GT-3500GE NEW MODEL 2001 Edition   SPEC TYPE OPERATOR,S INSTRUCTION MANUAL

GT-3500GE NEW MODEL 2001 Edition   SPEC TYPE OPERATOR,S INSTRUCTION MANUAL
OPERATOR, S INSTRUCTION MANUAL
GT-3500GE NEW MODEL
2001 Edition
®
PORTABLE IMPACT WRENCH
Email:[email protected] URL http://www.vessel.co.jp/exp/
Product of Japan
・ SPEC TYPE (Documents Included)
・USA GAS EMISSION CONTROL VERSION(EPA PHASE/CARB Tier 1)
・INTERNATIONAL SPEC MODEL
R
Tools
C
Copyright VESSEL CO., INC. 2001
99093030.02 Printed in Japan.
since
1916
"PHANTOM" moves quickly!
OPERATORS MANUAL
& SPAREPARTS LISTS
INDEX
PAGE No.
CHAPTER 1.
TECHNICAL DATA ----------------------------------------------------- 1
CHAPTER 2.
WARNINGS & SAFETY INSTRUCTIONS ------------------------ 2∼3
CHAPTER 3.
OPERATING INSTRUCTION ---------------------------------------- 4∼5
CHAPTER 4.
TROUBLE SHOOTING ------------------------------------------------ 6∼8
CHAPTER 5.
MAINTENANCE INSTRUCTION ------------------------------------ 9∼11
CHAPTER 6.
EXPLODED VIEWS AND SPAREPARTS LISTS --------------- 12
Engine - Exploded Diagram Drawing ------------------------------- 13
Engine - Parts List ------------------------------------------------------ 14
Engine components - Exploded Diagram Drawing ------------- 15
Engine components - Parts List ------------------------------------- 16
Recoil Starter - Exploded Diagram Drawing & Parts List ------ 17
Carburetor - Exploded Diagram Drawing & Parts List --------- 18
Impact Mechanism - Exploded Diagram Drawing --------------- 19
Impact Mechanism - Parts List --------------------------------------- 20
TECHNICAL DATA
CHAPTER 1.
CHAPTER 2.
WARNINGS AND SAFETY INSTRUCTIONS
INTRODUCTION
GT-3500GE GASOLINE ENGINE IMPACT WRENCH is a high quality tool with self-contained
heavy duty and high power two cycle engine as power source. And its unique design of impact
mechanism with VESSEL pneumatic V-Hammer ultra light weight impact wrench series, even
small engine (46.5 cc) can create higher fastening torque with enormous light weight only
19.50kg (42.99 lbs.)
Read these instructions carefully before operating, maintaining or servicing this tool.
Please keep these instructions in a safe accessible place.
Because of self-contained high power two cycle engine, it is very easily mobile to carry by one
man to any construction sites in the rain forest, hill or desert such remote areas where electricity
supply or air compressor, generator are not available.
The capacity of this tool is 32mm (1 1/4") bolt size and ideal for fastening and loosening bolts
of wood sleepers at railroad construction and many more applications.
Engine
Type
:Two Stroke, Forced, Air Cooled, Single Cylinder
Displacement
: 46.5cc, Φ43x32mm(Inner bore size x stroke)
Fuel Tank Capacity
: 1 liter
Fuel Mixture Ratio
: 25:1(gasoline : 2 cycle oil)
Revolution(idling)
: 2700 rpm ±250
Revolution(loaded, impact) : 7120 rpm
Revolution(non loaded, max) : 9880 rpm
Maximum Output
: 2.3 Ps/7500 rpm
Maximum Torque
: 0.34 kg-m/5500 rpm
Compression Rate
: 7.1 : 1
Fuel Consumption Rate
: 380 g/Ps.h
Ignition
Type
Spark Plug Type
: Electronic
: NGK BPMR6A
Carburetor
Type
: Diaphragm
Impact
Square Drive Size
Fastening Torque Range
: 25.4 mm(1")
: 1030Nm(Full Throttle : 760ft. lbf)
800Nm(Half Throttle : 590ft. lbf)
: 1200 rpm
Free Speed
Vibration
2
Unloaded
Loaded
: 4m/S
: 19m/S
Noise
Idle
Loaded
: 78dBA
: 100dBA
Capacity
Bolt Diameter
: 32 mm (1 1/4")
Weight
Without fuel
: 19.50 kg (42.99 lbs.)
Overall Dimensions
Length
Height
Width
: 700mm (28")
: 330mm (13")
: 390mm (15")
Accessories
Hex Key Wrench
4mm 1pc.
5mm 1pc.
6mm 1pc.
1pc.
10-13mm 1pc.
Spark Plug Wrench
Spanner
2
Read to fully understand and
observe the following safety
precautions and warnings.
Careless or improper use of
tool may cause serious or fatal
injury.
Always wear eye, head and
ear protectors when using this
tool.
WARNING!
Indicates instant possibility of
severe personal injury or loss
of life, if instructions are not
followed.
CAUTION!
Indicates a possibility of personal injury or equipment damage, if instructions are not
followed.
Operator safety
Tool safety
● Always
● Inspect
wear a safety face shield or goggles.
wear heavy, long pants, boots and
gloves. Do not wear loose clothing, jewellery,
short pants, sandals or go barefoot. Secure
hair so it is above shoulder length.
● Do not operate that tool when you are tired,
ill or under the influence of alcohol, drugs or
medication.
● Never let a child or inexperienced person
operate the machine.
● Wear hearing protection.
● Never start or run the engine inside a closed
room or building. Breathing exhaust fumes
can kill.
● Keep handles free of oil and fuel.
● Keep hands away from anvil.
● Do not grab or hold the unit by rotating anvil.
● Hold the handles firmly with both hands and
make sure to stand on the firm base or ground.
● Do not touch spark plug, high voltage cord during operation as it may cause electric shock.
● To avoid burn do not touch those places like
engine, muffler, exhaust where get very hot
during in use or even after stop engine until
it gets cool for the time being.
● When operation is prolonged, take a break
from time to time so that you may avoid possible whitefinger disease which is caused
by vibration.
the entire tool before each use. Replace damaged parts. Check for fuel leaks and
make sure all fasteners are in place and securely fastened.
● Replace parts that are cracked, chipped or
damaged in any way before using the tool.
● Keep others away when making carburetor
adjustments.
● Use only accessories as recommended for this
tools by the manufacturer.
● Always
WARNING!
Never modify the tool in any way. Do not use
your tool for any job except that for which it is
intended.
Fuel safety
● Mix
and pour fuel outdoors and where there
are no sparks or flames.
● Use a container approved for fuel.
● Do not smoke or allow smoking near fuel or
the tool or while using the tool.
● When filling up fuel, stop engine and make
sure engine is cool and choose the places
where no flamables and well ventulation.
● Wipe up all fuel spills before starting engine.
Note: To improve the performance, the specifications are subject to change without notice.
_ 1 _
_ 2 _
OPERATING INSTRUCTION
CHAPTER 3.
● Move
at least 3m away from fueling site before
starting engine.
● Stop engine before removing fuel cap.
● Empty the fuel tank before storing the tool. It is
recommended that the fuel be emptied after
each use. If fuel is left in the tank, store so fuel
will not leak.
● Store tool and fuel in area where fuel vapors
cannot reach sparks or open flames from
water heaters, electric motors or switches,
furnances, etc.
Maintenance safety
● Maintain
the tool according to recommended
procedures.
● Disconnect the spark plug before performing
maintenance except for carburetor adjustments.
● Keep others away when making carburetor
adjustments.
● Use only genuine replacement parts as recommended by the manufacturer.
Transport and storage
WARNING!
● Carry
the tool by hand with the engine stopped and the muffler away from your body.
● Allow the engine to cool, empty the fuel tank,
and secure the tool before storing or transporting in a vehicle.
● Empty the fuel tank before storing the tool. It
is recommended that the fuel be emptied
after each use. If fuel is left in the tank, store
so fuel will not leak.
● Store tool out of the reach of children.
● Clean the unit carefully and store it in a dry
place.
● Make sure engine switch is off when transporting or storing.
Antivibration systems do not guarantee that
you will not sustain whitefinger disease or carpal tunnel syndrome. Therefore, continual
and regular users should monitor closely the
condition of their hands and fingers. If any of
the above symptoms appear, seek medical
advice immediately.
GASOLINE
1.FUEL
Use only quality two cycle oil with gasoline at mixture ratio of 25:1
(Gasoline : Two cycle oil) (FIG. 3)
*Never use by gasoline only as engine will burn.
TWO CYCLE OIL
1
25
WARNING!
Do not smoke and keep all other fire away from fuel tank during
filling fuel as it causes fire or burn yourself. (FIG .3-1)
(FIG.3)
Fill up fuel after well mixed fuel and oil in a separate clean container.
CAUTION!
Wipe up all fuel spills before starting engine.
2.START UP ENGINE
(1) Place the tool on a firm stand or solid floor.
(2) Set gear change lever to neutral (N) position. (FIG. 3-2)
(3) Press priming bulb several times so that fuel flows through bulb
into carburetor. (FIG.3-3)
(4) Turn choke lever to closed position. (FIG. 3-4)
(5) Pull throttle lever,and then press the support button.
then the throttle lever is stayed there in the state of half-throttle,
and won't be back to the original location. (FIG.3-5)
(6) Pull recoil starter handle strongly, taking care to keep the handle
in your grasp and not allow to withdraw rope until the end. (FIG.3-6)
(FIG.3-1)
GEAR CHANGE LEVER
OIL POT PORT
(FIG.3-2)
If situations occur which are not covered in this
manual, take care and have a good judgement.
Contact your dealer if you need assistance.
CAUTION!
Return recoil starter rope gently to its original position.
(7) After initial fires, engine will continue to run, return choke lever
slowly to open position.
(8) If engine will stop after a few fires by procedure of (7), return choke
lever to open position and pull recoil starter handle strongly again.
(9) If engine does not start by procedure of (8), repeat procedures
from (4).
(10) After starting engine, return throttle lever to idle position for
slow engine. Then allow the engine about 2∼3 minutes to
warm up before in use.
WARNING!
*Once starting the engine, do not leave tool alone. Always hold handle tightly so that tool will not move around on the stand or floor.
*Before and during operation, always take a firm stance and keep
safety position from slipping of falling down.
CLOSED
CHOKE LEVER
PRESS
OPEN
(FIG.3-5)
_ 3 _
_ 4 _
(FIG.3-4)
PRIMING BULB
(FIG.3-3)
(FIG.3-6)
SYMPTOM
CHAPTER 4.
STOP SWITCH
_ 5 _
(FIG.3-10)
_ 6 _
Replace
ignition coil
● Bad
Correct connection
connection of high voltage cord in ignition with spark plug
● Poor
Adjust correct gap to 0.6 mm
spark plug gap
● Wider
Clean up or replace
plug
● Dirty
Repair or replace
circuit of stop switch lead wire
● Short
1. Bad connection/Ignition coil
2. Incorrect air gap/Ignition coil
3. Bad ignition coil
spark
● No
stop switch in stop position
● Ignition
<Electrical system>
Turn to on position
Air leak from carburetor
Incorrect carburetor adjustment
Bad diaphragm in carburetor
Incorrect carburetor valve hinge height adjustment
function of carburetor
● Poor
1. Remove spark plug
2. Exhaust exceeded fuel by pulling recoil starter handle 5-6 times
3. Install spark plug
4. Turn choke lever to open position and pull recoil starter handle
Repair
or disconnection of fuel pipe
2
(FIG.3-9)
● Bent
3
1
Yellow Sign
spark plug due to too much intake of
CORRECTIVE ACTION
2
fuel
ADJUSTMENT BUTTON
● Wet
4.STOPPING ENGINE
(1) Release throttle lever to decrease engine speed.
(2) Push stop switch to stop engine. (FIG. 3-10)
(3) Place the tool on firm stand or solid floor and turn gear change
lever to N (neutral) position.
fuel or shortage
Throttle lever
● Empty
(4) Once bolts or nuts fastened, release throttle lever for idling and
not allow driving shaft turn and remove socket from bolts or nuts.
ENGINE DOES
NOT START
move
<Fuel System>
Fine tune might be required by turning adjustment button from
number 1 to 3. The number should be set at the yellow sign area.
(FIG.3-9)
PROBABLE CAUSE
3.OPERATION.
CROSS SECTION SKETCH
(1) Select R (for clockwise direction) or L (counter clockwise diAdjustment button
rection) gear for fastening or loosening bolts and nuts.
(2) Always release throttle lever to allow slow engine for idling and
turn gear change lever and do not change gear when engine is
accelerating.
(3) This new model has implemented an adjustment button in order
to operate two different torque values.
A.FULL THROTTLE(MAXIMUM TORQUE)1030 Nm
move
If you squeeze the throttle lever fully, the machine shows the
Throttle lever
maximum torque,1030Nm.
B.HALF THROTTLE(MEDIUM TORQUE) about 800Nm
(FIG.3-8)
1.Press the adjustment button.
2.Squeeze the throttle lever and the adjustment valve will
PRESS
prevent the throttle lever from moving further more. In other
words, the throttle lever would hit at the adjustment valve
and would not create further torque. (FIG.3-8)
Fill up fuel at mixture ratio 25 gasoline : 1 two cycle oil
OPEPATING INSTRUCTION
TROUBLE SHOOTING - 1
CHAPTER 3.
TROUBLE SHOOTING - 2
CHAPTER 4.
SYMPTOM
PROBABLE CAUSE
CORRECTIVE ACTION
<Fuel System>
ENGINE INSTALLED
SOON AFTER
STARTING OR IS
LIKELY TO STOP
● Shortage
● Choke
● Air
of fuel
Fill up fuel at mixture ratio of 25 gasoline : 1 two cycle oil
lever in closed position
goes through to fuel system
● Poor
function of carburetor
Turn to open position
Check if cracks are found on pipe or connector and pipe is securely
fixed
Air leak from carburetor
Incorrect carburetor adjustment
Bad diaphragm in carburetor
Incorrect carburetor valve hinge height adjustment
_ 7 _
<Electrical system>
● Bad
spark plug
Replace
● Bad
ignition coil
Replace
TROUBLE SHOOTING - 3
CHAPTER 4.
SYMPTOM
ENGINE
OVERHEATS
PROBABLE CAUSE
● Bad
mixture ratio fuel
● Wrong
NON-REVOLUTION
OF ANVIL SHAFT
_ 8 _
OUTPUT POWER
REDUCTION
selection of spark plug
CORRECTIVE ACTION
Fill up correct mixture ratio fuel at 25 gasoline : 1 two cycle oil
Replace. Use pure and instructed parts only
● Clogged
cylinder with dirt
Clean up
● Clogged
cooling duct with dirt
Clean up
● Gear
change lever in neutral position
Turn to R (clockwise direction) or L (counter clockwise direction)
position
● Worn
out of drum shoe on clutch arm
Replace
● Dirty
air cleaner element
● Carbon
deposits in muffler, exhaust port on
Clean up
Clean up
cylinder
● Poor
cylinder pressure due to worn out of
piston, piston ring, cylinder
Replace
● Worn
out of anvil
Replace
● Worn
out of clutch
Replace
● Worn
out of cam plate
Replace
● Worn
out of hammer
Replace
● Broken
of return spring
Replace
CHAPTER 5.
MAINTENANCE INSTRUCTION
2. CHECK-UP SPARK CONDITION
MAINTENANCE/CHECK-UP/REPAIRING
(1) Remove spark plug and touch it to metal part except spark plug mounting thread.
It is recommended to practice regular check-up and maintenance in accordance with usage
frequency to keep your tool better condition and long life and eventually it reduces total running costs.
This practice also protects you from serious injuries.
Daily Check-Up
* Check all nuts and screws are securely tightened.
* Check fuel level, and when filling up fresh fuel, wipe up spill and clean fuel tank.
* Check oil level of gear box through window. Oil level should be center of window and if
lower than this level, add oil to this level.
Weekly Maintenance
WARNING!
* Never touch spark plug to the area at spark plug mounting
thread since remaining gas might be exploded.
(2) Pull recoil starter handle.
WARNING!
* When pulling recoil starter handle, do not touch the metal part
of spark plug or you will get electric shock.
* After wipe and clean up fuel around the place where spark plug
to touch and make sure no fire possibility and check spark plug.
0.6mm
REMOVE CARBON
(3) When in normal condition, you see spark.
(FIG.5-2)
3. SPARK PLUG (FIG. 5-2)
* Check the starter, especially cord and return spring.
* Clean the exterior of the spark plug.
* Remove spark plug and check the electrode gap. Adjust it to 0.6 mm, or change the
spark plug.
* Clean the cooling fins on the cylinder and check that the air intake at the starter is not
clogged.
* Clean the air filter.
Monthly Maintenance
* Rinse the fuel tank with gasoline.
* Clean the exterior of the carburetor and the space around it.
* Clean the fan and the space around it.
(1) Use recommended type of spark plug.
(2) In a best operation condition, electrodes on the spark plug show dark brown and keep dry.
If the spark plug is dirty, clean it and check the electrode gap. If readjustment is necessary,
the correct gap is 0.6mm.
The spark plug condition is influenced by the following factors ;
* An incorrect carburetor setting.
* Wrong fuel mixture (too much oil in the gasoline).
* A dirty air filter.
* Hard running conditions (under cold weather operation).
The spark plug should be replaced after about 100 operation hours or earlier if the electrodes are badly eroded.
1. CARBURETOR ADJUSTMENT
4. AIR FILTER (FIG. 5-3)
(1) When the engine is test run at the factory, the carburetor is properly adjusted, do not try to
touch it.
(2) When idle speed is higher (when the anvil is rotating) or lower (engine will stop), adjust to
correct speed by idle adjustment screw.
Turn to clockwise for higher idle
Turn to anti clockwise for lower idle (FIG. 5-1)
(3) How to adjust L adjustment screw(lower speed fuel adjustment) and H adjustment(higher speed fuel adjustment)
① Under idle condition, turn L adjustment screw to right or
left to look for the peak of idle speed. And from this position,
return adjustment screw to the left 1/8-1/4 turn.
② Full open throttle lever and turn H adjustment screw to
right or left and follow the same procedures as L adjustment screw explained.
③ Standard return screw degrees are :
IDLE ADJUSTMENT SCREW
(1) When the air filter gets dirty and closed with dust, it will cause various troubles :
* Carburetor malfunctions.
* Starting problems.
* Engine power reduction.
* Unnecessary wear on the engine parts.
* Abnormal fuel consumption.
(2) Cleaning the air filter
Air filter must be cleaned from dust and dirt regularly and
damaged filter must be replaced with a new one.
(FIG.5-1)
* Remove the air filter cover and the filter.
* Rinse it in warm soap suds and wring tight and dry it before
re-assembly.
* Damaged air filter must be replaced with a new one.
L adjustment screw : 1 1/8 return from full closed
H adjustment screw : 1 1/8 return from full closed
_ 9 _
_ 10
_
AIR FILTER
(CLEANER SPONGE)
(FIG.5-3)
CHAPTER 6.
5. FUEL FILTER (FIG. 5-4)
SPAREPARTS ORDER
If fuel filter is clogged with impurities in the fuel,
fuel will not flow into carburetor and it will make
engine malfunction. Regular check-up is recommended.
1. When order for spareparts, please indicate index number, part name
and quantity.
2. Quantity as number required here is for one unit.
* Drain all fuel from fuel tank and pull out fuel
filter line from tank.
* Pull filter element out of holder assembly and
rinse element in warm water with detergent.
* Rinse thoroughly until all traces of detergent
are eliminated.
* Squeeze, but do not wring and keep dry.
* If element is too dirty, replace it.
3. V marks indicate over-size shims for precise adjustment.
4. Minimum order is 10 pcs. or more for such small items like screws,
nuts and washers.
(FIG.5-4)
6. MUFFLER (FIG. 5-5)
Engine power reduction maybe cause by a lot of
carbon accumulated around exhaust port on
cylinder, muffler inlet or outlet in the long use.
Regular clean-up is recommended.
* Remove the muffler and clean up any excess
carbon from the exhaust port or muffler inlet
every 100 hours of operation.
* When cleaning up, remove carbon carefully not
to hurt piston, cylinder and do not let carbon
into crank case.
EXPLODED VIEWS AND SPAREPARTS LISTS
5. Each spareparts for engine is not supplied but as assembly or complete set only except spark plug.
6. Specifications are subject to change without notice.
= NOTE =
(FIG.5-5)
7. IMPACT MECHANISM
When contact places of anvil and hammer become worn-out to be dull by percussion, the tool
becomes output power reduction and due to extra longer percussion than normal condition
it will cause damage and earlier broken of parts.
* Empty all oil in the gear box and remove hammer housing complete and check the degree
of worn-out of anvil and hammer at least once every month. And give grease around hitting
area.
8. STORAGE
(1) Clean each part and apply two cycle oil on the metal part to prevent from corrosion.
(2) To keep tool for a long time(more than 3 weeks), drain fuel from fuel tank and keep running
engine without load until the engine will stop and exhaust all remaining fuel in the carburetor.
(3) Remove spark plug and pure two cycle oil into cylinder and pull recoil starter handle several
times to spread oil.
(4) Stop the recoil starter handle when you feel engagement.
(5) Damaged parts should be repaired before storage.
(6) Keep the tool where the place without dust, humidity also the temperature below 50 ℃.
(7) Store tool out of the reach of children.
(8) Keep fuel into safety container in the cool room or place where no flammable. And do not
use stale fuel as it causes engine troubles.
_ 11
_
_ 12
_
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