IW16

HYDRAULIC

IMPACT WRENCH

USER MANUAL

Safety, Operation and Maintenance

© 2014 Stanley Black & Decker, Inc.

New Britain, CT 06053

U.S.A.

66174 8/2014 Ver 14

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

ÜBEREINSTIMMUNGS-ERKLARUNG

DECLARATION DE CONFORMITE CEE

DECLARACION DE CONFORMIDAD

DICHIARAZIONE DI CONFORMITA

Hydraulic Tools

______________________________________________________________________

I, the undersigned:

Ich, der Unterzeichnende:

Je soussigné:

El abajo firmante: lo sottoscritto:

Weisbeck, Andy

Surname and First names/Familiennname und Vornamen/Nom et prénom/Nombre y apellido/Cognome e nome

hereby declare that the equipment specified hereunder: bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät: déclare que l’équipement visé ci-dessous:

Por la presente declaro que el equipo se especifica a continuación :

Dichiaro che le apparecchiature specificate di seguito:

Hydraulic Hand Held Impact Wrench

1. Category:

Kategorie:

Catégorie:

Categoria:

Categoria:

2.

Make/Marke/Marque/Marca/Marca

3.

Type/Typ/Type/Tipo/Tipo:

4.

Serial number of equipment:

Seriennummer des Geräts:

Numéro de série de l’équipement:

Numero de serie del equipo:

Matricola dell´attrezzatura:

Stanley

IW16150, IW16150S, IW16350

ALL MODELS NOTED ABOVE FROM

SERIAL NUMBER (042312097) and Above

Has been manufactured in conformity with

Wurde hergestellt in Übereinstimmung mit

Est fabriqué conformément

Ha sido fabricado de acuerdo con

E’ stata costruita in conformitá con

Directive/Standards

Richtlinie/Standards

Directives/Normes

Directriz/Los Normas

Direttiva/Norme

No.

Nr

Numéro

No n.

Approved body

Prüfung durch

Organisme agréé

Aprobado

Collaudato

EN

EN ISO

EN

Machinery Directive

792-6:1994

3744:2009

28927-2:2009

2006/42/EC:2006

Self

Self

Self

Self

5.

Special Provisions:

Spezielle Bestimmungen:

None

Dispositions particulières:

Provisiones especiales:

Disposizioni speciali:

6.

Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.

Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione

Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA Date/Datum/le/Fecha/Data 12-22-10

Signature/Unterschrift/Signature/Firma/Firma

Position/Position/Fonction/Cargo/Posizione Engineering Manager

2 ► IW16 User Manual

TABLE OF CONTENTS

DECLARATION OF CONFORMITY ..........................................................................................................................2

SAFETY SYMBOLS ..................................................................................................................................................4

SAFETY PRECAUTIONS ..........................................................................................................................................5

TOOL STICKERS & TAGS ........................................................................................................................................6

HOSE TYPES ............................................................................................................................................................7

HOSE RECOMMENDATIONS ..................................................................................................................................8

FIGURE 1. TYPICAL HOSE CONNECTIONS .......................................................................................................8

HTMA REQUIREMENTS ...........................................................................................................................................9

WRENCH TORQUE INFORMATION ......................................................................................................................10

WRENCH OPERATION .......................................................................................................................................... 11

EQUIPMENT PROTECTION & CARE ....................................................................................................................12

TROUBLESHOOTING ............................................................................................................................................13

SPECIFICATIONS ...................................................................................................................................................14

ACCESSORIES.......................................................................................................................................................15

IW16 PARTS ILLUSTRATION .................................................................................................................................16

IW16 PARTS LIST ...................................................................................................................................................17

VALVE HANDLE CHANGE NOTICE .......................................................................................................................18

IW16 EXTENSION HANDLE ILLUSTRATION ........................................................................................................19

UNDERWATER TOOLS DEPTH GUIDELINE .........................................................................................................20

IMPORTANT

To fill out a Product Warranty Recording form, and for information on your warranty, visit Stanleyhydraulics.com and select the Company tab, Warranty.

(

NOTE: The warranty recording form must be submitted to validate the warranty).

SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic Tools recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized and certified dealer. Please read the following warning.

WARNING

SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR

SERVICE OF THIS TOOL.

REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN

AUTHORIZED AND CERTIFIED DEALER.

For the nearest authorized and certified dealer, call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative.

IW16 User Manual ◄ 3

SAFETY SYMBOLS

Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.

DANGER

WARNING

CAUTION

CAUTION

NOTICE

IMPORTANT

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

This safety alert and signal word indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury.

This safety alert and signal word indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury.

This safety alert and signal word indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.

This signal word indicates a situation which, if not avoided, will result in damage to the equipment.

This signal word indicates a situation which, if not avoided, may result in damage to the equipment.

Always observe safety symbols. They are included for your safety and for the protection of the tool.

LOCAL SAFETY REGULATIONS

Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.

4 ► IW16 User Manual

SAFETY PRECAUTIONS

Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose. These safety precautions are given for your safety. Review them carefully before operating the tool and before performing general maintenance or repairs.

Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations. If so, place the added precautions in the space provided in this manual.

The model IW16 Hydraulic Impact Wrench will provide safe and dependable service if operated in accordance with the instructions given in this manual. Read and understand this manual and any stickers and tags attached to the tool and hose before operation.

Failure to do so could result in personal injury or equipment damage.

• The operator must start in a work area without bystanders. Flying debris can cause serious injury.

• Do not operate the tool unless thoroughly trained or under the supervision of an instructor. Establish a training program for all operators to ensure safe operation.

• Always wear safety equipment such as goggles, gloves, ear, head and breathing protection, and safety shoes at all times when operating the tool.

Use gloves and aprons when necessary.

• Inspect tool daily for loose fasteners, missing parts and leakage. Have tool repaired if necessary.

• The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.

• Maintain proper footing and balance at all times and do not overreach.

• Do not inspect or clean the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury. Be observant of hydraulic and water hose lying about the work area, they can be a tripping hazard.

• Always connect hoses to the tool hose couplers before energizing the hydraulic power source. Be sure all hose connections are tight and are in good condition.

• Do not operate the tool at oil temperatures above

140 °F/60 °C. Operation at higher temperatures can cause higher than normal temperatures at the tool which can result in operator discomfort.

• Do not operate a damaged, improperly adjusted, or incompletely assembled impact wrench.

• Never wear loose clothing that can get entangled in the working parts of the tool.

• Keep all parts of your body away from the rotating parts. Long hair or loose clothing can become drawn into rotating components.

• Always use accessories that conform to the specifications given in the OPERATION section of this manual.

• Do not reverse impact wrench rotation direction by changing fluid flow direction.

• Release the trigger if the power supply has been interrupted.

• When working near electrical conductors, always assume that all conductors are energized and that insulation, clothing and hoses can conduct electricity. Use hose labeled and certified as non-conductive.

• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by authorized and properly trained personnel.

• Serious injury or death could result from a tool or accessories dropped from an elevated height, also flying debris can cause serious injury.

• Warning: Hydraulic fluid under pressure could cause skin injection injury. If you are injured by hydraulic fluid, get medical attention immediately.

• During operation do not contact the impact mechanism, accessories or hardware as they can become very hot, use your (PPE) Personal Protection Equipment.

• Warning: Use of this tool on certain materials during demolition could generate dust potentially containing a variety of hazardous substances such as asbestos, silica or lead. Inhalation of dust containing these or other hazardous substances could result in serious injury, cancer or death. Protect yourself and those around you. Research and understand the materials you are cutting. Follow correct safety procedures and comply with all applicable national, state or provisional health and safety regulations relating to them, including, if appropriate arranging for the safe disposal of the materials by a qualified person.

IW16 User Manual ◄ 5

TOOL STICKERS & TAGS

12412 DANGER DECAL

30136

ROTATION DIRECTION

DECAL

D

30 LPM @ 138 B AR

EHTMA CATEGORY

11207 CIRCUIT

TYPE D DECAL (CE)

12535 CIRCUIT

TYPE E DECAL (CE)

25610 RAILROAD

HELP DESK DECAL

66305 SOUND

POWER LEVEL

DECAL (CE)

28788

MANUAL DECAL

(CE)

28323 CE DECAL

(CE)

08153 IW16 NAME TAG (US & CE)

09612 GPM DECAL

NOTE:

THE INFORMATION LISTED ON THE STICKERS

SHOWN, MUST BE LEGIBLE AT ALL TIMES.

REPLACE DECALS IF THEY BECOME WORN OR

DAMAGED. REPLACEMENTS ARE AVAILABLE FROM

YOUR LOCAL STANLEY DISTRIBUTOR.

The safety tag (P/N 15875) at right is attached to the tool when shipped from the factory. Read and understand the safety instructions listed on this tag before removal. We suggest you retain this tag and attach it to the tool when not in use.

6 ► IW16 User Manual

SAFETY TAG P/N 15875 (shown smaller then actual size)

HOSE TYPES

The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with

Stanley Hydraulic Tools. They are:

Certified non-conductive — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled

certified non-

conductive is the only hose authorized for use near electrical conductors.

Wire-braided (conductive) — constructed of synthetic rubber inner tube, single or double wire braid reinforcement, and weather resistant synthetic rubber cover. This hose is

conductive and must never be used near electrical conductors.

Fabric-braided (not certified or labeled non-conductive) — constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This

hose is not certified non-conductive and must never be used near electrical conductors.

HOSE SAFETY TAGS

To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic

Tools. DO NOT REMOVE THESE TAGS.

If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be obtained from your Stanley Distributor.

THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE

D A N G E R

1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE

WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN

DEATH OR SERIOUS INJURY.

FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP-

ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND

ELECTRIC LINES.

2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE

ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT-

TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND

TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH

SAFETY DEPARTMENT INSTRUCTIONS.

SEE OTHER SIDE

3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE

OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE.

KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT

CONTACT DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION

AND SEVERE PERSONAL INJURY.

4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR

CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT

USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.

5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAM-

AGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE

IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

SEE OTHER SIDE

SIDE 1 SIDE 2

(Shown smaller than actual size)

THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.

D A N G E R

1. DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS

NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE. USING THIS HOSE ON OR NEAR

ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.

2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY

TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC-

TRIC LINES.

3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR

HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE. KEEP HOSE

AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT

DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE

PERSONAL INJURY.

4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, CUTTING, OR CONTACT

WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO

PULL OR LIFT TOOLS, POWER UNITS, ETC.

SEE OTHER SIDE

SIDE 1

5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO

COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY.

NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

(Shown smaller than actual size)

SEE OTHER SIDE

SIDE 2

IW16 User Manual ◄ 7

HOSE RECOMMENDATIONS

Tool to Hydraulic Circuit Hose Recommendations

The chart to the right shows recommended minimum hose diameters for various hose lengths based on gallons

8 ► IW16 User Manual

All hydraulic hose must meet or exceed specifications as set forth by SAE J517.

HTMA / EHTMA REQUIREMENTS

HTMA / EHTMA REQUIREMENTS

HTMA

HYDRAULIC SYSTEM REQUIREMENTS

Flow Range

Nominal Operating Pressure

(at the power supply outlet)

TYPE I

4-6 gpm

(15-23 lpm)

1500 psi

(103 bar)

System relief valve setting

(at the power supply outlet)

TOOL TYPE

TYPE II

7-9 gpm

(26-34 lpm)

1500 psi

(103 bar)

TYPE RR

9-10.5 gpm

(34-40 lpm)

1500 psi

(103 bar)

TYPE III

11-13 gpm

(42-49 lpm)

1500 psi

(103 bar)

2100-2250 psi 2100-2250 psi 2200-2300 psi 2100-2250 psi

(145-155 bar) (145-155 bar) (152-159 bar) (145-155 bar)

Maximum back pressure

(at tool end of the return hose)

Measured at a max. fluid viscosity of:

(at min. operating temperature)

250 psi

(17 bar)

250 psi

(17 bar)

250 psi

(17 bar)

250 psi

(17 bar)

400 ssu* 400 ssu* 400 ssu* 400 ssu*

(82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)

Temperature: Sufficient heat rejection

capacity to limit max. fluid temperature to:

(at max. expected ambient temperature)

140° F

(60° C)

140° F

(60° C)

140° F

(60° C)

140° F

(60° C)

Min. cooling capacity at a temperature

difference of between ambient and fluid

temps

NOTE:

Do not operate the tool at oil temperatures above 140° F (60° C). Operation at higher temperatures can cause operator

discomfort at the tool.

Filter

Min. full-flow filtration

Sized for flow of at least:

(For cold temp. startup and max.

dirt-holding capacity)

3 hp

(2.24 kW)

40° F

(22° C)

25 microns

30 gpm

(114 lpm)

5 hp

(3.73 kW)

40° F

(22° C)

25 microns

30 gpm

(114 lpm)

6 hp

(5.22 kW)

40° F

(22° C)

25 microns

30 gpm

(114 lpm)

7 hp

(4.47 kW)

40° F

(22° C)

25 microns

30 gpm

(114 lpm)

Hydraulic fluid Petroleum based

(premium grade, anti-wear, non-conductive)

100-400 ssu* 100-400 ssu*

Viscosity (at min. and max. operating temps)

(20-82 centistokes)

100-400 ssu* 100-400 ssu*

NOTE:

When choosing hydraulic fluid, the expected oil temperature extremes that will be experienced in service determine the

most suitable temperature viscosity characteristics. Hydraulic fluids with a viscosity index over 140 will meet the requirements

over a wide range of operating temperatures.

*SSU = Saybolt Seconds Universal

EHTMA

HYDRAULIC SYSTEM

REQUIREMENTS

B

C

CLASSIFICATION

D

Flow Range

Nominal Operating Pressure

(at the power supply outlet)

System relief valve setting

(at the power supply outlet)

3.5-4.3 gpm 4.7-5.8 gpm

(13.5-16.5 lpm) (18-22 lpm)

1870 psi

(129 bar)

1500 psi

(103 bar)

2495 psi

(172 bar)

2000 psi

(138 bar)

7.1-8.7 gpm

(27-33 lpm)

1500 psi

(103 bar)

2000 psi

(138 bar)

9.5-11.6 gpm

(36-44 lpm)

1500 psi

(103 bar)

2000 psi

(138 bar)

11.8-14.5 gpm

(45-55 lpm)

1500 psi

(103 bar)

2000 psi

(138 bar)

NOTE: These are general hydraulic system requirements. See tool specification page for tool specific requirements

IW16 User Manual ◄ 9

WRENCH TORQUE INFORMATION

FACTORS THAT AFFECT TORQUE

An impact wrench is a rotary hammer that impacts the head of a bolt or nut. It does not apply a slow steady torque as a standard torque wrench. Therefore, several factors affect the result of torque when using impact wrenches:

1.

LONG BOLTS. Long bolts having high-friction threads with lubrication under the bolt head or associated nut can twist when impacted, then untwist before the next impact. This will especially happen if there is low friction between the bolt head or nut and the mating surface.

2. HEAVY, LOOSE OR MULTIPLE ADAPTERS.

Heavy, loose or multiple adapters between the wrench and socket can dissipate the intensity of the impact to the bolt head or nut.

3. AMOUNT OF IMPACT. Maximum torque results can be obtained by allowing continuous impacting of the socket against the bolt head or nut for at least 10 seconds.

4. HYDRAULIC FLOW RATE. If the flow rate to the tool is too low, the hammer (or impact) speed is reduced. If the flow is correct, a change in the relief pressure does not affect the impact force. Poorly designed hydraulic circuits can result in lower flow rates and reduced impact speeds when pressure is required during impacting.

BOLT GRADE AND THREAD

RECOMMENDATIONS

Allowable bolt torque is limited by both bolt thread diameter and grade of steel in the bolt. The IW16 Impact

Wrench is recommended for use on the following bolt grade and thread sizes:

SAE Grade 2 mm

SAE Grade 5

SAE Grade 8

1-1/8 to 1-7/8 inch / 28.5 / 47.6

1 to 1-5/8 inch / 25.4-41.2 mm

7/8 to 1-3/8 inch / 22.2-35 mm

PREOPERATION PROCEDURES

CHECK POWER SOURCE

1. Using a calibrated flow meter and pressure gauge, check that the hydraulic power source develops a flow of 7–12 gpm / 20-45 lpm at 1000–2000 psi /

70–140 bar.

2. Make certain that the hydraulic power source is equipped with a relief valve set to open at 2100 psi/145 bar minimum.

3. Check that the hydraulic circuit matches the tool for open-center (OC) operation.

4.

UNDERWATER MODELS ONLY. Make certain that the wrench impact mechanism is cleaned and greased with waterproof grease after each day’s use.

CONNECT HOSES

1. Wipe all hose couplers with a clean, lint-free cloth before making connections.

2. Connect hoses from the hydraulic power source to the tool fittings or quick disconnects. It is good practice to connect the return hose first and disconnect it last to minimize or eliminate trapped pressure within the wrench.

3. Observe the flow indicators stamped on the main body assembly and the hose couplers to ensure that the flow is in the proper directions. The female couple on the tools “IN” port is the inlet (pressure) coupler.

NOTE:

If the uncoupled hoses are left in the sun, pressure increase within the hoses can make them difficult to connect. Whenever possible, connect the free ends of hoses together.

WRENCH OPERATION

The IW16 is designed for 1-inch square hex drive. The

1-inch drive configuration is used with drive sockets for high impact (500–2500 ft lb / 680–3400 Nm) installation and removal of fasteners.

During normal operation it is common to see some grease leakage from around the anvil during hard use.

Refer to the IW16 Service Manual for the correct lubrication procedures.

Use at the low end of the 500–2500 ft lb / 680–3400

Nm torque range during continuous use over long periods of time (impact times exceeding 10 seconds). The high temperature generated in the impact mechanism can reduce steel part and lubricant durability within the wrench.

1. Observe all Safety Precautions.

2. Move the hydraulic circuit control valve to the “ON” position to operate the wrench.

10 ► IW16 User Manual

WRENCH OPERATION

WARNING

Always use sockets and accessories designed for impact type applications. DO NOT USE STANDARD

SOCKETS OR ACCESSORIES. THESE CAN

CRACK OR FRACTURE DURING OPERATION.

3. Select the direction of impact desired using the reversing valve located on the side of the wrench. To select clockwise direction, place the valve in the upward position. To select counter-clockwise direction, place the valve in the downward position.

NOTE:

To more accurately tighten bolts, lubricate threads, check with a torque wrench and duplicate time of impacting for other bolts of the same length and thread size.

4. Squeeze the trigger to activate the wrench.

5. Release the trigger to stop the wrench.

COLD WEATHER OPERATION

If the wrench is to be used during cold weather, preheat the hydraulic fluid at low engine speed. When using the normally recommended fluids, fluid temperature should be at or above 50° F/10° C (400 ssu/82 centistokes) before use.

Damage to the hydraulic system or wrench can result from use with fluid that is too viscous or too thick.

POST OPERATION—UNDERWATER

MODELS ONLY

The wrench impact mechanism must be cleaned and greased with waterproof grease after every day of use.

The main housing valve and motor are sealed and do not require maintenance unless they are malfunctioning.

Remove, clean, grease and assemble the impact mechanism as described in the IW16 Service Manual.

EXTENSION HANDLE

If the handle and anchor block are removed, all valve handle/motor housing bolts must be cleaned, installed with 242 Loctite® and re-torqued. Contact Stanley authorized service for procedure.

IW16 User Manual ◄ 11

TOOL PROTECTION & CARE

NOTICE

In addition to the Safety Precautions found in this manual, observe the following for equipment protection and care.

• Make sure all couplers are wiped clean before connection.

• The hydraulic circuit control valve must be in the

“OFF” position when coupling or uncoupling hydraulic tools. Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system.

• Always store the tool in a clean dry space, safe from damage or pilferage.

• Make sure the circuit PRESSURE hose (with male quick disconnect) is connected to the “IN” port. The circuit RETURN hose (with female quick disconnect) is connected to the opposite port. Do not reverse circuit flow. This can cause damage to internal seals.

• Always replace hoses, couplings and other parts with replacement parts recommended by Stanley

Hydraulic Tools. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.

• Do not exceed the rated flow (see Specifications) in this manual for correct flow rate and model number.

Rapid failure of the internal seals may result.

• Always keep critical tool markings, such as warning stickers and tags legible.

• Tool repair should be performed by experienced personnel only.

• Make certain that the recommended relief valves are installed in the pressure side of the system.

• Do not use the tool for applications for which it was not intended.

12 ► IW16 User Manual

TROUBLESHOOTING

If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem. When diagnosing faults in operation of the wrench, always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed in the following table. Use a flow meter known to be accurate. Check the flow with the hydraulic fluid temperature at least 80 ° F/27 ° C.

PROBLEM

Low performance or impact.

Wrench runs too fast. Impact mechanism or screws broken.

CAUSE

Incorrect hydraulic flow.

Defective quick disconnects.

Worn impact mechanism.

SOLUTION

Check that the hydraulic power source is producing 7-12 gpm/20-45 lpm at

1500-2000 psi/105-140 bar.

Check each quick disconnect.

Repair or replace the impact mechanism. See Service Mechanism Removal

Cleaning and Installation procedure to extend mechanism life.

Hammer pins broken.

Replace with integral frame (with pins).

Check relief adjustment screw setting.

Job may require a larger wrench.

See Service Manual.

Incorrect grease or periodic maintenance of the impact mechanism is not being performed.

Spools incorrectly installed.

Sockets or adapters too heavy or loose.

Valve(s) incorrectly reassembled. See

Service Manual.

Use the correct impact type sockets or adapters.

Long bolt with lubricated head.

Incorrect hydraulic flow (too high).

Supply and return hoses reversed.

Relief sleeve or spring damaged.

Adjusting screw is in too far.

Lubricate threads only.

Check that hydraulic power source is producing 7-12 gpm/20-45 lpm at 1500-

2000 psi/105-140 bar.

Install hoses correctly. Refer to Operation section in this manual.

Remove and replace spool assembly.

Adjust correctly.

Hard duty cycle and heat forces grease out.

Normal unless greasing instructions in

Service Manual are not followed.

Main shaft O-ring leaking.

Replace as required.

Grease leaks at anvil busing, wrench warm.

Grease leaks at anvil bushing, wrench cold.

Oil leak at motor cap face.

Oil leaks at reversing spool.

Fasteners loose.

Face O-ring worn or missing.

Tighten to recommended torque.

Replace as required.

Motor cap/main housing damaged.

Replace as required.

Damaged O-rings.

Replace as required. Check Service

Manual to avoid cutting O-rings on cross holes in the spool bore.

Wrong hydraulic fluid. Circuit too hot. Refer to Operation section for correct fluid/circuit specifications.

IW16 User Manual ◄ 13

SPECIFICATIONS

Drive Size .................................................................................................................................... 1-inch Square Drive

Weight ......................................................................................................................................................26 lbs/12 kg

Overall Length ................................................................................................................................ 14-1/2-inch/37 cm

Width .......................................................................................................................................................4-inch/11 cm

Pressure Range................................................................................................................1500-2000 psi/105-140 bar

Flow Range .................................................................................................................................7-12 gpm/20-45 lpm

Optimum Flow ....................................................................................................................................... 8 gpm/30 lpm

System Type ........................................................................................ Open and Closed Center, HTMA Type II or III

Porting ....................................................................................................................................................8 SAE O-ring

Output Speed (free spin) ...................................................................................................2000 rpm at 5 gpm/19 lpm

Input Speed ......................................................................................................................... 1200 Impacts per Minute

Connect Size and Type ....................................................................................................3/8-inch Male Pipe Adapter

Torque...........................................................................................................................500–2500 ft. lb/680–3400 Nm

SOUND AND VIBRATION DECLARATION

Test conducted on IW16157, S/N 9524, operated at standard 10 gpm input

Measured A-weighted sound power level, Lwa (ref. 1pW) in decibels 113.2 dBA

Uncertainty, Kwa, in decibels

Measured A-weighted sound pressure level, Lpa (ref. 20 µPa) at operator’s position, in decibels

Uncertainty, Kpa, in decibels

3 dBA

102.2 dBA

3 dBA

Values determined according to noise test code given in ISO 15744, using the basic standard ISO 3744

NOTE: The sum of a measured noise emission value and its associated uncertainty represents an upper boundary of the range of values which is likely to occur in measurements.

Declared vibration emission value in accordance with EN 12096

Measured vibration emission value: a

Uncertainty: K

Values determined according to ISO 8662-7

49 m/sec²

5.2 m/sec²

14 ► IW16 User Manual

ACCESSORIES

Description Part Number

Adapter, 1-inch to 3/4-inch Drive .......................................................................................................................31201

Extension, 10 inch, 1-inch Drive .......................................................................................................................31203

Socket Retainer Pin, 1-inch Square Drive Socket .............................................................................................33276

Socket Retainer Ring, 1-inch Square Drive Socket ...........................................................................................33277

SOCKETS

1-inch Square Drive 4-point Rectangular Head Lag Screw Socket 7/8 in. x 1-1/8 in...........................................66318

1-inch Square Drive 8-Point Deep × 1-5/16 inch ...............................................................................................25203

1-inch Square Drive 8-Point Deep × 1-3/8 inch .................................................................................................25204

1-inch Square Drive 8-Point Deep × 1-1/2 inch .................................................................................................25205

1-inch Square Drive 8-Point Deep × 1-9/16 inch ...............................................................................................25206

1-inch Square Drive 8-Point Deep × 1-7/8 inch .................................................................................................25208

1-inch Square Drive 8-Point Deep × 2 inch .......................................................................................................25209

1-inch Square Drive 8-Point Deep × 2-1/8 inch .................................................................................................25210

1-inch Square Drive 8-Point Deep × 2-3/16 inch ............................................................................................... 25211

1-inch Square Drive 8-Point Deep × 2-1/4 inch .................................................................................................25212

1-inch Square Drive 8-Point Deep × 1-5/8 inch .................................................................................................25216

1-inch Square Drive 8-Point Deep × 1-13/16 inch .............................................................................................25217

1-inch Square Drive 8-Point Deep × 1-11/16 inch .............................................................................................25218

1-inch Square Drive #70 Torx ............................................................................................................................26456

1-inch Square Drive 8-Point Deep × 1-1/4 inch .................................................................................................26529

1-inch Square Drive 4-Point Deep × 1 inch .......................................................................................................27710

Socket Sets

Socket Set, Includes 6 Sockets .........................................................................................................................33230

(25211, 25216, 25217, 25218, 26456, 27710)

Upright Handle Assy Kit...............................................72768

(Includes Upright Handle, decals, bolts, washers and Inst.)

IW16 User Manual ◄ 15

IW16 PARTS ILLUSTRATION

CAUTION

Make sure the correct capscrew is used in the correct location

TORQUE TO 55 ft lb IN

A CROSS PATTERN AS

SHOWN ABOVE

NOTE: Item 20 See page

18 Before Ordering

20

45

16

2

48

46

10

35

62

19

27

22

25

17

61

NOTE:

Item 43

21

See page

18 Before

Ordering

43

7

37

55

9

29

62

1

52

7

4

18

36

64

44

8

63

28

4

24

30

10 21

14

5

13

34

23

6

31

32

31

49

53

33

51

54

3

39

TORQUE TO 55 ft lb IN A CROSS PAT-

TERN AS SHOWN

ABOVE

11

12

NOTE: IF THE TOOL

IS EQUIPPED WITH

HOSE WHIPS OR

COUPLERS THEY CAN

BE INSTALLED IN ONE

OF TWO PORTS. THE

PORTS FACING DOWN

OR THE PORTS FACING

TO THE REAR, MAKE

SURE THE PLUGS (ITEM

# 55) ARE INSTALLED IN

THE PORTS WITHOUT

THE HOSES OR COU-

PLERS.

59

15

26

58

41

38

58

57

56

47

40

42

50

60

16 ► IW16 User Manual

25

26

27

28

29

21

22

23

24

34

35

36

37

38

39

40

41

42

30

31

32

33

13

14

15

16

17

18

7

8

9

10

11

12

19

20

4

5

6

2

3

ITEM

NO.

1

08139 1

08147 2

08148 1

08153 1

08180 1

09275 1

09277 1

09284 6

09612 1

09625 4

11207 1

12412 1

12535 1

PART

NO.

QTY DESCRIPTION

00016 1 O-RING*

00026 1

00231 4

O-RING*

LOCKWASHER 5/16" I.D.

00255 2

00580 1

00663 1

O-RING*

SETSCREW 1/4-20 X 1/4

RETAINING RING

00697 8

00717 1

00936 2

01211 2

03972 1

03973 1

04888 1

04939 1

05965 1

06533 1

07982 1

07984 1

07986 1

73046 1

LOCKWASHER 1/2" I.D

O-RING*

ADAPTER -8 (1/2) SAE X 3/8 NPT

O-RING*

COUPLER,3/8FEM. (SET 03971)

COUPLER,3/8MALE (SET 03971)

O-RING*

LEVER

ROLL PIN

O-RING*

SPRING REST

RELIEF ADJUSTMENT SCREW

RELIEF SEAT

SPOOL (See page 18 before ordering)

08015 2

08122 1

08125 1

08128 1

08131 1

08133 1

08135 1

08136 1

08137 1

BACK-UP RING*

COMPRESSION COIL SPRING

SEAL BACK-UP WASHER*

IDLER GEAR ASSY

COMPRESSION COIL SPRING

TRIGGER

RELIEF POPPET

MAIN SHAFT

MOTOR HOUSING ASSY

(INCLUDES ITEMS 61 THRU 64)

REVERSING SPOOL

THRUST WASHER

THRUST BEARING

NAME TAG - IW16

BACK-UP RING*

RETAINING RING EXTERNAL

HEX NUT 5/16-18UNC

HSHCS 1/2-13 X 1-3/4

GENERAL CAUTION STICKER

HSHCS 5/16-18 X 1-1/2

CIRCUIT TYPE "D" STICKER

DANGER STICKER - ELECTRICAL

CIRCUIT TYPE "E" STICKER

IW16 PARTS LIST

57

58

59

44

45

46

47

60

61

62

63

64

48

49

50

51

52

53

54

ITEM

NO.

43

55

56

72840

24677

08123

08146

07995

03252

23134

PART

NO.

QTY DESCRIPTION

73167 1 VALVE HANDLE ASSY (INCLUDES

ITEMS 55 and 62). SEE PAGE #18

BEFORE ORDERING

21986

22063

2

1

22064 1

24682 1

HSHCS 1/2-13 X 2-1/4

SPOOL CAP

ROD WIPER*

HAMMER CASE, LAND (INCL ITEM

56)

24758 1

23678 1

23817 1

28323_ 1

28788 1

30136 1

32087 1

66305 1

HAMMER CASE U/W MODIFIED

(INCL BUSHING72762)

HEADED PUSH PIN

THRUST SPACER

1 CE STICKER

STICKER - MANUAL

ROTATION DIRECTION STICKER

ASSIST HANDLE

GUARANTEED SOUND POWER

LEVEL 116 dBA

350237 2

21010 1

21011

24678

1

1

24680

24679

2

1

24757

56725

66727

47438

1

2

1

2

1

1

1

2

2

1

HOLLOW HEX PLUG - 8 SAE

BUSHING

BUSHING (UNDERWATER)

ANVIL

HAMMER PINS

HAMMER FRAME (INCLUDES ITEM

58 PINS)

HAMMER FRAME ONLY

HAMMER

IDLER SHAFT

BUSHING

INSERT

O-RING

STANDARD MECHANISM ASSY

(INCL ITEMS 47, & 56 THRU 60)

UNDERWATER MECHANISM (INCL

ITEMS 47 & 56 THRU 60)

HOSE ASSY for IW16150S (NOT

PICTURED)

HOSE ASSY for IW16150BN (NOT

PICTURED)

COUPLER SET FOR IW16150BN

SEAL KIT (P/N-09602)

* DENOTES PART IN SEAL KIT

IW16 User Manual ◄ 17

VALVE HANDLE CHANGE NOTICE

ALL IW16 IMPACT WRENCH MODELS

Notification of change in valve handle assembly and on/off spool.

Part numbers and compatibility (March 2013).

Beginning at serial number 031513001, the valve handle assembly has changed. The prior style (part #

17279) used a steel spool sleeve installed in the valve handle assembly. The new style valve handle assembly (part # 73167) does not use a spool sleeve.

New style valve spool assembly (part # 73046) is required for use in the new style valve handle assembly.

The new style valve handle assembly will only accept new style on/off spool (PN 73046). If replacing old style 17279 valve handle assembly with new style 73167, replacement of 73046 valve spool is also required.

New style on/off spool 73046 will fit old style and new style valve handle assemblies. Old style valve spool

P/N 07998 is no longer available and substitutes to new style 73046.

Please refer to the photos below of the old style and new style valve handle and on/off spools.

Old Style – No Longer Available New Style – Uses no sleeve in spool bore.

Please contact the Technical Service Department at 503-659-5660 with any questions.

18 ► IW16 User Manual

IW16 UPRIGHT HANDLE PARTS

IW16 UPRIGHT HANDLE KIT P/N-72768

ITEM

1

2

5

6

7

8

3

4

P/N

10792

25610

30136

66037

371071

72769

66035

31030

2

1

4

2

1

1

QTY DESCRIPTION

2

1

BOLT 5/8-11 x 1-1/4

RAILROAD HELPDESK STICKER

DIRECTION STICKER

UPRIGHT HANDLE W/TRIGGER LOCK

LOCKWASHER 5/8 PLATED

INST FOR P/N 72768

ISOLATOR

HANDLE GRIP

ROD ADJUSTMENT NUT IS LOCATED

IN THIS AREA OF THE UPRIGHT HANDLE

(NOT VISIBLE).

ADJUST ROD NUT UNTIL THE TRIG-

GER ON THE REMOTE HANDLE CAN

FULLY DEPRESS THE TRIGGER ON THE

WRENCH.

ITEM (3) “DIRECTION

STICKER”

GOES ON THIS SIDE OF

HANDLE

SAME AS ON THE TOOL

MAKE SURE HOSES ARE

INSTALLED INTO

REAR-FACING PORTS

TORQUE BOTH 5/8-11

BOLTS TO 90ft-lbs

IW16 User Manual ◄ 19

UNDERWATER TOOLS DEPTH GUIDELINE

UNDERWATER MODELS ONLY

CAUTION

DO NOT USE HYDRAULIC TOOLS UNDER-

WATER THAT ARE NOT DESIGNATED AS

AN “UNDERWATER” MODEL, OR THIS

WILL RESULT IN DAMAGE TO THE TOOL.

For underwater hydraulic tools the applications are broken down into four quadrants depending on type of tool and method of operation.

Operation Overview

Percussive

Tools: Breakers,

Hammer Drills and

Chipping Hammers

Max Depth: 500' limitations due to accumulator PSI max (increase 40

PSI for every 100')

Rotational

Tools: Grinders,

Saws, Chain Saws

Max Depth: 1000' -

Reference hose sizing guide below

Tools: Breakers,

Hammer Drills and

Chipping Hammers

Tools: Grinders,

Saws, Chain Saws

The types of tools are percussive and rotational, each with different characteristics allowing for different depth operation. With percussive tools, the nitrogen accumulator PSI must counter the increase in ambient pressure found at lower depths.

Since there is a maximum PSI for percussive tools they are limited to certain depths. Rotational tools do not have accumulators and thus capable of deeper depths.

Max Depth: 500' limitations due to accumulator PSI max (increase 40

PSI for every 100')

Max Depth: 1000' -

Reference hose sizing guide below

The methods are broken into diver operated or remote operated vehicle (ROV). ROV's can reach lower depths and with an on-board hydraulic power source that is depth compensated, can operate hydraulic tools at depths of thousands of feet. ROV operation is still limited to the tool, for example a percussive tool has the same depth limitation whether ROV or diver operated.

Recommended Hose Diameters

Depth (ft)

100

300

600

1000

8 GPM

5/8”

3/4”

1”

1”

12 GPM

5/8”

1”

1”

1-1/4”

20 ► IW16 User Manual

NOTES

IW16 User Manual ◄ 21

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie, Oregon 97267-5698 USA

(503) 659-5660 / Fax (503) 652-1780 www.stanleyhydraulics.com