RING OOD TRIGGER SAFETY STOP OOD COUPLER SLINE OOD MANIFOLD CONTROL OOD SPOOL DIRECTIONAL OOD SPOOL ON/OFF OOD PLATE MOTOR ADAPTER OOP PIN ROLL.156 X OOP PIN RETAINER OOD HAND GRIP OOD GRAPHIC SET COMPLETE OOP SPRING TRIGGER STOP OOP FITTING SHORT OOP RING RETAINER OOP HEAD IMPACT OOW BRACKET MOUNT OOD LINK ON/OFF OOP HOSE WHIP OOW TRIGGER OOP MOTOR HYDRAULIC 1 16

17 ITEM P/N DESCRIPTION QTY OOP COVER DUST OOP BOLT 3/8 X 4-1/2 SHCS OOW HANDLE COMPLETE OOP ZERK GREASE 1/ OOP WIPER SEAL OOW SPOOL STOP OOP SCREW SET SOCKET ¼-20 X 3/ OOP BOLT #10-24 X ½ SHCS OOP WASHER LOCK # OOP SPRING OOW MOUNT CHUCK GUARD OOP ¾ DRIVE 7/16 QUICK CHUCK OOP COVER DUST OOW GUARD CHUCK OOP BOLT 1/4NC X OOP BOLT 3/8NC X ¾ SHCS OOP WASHER LOCK 5/

18 18

19 19

20 H OOK TIE DRILL DEPTH GAUGE ITEM P/N DESCRIPTION QTY OOW MOUNT GUIDE OOW GAUGE STOP OOD KNOB CLAMPING OOP NUT 5/ OOP WASHER LOCK 5/

21 4.2 Graphic Set Complete (3492-OOD) 2124-OOD 3492-O1D 2382-O9D 2158-OOD D 2158-O8D 3149-OOD 2158-O1D..CLEAR COAT FOR SERIAL NUMBER 21

22 4.3 Tool Maintenance Caution: All maintenance must be done with the tool disconnected form power source. CLEANING AND MAINTENANCE RECOMMENDATIONS. Wipe all external surfaces after each use with a clean, lint free cloth to remove surface contaminants from the tool. To extend the life of the handle padding, do not allow sharp edges or foreign objects to rub on the padding. Grease the impact mechanism using th grease zerk located on top of the motor adapter plate. (Figure 4.3A) Apply 2 to 3 strokes (approximately 4 cc s) from a standard grease gun using Mobil HP or equivalent grease. ZERK Store all tools in an enclosed area to prevent weather from contaminating their systems. Daily: 1. Wipe all tool surfaces, fittings, and couplings free of grease, dirt, and foreign materials. WARNING: DO NOT ATTEMPT TO LOCATE HYDRAULIC LEAKS BY FEELING AROUND HOSES AND FITTINGS WITH HANDS. PIN HOLES LEAKS CAN PENETRATE THE SKIN. 2. Inspect the tool, hydraulic system, hoses, and fittings for signs of leaks, cracks, wear, and/or damage. Replace if necessary. 3. To prevent contamination, always install dust caps over the hydraulic ports when disconnected. Weekly: FIGURE 4.3A Grease leakage from around the square drive is common after lubrication and during hard use. Wipe the grease off to prevent it from splattering. NOTE: Do not attempt to repair this product. Only properly trained personnel should perform any maintenance service, and or repair to this tool. Monthly: 1. Perform a detailed inspection of the systems hoses, and fittings according to the hydraulic hose operator s manual and as stated in SAE standard j1273, May 1989 or latest revision. Replace 22

23 the hoses and/or fittings if necessary. Semi-annually: Remove the impact head (item 37) and clean the grease off the impact components. Also remove the grease from the impact housing. Mount the impact head (item 37) to the motor adapter plate (item 29) after placing the assembled hammer mechanism in the impact head. After assembly, apply 100 strokes of grease (133 cc s) to the lubricating zerk. SERVICE COMPLETE DIASSEMBLY OF THE TOOL IS NOT RECOMMENDED. RETURN TO PORTACO, INC. FOR REPAIRS. 23

24 4.4 Trouble Shooting The following chart can be used as a guide to correct any problem you may experience with the tool. To determine the problem in operation of the Tie Drill always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed in the table. Be sure you are using an accurate flow meter. Check the flow with the hydraulic fluid temperature at least 80 F/27 C. NOTE: Stop and depressurize the hydraulic system before connecting or disconnecting a tool. Failure to follow these instructions can lead to severe personal injury. Read and follow the instructions in this manual for the proper way to connect and disconnect tools from the hydraulic systems. PROBLEM CAUSE REMEDY Tool will not run or runs Power source slow. Poor impact performance. Coupler or Hose Directional spool not fully shifted. If after impact mechanism has been serviced. Mechanical failure Pressure and return hoses reversed Worn impact components Incorrect grease Cold hydraulic fluid Check power source flows and pressure (5-10 gpm/20-38 lpm at psi/ bar) Check for /remove obstruction Shift spool to either position. Check that all shims have been placed back between the impact head and adapter. Run impact to circulate grease. Disassemble tool and check for damage. Correct for proper flow direction. Disassemble front half of impact and check for damaged or severely worn parts. Remove and clean impact head (see maintenance section for procedures). Allow power source to warm up. 24

25 Trigger hard to pull Hydraulic fluid leaks between motor and manifold block. Hydraulic fluid leaks between adapter and motor. Hydraulic fluid leaks from control spools. Grease leaks between impact head and adapter. Grease leaks around impact drive shaft Grease leaks around impact drive shaft when cold. Back pressure too high Should not exceed 250 psi/ 17 Bar and 10 gpm/38 lpm Dirty spool Remove and clean spool and replace 0-rings and backups. Control linkage Inspect linkage between trigger and valve spool. Damaged seal Disassemble tool and replace seal. Damaged shaft seal Damaged seals Loose fasteners Heavy duty use. Impact mechanism over greased. Anvil bushing worn. Split tool between adapter and motor and replace seal. Replace all o-rings and backups on leaking spool. Tighten bolts. Normal due to heat build up. Wipe clean until grease stops leaking, adjust greasing maintenance to match duty cycle. Replace anvil bushing. NOTE: After reviewing trouble shooting chart and still unable to determine the problem call the service department at PortaCo inc. ( ) for advice 25

26 4.5 Technical Specifications MODEL Length Width Height Weight Max Pressure Max Flow DT-10-H3-O 4.50 in/11.4 cm in/8.3 cm in/45.7 cm 24.6-lbs/10.8 kg 2000 psi/150 bar 10 gpm/40 lpm Consumable Items List Description Part Number Source Coupler HYD FF-372-6FP M P PortaCo Inc. Coupler HYD FF-371-6FP F P PortaCo Inc. Cover Coupler # NR-37 BRUNNING P PortaCo Inc. Cover Coupler # NR P PortaCo Inc. 26

27 Hydraulic Fluid Requirements Viscosity (Fluid Thickness) METRIC U.S.A. 10 C 95 Centistokes 50 F 450 SSU Max 38 C C.S. 100 F SSU 60 C 16.5 C.S., Min. 140 F 85 SSU Min. Pour Point 10 F/-23 C Minimum (for cold startup) Viscosity Index (ASTM D 2220) 140 Minimum Demulsibility (ASTM D-1401) 30 Minutes Maximum Flash Point (ASTM D-92) 340 F/171 C Minimum Rust Inhibition (ASTM D-665 A & B) Pass Oxidation (ASTM D943) 1000 Hours Minimum Pump West Test (ASTM D2882) 60 mg Maximum Recommend Hydraulic Fluids Type Hydraulic fluid Chevron Clarity AW ISO 32 Exxon Univis J 32 Mobil D.T.E. 13 M Gulf Harmony AW-HVI Shell Tellus T 32 Texaco Rando HDZ 32 Union Unax AW-WR-32 Amsoil AWH ISO 32 Sunvis Low Pour H/032-product code Coupler recommendation: 3/8 inch FLAT FACE HTMA couplers rated at 2500 psi working pressure. Threads are to match fittings used on hoses or fittings used as adapters. Bolt Size #10-32 ¼-20 5/ /8-16 Torque 38 in. lbs. 76 in. lbs. 13 ft. lbs. 23 ft. lbs 27

28 DRILL BIT LIST If the drill required is not listed please call PortaCo, Inc and a service person will be able to assist your needs. 28

29 SERVICE AND REPAIR NOTES 29