Greenlee HW1V Impact Wrench BBB Manual

SERVICE MANUAL
HW1V
Impact Wrench
Serial Code BBB
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
52061484 REV 4
© 2017 Greenlee Textron Inc.
5/17
HW1V Impact Wrench
Table of Contents
Safety
Safety.............................................................................. 2
Purpose of this Manual................................................... 2
Other Publications........................................................... 2
Important Safety Information...................................... 3–4
Disassembly................................................................ 5–6
Inspection........................................................................ 6
Assembly..................................................................... 7–8
Illustrations and Parts List......................................... 9–11
Accessories................................................................... 12
Safety is essential in the use and maintenance of
Greenlee 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:
HW1V Serial Code BBB
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 52060654
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.
Mobilith SHC is a trademark of Exxon Mobil 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
HW1V 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
HW1V Impact Wrench
IMPORTANT SAFETY INFORMATION
Do not exceed the following hydraulic power source
maximums:
• Hydraulic flow: 46 l/min (12 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
HW1V Impact Wrench
Disassembly
Quick-Change Chuck
1. Slide the thrust ring (61) back to expose thrust ring
lock (60). Remove thrust ring lock, thrust ring, and
spring (62).
2. Slide the retaining sleeve (59) off of the anvil (58)
and remove three steel balls (63).
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
(41), unscrew and remove the cap.
2. Remove the anvil (58), hammer frame (55), hammer
(56), and hammer pin (57).
3. Remove spacer (40), thrust bearing (38), and thrust
washers (39) from hammer case cavity.
Tool Orientation
Front End
(hammer case end)
Left Side
Greenlee / A Textron Company
Motor
1. Remove cap screws (16) and remove motor cap (7)
from head (1). Remove O-ring (15). Remove dowel
pins (14).
2. Remove retaining ring (11) from idler shaft (13). Pull
idler shaft (13) with gear (10) from handle. Remove
gear from idler shaft. Remove the drive pin (12) from
idler shaft.
3. Remove retaining ring (11), gear (10), and Woodruff
key (9) from drive shaft (8). Push drive shaft toward
hammer case end and remove it from the handle.
Back End
(motor cap end)
Trigger and Super Spool™
1. Remove clips (47) from pins (46). Remove pins from
handle (5) and trigger spool (29).
Note: If trigger spool is not supported by covers
(48, 49), it may slide out the back.
2. Remove snap ring (35), washer (34), and spring (36).
Push trigger spool (29) out of handle (toward front of
tool).
3. Remove the retaining ring (32).
4. Remove Super Spool (30) and O-ring (33).
5. Remove O-ring (65) from spool (29).
6. Remove O-ring (27) and backup ring (28) from
handle (5).
Right Side
5
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW1V Impact Wrench
Disassembly (cont’d)
Inspection
Reversing Spool
1. Loosen set screws (21, 22) from cap (23) on left side
of tool. Remove cap (23) and pull reversing spool
(17) out of 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 (20), spring (19), and poppet (18).
3. Remove O-ring (26) from plug (20).
4. Remove O-ring (27) and backup ring (28) from
head (1).
5. Remove O-ring (24) and backup ring (25) from
spool (29).
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.
Handle and Head
1. Remove plastic covers (48, 49) by removing screws
(51).
2. Remove screws (44) from handle (5) to separate
head (1) from handle.
3. Remove dowel pins (45) and O-rings (33).
4. Remove snap ring (52), ball stop (53), and ball (54).
Bypass Valve
1. Remove stop (69) and plunger (70) from handle (5).
Pull knob (67) to remove bypass spool (66).
2. Remove O-ring (64) from bypass spool (66). If necessary, remove set screw (68) to separate knob (67)
and spool (66).
Greenlee / A Textron Company
6
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW1V Impact Wrench
Assembly
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 O-ring 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.
4. Install the drive pin (12) into the idler shaft (13). Align
the keyway in the remaining gear (10) with the drive
pin and install the gear onto the idler shaft. Install
the idler shaft with gear into the handle, meshing the
two gears together. Secure the gear with retaining
ring (11).
5. Install dowel pins (14) into head (1). Install new
O-ring (15) onto motor cap (7) groove.
6. Install motor cap (7) onto head (1). Secure motor
cap with cap screws (16). Torque cap screws to
14.3 Nm (130 in-lb). Refer to “Torque Sequence”
below.
Bypass Spool
1. Ensure pipe plug (6) is installed in handle (5).
2. Secure knob (67) onto the bypass spool (66) with
set screw (68), if disassembled.
3. Install O-ring (64) onto bypass spool (66).
4. Push onto knob (67) to install spool into handle (5)
from the back end.
5. Secure spool in place by installing stop (69) into
handle (5).
6. Install plunger (70) into handle (5) until it stops. Turn
back 1/2 rotation. Ensure knob (67) spins smoothly
and locks into three indicated settings.
Torque Sequence
6
1
2
3
Handle and Head
1. Install ball (54), ball stop (53), and snap ring (52) on
the return port of the handle (5).
2. Install dowel pins (45) and three O-rings (33) onto
handle (5). Install four screws (44) through handle
(5) and into head (1). Torque screws to 14.3 Nm
(130 in-lb).
Note: Ensure O-rings stay in grooves when connecting handle to head. O-rings can be secured in
place with O-ring lubricant.
3. Install plastic covers (48, 49) using screws (51) and
nuts (50). Nuts should be placed in right cover (49).
Torque screws until covers (48, 49) fit snug.
5
Trigger, Trigger Spool, and Super Spool
1. Install new O-ring (33) onto Super Spool (30). Install
Super Spool (30) and secure with retaining ring (32).
2. Install new O-ring (65) onto trigger spool (29).
3. Install new O-ring (27) and backup ring (28) into
handle (5).
Note: Install the backup ring (28) first. Pull the
backup ring with a pick so that it is positioned in the
groove toward the back side of the tool. Then install
the O-ring (27) into the groove in the handle (5).
4. Slide trigger spool into handle (5) from front end of
tool. Spool should bottom out onto handle covers
(48, 49).
Note: If handle covers (48, 49) are missing or
damaged, the trigger spool will need to be dead
stopped to prevent it from sliding out of the back
when spring (36) is installed.
5. Slide spring (36) and washer (34) onto spool (29)
inside handle (5). Secure spring and washer with
retaining ring (35).
6. Install pin (46) into trigger (37) through handle (5).
Install second pin (46) through trigger (37) and
trigger spool (29). Secure pins with retaining rings
(47).
Motor
1. Use an O-ring tool to install a new O-ring (3) from
the back end of the head (1).
2. Lubricate drive shaft (8) and slide it into the head (1)
from the hammer case end.
3. Install Woodruff key (9) onto the drive shaft. Align
the keyway in the gear (10) with the Woodruff key
on the drive shaft and install the gear onto the drive
shaft. Secure the gear with the retaining ring (11).
Greenlee / A Textron Company
4
7
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW1V Impact Wrench
Assembly (cont’d)
Reversing Spool
1. Install new O-ring (24) and backup ring (25) onto
reversing spool (17).
2. Install new O-ring (27) and backup ring (28) into
head (1).
3. Install new O-ring (26) onto plug (20).
4. Screw cap (23) onto spool (17) end closest to O-ring
(24).
5. Slide spool (17) into head (1) from the right side.
6. Install poppet (18), spring (19), plug (20), and cap
(23) onto the opposite spool end. Use one wrench
on each cap (23) and tighten to 31 Nm (23 ft-lb).
7. Install set screw (21) followed by screw (22).
8. Use the Relief Pressure Check Kit shown in the
“Accessories” section to check the relief pressure.
Hammer Case Components
1. Apply Mobilith SHC™ PM 460 grease to thrust
bearing (38) and work the grease into needle rollers.
Apply a light film of grease to the thrust washers
(39). Stack the thrust washers and thrust bearing
properly and place the stack onto the drive shaft.
2. Place spacer (40) over the drive shaft with the flange
upward.
Impact Mechanism
1. Apply Mobilith SHC™ PM 460 grease to the surfaces of the hammer frame (55), hammers (56),
hammer pin (57), and anvil (58).
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 Mobilith
SHC™ PM 460 grease. Install anvil into hammer
frame and through hammers.
4. Install O-ring (43) over threads on hammer case
cap (41).
5. Slide the hammer case cap assembly (41, 42) 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).
Remove Spool
This Direction
Quick-Change Chuck
1. Slide thrust ring lock (60) over anvil to the groove
closest to hammer case cap.
2. Insert three balls (63) into the holes in the anvil. Slide
the retaining sleeve (59) onto anvil with the flanged
end upward. Insert spring (62) and thrust ring (61)
into retaining sleeve. Slide the thrust ring back and
install thrust ring lock (60) onto the anvil.
Install Spool
This Direction
Greenlee / A Textron Company
8
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Greenlee / A Textron Company
23
16
25
15
24
7
50
49
17
14
28
27
12
13
2
32
67
68
10
9
37
46
33 30
11
66
70
9
54
5
64
8
44
2
69
45
52
53
3
29
33
6
4
1
65
39
36
38
47
39
27
35
18
40
28
48
34
19
20 26 23
22
21
51
42
43
Refer to separate
illustration for
impact mechanism.
41
HW1V Impact Wrench
Illustration—Main
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW1V Impact Wrench
Illustration—Impact Mechanism
56
55
56
57
58
63
59
62
61
60
Greenlee / A Textron Company
10
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW1V Impact Wrench
Parts List
UPC No.
Key 78-3310-
Part No.
Description
1
00374
52060638
Head assembly (includes items 2–4).....1
2
41591
50415911
Bearing, needle, .439 x .625 x .500.......4
3*
O-ring, .500 x .687 x .093-80.................1
4
49243
50492438
Bearing...................................................1
5
00608
52062053
Handle assembly (includes item 6)........1
90505018
1/8" pipe plug........................................1
7
00405
52061528
Motor cap assembly
(includes item 2).....................................1
6
8
49242
50492420
Shaft, drive.............................................1
9
41592
50415921
Key, Woodruff, .125 x .375.....................1
10
41630
50416302
Gear, 11 tooth........................................2
11
41621
50416212
Ring, retaining, .437...............................2
12
41593
50415930
Pin, dowel, .123 x .209..........................1
13
40168
50401682
Shaft, idler..............................................1
14
41624
50416242
Pin, dowel, .250 x .625..........................2
15*
O-ring, 2.000 x 2.125 x .062 70D .........1
16
Skt hd cap screw, .3125-18 x 1.25
button, 316 SS.......................................6
17
00382
52060645
Spool, directional reversing...................1
18
48515
50485156
Poppet...................................................1
19
48543
50485431
Spring, comp, .177 x .329 x 1.09..........1
20
48621
50486217
Plug, spec..............................................1
21
Screw, skt set, flat point,
5/16-24 x .250.......................................1
22
23
00404
52061456
UPC No.
Key 78-3310-
Qty
Part No.
44
Description
Qty
Screw, cap, soc hd, 1/4-20 x .625,
316 SS...................................................4
45
00388
52060665
Pin, .3125 x .5 dowel.............................2
46
00395
52060651
Pin, trigger impact wrench.....................2
47
42827
50428270
Ring, retaining........................................2
48
00393
52060669
Cover, impact wrench handle, left.........1
49
00389
52060666
Cover, impact wrench handle, right.......1
50
8-32 lock nut, .172 thick,
nickel-plated..........................................3
51
Skt hd cap screw, 8-32 x 1.00
button, 316 SS.......................................3
52
41600
50416003
Ring, retaining, .687...............................1
53
49234
50492349
Stop, ball................................................1
54
50681
90506812
Ball (3/8 dia.)..........................................1
55
Hammer frame.......................................1
56
Hammer ................................................2
57
Hammer pin...........................................2
58
Anvil, quick-change...............................1
59
49277
50492772
Retaining sleeve.....................................1
60
49279
50492799
Thrust ring lock......................................1
61
49280
50492802
Thrust ring .............................................1
62
49278
50492780
Sleeve spring.........................................1
63
49276
50492764
Ball.........................................................3
64*
O-ring, .187 x .312 x .062 70-D ............1
Screw, set, #8-32 x .250
skt brass tip...........................................1
65*
O-ring, .500 x .625 x .062 70-D.............1
66
00390
52060648
Spool, bypass valve...............................1
Cap, reversing spool..............................2
67
00394
52060650
Knob, bypass valve...............................1
24*
O-ring, .437 x .625 x .093
70-D nitrile.............................................1
25*
Ring, 8-111 Parbak................................1
69
00398
52060652
Stop, bypass valve................................1
26*
O-ring, .250 x .375 x .062-90.................1
70
00391
52060667
Plunger, ball, 1/4-20...............................1
27*
O-ring, .612 x .818 x .103-70.................2
28*
Ring, 8-114 Parbak................................2
29
52060643
Spool, directional trigger........................1
Decals
30
52063610
Super Spool...........................................1
32
50485407
Ring, retaining........................................1
00380
48540
33*
O-ring, .375 x .500 x .062-70.................4
34
48310
50483102
Washer, flat, .376 x .734 x .03................1
35
41648
50416480
Ring, retaining, .750...............................1
36
00399
52060673
37
00381
52060659
68
Screw, skt set, 8-32 x .1875,
cup point................................................1
00400
52061451
Decal, F/R, logo.....................................1
00401
52061452
Decal, warning.......................................1
Repair Kits
Spring, trigger........................................1
00406
52061529
Reversing spool assembly
(includes one each of items 16–26
and two of item 23)
Trigger, impact wrench...........................1
Handle cover kit (includes items 48–51)
49270
50492705
Impact mechanism assembly
(includes items 55–63)
00607
52062052
38
48318
50483188
Bearing, thrust.......................................1
39
48319
50483196
Washer, thrust........................................2
40
48364
50483641
Spacer...................................................1
*
00375
52060639
Seal kit (HW1V)
(includes all items marked with *)
41
00408
52061531
Cap, hammer case assembly
(includes item 42)...................................1
00407
52061530
Bypass spool assembly
(includes items 66–68)
42
49284
50492845
43*
Bearing...................................................1
O-ring, 2.125 x 2.250 x .062-70.............1
Greenlee / A Textron Company
11
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW1V Impact Wrench
Accessories
100
101
Key
UPC No.
78-3310-
Part No.
100
49314
50493140
101
00376
52060640
49004
50490044
Description
Adapter, heavy-duty, 7/16" quick-change hex
to 1/2" square drive.......................................................................... 1
Trigger guard assembly.................................................................... 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