H8508-3 Low Torque Impact Wrench, AKW Instruction Manual

SERVICE MANUAL
H8508-3 Low Torque
Impact Wrench
Serial Code AKW
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
52041931 REV 2
© 2011 Greenlee Textron Inc.
3/11
H8508-3 Low Torque Impact Wrench
Table of Contents
Safety
Safety.............................................................................. 2
Purpose of this Manual................................................... 2
Other Publications........................................................... 2
Important Safety Information...................................... 3–4
Disassembly.................................................................... 5
Inspection........................................................................ 6
Assembly..................................................................... 6–8
Illustrations and Parts List......................................... 9–13
Accessories................................................................... 14
Safety is essential in the use and maintenance of
Greenlee Utility tools and equipment. This manual and
any markings on the tool provide information for avoiding hazards and unsafe practices related to the use of
this tool. Observe all of the safety information provided.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe service procedures for the following Greenlee
Utility tool:
H8508-3
Serial Code AKW
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge at www.greenlee.com.
Other Publications
Operation Manual: Publication 52041907
SAE Standard J1273 (Hose and Hose Assemblies):
Publication 99930323
All specifications are nominal and may change as design
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Super Spool is a trademark of Greenlee Textron Inc.
Loctite is a registered trademark of Loctite Corporation.
Mobilgrease is a registered trademark of Mobil Oil Corporation.
Super Spool is protected by U.S. Patent No. 4548229.
KEEP THIS MANUAL
Greenlee / A Textron Company
2
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
Skin injection hazard:
• Do not use hands to check for
leaks.
• Do not hold hose or couplers while
the hydraulic system is pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punctures
skin causing serious injury, gangrene, or death. If you are injured by
escaping oil, seek medical attention
immediately.
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, defined below,
indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from flying
debris or hydraulic oil.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Tool and accessory may be hot
during and after operation.
Contact with hot surfaces could result
in serious injury.
Read and understand all of the
instructions and safety information
in this manual before operating or
­servicing this tool. Refer also to the
Operation Manual listed under “Other
Publications.”
Failure to observe this warning could
result in severe injury or death.
Greenlee / A Textron Company
3
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
IMPORTANT SAFETY INFORMATION
Do not exceed the following hydraulic power source
maximums:
• Hydraulic flow: 38 l/min (10 gpm)
• Pressure relief: 138 bar (2000 psi)
• Back pressure: 13.8 bar (200 psi)
Failure to observe this warning could result in severe
injury or death.
Do not reverse hydraulic flow. Operation with hydraulic
flow reversed can cause tool malfunction. Connect the
supply (pressure) hose and return (tank) hose to the
proper tool ports.
Failure to observe this warning could result in severe
injury or death.
Procedure for connecting or disconnecting hydraulic
hoses, fittings, or components:
1. Move the flow lever on the hydraulic power
source to the OFF position.
2. Stop the hydraulic power source.
3. Follow the sequence under “Hose Connections”
in the Operation Manual to prevent pressure
buildup. In case some ­pressure has built up,
loosen hoses, fittings, or components slowly.
Do not disconnect tool, hoses, or fittings while
the power source is running or if the hydraulic fluid is
hot. Hot hydraulic fluid could cause serious burns.
Do not change accessories, inspect, or clean tool when
it is connected to a power source. Accidental start-up
can result in serious injury.
Failure to observe this warning could result in severe
injury or death.
Greenlee / A Textron Company
Note: Keep all decals clean and legible, and replace
when necessary.
4
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Disassembly
Quick-Change Chuck
1. Remove adapter (61) from retaining sleeve (50).
Note: To prevent the loss of any steel balls, perform
the next step over a clean, empty container.
2. Slide the thrust ring (52) back to expose thrust ring
lock (51). Remove thrust ring lock, thrust ring, and
spring (53). Slide the retaining sleeve off of the anvil
(49) and remove two steel balls (54).
Complete disassembly of the tool is not recommended.
If a complete overhaul is necessary, return the tool to
your nearest Greenlee Utility Authorized Service Center.
The disassembly procedure is divided into sections of
the tool. Disassemble only the section(s) necessary to
complete the repair.
Disassemble the tool on a flat, clean surface. Take care
not to lose or damage any parts that may fall free during
disassembly.
In order to simplify the disassembly and assembly
instructions, refer to “Tool Orientation” below to
identify the sides and ends of the tool.
Hammer Case Components
1. Using a wrench on the flats of the hammer case cap
(55), unscrew and remove the cap.
2. Remove the anvil (49), hammer frame (46), hammer
(47), and hammer pin (48).
3. Remove spacer (45), thrust bearing (43), and thrust
washers (44) from hammer case cavity.
Tool Orientation
Front End
(hammer case end)
Left Side
Motor
1. Remove cap screws (16) and remove motor cap (6)
from handle (1). Remove gasket (15). Remove dowel
pins (14).
2. Pull idler shaft (13) with gear (10) from handle.
Remove gear from idler shaft. Remove the drive key
(12) and retaining clip (11) from idler shaft.
3. Remove retaining ring (11), gear (10), and Woodruff
keys (9) from drive shaft (8). Push drive shaft toward
hammer case end and remove it from the handle.
Back End
(motor cap end)
C
Trigger and Super Spool™
1. Remove roll pin (42) from trigger spool (29) by
pressing or tapping it out with a hammer and punch.
Note: Support trigger (41) to prevent bending the
trigger spool (29).
2. Remove washer (39), spring (38), retaining ring (37),
and washer (36). Push the trigger spool (29) out of
the handle (toward the front of the tool).
3. Remove the retaining ring (33).
Note: Perform Step 4 over an empty container to
catch the steel ball (32) when it falls free.
4. Remove Super Spool (31) and O-ring (34).
Right Side
O
Reversing Spool
1. Loosen and remove cap (24) on left side of tool and
pull the reversing spool (19) out the right side of
tool.
Note: Attempting to push the reversing spool the
opposite way through the bore will damage the
O-rings and could allow particles of O-ring to get
into the motor.
2. Remove plug (22), spring (21), and poppet (20).
3. Repeat Step 2 for the right side of reversing
spool (19).
Greenlee / A Textron Company
5
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Inspection
Assembly
Clean all parts with solvent and dry them thoroughly.
Inspect each component as described in this section.
Replace any component that shows wear or damage.
1. Bearings: Insert shaft into bearing. Spin shaft.
If shaft does not spin smoothly, replace the entire
assembly with the bearings already pressed in.
2. Motor cap and handle: Inspect mating surfaces,
gear cavities, oil passageways, etc. for grooves or
nicks. If any component shows wear or damage,
replace the entire assembly with the bearings
already pressed in.
3. Thrust rings: Replace any thrust ring that is
out-of-round or has been sprung.
4. Bearing (inside hammer case cap): Slide the anvil
into the bearing. Spin the anvil. If the anvil does
not turn smoothly, inspect the bearing surface. If
the bearing surface shows uneven wear, replace
hammer case cap as an assembly with the bearing
already pressed in.
5. Thrust bearing and thrust washers: Spin the bearing
against the washers. If bearing does not spin
smoothly, replace the bearing and washers.
6. Inspect all other disassembled components for
cracks, grooves, or nicks.
Refer to the Illustrations and Parts List for correct orientation and placement of parts.
Replace any O-rings, V-rings, seals, and gaskets on
parts that have been disassembled. Apply hydraulic
fluid or O-ring lubricant to all O-rings and all metal surfaces which they must slide over. When installing an Oring which must slide over sharp surfaces, use a rolling
motion and be careful not to damage the O-ring.
Wherever the assembly results in metal-to-metal
contact, coat the surfaces with hydraulic fluid or O-ring
lubricant.
Greenlee / A Textron Company
6
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Assembly (cont’d)
Reversing Spool
1. Install a new O-ring (25) onto reversing spool (19).
Install a new O-ring (26) into the handle. Install new
O-rings (30) on both plugs (22).
2. Install one poppet (20), spring (21), and plug (22) on
the left end (the end closest to the O-ring installed
on the spool in Step 1) of the spool. Secure assembly with cap (24).
3. Slide the reversing spool assembly into the handle
from the right side.
4. Install poppet (20), spring (21), and plug (22) into
opposite end of spool. Secure with cap (24).
Use one wrench on each cap and tighten to
31 Nm (23 ft-lb).
5. Use the Relief Pressure Check Kit shown in the
“Accessories” section to check the relief pressure.
Motor
1. Use an O-ring tool to install a new O-ring (4) from
the back end of the tool (1).
2. Lubricate drive shaft (8) and slide it into the tool
from the hammer case end.
3. Install Woodruff keys (9) onto the drive shaft. Align
the keyway in the gear (10) with the Woodruff keys
on the drive shaft and install the gear onto the drive
shaft. Secure the gear with the retaining ring (11).
4. Install the drive key (12) into the idler shaft (13).
Align the keyway in the remaining gear (10) with the
drive key and install the gear onto the idler shaft.
Install the idler shaft with gear into the handle,
meshing the four gears together. Install retaining
ring (11).
5. Install dowel pins (14) into handle. Install new
gasket (15).
6. Install motor cap (6) onto handle. Secure motor cap
with cap screws (16) and washers (63). Torque cap
screws to 10 to 11 Nm (95 to 100 in-lb). Refer to
“Torque Sequence” below.
Remove Spool
This Direction
20
25
30
Torque Sequence
60
5
7
23
24
1
4
3
2
8
Greenlee / A Textron Company
26
21 19
22
Install Spool
This Direction
6
7
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Assembly (cont’d)
Trigger, Trigger Spool, and Super Spool
1. Install O-ring (34) on the Super Spool (31). Install
ball (32) in trigger spool cavity. Install Super Spool
(31) into the trigger spool (29). Secure it with the
retaining ring (33).
2. Install O-ring (35) onto trigger spool assembly.
Install O-ring (27) and backup ring (28) in handle.
3. Slide trigger spool into handle from front end of
the tool. Slide washer (36) onto trigger spool and
secure with the retaining ring (37).
4. Slide spring (38) and washer (39) onto trigger
spool (29). Secure trigger (41) to trigger spool (29)
with spring pin (42).
5. Secure link (40) to handle and trigger with
spring pins (42).
Note: Support trigger (41) so pressing or tapping
on spring pins (42) does not bend trigger spool (29).
Hammer Case Components
1. Apply Mobilgrease® HP to thrust bearing (43) and
work the grease into needle rollers. Apply a light film
of grease to the thrust washers (44). Stack the thrust
washers and thrust bearing properly and place the
stack onto the drive shaft.
2. Place spacer (45) over the drive shaft with the flange
upward.
Impact Mechanism
1. Apply Mobilgrease HP to the surfaces of the
hammer frame (46), hammers (47), hammer pin (48),
and anvil (49).
2. Install the two hammers, 180° from each other, into
hammer frame. Install pins into hammer frame and
through the hammers, then slide the assembly onto
the spline of drive shaft.
3. Pack hammer frame center space with Mobilgrease
Special #53030-3. Install anvil into hammer frame
and through hammers.
4. Install O-ring (62) over threads on hammer case
cap (55).
5. Apply Loctite® primer to threads of cap. Apply
Loctite primer to threads of handle at cap interface,
ensuring threads are free of grease and other contaminants prior to application.
6. Slide the hammer case cap assembly (55, 56) over
the anvil and, using a wrench on the flats of the
cap, screw the assembly into the handle. Torque to
108 to 115 Nm (80 to 85 ft-lb).
Super Spool (shown in open-center position)
35
32
31
29
34 33
Quick-Change Chuck
1. Slide thrust ring lock (51) over anvil to the groove
closest to hammer case cap.
2. Insert three balls (54) into the holes in the anvil. Slide
the retaining sleeve (50) onto anvil with the flanged
end upward. Insert spring (53) and thrust ring (52)
into retaining sleeve. Slide the thrust ring back and
install thrust ring lock (51) onto the anvil. Insert the
drive shank (61) into the chuck.
Greenlee / A Textron Company
8
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Illustrations
H8508-3 Impact Wrench, Side View
55
52
61
46 47 47
48
8 45 44 43 44
6
5 4 3 15 14
54
51
50
10
9
11
12
53 54
11
13
7
10
49
56 62
40
27
42
39
41
31
37
36
35
29
34
33
28
32
1
Greenlee / A Textron Company
9
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Illustrations
Reversing Spool
20
25
30
60
23
24*
26
21 19
22
* Torque item (24) to 31 Nm (23 ft-lb)
Trigger Spool
35
32
31
34 33
29
Greenlee / A Textron Company
10
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Illustrations
Motor Cap View
18
17
16 Torque all to 10 to 11 Nm
(95 to 100 in-lb)
63
C
O
Greenlee / A Textron Company
11
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Parts List
H8508-3 Impact Wrench
Key
UPC No.
78-3310-
Part No.
1
50020
52044404
3
4*
5
6
26339
52044406
7
41591
50415911
8
26340
52033477
9
41592
50415921
10
41630
50416302
11
41621
50416212
12
41593
50415930
13
40168
50456962
14
41624
50416242
15*
16
17
48328
50483285
18
43701
50437011
19
20
21
22
23
24
25*
26*
27*
28*
29
48696
50486969
30*
31
48697
50486977
32
43829
50438298
33
48540
50485407
34*
35*
36
48310
50483102
37
41648
50416480
38
48311
50483110
39
48312
50483129
40
48313
50483137
41
48360
50483609
42
48542
50485423
43
48318
50483188
44
48319
50483196
45
48364
50483641
Greenlee / A Textron Company
Description
Qty
Handle kit (includes items 3, 4, and 5)............................................. 1
Bearing, needle, .439 x .625 x .500 ................................................. 2
O-ring, .500 x .687 x .093–80........................................................... 1
Bearing............................................................................................. 1
Motor cap kit (includes item 7)......................................................... 1
Bearing, needle, .439 x .625 x .500.................................................. 2
Shaft, drive....................................................................................... 1
Key, Woodruff, .125 x .375............................................................... 3
Gear, 11-tooth.................................................................................. 4
Retaining ring, .437.......................................................................... 2
Pin, drive, .123 x .209....................................................................... 1
Shaft, idler........................................................................................ 1
Pin, dowel, .250 x .625..................................................................... 2
Gasket.............................................................................................. 1
Screw, cap, 1/4–20 x 2.00 socket hd............................................... 8
Eye.................................................................................................... 1
Screw, cap, #10–32 x .375 btn skt hd.............................................. 3
Reversing spool................................................................................ 1
Poppet.............................................................................................. 2
Spring, comp., .177 x .329 x 1.09.................................................... 2
Plug.................................................................................................. 2
Screw, set, 5/16–24 x .250 socket................................................... 2
Cap................................................................................................... 2
O-ring, .500 x .625 x .062–70........................................................... 1
O-ring, .625 x .750 x .062................................................................. 1
O-ring, .612 x .818 x .103................................................................. 1
Backup ring, .640 x .812 x .048....................................................... 1
Spool, trigger ................................................................................... 1
O-ring, .250 x .375 x .062–90........................................................... 2
Super Spool...................................................................................... 1
Ball, .344, steel ................................................................................ 1
Retaining ring, .500.......................................................................... 1
O-ring, .375 x .500 x .062–70........................................................... 1
O-ring, .500 x .625 x .062–70........................................................... 1
Washer, flat, .376 x 734 x .030......................................................... 1
Retaining ring, .750.......................................................................... 1
Spring............................................................................................... 1
Washer, flat, .359 x .562 x .030........................................................ 1
Link................................................................................................... 1
Trigger............................................................................................... 1
Pin, roll, .156 x .875.......................................................................... 3
Bearing, thrust, .500 x .937 x .078................................................... 1
Washer, thrust, .500 x .937 x .030.................................................... 2
Spacer.............................................................................................. 1
12
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Parts List (cont’d)
H8508-3 Impact Wrench (cont’d)
Key
UPC No.
78-3310-
Part No.
46
47
48
49
50
51
52
53
54
55
49283
50492837
56
60
48622
50486225
61
49314
50493140
62*
41803
50418032
63
Description
Qty
Hammer frame.................................................................................. 1
Hammer............................................................................................ 2
Hammer pin...................................................................................... 2
Anvil, quick change.......................................................................... 1
Retaining sleeve............................................................................... 1
Thrust ring lock................................................................................. 1
Thrust ring........................................................................................ 1
Sleeve spring.................................................................................... 1
Ball.................................................................................................... 3
Cap, hammer case assembly (includes Item 56).............................. 1
Bearing............................................................................................. 1
Screw, set, #8–32 x .250 socket...................................................... 2
Adapter, heavy-duty, 7/16" quick change hex
to 1/2" square drive.......................................................................... 1
O-ring, 2.125 x 2.250 x .062–70....................................................... 1
Washer, 6 mm, hard......................................................................... 8
Decals
48781
46292
50487817
50462920
Decal, Greenlee Utility...................................................................... 2
Decal, impact wrench....................................................................... 1
Repair Kits
48382
50483820
*
48538
50485385
49270
50492705
Greenlee / A Textron Company
Reversing spool assembly
(includes items 19-26 and 30)
Seal kit (includes all items marked with an *)
Impact mechanism (includes items 46-54)
13
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
H8508-3 Low Torque Impact Wrench
Accessories
61
64
Key
UPC No.
78-3310-
Part No.
61
49314
50493140
64
12688
52043010
49004
50490044
Description
Adapter, heavy-duty, 7/16" quick change hex
to 1/2" square drive.......................................................................... 1
Trigger guard assembly, H8508 Series............................................. 1
Kit, relief pressure check.................................................................. 1
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
www.greenlee.com
Qty
USA Tel: 800-435-0786
Fax: 800-451-2632
Canada Tel: 800-435-0786
Fax: 800-524-2853
International Tel: +1-815-397-7070
Fax: +1-815-397-9247