JARVIS. Models USSS -1, USSS -2 and USSS -2A Pneumatic Stunners

Transcription

1 \ Models USSS -1, USSS -2 and USSS -2A Pneumatic Stunners Rear Handle for Knocker Box USSS--2A Side Handle for Knocker Box USSS--1 U.S. Patent No. 6,135,871 Patents Pending Worldwide Rear Handle for V or Center Track Restrainer USSS--1 EQUIPMENT SELECTION... Ordering No. TABLE OF CONTENTS... Page USSS--1 Stunner (see page 4) AST--101 Stunner Tester, 115V AST--101 Stunner Tester, 230V USSS--2 Stunner (see page 4) AST--102 Stunner Tester, 115V AST--102 Stunner Tester, 230V USSS--2A Stunner (see page 4) AST--103 Stunner Tester, 115V AST--103 Stunner Tester, 230V Air Compressor Package (see page 4) Air Filter--Regulator--Lubricator Multi--Set Point Regulator, 115V Multi--Set Point Regulator, 230V Balancer Notice to Employer and Safety Director 2 Notice to Operators, Maintenance and Cleanup Personnel... 3 Part Numbers... 4 Main Components... 5 Parts Diagram and List... 6 Specifications Installation Instructions Operation Instructions Maintenance Instructions Troubleshooting Chart... 24

2 noticetoemployer and safety director page 2 of 28 Keep body parts clear NOTICE TO EMPLOYER AND SAFETY DIRECTOR AVOID INJURY 1. Remove and repair any tool that malfunctions. All personnel must be instructed to remove any malfunctioning equipment. 2. Ensure that all employees who use this tool are trained in the proper use of this tool and are aware of the dangers that may arise if they do not follow procedures outlined in this brochure. 3. Ensure that all employees are instructed not to walk in front of the tool during its use, and to never put fingers, hands or other parts of the body directly in front of the tool. 4. Enclosed are four (4) copies of NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PER- SONNEL. Post one copy on the employees bulletin board; give one copy to the operator(s); give one copy to the maintenance foreman; and give one copy to the sub -contract cleanup / internal cleanup foreman. Additional copies will be provided upon request. 5. The tool is designed and intended to be powerful. This fact should be obvious to your employees, but you must emphasize it to them. 6. Ensure eye and ear protection is worn at all times when operating the tool. 7. Never make modifications or alterations to the tool. Replace any missing or illegible labels. 8. Ensure that proper procedures are established in accordance with OSHA s lockout/tagout procedures (29 CFR ) to prevent accidental startup or release of stored energy. 9. Follow our installation and maintenance instructions for proper installation and care of the tool. 10. Avoid injury. Do not permit the tool to be misused. 11. If you resell or distribute a Jarvis product, you must provide the purchaser with the appropriate safety sheets and tool brochure. Additional copies of safety sheets and tool brochures will be provided upon request.

3 notice to operators, maintenance and cleanup personnel page 3 of 28 Keep body parts clear NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PERSONNEL ANY MALFUNCTIONING TOOL MUST BE REMOVED FROM SERVICE REPORT ANY PROBLEMS TO YOUR SUPERVISOR 1. Disconnect air hose and shut the power off in accordance with OSHA s lockout/tagout procedures (29 CFR ) before performing any repair or maintenance. 2. Disconnect air hose - or have the air hose disconnected - in accordance with OSHA s lockout/tagout procedures (29 CFR ) before performing any cleanup. 3. Disconnect air hose when the tool is not being used. 4. Never put fingers, hands or other parts of the body directly in front of the tool. 5. Always wear eye and ear protection when operating the tool. 6. Always keep all body parts away from the stunning rod guide when triggers are activated. 7. Test the tool prior to use or daily. Using the Jarvis Stunner Tester is the preferred testing method; however the following procedure can also be used: Depress the main handle trigger and displace the stunning rod guide by pushing it against an uninflated rubber tire. The stunner should not activate until the auxiliary handle trigger is depressed. After the tool has been activated, release both triggers to prepare for the next firing. The stunning rod guide must return to the extended position. If the tool malfunctions, remove it from service and report or repair it immediately. 8. Never squeeze the triggers unless you want to use the tool. 9. Never make modifications or alterations to the tool. Replace any missing or illegible labels.

4 stunner and compressor part numbers page 4 of 28 Stunner Part Numbers Stunner Type Side Handle for Knocker Box Rear Handle for V or Center Track Restrainer Rear Handle for Knocker Box USSS USSS n/a USSS--2A Air Compressor Packages ( 250 psi / bars ) Voltage / Hertz Horsepower Part Number 460 / / / / / / / / / /

5 main components page 5 of 28 USSS -1 / USSS -2 Main Components Side Handle Assembly Knocker Box Figure D Rear Handle Assembly Figures E and F Nose Assembly Figure A Main Housing Assembly Figure B Hanger for Knocker Box Hanger for V orcenter Track Restrainer Catch Housing Assembly Figure C Main Handle Assembly Figure F

6 parts diagram and list page 6 of 28 Figure A Nose Assembly B USSS -2A * ** * ** USSS -2 * USSS -1 BB * Tighten to lbf--ft ** Tighten to 8--9 lbf--ft B Tighten to 5--6 lbf--ft BB Not used in current tools ITEM PART NO. PART NAME QTY External Retaining Ring Cupped Washer Spring Stunning Rod Guide, USSS O--ring, USSS ** Socket Head Cap Screw Ribbed Lock Washer Pair Nose Housing Cover, USSS * Socket Head Cap Screw Ribbed Lock Washer Pair O--ring, USSS Nose Housing, USSS Bumper (two per stunner) BB Bumper (one per stunner) Bumper, USSS O--ring, USSS Nose Housing, USSS Nose Housing Cover, USSS O--ring, USSS Stunning Rod Guide, USSS2 1 Install with flat side facing flat side. ITEM PART NO. PART NAME QTY Head Contact Spring Adj. Head Contact, USSS Socket Head Cap Screws Adj. Head Contact, USSS2A Spring B Socket Head Cap Screws Washer Nose Hsg. Cover, USSS2A Sliding Rod Guide, USSS2A O--ring, USSS2A Nose Housing, USSS2A Rod Guide Pilot Bumper, USSS2A Seal Kit, Nose & Body, USSS1 (includes items 5, 12, 36, 47, 54, 57, 63 and 64) Seal Kit, Nose & Body, USSS2 (includes items 16, 19, 36, 47, 54, 57, 63 and 64) Seal Kit, Nose & Body, USSS2A (includes items 30, 36, 47, 54, 57, 63 and 64)

7 parts diagram and list page 7 of 28 Figure B Main Housing Assembly BB B * Tighten to lbf--ft ** Tighten to lbf--ft B Rod and piston tool is available for items 34, 35 and 37 BB Cylinder liner tool is available for item 38 ITEM PART NO. PART NAME QTY B Stunning Rod, USSS B Rod Piston, USSS O--ring B Locking Nut USSS Rod and Piston Assy, USSS1 (items 34, 35 and 37) BB Cylinder Liner Stunning Rod End, USSS Stun Rod & Piston, USSS Stunning Rod Nut, USSS Rod and Piston Assy, USSS2 (items ) End Cap Stun Rod & Piston, USSS2A Rod and Piston Assy, USSS2A (items ) Catch Release Tube Catch Supply Air Tube Danger Label Seal Main Housing (includes 1 items , 59, 60, 62, 63) Stud Stud Hex Lock Nut Spacer Stud O--ring Hanger Bracket Check Valve O--ring Hex Jam Nut Swivel Bolt Backup * Hex Head Screw Hanger Swivel Washer ** Hanger Swivel Bushing O--ring O--ring 2 ** *

8 parts diagram and list page 8 of 28 Figure C Catch Housing Assembly * * Tighten to Ibf--ft. ITEM PART NO. PART NAME QTY O--ring Socket Set Screw O--ring Catch Base Plate, USSS Seal Catch Release Piston, USSS Catch Base Plate, USSS2, 2A Catch Rel. Piston, USSS2, 2A Seal Catch Piston Cylinder Ribbed Lock Washer Pair * Hex Lock Nut Elbow Fitting Blue Tubing ft Catch Release Dog Catch Pivot Pin Catch Base Plate Assy (items , 79 and 80) Seal Kit, Catch Hsg. (includes items 47, 65, 67, 69, and 73)

9 parts diagram and list page 9 of 28 Figure D Auxiliary Side Handle Assembly Knocker Box * * * * * not used in current tools ITEM PART NO. PART NAME QTY Split Lock Washer Handle Bracket Rod Handle Mtg. Plate, Thin Handle Mtg. Plate, Thick Acorn Nut Hex Nut Split Lock Washer Auxiliary Handle Bracket Spring Spacer Spring Handle Valve and Spool 1 (includes item 63) Top Spacer Hose Fitting Trigger Stop Exhaust Muffler 1 ITEM PART NO. PART NAME QTY Auxiliary Handle Auxiliary Handle Trigger Roll Pin * Auxiliary Handle Bracket * Rod Handle Bracket * Handle Bracket Assembly (includes items 58, 84, 99 and 100) Handle Bracket Assembly (includes items 55, 58, 60, and ) Auxiliary Handle Assembly (includes items 6, 7, 51 and )

10 parts diagram and list page 10 of 28 Figure E Auxiliary Rear Handle Assembly V or Center Track Restrainer ITEM PART NO. PART NAME QTY Spacer Hanger Bracket Hex Head Screw Hex Head Screw Lock Washer Support Arm Hex Jam Nut Acorn Nut Auxiliary Handle Bracket page 9 Auxiliary Handle Assembly Spacer Handle Mounting Stud Auxiliary Handle Kit (items (87, , 111 and 112)

11 parts diagram and list page 11 of 28 Figure F Auxiliary Rear Handle Assembly Knocker Box ITEM PART NO. PART NAME QTY Hex Head Screw Retaining Washer Hanger Bracket Bushing Hanger Bracket Auxiliary Handle Mtg. Kit (items 87, , 108, 109 and )

12 parts diagram and list page 12 of 28 Figure G Main Handle Assembly * ** * ITEM PART NO. PART NAME QTY O--ring O--ring Main Valve Body Spring Washer O--ring Main Valve and Spool 1 (includes item 121) Spring Main Valve Cover Socket Head Cap Screw O--ring Socket Head Cap Screw Trigger Valve Keeper 1 * Sleeve Removal Tool is available for items 122 and 136 ** Spool Removal Tool is available for item 136 ITEM PART NO. PART NAME QTY Trigger Valve Spacer Trigger Valve Body Reducer Bushing Hose Assembly, 18 in Quick Connect Plug Quick Connect Socket Hose Assy, 16 ft w/item Coiled Hose Assy, 25 ft (with item 134) Trigger Valve Sleeve and 1 Spool (includes item 121) Spring Exhaust Plate Roll Pin Main Handle Trigger Socket Head Cap Screw Main Handle Seal Kit, Handles (includes items 63, 117, 118, 121, 126)

13 tubing connection diagram page 13 of 28 Figure H Tubing Connections Tubing B Tubing A Tubing C

14 parts diagram page 14 of 28 Figure I Multi -Set Point Regulator V V

15 calibration procedure and list page 15 of 28 ITEM PART NO. PART NAME QTY Electrical Enclosure Mounting Plate Hex Nut Split Washer Flat Washer Pan Head Screw Terminal Rail Terminal Block, Yellow/Green Terminal Block, Grey Terminal Marker Terminal Block, Fuse Fuse, Time Delay Terminal Marker Pan Head Screw Internal Lock Washer Power Supply Power Cord, 115V Power Cord, 230V Strain Relief Connector Locking Nut Gage Mounting Bracket Coupling Connector Elbow Plastic Tubing 19 in Exhaust Muffler Locking Nut Clamp 1 ITEM PART NO. PART NAME QTY Nipple, 4 inch Support Bracket Pan Head Screw Reducer Bushing Nipple Union Hex Nut Volume Booster Lubricator Support Bracket Servo Valve Reducing Bushing Street Elbow Cord with Connector Mounting Plate Electrical Enclosure Bulkhead Fitting Wiring Diagram, 115V Wiring Diagram, 230V Name and Information Label Drive Screw Ball Valve Pressure On/Off Label Air Filter Switch, Two Position Small, Medium, Large Label Switch, Three Position Pressure Gage In Line Air Filter Connector Elbow Plastic Tubing 13 in Tubing Connector 1

16 SPECIFICATIONS USSS -1 Operating Pressure psi bar Air Consumption (per cycle) 1.45 ft 3 41 L Penetrating Shaft Diameter in 15.9 mm Control Handles Pneumatic Dual Trigger Overall Dimensions (l x w x h) 19x5.5x15in 483 x 140 x 381 mm Weight 32.4 lbs 14.7 kg USSS -2, 2A Operating Pressure psi bar Air Consumption (per cycle) 1.45 ft 3 41 L Non -Penetrating Shaft Dia in 34.9 mm Control Handles Pneumatic Dual Trigger Overall Dimensions (l x w x h) 19x5.5x15in 483 x 140 x 381 mm Weight 35.8 lbs 16.3 kg INSTALLATION INSTRUCTIONS IMPORTANT: ALWAYS DISCONNECT AIR HOSE IN ACCORDANCE WITH OSHA S LOCKOUT/TAGOUT PROCEDURES (29 CFR ) BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS. ALL WIRING MUST BE DONE IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL ELECTRICAL CODES. Refer to Figures A through G on pages 6-12 for referenced items. For USSS -1 1 Install compressor for operating between 160 and 190 psi ( bar). 1.1 Install compressor in a location that allows good air circulation and easy access from stunning box. 1.2 Install the air filter -regulator -lubricator at the operator s station. 1.3 Connect hose assembly (item 135) to air filter - regulator -lubricator. For USSS -2, 2A 2 Install compressor for operating between 190 and 245 psi ( bar). specifications, installation and operation instructions page 16 of Install compressor in a location that allows good air circulation and easy access from stunning box. 2.2 Install the air multi -set point regulator at the operator s station. 2.3 Connect hose assembly (item 135) to multi -set point regulator. 3 Install balancer: 3.1 Install a balancer over the stunning box to suspend Pneumatic Stunner. Jarvis part number is available. 4 Install Pneumatic Stunner: 4.1 Mount stunner (with balancer) hanging from a rail that allows movement lengthways across the stunning box. 5 Fill the air lubricator: 5.1 Use SAE 10 oil approved for USDA H1 service to lubricate the air and to extend service life of bumpers (items 14, 15 or 33). 5.2 Adjust the lubricator to obtain three to four drops of oil for every use of the stunner. 6 Connect the Pneumatic Stunner to air line: 6.1 Ensure auxiliary handle trigger (item 97) and main handle trigger (item 140) move freely before the stunner is connected to the air line. 6.2 Connect quick connect socket (item 134) on hose assembly (item 135) to quick connect plug (item 133) on tool. OPERATION INSTRUCTIONS Note: Eye and ear protection must be worn at all times while operating the USSS-1 / USSS-2, 2A Pneumatic Stunner. Note: Always disconnect quick connect socket (item 134) on hose assembly (item 135) when tool is not being used. Use care when removing this connector. It is easier to remove the connector if the air in the line is vented. Operating air pressure must range between 160 and 190 psi for the USSS -1 and between 190 and 245 psi for the USSS -2, 2A. Jarvis compressor packages are available. See page 4 for part numbers.

17 operation and maintenance instructions page 17 of 28 1 Connect air hose. 2 Each day, before you begin operation, go through the following check list: 2.1 Make sure that the compressed air supply is at the proper pressure and that the lubricator is up to the full mark. 2.2 Make sure the tool is working correctly. Use Jarvis AST -101 Stunner Tester for USSS -1, AST -102 Stunner Tester for USSS -2 or AST -103 Stunner Tester for USSS -2A to insure stunning rod (item 34, 40 or 43) is traveling at the proper speed. As an alternative, the following procedure can be used: Depress the main handle trigger (item 140) and displace the stunning rod guide (item 4, 20 or 29) by pushing it against an unmounted rubber tire. The stunner should not activate until the auxiliary handle trigger (item 97) is depressed. If the tool malfunctions, remove it from service and report the problem to your supervisor immediately. 2.3 Make sure that the stunner moves freely on the balancer. 3 Guide stunner to the animal s head. Note: Keep body parts away from stunning rod guide (item 4, 20 or 29) when triggers are activated. 4 Depress and hold the main handle trigger (item 140) to arm the stunner. 5 Displace the stunning rod guide (item 4, 20 or 29) against the head of the animal. 6 Depress the auxiliary handle trigger (item 97) to release and fire the stunning rod (item 34, 40 or 42). The stunning rod will extend and then retract into stunning rod guide (item 4, 20 or 29). Note: Tool is inoperable until both both auxiliary and main handle triggers have been released. 7 Repeat procedure for next animal placed in stunning box. 8 Disconnect quick connect socket (item 134) on hose assembly (item 135) from quick connect plug (item 133) on tool after stunning has been completed. MAINTENANCE INSTRUCTIONS ALWAYS DISCONNECT THE AIR SUPPLY IN ACCOR- DANCE WITH OSHA S LOCKOUT/TAGOUT PROCE- DURES(29 CFR ) BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS. Refer to Figures A through G on pages 6-12 for referenced items. Refer to Troubleshooting Chart on pages for troubleshooting procedures. Always disconnect quick connect socket (item 134) on hose assembly (item 135) from quick connect plug (item 133) on tool before attempting any maintenance or repairs. Use care when removing this connector. It is easier to remove the connector if the air in the line is vented. 1 DAILY: 1.1 Remove nose housing (item 13, 17 or 31) from main housing (item 48). 1.2 Check condition and operating smoothness of stunning rod guide (item 4, 20 or 29). Lubricate with light oil or replace if necessary. 1.3 On USSS -1, check condition of external retaining ring (item 1) and spring (item 3). Replace if necessary. 1.4 Remove stunning rod assembly. Check condition of rod (item 34, 40 or 43), rod piston (item 34), piston o -ring (item 36) and stunning rod nut (item 37 or 41). 1.5 Look inside cylinder liner (item 38) to make sure catch release dog set screws (item 66) have not loosened. Tighten or replace if necessary. 1.6 Check condition of bumpers (item 14, 15 or 33). Replace or rotate if necessary. 1.7 Spray oil on stunning rod o -ring (item 36) and around inside of cylinder liner (item 38). 1.8 Install stunning rod assembly and nose housing. Tighten socket head screws (item 9) to lbs -ft. 1.9 Check tightness and condition of socket head cap screws (items 6, 9, 26, 125, 127 and 141) and hanger swivel bushings (item 62). Replace if necessary Check all air hoses for wear. Replace if necessary.

18 1.11 Check condition and operating smoothness of auxiliary handle trigger (item 97) and main handle trigger (item 140). Lubricate or replace if necessary Check condition of hanger bracket (item 55, 102 or 116) and tightness of hex jam nuts (items 58 or 107). Replace if necessary. 2 WEEKLY: 2.1 Remove nose housing cover (item 8, 18 or 28). 2.2 Remove stunning rod guide (item 4, 20 or 29). 2.3 Check condition of all o -rings and replace if necessary. 2.4 Spray oil around nose housing cover and stunning rod guide o -rings (item 5 and 12, 16 and 19 or 30). 2.5 Reinstall nose housing cover (item 8, 18 or 28) and tighten screws (item 6) to 8-9 lbf -ft or item 26 to 5-6 lbf-ft. 2.6 Remove trigger valve (item 136) and main valve (item 122). Blow out any debris that may be present. 2.7 Remove, inspect and clean check valve (item 56). Replace if necessary. 3 MONTHLY: 3.1 Remove catch housing assembly. Refer to section Inspect and clean all parts. 3.3 Replace all of the following after 80,000 cycles: catch housing assembly o -ring (item 65), catch dog o -ring (item 67), catch base plate seal (item 69), catch release cylinder seal (item 69) and catch release piston seal (item 73). 4 NOSE DISASSEMBLY: 4.1 Remove (6) socket head cap screws (item 9), ribbed lock washers (item 10) and spring washers (item 11) from nose housing (item 13, 17 or 31). 4.2 Remove nose housing (item 13, 17 or 31) from main housing (item 48) by sliding complete assembly off stunning rod (item 34, 40 or 43). 4.3 Remove socket head cap screws (item 6 or 26) and ribbed lock washers (item 7 or 27) from nose housing cover (item 8, 18 or 28). maintenance instructions page 18 of Remove housing nose cover (item 8, 18 or 28) and o -ring (item 5 or 19) from nose housing (item 8 or 18). For USSS Remove external retaining ring (item 1), cupped washer (item 2), spring (item 3) and stunning rod guide (item 4) from nose housing cover (item 8). For USSS -2, 2A 4.6 Loosen (2) socket head cap screws (item 23) in adjustable head contact (item 22 or 24). Remove adjustable head contact (item 22 or 24), head contact spring (item 21 or 25) and stunning rod guide (item 20 or 29) from nose housing cover (item 18 or 28). 4.7 Inspect all parts for wear and replace if necessary. 5 NOSE INSTALLATION: 5.1 Reverse steps and procedures outlined in section 4. See special notes below: Apply Jarvis 1315 White Grease to o -rings (item 5 and 12, 16 and 19 or 30) before inserting them into tool. For USSS -1, Tighten (4) socket head cap screws (item 6) to 8-9 Ibf-ft Tighten (6) socket head cap screws (item 9) to lbf -ft. For USSS Ensure external retaining ring (item 1) is seated correctly in groove on stunning rod guide (item 4) for USSS -1. For USSS -2A Tighten (6) socket head cap screws (item 26) to 5-6 Ibf-ft Tighten (6) socket head cap screws (item 9) to lbf -ft. 6 BUMPER DISASSEMBLY: 6.1 Remove nose assembly. Refer to section Remove o -rings (item 12, 16 or 30) and bumpers (item 14, 15 or 33). 6.3 Inspect bumpers for wear and replace if necessary.

19 maintenance instructions page 19 of 28 7 BUMPER INSTALLATION: 7.1 Reverse steps and procedures outlined in section 6. See special notes below: Make sure bumpers are installed with flat side facing flat side. See Figure A, page Refer to section 5 for correct installation of nose assembly. 8 STUNNING ROD DISASSEMBLY: 8.1 Remove nose assembly. Refer to section Remove bumpers. Refer to section Remove catch housing assembly. Refer to section Remove stunning rod assembly (items 34-37, or 41-43) from catch base plate (item 68 or 71). Inspect stunning rod for wear and sharpen end (USSS -1 only) or replace stunning rod end (USSS -2, 2A) if necessary. 8.5 Use disassembly tool to unthread locking nut (item 37) from stunning rod (item 34). See Figure Reverse steps and procedures outlined in section 8. See special notes below: Make sure stunning rod piston (item 35) is tightly secured with locking nut (item 37). Use Loctite 271 on threads Refer to section 15 for correct installation of catch housing assembly Refer to section 7 for correct installation of bumpers Refer to section 5 for correct installation of nose housing assembly. 10 CYLINDER LINER DISASSEMBLY: 10.1 Remove nose assembly. Refer to section Remove bumpers. Refer to section Remove catch housing assembly. Refer to section Remove stunning rod. Refer to section Use removal/installation tool to remove cylinder liner (item 38). See Figure 2. Figure 2 Figure 1 Piston Clamp Stunning Rod Clamp Rod and Piston Disassembly Tool Tighten assembly into piston clamp using two threaded handles. Secure stunning rod clamp to stunning rod. Hold stunning rod clamp in a vise and use handles to unthread locking nut from stunning rod. 8.6 Inspect stunning rod (item 34, 40 or 43), o -ring (item 36) and locking nut (item 37 or 41) for wear. 9 STUNNING ROD INSTALLATION: Cylinder Liner Insertion/Removal Tool Insert tool into cylinder liner from catch end of main housing (item 48) Gently tap on rod to dislodge cylinder liner Carefully twist cylinder liner (item 38) out of main housing (item 48) Remove and discard o -rings (item 64) from main housing (item 48). Note: Replace o -rings (item 64) whenever cylinder liner is removed.

20 10.7 Inspect cylinder liner for wear and replace if necessary Inspect catch release tube (item 44), catch supply air tube (item 45) and seals (item 47) for wear. Replace if necessary. 11 CYLINDER LINER INSTALLATION: 11.1 Reverse steps and procedures outlined in section 10. See special notes below: Apply Jarvis 1315 White Grease to o -rings (item 64) and to o -ring grooves inside of main housing (item 48). Ensure o -rings (item 64) are in correct position Insert cylinder liner (item 38) into nose housing end of main housing (item 48). Insert tool into nose housing end of cylinder liner. See Figure Gently tap on rod end of tool to seat cylinder liner Refer to section 15 for correct installation of catch housing assembly Apply Jarvis 1315 White Grease to seals (item 47) and to inside of main housing (item 48) Refer to section 8 for correct installation of stunning rod Ensure catch release tube (item 44) and catch supply air tube (item 45) align with air passages on catch base plate (item 68 or 71) and nose housing (item 13, 17 or 31) Refer to section 7 for correct installation of bumpers Refer to section 5 for correct installation of nose assembly. 12 HANGER BRACKET DISASSEMBLY: Note: If hex head screws (item 60) do not have to be removed, skip to steps 12.6 and Remove nose assembly. Refer to section Remove bumpers. Refer to section Remove catch housing assembly. Refer to section Remove stunning rod. Refer to section Remove cylinder liner. Refer to section Remove hex jam nuts (item 58) while holding hanger swivel bushings (item 62). maintenance instructions page 20 of 28 For Knocker Box Side Handle Assembly 12.7 Remove hanger bracket (item 55) and hanger swivel washers (item 61). For Rear Handle Assembly 12.8 Remove hex head screws (item 104), lock washers (item 105) and support arms (item 106). Remove acorn nuts (item 108) and lock washers (item 87) if necessary to remove complete handle mounting bracket Remove hanger swivel bushings (item 62) and o -rings (item 63) Remove hex head screws (item 60) and swivel bolt backups (item 59) from inside of main housing (item 48) Inspect all parts for wear and replace if necessary. 13 HANGER BRACKET INSTALLATION: 13.1 Reverse steps and procedures outlined in section 12. See special notes below: Tighten hex head screws (item 60) to Ibf-ft Tighten hanger swivel bushings (item 62) to Ibf -ft Use Loctite 271 on hex head screws (item 60), hanger swivel bushings (item 62) and hex jam nuts (item 58) Refer to section 11 for correct installation of cylinder liner Refer to section 9 for correct installation of stunning rod Refer to section 15 for correct installation of catch housing assembly Refer to section 7 for correct installation of bumpers Refer to section 5 for correct installation of nose assembly. 14 CATCH HOUSING DISASSEMBLY: 14.1 Remove (6) hex lock nuts (item 76) and ribbed lock washers (item 75) Separate catch piston cylinder (item 74) from catch base plate (item 68 or 71). Two m6 x 1 screws can be inserted into threaded holes in catch cylinder to assist if necessary.

21 maintenance instructions page 21 of Remove o -ring (item 65), seal (item 69), seal (item 73) and catch release piston (item 70 or 72) Remove catch base plate (item 68 or 71) from main housing (item 48) Remove o -ring (item 67) Remove (6) socket set screws (item 66) securing catch pivot pins (item 80) Remove (6) catch pivot pins (item 80) and (6) catch release dogs (item 79) from catch base plate (item 68 or 71). Note: A twisting motion may be needed to remove catch pivot pins from catch base plate Inspect all parts for wear and replace if necessary. 15 CATCH HOUSING INSTALLATION: 15.1 Reverse steps and procedures outlined in section 14. See special notes below: Make sure that flats on catch pivot pins (item 80) are aligned with socket set screws (item 66). Use Loctite 271 on threads Make sure o -ring (item 67) is properly installed in groove of catch base plate (item 68 or 71) Apply Jarvis 1315 White Grease to seals (items 47, 69 and 73), o -ring (item 65) and to inside of main housing (item 48) Make sure catch release tube (item 44) and catch supply air tube (item 45) align with air passages on catch base plate (item 68 or 71) and nose housing (item 13, 17 or 31) Be careful not to pinch seal (item 73) when inserting catch release piston (item 70 or 72) into catch piston cylinder (item 74) Tighten hex lock nuts (item 76) to Ibf - ft. 16 AUXILIARY HANDLE DISASSEMBLY: 16.1 Remove hose fittings (item 93) and blue tubing (item 78) connections between auxiliary handle (item 110) and catch housing assembly, and between auxiliary handle and main handle Remove (3) acorn nuts (item 85) and ribbed lock washers (item 75) securing handle mounting plate (item 84) to studs (item 49) on main housing (item 48) On rear auxiliary handle assembly also remove hex jam nuts (item 58) while holding hanger swivel bushings (item 62); remove hex head screws (item 104), lock washers (item 105) and support arms (item 106) Remove auxiliary handle assembly from main housing Examine seals (item 47) on studs (item 49). Replace if necessary Remove (3) socket head cap screws (item 6), (2) hex lock nuts (item 51) and (1) ribbed lock washer (item 7) securing auxiliary handle bracket (item 88 or 99) to auxiliary handle (item 110) Remove auxiliary handle bracket (item 88 or 99) Remove exhaust muffler (item 95) from auxiliary handle (item 110). Clean or replace muffler Remove spring spacer (item 89) and spring (item 90) Remove (2) socket head cap screws (item 23) and trigger stop (item 94) from auxiliary handle (item 110) Remove roll pin (item 98) and auxiliary handle trigger (item 97) from auxiliary handle (item 110) Use a 3/8 inch diameter brass rod to push on the top spacer (item 92) to remove the handle valve spool and sleeve (item 91) from the auxiliary handle (item 110) Remove (6) o -rings (item 63) on handle valve sleeve (item 91) Inspect all parts for wear and replace if necessary. 17 AUXILIARY HANDLE INSTALLATION: 17.1 Reverse steps and procedures outlined in section 16. See special notes below: Apply Jarvis 1315 White Grease to o -rings (item 63) Remove seal (item 47), check valve (item 56) and o -ring (item 57) from main housing (item 48).

22 maintenance instruction page 22 of Remember to insert top spacer (item 92) before inserting handle valve sleeve (item 91) into bore in auxiliary handle (item 110) Carefully insert hanger valve spool (item 91) into hanger valve sleeve. Do not force spool into sleeve. 18 MAIN HANDLE DISASSEMBLY: 18.1 Remove fitting (item 93) and blue tubing (item 78) connection to auxiliary handle (item 110) Remove (4) hex lock nuts (item 51) and (4) ribbed lock washers (item 7) securing main handle (item 142) to studs (item 53) in main housing (item 48). Note: If removal of stud (item 53) is necessary, nose assembly and cylinder liner (item 38) must be removed to access hex lock nut (item 51). Refer to section Remove (5) socket head cap screws (item 125) and (5) ribbed lock washers (item 27) securing exhaust plate (item 138) to main valve body (item 119), trigger valve body (item 130) and main handle (item 142) Remove exhaust plate (item 138) Remove trigger valve body (item 130) and main handle (item 142) from main valve body (item 119) Remove o -ring (item 126) from top of trigger valve body (item 130) Remove (2) socket head cap screws (item 141) and (2) ribbed lock washers (item 7) from main valve body (item 119) Separate main handle (item 142) from trigger valve body (item 130) Remove (3) socket head cap screws (item 125) and (3) ribbed lock washers (item 7) from main valve body (item 119) Remove main valve body (item 119) from main housing (item 48) Remove o -rings (items 117 and 118) from top of main valve body (item 119) Remove (4) socket head cap screws (item 26) and (4) ribbed lock washers (item 27) from main valve cover (item 124) Remove main valve cover (item 124) from main valve body (item 119) Remove spring (item 123) from main valve spool (item 122) Carefully remove main valve spool from main valve sleeve. Note: There are no seals inside the valve. The spool is a very close fit in the sleeve and will leak or bind if scratched Use valve sleeve removal tool to remove main valve sleeve (item 122) from main valve body (item 119). See Figure 3. Valve Sleeve Removal Tool Figure 3 Rubber Sleeve Insert the tool into main valve sleeve. Turn wing nut counterclockwise while holding hex nut with a wrench until rubber sleeve grips main valve sleeve. Carefully remove main valve sleeve Remove spring washer (item 120) Remove (6) o -rings (item 121) Remove socket head cap screw (item 127) and ribbed lock washer (item 7) from trigger valve keeper (item 128) Remove trigger valve keeper (item 128), trigger valve spacer (item 129) and spring (item 137) Use trigger valve spool removal tool to carefully remove trigger valve spool (item 136) from trigger valve body (item 130). See Figure Insert the slotted end of the tool into the hole in the trigger valve spool. Turn the wing nut counterclockwise while preventing the hex nut from turning to expand the end of the tool. Carefully remove the trigger valve spool.

23 maintenance instructions page 23 of 28 Figure 4 Valve Spool Removal Tool Use valve sleeve removal tool to remove the trigger valve sleeve (item 136) from trigger valve body (item 130). See Figure Insert the tool into sleeve. Tighten wing nut while preventing the hex nut from turning until rubber sleeve grips the trigger valve sleeve. Carefully remove sleeve Remove spring washer (item 120) Remove (4) o -rings (item 121) Remove roll pin (item 139) and main handle trigger (item 140) from main handle (item 142) Inspect all parts for wear and replace if necessary. 19 MAIN HANDLE INSTALLATION: 19.1 Reverse steps and procedures outlined in section 18. See special notes below: Apply Jarvis 1315 White Grease to seals (item 47) and o -rings (items 57 and 121) Carefully insert main valve spool (item 122) into main valve (item 122). Do not force main valve spool into main valve sleeve Carefully insert trigger valve spool (item 136) into trigger valve sleeve (item 136). Do not force trigger valve spool into trigger valve sleeve Make sure tapered end of check valve (item 56) is toward main housing (item 48). See Figure 5. Toward Main Housing Figure 5 Tapered End Check Valve

24 troubleshooting chart page 24 of 28 Troubleshooting Chart Refer to Figures A through G on pages 5-12 for referenced items. Problem Probable Cause Solution Delay in stunning rod firing. Plugged nose housing (item 13, 17 or 31) air passages. Blow air through nose housing air passages. Unclog if necessary. Plugged catch release tube (item 44) or catch supply air tube (item 45). Blow air through tubes. Unclog if necessary. Plugged blue tube (item 78) between catch piston cylinder (item 74) and B or C on auxiliary handle (item 110). Debris between stunning rod guide (item 4, 20 or 29) and stunning rod (item 34, 40 or 43). Blow air through blue tubes between auxiliary handle and catch piston cylinder. Disassemble nose assembly and clean stunning rod guide and stunning rod. Stunner does not activate. Plugged trigger valve (item 136). Pull trigger (item 140) and release. Air should fill main housing and exhaust through exhaust plate (item 138) when trigger is released. If not, remove, disassemble and clean all trigger valve components. Plugged main valve (item 122). Plugged nose housing (item 13, 17 or 31) air passages. Plugged catch release tube (item 44) or catch supply air tube (item 45). Plugged blue tube (item 78) between catch piston cylinder (item 74) and B or C on auxiliary handle (item 110). Plugged handle valve (item 91). Defective cylinder liner o -rings (item 64). Pull both triggers (item 97 and 140) and release trigger (item 97). Air should fill main housing and exhaust through exhaust plate (item 138) when trigger is released. If not, remove, disassemble and clean all main valve components Blow air through nose housing air passages. Unclog if necessary. Blow air through tubes. Unclog if necessary. Blow air through blue tubes between auxiliary handle and catch piston cylinder. Remove hose from top of catch housing going to C on auxiliary handle (item 110). Air should flow when stunning rod guide is actuated. If not, remove, disassemble and clean all handle valve parts. If air leaks past the liner, it flows through check valve (item 56) and moves main valve preventing air from pressurizing the stunning rod piston (item 34, 40 or 43). Replace and lubricate o -rings.

25 troubleshooting chart page 25 of 28 Troubleshooting Chart (cont d) Refer to Figures A through G on pages 5-12 for referenced items Problem Probable Cause Solution Stunner fires before stunning rod activation. Stunning rod does not return after activation. Air escaping from nose housing when trigger is pressed. Deteriorated catch release piston seal (item 73). Worn locking nut (item 37 or 41). Worn catch release dogs (item 79) or catch pivot pins (item 80). Stunning rod piston (item 35, 40 or 43) sticking to liner (item 38). Deteriorated catch tension o -ring (item 67). Defective check valve (item 56). Check valve (item 56) installed backwards Plugged nose housing (item 13, 17 or 31) air passages. Plugged catch release tube (item 44) or catch supply air tube (item 45). Plugged blue tube (item 78) between catch piston cylinder (item 74) and B or C on auxiliary handle (item 110). Defective main valve spring (item 123). Plugged handle valve (item 91). Damaged or worn bumper (item 14, 15 or 33). Damaged stunning rod o -ring (item 36). Damagedmainvalveo-ring (item 121). Damaged stunning rod guide o -ring (item 5, 19 or 30). Damaged nose o -ring (item 12, 16 or 30). Replace and lubricate seal. Replace stunning rod locking nut. Replace catch release dogs or catch pivot pins. Remove and clean stunning rod piston and cylinder liner. Replace o -ring. Replace check valve. Reinstall if necessary. Blow air through nose housing air passages. Unclog if necessary. Blow air through tubes. Unclog if necessary. Blow air through blue tubes between auxiliary handle and catch piston cylinder. Replace spring. Remove hose from top of catch housing going to C on auxiliary handle (item 110). Air should flow when stunning rod guide is actuated. If not, remove, disassemble and clean all handle valve parts. Replace bumper. Clean out air passages. Change bumpers more often. Replace o -ring. Replace o -ring. Replace o -ring. Replace o -ring.

26 troubleshooting chart page 26 of 28 Troubleshooting Chart (cont d) Refer to Figures A through G on pages 5-12 for referenced items Problem Probable Cause Solution Air escaping from exhaust plate (item 138) when trigger is pressed. Damaged trigger valve o -ring (item 121). Replace o -rings. Bumper breaks into several pieces or chunks. Replace bumpers more often. Clean air passages and valves to prevent future problems.

27 notes page 27 of 28

28 page 28 of ANDERSON UNITED ROAD, STATES MIDDLETOWN, OF AMERICA CONNECTICUT E--MAIL TEL FAX