Summary of Contents for PANDROL 02500
- Page 1 Impact Wrench MODEL 02500 OPERATION AND MAINTENANCE MANUAL ENG_OMM_IMPACT_WRENCH_P01 09th November 2021 Partners in excellence...
-
Page 2: Revision
The manual is intended for people who handle and operate the machine. It is originally written in English and translated into the local language by Pandrol. Pandrol reserves the right to change specifications, equipment, instructions and maintenance guidelines without prior notice. -
Page 3: Table Of Contents
8.2. Warning labels and information symbols Limited warranty 9.1. Exclusions to limited warranty 9.2. Limitation of liability Customer information 11. Seal kit information Assembly 12.1. Parts diagram 12.2. Parts list 12.3. Parts diagram and list Disclaimer Contact 15. Recycling and Environment OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 3 av 24 @Pandrol 2021... -
Page 4: Safety Information
• All safety precautions are given for your safety. Read to understand and follow all safety, maintenance and operation instructions before you use or maintain the tool. • Review the manual daily before using the tool. • Follow all safety guidelines given you by your supervisor. Do not use the tool if you have any questions about the operation, safety or maintenance of this tool . Failure to follow these instructions can result in personal injury or equipment damage. • Pandrol has no control over the tool use or operation once it leaves the plant. Pandrol has no control over operator or maintainer selection. The customer must assume responsibility for the tool suitability for a particular function. • During use of the tool, good judgement must be used to work safely and efficiently without endangering themselves or bystanders. • Understanding of the operation and maintenance manual is essential for anyone using or maintaining the tool. -
Page 5: Personal/Safety Equipment
Do not wear clothing which may become entangled in the tool. • Always keep work area free of tools or any other objects which may impair sound footing. • Caution - oil injection hazard exists with this tool. Oil injection is a condition where the hydraulic oil is forced under the skin through pressure in the line. Always wear gloves and repair leaks immediately. • Do not carry the tool by the pigtail hoses. • Do not over torque track and frog bolts. • Do not use defective sockets or those not manufactured for impact wrenches. • Do not attempt to loosen locked up wrench with any hand tool. Disconnect from power source and then repair wrench. • Use a socket retaining ring to keep socket on the anvil. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 5 av 24 @Pandrol 2021... -
Page 6: Qualified Personnel
3.5. Qualified personnel The machine is only to be used by trained personnel, thoroughly familiar with and trained in general railway workmanship. The equipment should be operated according to the conditions and standard regulations applying to the track they are working on. The equipment must be serviced, maintained, or in any way modified only by trained personnel, who are familiar with the Operation & Maintenance Manual and have received training and information from Pandrol. In order to avoid personal injury and/or material damage, everyone involved with assembling, starting-up or overhaul must possess relevant knowledge of the equipment, its use, maintenance requirements and procedures. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 @Pandrol 2021 6 av 24... - Page 7 4. Summary The 1” Impact Wrench is capable of handling the toughest jobs. Crossing,frog or track bolts are no problem for this rugged tool. Anti-vibration designand optional handle provide an efficient,safe and ergonomic work position for the task at hand. A torque adjustmentknob “dials in” torque from 0-3500 ft lb. Designed for 5 or 10 GPM. Fig 1. Fig 2. Fig 3. Flow Pressure Dimensions Weight 5 GPM (19 LPM) 2000 PSI (140 BAR) A - 18” (45.7 cm) 37 lbs (16.8 kg) B - 8” (20.3 cm) 10 GPM (38 LPM) C - 10” (25.4 cm) OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 7 av 24 @Pandrol 2021...
-
Page 8: Operation
5. Operation • With the power source in the “OFF” position, connect the hoses. Do not drag the service hose by pulling with the tool. Loop the service hose in the work area in such a way to relieve stress on the hose and quick disconnect fittings while working. Be aware of hose location at all times. • Connect the tool to the power source. • Turn the power source “ON” to supply 10 GPM to tool. • To tighten bolts, push the lever handle (located on both sides of impact wrench manifold) forward. To loosen bolt, pull lever handle back. • Pull the trigger up to start the wrench. • Never operate the tool on any higher flow than 10 GPM. The tool is designed to accept only the recommended 10 GPM and will malfunction and overheat the oil if used otherwise. • Turn the power source “OFF” before disconnecting wrench. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 @Pandrol 2021 8 av 24... -
Page 9: Hammer Installation
5.1. Hammer installation Although the hammers are identical parts, they must be installed in opposing positions for proper operation. The relief cut sides will face each other when properly fitted inside the hammer Frame, but the hammer pin notch will be assembled 180° apart with (1) at the 12:00 Position and the other at the 6:00 position. 5.2. Cold weather operation Hydraulic system performance is affected when the temperature drops below 50°F. Therefore, measures should be taken to pre-warm tools and fluids before operating. Fig 4. NOTE! • Refer to operating procedures of this manual before starting OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 9 av 24 @Pandrol 2021... -
Page 10: Trouble Shooting Guide
• Check that flow is 10 GPM and system pressure is set at 2000 Trigger sticks… • Check for dirt or clearance in trigger housing • Check for reverse flow (pigtails or qd’s recently changed) • Check back pressure on return line (at tool return should be 150 PSI or less). Hydraulic oil running out of • Replace front shaft seal using part no. 02598 Shaft seal kit. front end… OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 @Pandrol 2021 10 av 24... -
Page 11: Torque / Tension Calibration Procedure
6.2. Torque / tension calibration procedure (Using Pandrol part #01650 – Torque gauge) • Install test gauge in pressure line at tool and connect to power source supply hoses – 5 GPM. Refer to bolt tightening chart specification required for the grade and size bolt being used. (Always follow • manufacturer’s recommendations.) • Loosen lock collar on torque adjustment knob. • If torque adjustment knob is turned all the way in, back adjustment knob out one and a half turns counterclockwise to decrease initial torque. • Begin tightening bolt, keeping a close watch on the torque gauge. Turn the adjustment knob in clockwise increasing the pressure until the desired setting is reached. • Loosen and retighten the test bolt a couple of times to verify the setting. • Retighten the lock collar. • Torque gauge may be removed once desired torque is set. Over-torquing bolts will cause bolt failure under traffic. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021... -
Page 12: Torque / Tebsion Calibration
OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 @Pandrol 2021 12 av 24... -
Page 13: Review Of Hydraulic Principles
3.43 6.86 10.30 13.70 17.20 20.60 5.15 10.30 15.40 20.60 25.70 30.90 7.2. Back pressure Back pressure measured at the tool return port must not exceed the manufacturers back pressure rating. Most manufacturers list the maximum back pressure for their hydraulic tools at 250 PSI. Back pressure measured on the return side of the tool is the force required to get the oil back to the tank. In almost all cases the lower the back pressure the better the tool performance. First, the back pressure is subtracted from the maximum tool pressure to arrive at a maximum tool operating pressure. For example, tools with 2000 PSI operating pressure are installed on a system with 250 PSI back pressure. This leaves 1750 PSI as a maximum tool pressure. Imagine a system with 500 PSI back pressure. 2000 Minus 500 PSI back pressure leaves only 1500 PSI for the tool. Second, tools are designed for pressure to build on the pressure side of the tool. If too much pressure builds on the return side, not only is performance effected, but seals may blow. This is why it is very important to direct the flow into the tool correctly. Reversing the hoses to test may result in blown seals, damage to the tool, and personal injury. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 13 av 24 @Pandrol 2021... -
Page 14: Maintenance
8.1. General Maintenance and overhaul is to be carried out by qualified personnel only Warranty is based on parts and spares delivered by Pandrol. Check tools DAILY for proper operation, leaks, or damage. Inspect hoses DAILY. Replace cut, burned, or otherwise damaged hoses. -
Page 15: Warning Labels And Information Symbols
8.2. Warning labels and information symbols Below are examples of warning labels and information symbols on the machine. If any of these labels become damaged or lost, they are to be replaced with new original warning labels that are available from Pandrol. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 15 av 24 @Pandrol 2021... -
Page 16: Limited Warranty
As a condition precedent to Pandrol’s obligation hereunder, the defective product must not have been altered or modified without the express written approval of Pandrol. The product must not have been subjected to deliberate damage, shipping damage, neglect, tampering by unauthorized personnel or damage by improper use, storage or maintenance. Serial numbers must not have been altered, defaced or removed. Such action voids limited warranty. 9.1. Exclusions to limited warranty This limited warranty is exclusive and is in lieu of any other warranty, written or oral, expressed or implied, including, without limitation, any implied warranty or merchantability or fitness for a particular purpose. Limited warranty does not cover normal wear and tear items such as filters, hoses, couplers, bits, sockets, augers, and batteries 9.2. Limitation of liability Except as provided above, Pandrol shall in no event be liable or responsible for any injury, loss or damage, direct, incidental or consequential, arising out of the use or misuse or inability to use the product, however caused and on any theory of liability including, without limitations, breach of contract, tort, (including negligence or street liability) and not withstanding any failure of any remedy herein of its essential purpose, even if Pandrol was aware of this possibility of such damage. Pandrol’s limited warranty as set forth above shall not be enlarged, diminished or affected by, and no obligation or liability shall arise or go out of the rendering of technical advice or service by Pandrol or its agents. The foregoing may not be changed except by written agreement signed by an authorized officer of Pandrol, the remedies set forth herein are exclusive. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 @Pandrol 2021 16 av 24... -
Page 17: Customer Information
10. Customer information Name Company Serial # of your Pandrol tool Upon receiving your Pandrol tool, make sure to list serial number above so that a good record is kept for order information. Pandrol hydraulic tool list All Pandrol Hydraulic Tools operate at 5 GPM (19 LPM) or 10 GPM (38 LPM) @ 2000 PSI (140 BAR) Power units: 00100K – Gasoline powered (1) 10 GPM or (2) 5 GPM circuits... - Page 18 Track tools: 03900A – Reversing rail saw 05100A & 05100B – Power weld shear 03500 – Self feed rail drill 04500D – 1/2” Hydraulic drill impact wrench 08200 – Tamper 02800A – 60 Ton bridge spreader 01200 – Spring anchor applicator 01100A – Spike puller (Single, 2 stage & trigger versions available) 00800A – 16” Rail saw 05000 – Hand pump weld shear 02500 – 10 GPM 1” Impact wrench 08300 – Spike driver 01600A – 5 GPM 1” Impact wrench 01100RM – Light-weight spike puller Other products: Hydraulic manifolds Hydraulic test gauges Hose reels Hydraulic hoses Accessories Drill bits Shear Blades Saw Blades Grinding Stones Sockets OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021...
-
Page 19: Seal Kit Information
11. Seal kit information Seal kit for motors without bearing manufactured after april 2003 Without bearing Fig 6. Fig 5. #02599 - Internal seal kit #02598 - 18mm shaft seal kit OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 19 av 24 @Pandrol 2021... -
Page 20: Assembly
12. Assembly 12.1. Parts diagram OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 @Pandrol 2021 20 av 24... -
Page 21: Parts List
12.2. Parts list OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 21 av 24 @Pandrol 2021... -
Page 22: Parts Diagram And List
12.3. Parts diagram and list OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 @Pandrol 2021 22 av 24... -
Page 23: Disclaimer
13. Disclaimer Pandrol exempts itself from liability in the event of usage that deviates from that recommended in this manual. 14. Contact Address Phone Internet and E-mail www.Pandrol.com 15. Recycling and Environment Sustainable environment is a great part of Pandrol. All components of the product can either be: • Recycled • Taken care of • Be re-used We recommend you to follow your local region regulations of environmental and recycling policies. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_IMPACT_WRENCH_P01 I 09th November 2021 23 av 24 @Pandrol 2021... - Page 24 Find out more at pandrol.com Pandrol ©Pandrol Partners in excellence...