RACINE RAILROAD PRODUCTS 1524 FREDERICK STREET RACINE, WI (262) M Hydraulic Impact Wrench - 7/16"

Transcription

1 RACNE RALROAD PRODUCTS 524 FREDERCK STREET RACNE, W (262) M Hydraulc mpact Wrench - 7/6" EXPLODED VEW OF THE HYDRAULC MPACT WRENCH -7/6" 5 (0 \ 0 " ) 2 36 / 3 J..//

2 Secton 4 Parts Lsts and llustratons The followng parts lsts are sorted by descrpton, n alphabetcal order, and grouped by the assembly that the ndvdual parts are used on. The lsts provde the part descrpton, quantty used requred and part number for each part, as well as the part number of the assembly that the part s used on. A "Lst" n the "Dwg" column ndcates that a parts lst for the assembly s ncluded n Sectons 5.2 or 5.3 of ths manual. A "Dwg" n the "Dwg" column ndcates that a drawng of the part (wth parts lst) s ncluded n Secton 5.4 of ths manual. Secton 5. Secton 5.2 Secton 5.3 Secton 5.4 Recommended Spare Parts Lst Standard Parts Lst Customer Optons Parts Lst Lst of llustratons 4. Recommended Spare Parts Lst The followng parts are commonly used consumable, wear and / or routne mantenance tems. We recommend that these parts be stocked n the quanttes ndcated below to mantan your machne at peak performance. Hydraulc mpact Wrench-7/6" Recommended Spare Parts Lst! Descrpton Qty Part No. tem No. - - Used on 4.2 Standard Parts Lst Ths lst ncludes all servceable parts used on a standard model machne that has no customer optons nstalled. See Secton 5.3 for parts used on optonal features that are added to the standard model. NOTE: SEE EXPLODED VEW DWG. OF HYD.MPACT WRENCH-7/6" B.O.M.FOR PARTS. l... PN: Descrpton Qty Part # tem No. Used On VALVE HOUSNG,D0a. \l(j\.,: ~ -. FTTNG OOO~<6OS 2 PVOT BOLT 3 - COVER 4 - CAP SCREW, SPOOL 6 TRGGER!D(X)~S3~ 7 - CAP SCREW, /6" MPACT MECHANSM ASSEMBLY 9 - SPACER 0 - THRUST BEARNG OOOz..8l0 - THRUST BEARNG WASHER /oac ~~ HYDRAULC MOTOR ASSEMBLY 3 - SNAP RNG M Rev Draft 2 Feb 03.doc

3 r ~.' / COVER SPRNG a-rng (.56" 0.0. X.44".0.) CAP SCREW, NC LOCKWASHER DRECTON SPOOL BUTTON FLATHEAD CAP SCREW a-rng FLUDC TUBE NUT, (8-32) RETANNG RNG SHAFT SEAL BEARNG HOUSNG a-rng SHAFT KEY SPRAL CLP RETANNG RNG GEROTOR a-rng CAP SCREW ROLL PN 7/6" HEX ANVL ASSEMBLY THRUST LOCK,....' THRUST RNG.~ SPRNG RETANNG SLEEVE r" BALLS - ANVL ANVL HAMMER CASE (NCLUDES TE~.t 50) HAMMER CASE GASKET GASKET RETANER HAMMER BUSHNG HAMMER HAMMER FRAME HAMMER PN QUAD RNG FTTNG 3/8 NCH DAMETER BALL BEARNG WASHER HANDLE SUB ASSEMBLY SPRNG a-rng HELl COL LEE PLUG a-rng SET 5 /oooa ~~ bo8 8 - L.../ 00 qofo t ~ao (~tb\t) J..~O\ '5 b3'd \ DOt>;lCO\ ~t;oolf4q ldoo a~\q ~ S0\ 0lt,39 ~l<&oo~ lPJ5JL{ t 600~~ as~lq86 55 ~?olqo(p 56 ' f' M Rev Draft 2 Feb 03.doc

4 :.,r" Operatng and Servce Manual Hydraulc mpact Wrench - 7/6" (Reference Seral Number Plate) (' Racne Ralroad Products 524 Frederck Street Racne, W Phone: (262) Fax: (262) M Rev Draft 2 Feb 03.doc

5 Record of Chang Use ths page to record changes, updates and correctons made to ths manual. Rev. / Chg. / Bulletn No: Date Rev 6JAN03! Descrpton of Changes ntals, ntal Release RA!!!! r, ~ \ \ ;! \!!! \ \ M RevDraft 2 Feb 03.doc

6 Table of Contents Cover Page Record of Changes Table of Contents Lst of Fgures & Tables v Secton General nformaton and Overvew Purpose Cancellaton Scope Defntons General Safety Precautons and Devces Machne Descrpton and Specfcatons Machne dentfcaton Machne Components and Major Assembles...9 Operator Controls Servce Manuals and Tools... Warranty Terms and Condtons 2-8 Secton 2 ntal Set-up and Adjustment 2-2. nspecton and Warranty Regstraton ntal Assembly and n-servce Mantenance Setup and Adjustments 2-3 Secton 3 Operatng Procedures 3-3. Safety Precautons and Devces -_ Transportaton & Handlng Normal Operatng Parameters Normal Start-up Procedures Normal Operatng Procedures Normal Shut-Down Procedures Emergency Procedures 3-2 Secton 4 Mantenance Procedures _ Safety Precautons and Devces Daly nspecton, Fuelng and Lubrcaton Routne Adjustments and Mantenance Trouble Shootng Specal Tools. Secton 5 Parts Lsts and llustratons '" 4-5. Recommended Spare Parts Lst Standard Parts Lst Customer Optons Lsts by Seral Number Lst of llustratons '". Secton 6 Parts and Servce Support 5-6. Non-Warranty Parts Sales Techncal Support & Servce Warranty Parts & Servce M Rev Draft 2 Feb 03.doc

7 Table of Contents Secton 7 Appendces 6-7. Sales Representatves M Rev Draft 2 Feb 03.doc

8 Ths lst dentfes where photos, tables and other fgures are located wthn the text of ths manual. All parts lsts and drawngs are provded n Secton 5. Fgures Fgure Hydraulc mpact Wrench-7/6" - Front Cover Page - Fgure 2 Hydraulc mpact Wrench-7/6" - Left Sde Vew 2-4 Fgure 3 Hydraulc mpact Wrench-7/6" - Rght Frontal Vew '" 2-4 Fgure 4 Hydraulc mpact Wrench-7/6" - Showng 2-5 Fgure 5 Hydraulc mpact Wrench-7/6" - Showng 2-5 Fgure 6 Hydraulc mpact Wrench-7/6" - Manufacturer's Data Plate 2-6 Fgure 7 Hydraulc mpact Wrench-7/6" - Cauton Decal., M Rev Draft 2 Feb 03.doc

9 Secton General nformaton and Over vew. Purpose Ths manual provdes general nstructons for operatng and mantanng the Racne Ralroad Products Hydraulc mpact Wrench-7/6"..2 Cancellaton Not Applcable, ntal Release. Record subsequent changes made to ths manual on page..3 Scope Ths Bulletn apples to all Racne Ralroad Products Hydraulc mpact Wrench-7/6" power tool Reference Seral Number Plate..4 Defntons Ths manual uses the followng standard terms for clarty:.4. DANGER' An operatng procedure. practce, or condton, etc., whch WLL RESULT N NJURY OR DEATH f not carefully observed or followed..4.2 WARNNG! An operatng procedure. practce, or condton, etc., whch may result n njury or death f not carefully observed or followed..4.3 Cauton! An operatng procedure, practce, or condton, etc., whch may result n damage to equpment f not carefully observed or followed..4.4 Note: An essental operatng procedure, practce, or condton, etc..5 General Safety Precautons and Devces WARNNG! Falure to follow safety precautons when operatng ths equpment can result n serous njury or death to the operator or other persons n the area. Observe the followng precautons whenever you are operatng, workng on or near ths equpment. Always wear approprate work clothng when operatng ths equpment. DO NOT WEAR loose clothng, jewelry, rado belts, etc., when you are operatng, workng on or near ths equpment M Rev Draft 2 Feb 03.doc

10 .5. Always wear approprate personal protectve clothng when operatng ths equpment (e.g. Orange safety vest, hard hat, safety glasses wth sde shelds, full-face sheld, hearng protecton, steel-toed safety boots, leather gloves, dust resprator, leggngs, etc.)..5.2 Always lft heavy objects wth the knees and legs (not the arms and back). Always use care when carryng the Hydraulc mpact Wrench and ensure proper footng and crew coordnaton when carryng or postonng the Hydraulc lmpact Wrench..5.3 Ths equpment may be operated from ether sde of the ral. Remove ballast that may hnder the proper placng of the Hydraulc lmpact Wrench verses the ral work area..5.4 Keep your hands, arms, feet. head, clothng, etc., out of the operatng area and away from all rotatng or movng components when you are operatng, workng on or near ths equpment..5.5 Ensure that all guards, covers, hoses and operatng components are n good workng order and that all controls are n the approprate poston before startng the engne. Ensure that nstalled safety equpment (e.g. fre extngushers, frst ad kts, lockng and safety devces) are nstalled properly and are n good workng order. DO NOT OPERATE the machne untl unsafe condtons have been corrected..5.6 Operate the POWER SOURCE ENGNE only n a well-ventlated area and ensure that the ar flter(s), ar flter cover(s), muffler are n good condton. DO NOT crank the engne wth the spark plug removed..5.7 Keep the machne clean and free of debrs. Operate the machne n a safe and responsble manner. Exercse cauton when workng on or near rotatng or movng components, hot components and fuel systems. Be aware of potental fre hazards and prevent sparks., etc., from startng fres on rght-of way..5.8 Comply wth all nstructons provded on any decals or placards nstalled on the machne and wth any relevant amplfyng nformaton provded n ths manual or other general operatng procedures..5.9 When you leave ths equpment, even for a short tme, shut off the hydraulc motor and dsengage the hydraulc supply hoses..5.0 Shut off the power source engne, ensure that all controls are n a safe poston and nstall all approprate lockng and safety devces before dong any of the followng: Lubrcatng Adjustng Makng Repars Performng Servce.5. Comply wth all Lock Out / Tag Out Procedures and other safety procedures establshed for your work envronment..6 Machne Descrpton and Specfcatons The Racne Ralroad Products Hydraulc mpact Wrench-7/6" s a portable, remotely powered, hand held power tool desgned for drllng holes n wood cross-tes, trestle-work and M Rev Draft 2 Feb 03.doc

11 road crossngs for lag screw or structural fastener nstallaton. The Racne Ralroad Products Hydraulc mpact Wrench-7/6" accommodates lght mpact auger bts. Fgure 2 Hydraulc mpact Wrench-7/6 Rght Hand Vew. Fgure 3 Hydraulc mpact Wrench-7/6" Operators Vew M Rev Draft 2 Feb 03.doc

12 '{J' Fgure 4 Hydraulc mpact Wrench Operator's Vew..6. Manufacturer: Fgure 5 Hydraulc mpact Wrench-/6" Drve Socket Vew. Racne Ralroad Products, nc. 524 Frederck Street P.O. Box Racne, W M Rev Draft 2 Feb 03.doc

13 ~ Phone: (262) E-mal: Webste: Physcal Data: Tool Specfcatons: 7/6" Quck Change, Hydraulc System: Open-center or Closed-center Length: 9.00 n. (-23.0 cm) Wdth: 3.00 n. (-7.60 cm) Heght, Work Mode: 9.00 n. (-23.0 cm) Weght: (less tools) 7.25 bs. (-3.29kg) Optons and Accessores: Contact: Racne Ralroad Products 524 Frederck Street P.O. Box Racne, W Sockets and adapters Phone: (262) (262) Mechancal Data Hydraulc Motor: Gerotor type Maxmum Flow: 4-7 gpm (-5-27pm) Maxmum Pressure: ps ( MPa) Maxmum mpact Tme: 0 seconds Drve Sze: 7/6" socket (-. cm) Torque GPM (60 9 LPM) Settng at tool: 2000 ps (3.8 Mpa) Back Pressure 200 ps (.38 Mpa) Fltraton: 25 Mcron (Nomnal) Pressure & Return Ports: NO.6 (9/6"-8 UNF) SAE O-Rng.6.2 Performance Data: Producton Rate:.7Machne dentfcaton: The Manufacturer's data plate s located on the sde of the assembly. Please provde the Racne Ralroad Products Model and Seral Number, and any locally assgned dentfcaton number, to our customer servce personnel when contactng the factory for parts, servce or warranty support. Fgure 6 Manufacturer's Data Decal ;.M Rev Draft 2 Feb 03.doc

14 .7 Machne Components and Major Assembles The Socket spndle and mpactng mechansm assembly. The Hydraulc motor and adapter asserrlbly. The Hydraulc control valve/trgger group wth housng. The Handle group wth hydraule portng. The Hydraulc whp hose assembles..8 Operator Controls.8. Refer to Fgures through 5 to dentfy and locate the controls and major components of the Hydraulc mpact Wrench-7/6"..9 Servce Manuals and Tools.9. Operatng and Servce Manuals: One Operatng and Servce Manual s provded wth each machne. Manuals are shpped wth each machne..9.2 Operatng and Servce Manual Changes: The Operatng and Servce Manual may be updated to reflect product development and/or revsed operatng and mantenance procedures. f appropnate, Servce Bulletns may be released to provde addtonal operatonal, mantenance and/or safety nformaton. Record all changes made to ths Manual n the Record of Changes on page. Submt recommendatons and requests for Operatng and Servce Manual Changes to: Racne Ralroad Products, nc. Attn: Techncal Servce Manager 524 Frederck Street P.O. Box Racne, W Phone: (262) E-mal: techserv@racneralroad.com Webste: M Rev Draft 2 Feb 03.doc

15 . ~\.0 Warranty Terms and Condtons.0. Warranty Perod: Each new machne, and new parts of our manufacture, are warranted aganst defects n materal and workmanshp for one year from the date of shpment from our factory. When contactng the factory for parts, servce or warranty support, please provde the Racne Ralroad Products Model and Seral Number and any locally assgned dentfcaton number to our customer servce personnel to help them dentfy your machne and better serve you..0.2 Vendor Parts Warranty Perod: Other equpment and parts used, but not manufactured by Racne Ralroad Products. nc.. are covered drectly by the manufacturers warranty for ther products..0.3 Warranty Parts and Servce: We Wll repar or replace, wthout charge, F.G.B. factory, Racne, Wsconsn, USA. any part of our manufacture whch s proven to be defectve durng the warranty perod. Materal clamed defectve must be returned, f requested, to the factory wthn 30 days from the date of the clam for replacement. Ordnary wear and tear, abuse, msuse and neglect are not covered by ths warranty. Dependng upon the crcumstances. we may provde techncal assstance and/or techncal servce support. Wthout charge. to assst n the correcton of warranty related problem. 0.4 Non-Warranty Parts and Servce: Materal damaged through normal wear and tear, abuse, msuse and/or neglect are not covered by ths warranty. Non-Warranty Parts and Techncal Servce polces and procedures are provded n Secton 6 of ths manual M Rev Draft 2 Feb 03.doc

16 \ Secton 2 ntal Set-up and Adjustment 2. nspecton and Warranty Regstraton The Hydraulc mpact Wrench -7/6" s normally shpped va common carrer n a cardboard carton. The warranty perod begns on the date of shpment from our factory. Upon delvery by the carrer. nspect the Hydraulc mpact Wrench and shppng materals for damage. Ensure that all tems ndcated on the packng lst have been receved. Address tems lost or damaged n shpment wth the freght carrer. 2.. Removng Packng Materals / Delvery nspecton: Remove the packng materals and nventory the contents of the packng lst. Ensure that Operatng and Servce Manuals, tool kts and any other materals sent wth the machne are n good condton Product Regstraton Card: Please fll out and return the Product Regstraton Card to help us better serve you. Your feedback on the Product Regstraton Card helps us mprove our products and servce. Note: Unless otherwse ndcated, the address and contact name provded on the Product Regstraton Card wll be the malng address for future Servce Bulletns and Customer Servce nformaton. Note: Please contact our Servce Department at the address provded n Secton 6 of ths manual f you have any problems wth or questons about your new machne. 2.2 ntal Assembly and n-servce Mantenance The Hydraulc mpact Wrench-7/6" was tested after assembly at our factory. After asserrlbly, the machne should receve a thorough n-servce nspecton before ntal operaton. f you do not feel qualfed to perform ths n-servce work yourself, contact a competent mechanc or the Racne Ralroad Products Servce Department for techncal support Uncratng a new machne: Support the Hydraulc mpact Wrench-7/6"and cut the bandng (f any) to release the machne from the shppng carton. Manually lft the Hydraulc mpact Wrench-7/6". optons and accessores separately and clear of the carton and place on a safe surface ntal Assembly: After unpackng and nspectng the Hydraulc mpact Wrench-7/6",optons and accessores prepare the unt for servce by dong the followng: Hydraulc Systems: Use a calbrated flow meter and pressure gauge to check the hydraulc power source for 5-0 gpm/20-38 pm at ps/ bar. A relef valve settng between ps/45-55 bar s requred for the operaton. The hydraulc system's back pressure should be less than 250 ps/7 bar, neasured at the tool end of the operatng hoses. All system's checks should be made at mnmum operatng temperatures (maxmum flud vscosty of 400 ssu/82 centstokes. The hydraulc flud coolng system should lmt maxmum flud temperature to 40 0 F/60 C at the maxmum expected ambent temperature. The mnmum cool capacty M Rev Draft 2 Feb 03.doc

17 should be 5 hp/3.73kw at a 40 F/22 C dfference between ambent temperature and flud temperature. A mnmum of 25 mcron fltraton s requred for the hydraulc system. For cold weather startup and maxmum drt holdng capacty a flter element szed for 30 gpm/4 cpm s recommended. Hydraulc flud requrements: Vscosty (Flud Thckness) U.S.A. METRC 50 F 450 SSU Max. 0 C 95 Centstokes 00 0 F SSU 38 C C.S F 85 SSU Mn C 6.5 C.S., Mn. Pour Pont 0 F/23 C Mnmum (for cold startup) Vscosty ndex (ASTM ) 40 F Mnmum Demulsblty (ASTM 0-40) 30 Mnutes Maxmum Flash Pont (ASTM 0-92) F/7 0 C Mnmum Rust nhbton (ASTM A & B) Pass Oxdaton (ASTM 0943) 000 Hours Mnmum Pump Wear Test (ASTM 02882) 60 mg Maxmum Recommended hose sze:.500 nch/2mm.0. up to 50 f./5m long Recommended hose sze:.625 nch/6 mm >0> up to 00 ftl30 m tong The Racne Hydraulc power unt s recommended for hydraulc supply. Ths unt s equpped wth two 5 gpm/20 pm crcuts that can be combned for one 0 gpm/40 pm crcut. f the tool s used n cold weather, preheat the hydraulc flud by runnng power source at low engne speed. Flud temperature should be at or above 50 0 F/0 C (400 ssu/82 centstokes) before use, when usng recommended fluds. Usng too thck of flud may result n tool damage. CHECK THE POWER SYSTEM TYPE: THE HYDRAULC MPACT-7/6" MAY BE USED WTH OPEN OR CLOSED CENTER SYSTEMS. Check hydraulc hosed for cracks. leakage and damage. f the hoses or couplers show any of these wear characterstcs. replace them before operatng the tool. NEVER attempt to locate leaks wth your hands, personal njury may occur from pressure system. Tool Trgger Check that trgger presses toward handle easly and returns to the "OFF" poston when released. f trgger stcks or does not operate easly check for obstructons. f trgger does not return to Off' poston when released, check the return sprngs. DO NOT OPERATE A TOOL F THE TRGGER S NOT WORKNG! Hose Connectng Wpe quck couplers wth a clean lnt free cloth before connectng them. Connect hoses from power source to the tool. t s recommended that you connect the return hoses frst and dsconnect last to mnmze or avod trappng pressure wthn the tool. When connectng the quck couplers, the flow should run from male coupler to female coupler. The female coupler on the tool s the nlet. Quck couplers are marked wth an arrow to show flow drecton. Turn on the hydraulc crcut at your power source. Note: When possble, connect the free ends of uncoupled hoses to prevent pressure buld up n the hoses. The sun can also ncrease pressure n the hoses and make connectng dffcult M Rev Draft 2 Feb 03.doc

18 Be sure the pressure hose s connected to the pressure port and the return hose connected to the return port. Pressure port s at the poston and return port s at the poston. See parts vew f uncertan. Do not attempt to reverse the tool by hookng the pressure hose to return port of the tool. The wrench s equpped wth a spool to reverse the drecton of rotaton. Reversng the hoses can cause severe damage to the wrench. Sockets and Accessores Do not use drlls bts or accessores whch are not ntended for mpact type applcatons. They may crack or fracture durng use. Use only mpact rated sockets and accessores. f adapters are requred, use components whch are n good condton only. Loose, multple adapters and excess weght between the wrench and socket can reduce the ntensty of the mpact to the nut or bolt head. 2.3 Setup and Adjustments The Hydraulc mpact Wrench-7/6" s a power tool that requres famlarzaton by the end user. t s hghly recommended that ths manual be referred to before attemptng a testng exercse wth the mpact Wrench M Rev Draft 2 Feb 03.doc

19 Secton 3 Operatng Procedures 3. Safety Precautons and Devces Before operatng the Hydraulc mpact Wrench -7/6" perform a daly nspecton of the tool as descrbed n Secton 4.2. Ensure that all general safety precautons are observed and that proper personal protectve clothng s worn as descrbed below. Fgure 3.- Personal Protectve Equpment: At-a mnmum, the followng Personal Protectve Equpment should be worn by the operator: Safety Glasses Hearng Protecton Safety Helmet Hgh Vsblty Safety Vest Leather Work Gloves Steel Toed Safety Shoes 3.2 Transportaton & Handlng The Hydraulc mpact Wrench - 7/6" s typcally transported to the job ste by truck or ral. Upon arrval at the Job ste. the Hydraulc mpact Wrench S lfted nto poston manually. 3.3 Normal Operatng Parameters 3.3. Motor: 4-7 GPM Maxmum Speed: 620 RPM Performance Data: MAX MUM 450 FT./LBS. OF TORQUE AT 2000 PS Producton Rate:.RECOMMENDED 0 SECOND NTERVAL PER APPLCATON 3.4 Normal Start-up Procedures Before startng the Hydraulc mpact Wrench-7/6", perform a daly nspecton as descrbed n Secton 4.2. Cauton! DO NOT OPERATE MPACT WRENCH WHEN BYSTANDERS ARE NEAR THEWORK AREA Note: Dependng on temperature, let the hydraulc motor warm up before applyng full load. Cauton! DO NOT OPERATE MPACT WRENCH NEAR FLAMMABLE MATERALS OR ENERGZED TRANSMSSON LNES. Normal Operatng Procedures: M Rev Draft 2 Feb 03.doc

20 The Racne Ralroad Products Hydraulc mpact Wrench - 7/6" s desgned to effcently drll holes and loosen nuts and bolts. The tool uses a 7/6" nch socket drve and requres hgh mpact drll bts. The wrench may be used for other applcatons where mpacts are typcally used. The wrench s equpped Wth a spool whch reverses the drve drecton. nsulated handles reduce vbraton and operator fatgue. The safety lock on the trgger helps prevent accdental startng of the tool. A rotatng front handle allows comfortable operaton n both the vertcal and horzontal postons. Operaton Wth hydraulc power source connected to the tool, shft the spool to the drecton of rotaton desred. When standng behnd the tool (the hose end) pushng the spool to the rght rotates the socket clockwse, and to the left rotates counterclockwse. Do not shft the spool whle the tool S operatng, damage to nternal components may occur. Grasp both handles frmly, place socket on fastener, squeeze the trgger lock to the handle and pull the trgger toward the handle grp actvatng the tool. Always hold the tool wth both hands to mantan control. To stop the mpact Wrench-7/6" just release the trgger. When the fastener contacts the surface of the materal beng fastened, lmt mpact tme to 0 seconds. Excessve wear wll occur to the hammer mechansm due to the heat buld up. Shut-Down Procedures To safely transport and store the Hydraulc mpact Wrench-7/6" perform a normal shut down as follows:. Stop the Hydraulc mpact Wth the sprng loaded trgger release valve.. 2. Shut down the hydraulc power source. 3. Dsconnect the hydraulc hoses from Hydraulc mpact Wrench.. 4. Remove the socket or adapter tool. 4. Prepare the unt for transport as outlned n Secton 3.2 above. Note: A photo and detaled dscusson regardng the operaton of the Controls are provded n Secton Emergency Procedures n the event of any malfuncton, MMEDATELY SHUT-OFF THE HYDRAULC POWER SOURCE and correct the problem. WARNNG! DO NOT PERFORM MANTENANCE ON THE HYDRAULC MPACT WRENCH WHLE THE POWER SOURCE OR HYDRAULC MPACT WRENCH MOTOR ARE RUNNNG. Secton 4 Mantenance Procedures 3.6 Safety Precautons and Devces Normal mantenance of the HydraUlc mpact Wrench can be performed wthout any specal.mantenance related safety devces. Before operatng the HydraUlc mpact Wrench-7/6", perform a daly nspecton of the power tool as descrbed n Secton 4.2. Ensure that all general safety precautons are observed and that proper personal protectve clothng s worn as descrbed n Sectons.5 and M Rev Draft 2 Feb 03.doc

21 WARNNG! DO NOT PERFORM MANTENANCE ON TH"E HYDRAULC WRENCH WHLE THE MOTOR S RUNNNG OR HOSES ARE CONNECTED Safety Devces: Upon completon of mantenance, ensure that the foffowng Safety Devces are nstalled on the Hydraulc mpact Wrench-7/6": The mpact Wrench s workng properly. The handles and trgger/trgger locks are secured. Lubrcaton of the wrench s n order. Hydraulc hoses are safe to use and connected securely. The sockets and accessores are n good condton No Specal Procedures Requred, See Local Requrements. 3.7 Daly nspecton and Lubrcaton At a mnmum, perform the followng routne daly mantenance on the Hydraulc mpact Wrench -7/6" to keep t n good workng condton Daly nspecton: Before operatng the Hydraulc mpact Wrench-7/6;t', nspect the followng and correct any problems as necessary: General Condton of the tool. All Guards and Safety Devces are nstalled and Operable. All Controls are Operable. Hose Condton Grease Type and Locatons: Bearng and bushngs are used on the Hydraulc mpact Wrench to reduce daly mantenance. Ensure that all bearngs and movng parts are properly lubrcated wth on weekly ntervals. Sem-annually remove the mpact head and clean the grease off the mpact components. Also remove the grease from the mpact housng Remove the thrust washers and thrust bearng and wpe clean. Before renstallng them, check for damage and replace f n poor condton. Mount the mpact head to the motor adapter after placng the assembled hammer mechansm n the mpact head. Make sure all parts are n proper poston before mountng the mpact head. Apply grease pror to re-assembly Lubrcatng Grease Type: Moble HP or equvalent 3.8 Routne Adjustments and Mantenance Ths secton outlnes basc adjustments and mantenance requred for daj~y operaton of the Hydraulc mpact Wrench-7/6". These nstructons are ntended for operator level, feld mantenance and not repar shop or overhaul level procedures. 3.9 Trouble Shootng The followng chart can be used as gude to correct any problem you may be experence wth the Hydraulc mpact Wrench - 7/6"". To determne the problem n operaton of the mpact wrench, always check that the hydraulc power source s supplyng the correct hydraulc flow and pressure to the tool as lsted n the table. Be sure you are usng an accurate flow-meter. Check the flow wth the hydraulc flud temperature at least 80 0 F/27 C. Always check the power source and hoses before dsassemblng the mpact wrench M Rev Draft 2 Feb 03.doc

22 Problem Tool wll not operate. Tool runs at low speed Tool runs too fast Ol leakage from trgger area. Possble Cause Tool not properly connected. Low ol volume and/or pressure. Low ol volume and/or pressure Contamnated hydraulc system. Relef valve blocked or contamnated Excessve pressure or flow. Damaged O-rngs n spool Remedy Check pressure and return connectons and dsconnects. Check hydraulc power source. Tool wll not operate f nlet pressure s below 000 PS or flow s less than 4 GPM. Check hydraulc power source for recommended flow, pressure and proper condtons. Remove contamnaton and clean hydraulc system. Check relef valve. Clean or replace as necessary. Verfy correct hydraulc power source s beng used Adjust hydraulc power supply Replace a-rngs. Factory Servce Requred. Actuaton Trgger stcks Excessve flow Factory Servce Requred Tool Trgger plunger stcks or works hard Broken sprng Contamnaton Check for drt or deposts Trgger bndng (trgger bent, trgger pvot pn too tght, etc. Check trgger, sleeve spool for bndng. Replace sprng. Clean sleeve and spool. Check hydraulc system Clean conponents. nspect, adjst trgger where bndng occurs. Systems overheats. Excessve flow Reduce RPM of engne. Hydraulc ol leakage from trgger area. WARNNG! Do not use tool. Tool wth leak may cause severe bodly njury. neffcent coolng. Tool components loose. Damaged a-rngs or gaskets. Tool components worn or damaged. ncrease reservor sze and/or add ol cooler. Factory servce may be requred. Replace worn or damaged a- rngs or gaskets. Dsassemble tool. Replace worn or damaged components M Rev Draft 2 Feb 03.doc

23 Power source works but tool napproprate hydraulc system. Check type of hydraulc power lacks power or does not source: open -center or closedoperate. center. 3.0 Specal Tools: None specfed.mm\\b MAX. FLOW: 5GPM/20lPM MAX. PRESSURE: 2000 PS" 50 BAR o MPROPER USE MAY CAUSE SEVER NJURY o READ AND UNDERSTAND OPERATORS MANUAL BEFORE OPERAllNG TOOL o KEEP All GUARDS N PLACE odurng OPERATON WEAR GLOVES, MCL.OTHNG AND FOOTWEAR ~OOlNGDP RAnONALWAYSWEARAPPROVED SAFETY PROTECTON FOR:, EAR EYE HEAD, 0.. Fgure 7 Cauton Decal M Rev Draft 2 Feb 03.doc

24 Placard Lst, Hydraulc mpact Wrench PN: Descrpton Qty Part # Used On PLATE, SERAL NUMBER DECAL, LOGO Customer Optons Lsts by Seral Number These lsts nclude all parts that are specfed as customer optons and not ncluded n a base-model. These lsts are sorted by customer opton. RRP Sere No:! RRP Part No:!! HW ' \! Customer Optons Parts Lst Descrpton Qty Part No. Dwg Used on STANDARD MODEL: NOT APPLCABLE M Rev Draft 2 Feb 03.doc

25 Secton 5 Parts and Servce Support 5. Non-Warranty Parts Sales Materal damaged through normal wear and tear, abuse, msuse and/or neglect are not covered by our warranty and should be ordered drectly from our Customer Servce Department. Parts for models that are no longer n producton may not be avalable. 5.. Parts & Customer Servce Address: Please contact us at the followng address for parts and customer servce support: Racne Ralroad Products, nc. Attn: Customer Servce 524 Frederck Street P.O. Box Racne, W Phone: E-mal: Webste: Extenson: 05 custserv@racneralroad.com Non-Warranty Parts Orders: When placng a parts order please provde the followng nformaton: Company Name and Bllng Address Purchase Order Number and ssung Authorty Shppng Address Specal Handlng nstructons Contact Phone Number Machne Model and Seral Number Part Numbers and Quanttes Beng Ordered Note: Please use Racne Ralroad Products part numbers when orderng parts. Racne Ralroad Products part numbers are shown on the parts lsts and drawngs n Secton 5 of ths manual and have only sx (6) numbers. Any part number wth other than sx numbers (e.g. contans alpha-numerc characters) s a Vendor Part Number and NOTa Racne Ralroad Products part number. 5.2 Techncal Support & Servce Telephone and web-based techncal support s avalable for current producton models through our Techncal Servce Department. Servce Manuals and lmted techncal support may be avalable for models that are no longer n producton. n the future, Techncal Support features wll be expanded on our home page on the world-wde-web Telephone and E-mal Techncal Support: Telephone and E-mal techncal support s avalable on normal U.S. busness days from 8:00 AM to 5:00 PM U.S. Central Tme Zone (GMT +6 (+5 Daylght Savngs Tme)). Contact us at: Phone: E-mal: Webste: (262) Extenson: techserv@racneralroad.com M Rev Draft 2 Feb 03.doc

26 5.2.2 Non-Warranty Techncal/Feld Servce Support: Dependng upon the crcumstances and avalablty of techncal servce personnel, we may provde techncal assstance and/or feld servce support, at the customer's expense, to assst n the correcton of nonwarranty related problems. Contact our Techncal Servce Department to coordnate Non-Warranty Techncal/Feld Servce Support Warranty Techncal/Feld Servce Support: Dependng upon the crcumstances and avalablty of techncal servce personnel, we may provde techncal assstance and/or feld servce support, at no charge to the customer, to assst n the correcton of warranty related problems. Contact our Techncal Servce Department to coordnate Warranty Techncal/Feld Servce Support. 5.3 Warranty Parts & "Servce Warranty parts and servce are coordnated through our Techncal Servce Department. Our warranty terms and procedures are provded n Secton. of ths manual Warranty Parts Clams: Materal clamed to be defectve must be returned to our factory for evaluaton. Defectve materals wll be replaced, or your account wll be credted f replacement materals have already been purchased. Please contact our Techncal Servce Department at the address provded below f you have any questons or problems Warranty Servce Support: Dependng upon the crcumstances and avalablty of techncal servce personnel, we may provde techncal assstance and/or feld servce support, at no charge to the customer, to assst n the correcton of warranty related problems. Contact our Techncal Servce Department at the address provded below to coordnate Warranty Techncal/Feld Servce Support. Racne Ralroad Products, nc. Attn: Techncal Servce Manager 524 Frederck Street P.O. Box Racne, W Phone: E-mal: Webste: (262) Extenson: techserv@racneralroad.com M Rev Draft 2 Feb 03.doc

27 Secton 6 Appendces 6. Sales Representatves For more nformaton about ths. or any of our other products, please contact the nearest Representatve shown on our Sales Representatves Lst. 6.2 The Owner's Manuals provded was current at the tme of prntng M Rev Draft 2 Feb 03.doc

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