SERVICE MANUAL

52041908 REV 2

H8508-1

Impact Wrenches

Serial Code AKP

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

© 2011 Greenlee Textron Inc.

3/11

H8508-1 Impact Wrench

Table of Contents

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

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:

H8508-1 Serial Code AKP

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

Greenlee / A Textron Company

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

2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

H8508-1 Impact Wrench

IMPORTANT SAFETY INFORMATION

SAFETY

ALERT

SYMBOL

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.

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.

Immediate hazards which, if not avoided, WILL result in severe injury or death.

Hazards which, if not avoided, COULD 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 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

H8508-1 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.

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.

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.

Note: Keep all decals clean and legible, and replace when necessary.

Greenlee / A Textron Company 4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

H8508-1 Impact Wrench

Disassembly

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.

Tool Orientation

Front End

(hammer case end)

Left Side

C

O

Back End

(motor cap end)

Right Side

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).

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.

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 pin

(12) and retaining clip (11) 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.

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).

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

H8508-1 Impact Wrench

Inspection

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.

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 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

H8508-1 Impact Wrench

Assembly (cont’d)

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 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).

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. 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.

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.

Remove Spool

This Direction

20 25 30

Torque Sequence

1

5 7

4

26 21 19

60

23

24

22

3 2

Install Spool

This Direction

8 6

Greenlee / A Textron Company 7 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

H8508-1 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).

Super Spool (shown in open-center position)

35 32

29

31

34 33

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).

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

H8508-1 Impact Wrench

Illustrations

H8508-1 Impact Wrench, Side View

61 51

52 54

55 46 47 47 48 8 45 44 43 44 5 4 3 15 14 6

50 53 54 49

56 62 40

42

39

41

37

36

35

29 32

28

34

33

31

10

9

11

12

11

13

7

10

27

1

Greenlee / A Textron Company 9 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

H8508-1 Impact Wrench

Illustrations

Reversing Spool

26

20 25 30

60

23

24*

21 19 22

* Torque item (24) to 31 Nm (23 ft-lb)

Trigger Spool

29

35 32

31

34 33

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Illustrations

Motor Cap View

H8508-1 Impact Wrench

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

H8508-1 Impact Wrench

Parts List

H8508-1 Impact Wrench

Key

UPC No.

78-3310- Part No.

34*

35*

36

37

38

39

40

41

42

43

44

45

10

11

12

13

14

15*

16

17

1

3

50020 52044404

4*

5

6

7

8

9

48307

41591

49242

41592

50483072

50415911

50492420

50415921

41630

41621

41593

40168

41624

43954

48328

50416302

50416212

50415930

50401682

50416242

50439545

50483285

26*

27*

28*

29

30*

31

32

33

18 43701 50437011

19

20

21

22

23

24

25*

48696

48697

43829

48540

50486969

50486977

50438298

50485407

48310

41648

48311

48312

48313

48360

48542

48318

48319

48364

50483102

50416480

50483110

50483129

50483137

50483609

50485423

50483188

50483196

50483641

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 assembly (includes item 7) ............................................. 1

Bearing, needle, .439 x .625 x .500 ................................................. 2

Shaft, drive ...................................................................................... 1

Key, Woodruff, .125 x .375 .............................................................. 1

Gear, 11-tooth ................................................................................. 2

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 1.250 socket hd ............................................ 8

Eye ................................................................................................... 1

Screw, cap, #10–32 x .375 btn skt hd ............................................. 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

Greenlee / A Textron Company 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

H8508-1 Impact Wrench

Parts List (cont’d)

H8508-1 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

62*

63

49314 50493140

Decals

48781

46292

50487817

50462920

Description Qty

Hammer frame ................................................................................. 1

Hammer ........................................................................................... 2

Anvil, quick change ......................................................................... 1

Thrust ring lock ................................................................................ 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

Decal, Greenlee Utility ..................................................................... 2

Decal, impact wrench ...................................................................... 1

Repair Kits

48382

* 48538

49270

50483820

50485385

50492705

Reversing spool assembly

(includes items 19-26 and 30)

Seal kit (includes all items marked with an *)

Impact mechanism for H8508-1

(includes items 46-54)

Greenlee / A Textron Company 13 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

H8508-1 Impact Wrench

Accessories

61

64

UPC No.

Key 78-3310- Part No.

61

64

49314

12688

49004

50493140

52043010

50490044

Description Qty

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

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