Greenlee HW3 Impact Wrench Manual

Greenlee HW3 Impact Wrench Manual
SERVICE MANUAL
HW3
Impact Wrench
Serial Code BBF
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
52063856 REV 2
© 2013 Greenlee Textron Inc.
6/13
HW3 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
Illustration 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:
HW3 Serial Code BBF
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 52063857
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.
Cool Grip and Super Spool are trademarks of Textron Innovations Inc.
Loctite is a registered trademark of Loctite Corporation.
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
HW3 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
HW3 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
HW3 Impact Wrench
Disassembly
Hammer Case Components
1. Using snap ring pliers, remove snap ring (67).
Remove cap (41).
2. Remove the anvil (59), hammer frame (56), hammer
(57), and hammer pin (58).
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.
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 gears (10) from head. Remove
gear from idler shaft. Remove the key (9) from idler
shaft.
3. Remove retaining ring (11), gears (10), and Woodruff
key (9) from drive shaft (8). Push drive shaft toward
hammer case end and remove it from the head.
4. Remove spacer (40), thrust bearing (38), and
washers (39) from shaft (8).
Tool Orientation
Trigger and Super Spool™
1. Remove clips (48) from pins (47). Remove pins from
handle (5) and trigger spool (29).
Note: If trigger spool is not supported by covers
(49, 50), 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 (69) from spool (29).
6. Remove O-ring (27) and backup ring (28) from
handle (5).
Back End
(motor cap end)
Front End
(hammer case end)
Left Side
Greenlee / A Textron Company
Right Side
5
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW3 Impact Wrench
Disassembly (cont’d)
Inspection
Reversing Spool
1. 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 O-ring (27) and backup ring (28) from
head (1).
3. 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 (50, 49) by removing screws
(52).
2. Remove screws (45) from handle (5) to separate
head (1) from handle.
3. Remove dowel pins (46) and O-rings (33, 60).
4. Remove snap ring (53), ball stop (54), and ball (55).
Flow Control
1. Remove piston stop (63) from handle (5).
2. Remove O-ring (61) and backup ring (62) from
piston stop (63).
3. Remove plug (66), spring (65), and piston (64) from
handle (5).
Greenlee / A Textron Company
6
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW3 Impact Wrench
Assembly
Torque Sequence
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.
6
1
2
3
Handle and Head
1. Install ball (55), ball stop (54), and snap ring (53) on
the return port of the handle (5).
2. Install dowel pins (45), three O-rings (33), and O-ring
(60) onto handle (5). Install four screws (45) 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 Cool Grip™ handle covers (49, 50) using
screws (52) and nuts (51). Nuts should be placed in
right cover (50). Torque screws until covers (49, 50)
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)
in trigger spool (29).
2. Install new O-ring (69) 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 (29) into handle (5) from front end
of tool. Spool should bottom out onto handle covers
(49, 50).
Note: If handle covers (49, 50) 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 (47) into trigger (37) through handle (5).
Install second pin (47) through trigger (37) and
trigger spool (29). Secure pins with retaining rings
(48).
Motor
1. Use an O-ring tool to install a new O-ring (3) from
the back end of the head (1).
2. Install spacer (40) onto drive shaft (8). Apply Mobilith
SHC™ PM 460 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 (8).
3. Lubricate drive shaft (8) and slide it into the head (1)
from the hammer case end.
4. Install Woodruff keys (9) onto the drive shaft. Align
the keyways in the gears (10) with the Woodruff
key on the drive shaft and install the gears onto the
drive shaft. Secure the gears with retaining ring (11).
5. Install the Woodruff key (9) into the idler shaft (13).
Align the keyway in the remaining gears (10) with the
key and install the gears onto the idler shaft. Install
the idler shaft with gear into the head, meshing the
two gears together. Secure the gear with retaining
ring (11).
6. Install dowel pins (14) into head. Install new O-ring
(15) onto motor cap (7) groove.
7. 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.
Greenlee / A Textron Company
4
7
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW3 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. Screw cap (23) onto spool (17) end closest to O-ring
(24).
4. Slide spool (17) into head (1) from the right side.
5. Install cap (23) on opposite spool (17) end. Use
one wrench on each cap (23) and tighten to 31 Nm
(23 ft-lb).
Impact Mechanism
1. Apply Mobilith SHC™ PM 460 to the surfaces of the
hammer frame (56), hammers (57), hammer pin (58),
and anvil (59).
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 (8).
3. Pack hammer frame center space with Mobilith
SHC™ PM 460. Install anvil into hammer frame and
through hammers.
4. Install O-ring (43) on hammer case cap (41). Install
roll pin (44) on hammer case cap (41).
5. Slide the hammer case cap assembly (41) over the
anvil.
6. Install snap ring (67) onto head (1).
Remove Spool
This Direction
Flow Control
1. Install O-ring (61) and backup ring (62) onto piston
stop (63).
2. Install piston stop (63) into handle (5).
3. Install piston (64), spring (65), and plug (66) into
handle (5).
Install Spool
This Direction
Greenlee / A Textron Company
8
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Greenlee / A Textron Company
15
16
51
7
50
23
28
25 24
2
27
9
47
65
10
37
33 30
66
9 13
32
17
11
5
45
64 33
46
2
14
3
53
54
55
60
68
29
69
63
39
36
4
35
48
40
34
61 62
39 38
1
57
49
27 28
9
8
58
52
Refer to separate
illustration for
impact mechanism.
56
43
42
67
59
44
41
HW3 Impact Wrench
Illustration
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW3 Impact Wrench
Parts List
Key
UPC No.
78-3310-
Part No.
Description
1
00995
52063853
Head assembly (includes items 2–4)................................................ 1
2
41591
50415911
Bearing, needle, .439 x .625 x .500.................................................. 4
Qty
3*
O-ring, .500 x .687 x .093-80........................................................... 1
4
49248
50492438
Bearing............................................................................................. 1
5
00922
52063614
Handle ............................................................................................. 1
7
00994
52063852
Motor cap assembly (includes item 2).............................................. 1
8
00918
52063611
Shaft, drive....................................................................................... 1
9
41592
50415921
Key, Woodruff, .125 x .375............................................................... 3
10
41630
50416302
Gear, 11-tooth.................................................................................. 4
11
41621
50416212
Ring, retaining, .437......................................................................... 2
13
45696
50456962
Shaft, idler........................................................................................ 1
14
41624
50416242
Pin, dowel, .250 x .625..................................................................... 2
15*
O-ring, 2.000 x 2.125 x .062-70D nitrile........................................... 1
16
Screw, socket head cap, 5/16-18 x 1.25 button, 316 SS................ 6
17
00931
52063616
Spool, directional reversing.............................................................. 1
23
00404
52061456
Cap, reversing spool........................................................................ 2
24*
O-ring, .437 x .625 x .093-70D nitrile............................................... 1
25*
Ring, 8-111 Parbak.......................................................................... 1
27*
O-ring, .612 x .818 x .103-70D nitrile............................................... 2
28*
Ring, 8-114 Parbak.......................................................................... 2
29
00380
52060643
Spool, directional trigger.................................................................. 1
30
00917
52063610
Super Spool...................................................................................... 1
32
48540
50485407
Ring, retaining.................................................................................. 1
33*
O-ring, .375 x .500 x .062-70D nitrile............................................... 4
34
48310
50483102
Washer, flat, .376 x .734 x .03.......................................................... 1
35
41648
50416480
Ring, retaining, .750......................................................................... 1
36
00399
52060673
Spring, trigger................................................................................... 1
37
00381
52060659
Trigger, impact wrench..................................................................... 1
38
48318
50483188
Bearing, thrust.................................................................................. 1
39
48319
50483196
Washer, thrust................................................................................... 2
40
00942
52063628
Spacer.............................................................................................. 1
41
00992
52063851
Cap, hammer case assembly (includes items 42–44)...................... 1
42
Bearing............................................................................................. 1
43*
O-ring, 3.000 x 3.125 x .062-70D nitrile........................................... 1
44
Roll pin, 1/8...................................................................................... 1
45
Screw, socket head cap, 1/4-20 x .625, 316 SS.............................. 4
46
00388
52060665
Pin, .3125 x .5 dowell....................................................................... 2
47
00395
52060651
Pin, trigger impact wrench............................................................... 2
48
42827
50428270
Ring, retaining.................................................................................. 2
49
00393
52060669
Cool Grip™ handle cover, impact wrench, left................................. 1
50
00389
52060666
Cool Grip™ handle cover, impact wrench, right.............................. 1
51
Lock nut, 8-32, .172 thick, nickel-plated.......................................... 3
52
Screw, socket head cap, 8-32 x 1.00 button, 316 SS...................... 3
Greenlee / A Textron Company
10
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW3 Impact Wrench
Parts List (cont’d)
Key
UPC No.
78-3310-
Part No.
Description
Qty
53
41600
50416003
Ring, retaining, .687......................................................................... 1
54
49234
50492349
Stop, ball.......................................................................................... 1
55
50681
90506812
Ball, 3/8 dia...................................................................................... 1
56
Hammer frame.................................................................................. 1
57
Hammer ........................................................................................... 2
58
Hammer pin...................................................................................... 2
59
Anvil, quick change.......................................................................... 1
60*
O-ring, .563 x .687 .062-70D nitrile.................................................. 1
61*
O-ring, .250 x .375 .062-70D nitrile.................................................. 1
62*
Ring, 8-010 Parbak.......................................................................... 1
63
00937
52063619
Stop, flow control piston.................................................................. 1
64
01594
52000983
Piston, bypass.................................................................................. 1
65
00941
52063626
Spring, compression........................................................................ 1
66*
00943
52063629
SAE-3 plug....................................................................................... 1
67
00945
52063631
Ring, internal retaining ..................................................................... 1
68
00947
52063632
Handle, support................................................................................ 1
69*
O-ring, .500 x .625 .062-70D nitrile.................................................. 1
Decals
00400
52061451
Decal, F/R, logo................................................................................ 1
00401
52061452
Decal, warning.................................................................................. 1
52066409
Impact mechanism assembly (includes items 56–59)
Repair Kits
02252
00607
52062052
Handle cover kit (includes items 49–52)
*
00996
52063854
Seal kit (includes items marked with an asterisk)
Greenlee / A Textron Company
11
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
HW3 Impact Wrench
Accessories
100
101
Key
UPC No.
78-3310-
Part No.
Description
100
41964
50419640
3/4" square to 5/8" hex quick-change adapter................................ 1
101
00376
52060640
Trigger guard assembly.................................................................... 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
USA Tel: 800-435-0786
Fax: 800-451-2632
Qty
Canada Tel: 800-435-0786
Fax: 800-524-2853
International Tel: +1-815-397-7070
Fax: +1-815-397-9247
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