Fairmont H8500A User manual

SERVICE MANUAL
H8500A
Hydraulic Impact Wrench,
Drill and Screwdriver
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99912902 REV 5 © 2008 Greenlee Textron Inc. 1/08
Serial Code FJP

H8500A Hydraulic Impact Wrench, Drill and Screwdriver
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Purpose
This manual is intended to familiarize personnel with the
safe service procedures for the following Fairmont tool:
H8500A (42299) Serial Code FJP
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
Other Publications
Operation Manual: Publication 99930269
Specications and Parts: Publication 99930986
SAE Standard J1273 (Hose and Hose Assemblies):
Publication 99930323
All specications 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.
Loctite and 242 are registered trademarks of Loctite Corporation.
KEEP THIS MANUAL
Table of Contents
Safety ............................................................................ 2
Purpose ......................................................................... 2
Other Publications......................................................... 2
Important Safety Information .....................................3–4
Disassembly .................................................................. 5
Inspection...................................................................... 6
Assembly....................................................................6–7
Illustration and Parts List..........................................8–10
Safety
Safety is essential in the use and maintenance of
Fairmont tools and equipment. This service 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.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
H8500A Hydraulic Impact Wrench, Drill and Screwdriver
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, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
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.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool. Refer also to the
following manuals, which are listed
under Other Publications:
Operation Manual
Specications and Parts Manual
Failure to observe this warning could
result in severe injury or death.
•
•
Skin injection hazard:
Oil under pressure easily punctures
skin causing serious injury, gan-
grene or death. If you are injured by
escaping oil, seek medical attention
immediately.
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.
•
•
•
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
Tool, accessory, and other compo-
nents may be hot during and after
operation. Allow to cool before han-
dling, or handle with heat-resistant
gloves.
Failure to observe this warning could
result in severe injury.

H8500A Hydraulic Impact Wrench, Drill and Screwdriver
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
Do not exceed the maximum hydraulic ow, pressure
relief or back pressure listed in the Specications and
Parts manual.
Failure to observe this warning could result in severe
injury or death.
Do not disconnect tool, hoses or ttings while the
power source is running or if the hydraulic uid is hot.
Hot hydraulic uid could cause serious burns.
Do not reverse hydraulic ow. Operation with
hydraulic ow reversed can cause tool malfunction.
Connect the pressure (supply) hose and tank (return)
hose to the proper ports.
Failure to observe this warning could result in severe
injury or death.
Hydraulic oil can cause skin irritation.
Handle the tool and hoses with care to prevent skin
contact with hydraulic oil.
In case of accidental skin contact with hydraulic oil,
wash the affected area immediately to remove the
oil.
Failure to observe these precautions may result in
injury.
•
•
Notes: Keep all decals clean and legible. Replace when
necessary.
When disposing of any components (hydraulic hoses,
hydraulic fluid, worn parts, etc.), do so in accordance
with federal, state and local laws or ordinances.
IMPORTANT SAFETY INFORMATION

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
H8500A Hydraulic Impact Wrench, Drill and Screwdriver
Disassembly
Complete disassembly of the tool is not recommended.
If a complete overhaul is necessary, return the tool to
your nearest Fairmont 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 at, clean surface. Take care
not to lose or damage any parts that may fall free during
disassembly.
Quick-Change Chuck
1. Remove the adapter drive shank (73) from the chuck.
2. Remove the lock ring (72), ring (71), and spring (70).
Note: To prevent the loss of any steel balls, perform
the next step over a clean, empty container.
3. Slide the sleeve (69) off and remove the three steel
balls (68).
Case Components
1. Scribe a line across the case (63) and handle (1) to
align the parts correctly during assembly.
2. Remove four cap screws (67) and remove the case
(63) from the handle. Remove the gasket (66).
3. Remove the anvil (60), thrust bearing (61), and thrust
races (62) from the case. If necessary, press the
roller bearing (64) and seal (65) from the case.
4. Remove the hammer assembly (51–59) from the
handle assembly.
5. If the hammer assembly components require
disassembly, compress the hammer (55) and carrier
pinion (51) together in a vise or a press. Remove the
two steel balls (59). Release the assembly from the
vise or press.
6. Remove the hammer from the carrier pinion.
Remove the thrust races (57), thrust bearing (56),
and spring (58). Drive out the dowel pins (54) to
remove the gears (52).
7. Remove the ring gear (4) and the dowel pin (5) from
the handle assembly.
Motor
1. Scribe a line across the motor cap (47) and handle
(1) to align the parts correctly during assembly.
2. Remove eight cap screws (49) and the cap from the
handle. Remove the gasket (46) and, if necessary,
the dowel pins (45).
3. Pull the idler shaft (43) with gear (40) from the
handle. If necessary, remove the drive pin (44).
4. Remove the retaining ring (42), gear (40), and
Woodruff key (41) from the drive shaft (39). Pull the
drive shaft from the handle.
Note: To prevent the loss of any steel balls, perform
the next step over a clean, empty container.
5. Remove the inner race (38) and the 18 steel balls
(37) from the handle.
6. Use an O-ring tool to remove the O-ring (2) without
removing the needle bearing (3).
Trigger, Control Spool, and Super Spool™ Sleeve
1. Remove the retaining ring (25) and cap (24) from the
Super Spool sleeve (19). Remove the spring (29).
2. Remove the connecting link (33) from the trigger (32)
and control spool (26). Remove one nut (35) and one
machine screw (34) from the trigger (32). Remove
the trigger.
3. Remove the retaining ring (31) and washer (30).
Remove the control spool (26) from the Super Spool
sleeve (19). Remove the O-ring (27) from the control
spool (26). Remove the ball (28) from the control
spool.
4. Remove the external retaining ring (22) from the
Super Spool sleeve. Remove the sleeve from the
handle.
5. Remove the O-rings (20, 21, 23) from the Super Spool
sleeve. Remove the O-ring (18) from the handle.
Directional Spool
1. Remove the cap screws (17) and buttons (16) from
the directional spool (14).
2. Slide the directional spool partially out of the handle
to expose either O-ring (15). Remove the exposed
O-ring. Remove the spool by pushing it back
through the handle. Remove the other O-ring.
Note: Attempting to force the directional spool
through the bore against the O-ring will damage the
O-ring and could allow particles of O-ring to get into
the motor.
Flow Control Cartridge
1. Remove the retaining ring (9). Remove the ow
control cartridge (6) from the handle.
2. Remove the O-rings (7, 8) from the cartridge.
Do not attempt to repair the ow control cartridge.
It contains no replaceable parts.
Failure to observe this warning can result in severe
injury or death.
Adjustable Torque Output Screw
or Non-Adjustable Torque Output Plug
1. Remove the roll pin (13) from the handle. Twist the
screw (10) or plug (74) counterclockwise to remove
it from the handle.
2. Remove the O-ring (11) and backup ring (12).

H8500A Hydraulic Impact Wrench, Drill and Screwdriver
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Inspection
Clean all parts with an appropriate cleaning solution
and dry them thoroughly. Inspect each component as
described in this section. Replace any component that
shows wear or damage.
1. Motor Cap (47) with Bearings (48): Insert shaft
into bearings. Spin shaft. If the shaft does not spin
smoothly, replace the entire assembly with bearings
already pressed in.
2. Handle (1) with Bearings (3): Insert shaft into bear-
ings. Spin shaft. If the shaft does not spin smoothly,
replace the entire assembly with bearings already
pressed in.
3. Races (36, 38) and Steel Balls (37): Insert all 18
balls (37) into the outer race (36). Install the inner
race (38) over the steel balls. Slide the drive shaft
(39) into the races and spin the shaft. If the shaft
does not spin smoothly, replace the inner race (38)
and steel balls (37). If the outer race (36) is worn or
damaged, replace the entire handle assembly with
the outer race already pressed in.
4. Gear with Internal Bearings (52): Insert a dowel
pin (54) into the bearing. While holding the dowel
between a thumb and forenger, roll the gear in the
palm of your other hand. Repeat for the other gear.
If either gear does not spin smoothly, replace both
gears with bearings already pressed in.
5. Inspect all other disassembled components for
cracks, grooves or nicks.
Assembly
Refer to the Illustration 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
uid 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 uid or O-ring lubricant.
Some steps of the assembly procedure require a
removable type of thread sealing and locking compound,
such as Loctite®242®or equivalent. Follow the manu-
facturer’s instructions for curing.
Motor
1. Use an O-ring tool to install the O-ring (2) into the
handle.
2. Lubricate the outer race (36) liberally with grease.
Install the 18 steel balls (37) into the outer race (36).
Install the inner race (38) over the steel balls.
3. Slide the drive shaft with gear (39) into the races
and through the handle.
4. Install the Woodruff key (41) and one gear (40) onto
the drive shaft (39), guiding the keyway in the gear
over the Woodruff key. Fasten the gear to the drive
shaft with the retaining ring (42).
5. Install the drive pin (44) into the idler shaft (43).
Slide the remaining gear (40) onto the idler shaft,
guiding the keyway in the gear over the drive pin.
Install this assembly into the handle (1), meshing
the two gears (40).
6. Install the dowel pins (45) into the handle. Install the
gasket (46).
7. Assemble the motor cap (47) to the handle (1),
aligning the scribe marks.
8. Apply a removable type of thread sealing and
locking compound, such as Loctite 242 or equivalent,
to the eight cap screws (49). Follow the manufactur-
er’s instructions for curing.
9. Secure the motor cap (47) with the eight cap screws
(49). Using the sequence shown here, torque to
9 newton-meters (80 in-lb).
Torque Sequence
1
3
4
2
5 7
8 6

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
H8500A Hydraulic Impact Wrench, Drill and Screwdriver
Assembly (cont’d)
Directional Spool
1. Assemble one O-ring (15) to the directional
spool (14).
2. Slide the directional spool into the handle just far
enough to expose the O-ring groove. Install the
second O-ring (15).
3. Apply a thread sealing and locking compound, such
as Loctite 242 or equivalent, to the threads of the
cap screws (17). Assemble the buttons (16) to the
spool and secure with the cap screws. Torque to
3.2 to 3.9 newton-meters (30 to 35 in-lb).
Trigger, Control Spool, and Super Spool Sleeve
1. Install the O-ring (18) into the handle.
2. Assemble the O-rings (20, 21, 23) to the Super Spool
sleeve (19).
3. Slide the sleeve assembly (19) into the handle from
the motor cap side, and secure with the retaining
ring (22).
4. Install the steel ball (28) and O-ring (27) onto the
control spool (26). Slide the control spool (26) into
the sleeve (19). Install the washer (30) and secure it
with the retaining ring (31).
5. Slide the spring (29) into the control spool (26).
Install the cap (24) and secure it with the retaining
ring (25). Fasten the trigger (32) to the handle (1)
with a machine screw (34) and nut (35). Fasten the
link (33) to the trigger (32) and spool (26).
Case Components
1. Install the ring gear (4) into the handle (1), aligning
the notches. Secure the ring gear with the dowel
pin (5).
2. Install the gears (52) into the carrier pinion (51) and
secure with the dowel pins (54). Install the spring
(58), thrust races (57), thrust bearing (56), and
hammer (55).
3. Press the hammer and carrier pinion assembly
together in a vise or press. Insert the two steel balls
(59) into the grooves. Release the hammer and
carrier pinion assembly from the vise or press.
4. Install the hammer assembly into the handle,
meshing the gears (52) in the hammer assembly
with the ring gear (4) in the handle.
Note: Apply an anti-seize and extreme pressure
lubricating compound to the mating surfaces of the
carrier pinion (51) and anvil (60).
5. Install the seal (65) and roller bearing (64) into the
case (63). Insert the thrust races (62), thrust bearing
(61), and anvil (60) into the case.
6. Place the gasket (66) onto the handle (1). Set the
case assembly onto the handle, aligning the scribe
marks. Fasten the case to the handle with the cap
screws (67). Tighten securely.
Quick-Change Chuck
1. Insert three steel balls (68) into the holes in the
anvil (60).
2. Slide the sleeve (69) onto the anvil.
3. Insert the spring (70) and ring (71) into the sleeve.
Secure the sleeve to the anvil (60) with the lock
ring (72).
4. Insert the drive shank (73) into the chuck.
Flow Control Cartridge
1. Assemble the O-rings (7, 8) to the cartridge.
2. Install the ow control cartridge (6) and secure with
the retaining ring (9).
Adjustable Torque Output Screw
or Non-Adjustable Torque Output Plug
1. Install the backup ring (12) and O-ring (11).
2. Twist the screw (10) or plug (74) clockwise until the
threads engage.
3. Secure with the roll pin (13).

H8500A Hydraulic Impact Wrench, Drill and Screwdriver
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Illustration
3
35
65
63
69
67
59
32
34
11
15
12
14
10
74
12
9
31
30
27
26
8
7
6
17
16 15
11
13
28
19
23
29
20
21
24
49
43
25
33
70
71
72
58
55
57
56
57
73
41
39
54
18
17
16
22
51
52, 53
38
37
36
1
2
50
46
44
40
42
45
47, 48
3
4
5
64
62
61
62
60
66
68
75

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
H8500A Hydraulic Impact Wrench, Drill and Screwdriver
Parts List
UPC No.
Key 78-3310- Part No. Description Qty
1 52001065 Handle (includes item 4).................................................... 1
2* 41503 50415033 O-ring, .500 x .687 x .093"–80 .......................................... 1
3 41591 50415911 Needle bearing, .439 x .625 x .500".................................. 2
4 40152 50401524 Internal gear ...................................................................... 1
5 41809 50418091 Pin, dowel, .125 x .500" .................................................... 1
6 43302 50433024 Flow control cartridge (includes items 7 and 8) ................ 1
7* 41491 50414911 O-ring, .500 x .625 x .062"–70 .......................................... 1
8* 41627 50416271 O-ring, .437 x .562 x .062"–70 .......................................... 1
9 41600 50416003 Retaining ring, .687".......................................................... 1
10 41094 50410942 Screw, adjustable torque output ....................................... 1
11*+ 42729 50427290 O-ring, .250 x .375 x .062" ................................................ 1
12*+ 41843 50418431 Back-up ring, single turn ................................................... 1
13*+ 42053 50420533 Pin, roll, .078 x .875" ......................................................... 1
14 40215 50402154 Spool, directional............................................................... 1
15* 41489 50414890 O-ring, .437 x .562 x .062"–68 .......................................... 2
16 40228 50402283 Button................................................................................ 2
17 41715 50417151 Screw, cap, #10–24 x .500" at head socket.................... 2
18* 41559 50415590 O-ring, .875 x 1.00 x .062"–70 .......................................... 1
19 41097 50410971 Sleeve, Super Spool.......................................................... 1
20* 42089 50420891 O-ring, .787 x .889 x .051"–70 .......................................... 1
21* 41534 50415342 O-ring, .750 x .875 x .062"–90 .......................................... 1
22 41298 50412981 Retaining ring, .875", external ........................................... 1
23* 41371 50413712 O-ring, .437 x .625 .094"–90 ............................................. 1
24 41095 50410952 Cap.................................................................................... 1
25 41712 50417122 Retaining ring, .750", external ........................................... 1
26 48681 50486810 Spool, control (includes Item 28)....................................... 1
27* 41585 50415850 O-ring, .312 x .437 .062"–70 ............................................. 1
28 50412681 Ball, .156", aluminum ........................................................ 1
29 42865 50428651 Spring, compression ......................................................... 1
30 41096 50410962 Washer, .355 x .615 x .030"............................................... 1
31 41297 50412971 Retaining ring, .625", internal ............................................ 1
32 40406 50404063 Trigger................................................................................ 1
33 41636 50416361 Connecting link.................................................................. 1
34 41583 50415831 Screw, machine, #10–24 x 1.125", round head................. 1
35 41676 50416760 Nut, hex, #10–24, elastic stop........................................... 1
36 40392 50403922 Race, outer bearing........................................................... 1
37 41723 50417232 Ball, .125", steel .............................................................. 18
38 40393 50403932 Race, inner bearing ........................................................... 1
39 50440250 Drive shaft with gear.......................................................... 1
40 41630 50416302 Gear, 11-tooth ................................................................... 2
41 41592 50415921 Key, Woodruff #213, .125" x .375" .................................... 1
42 41621 50416212 Retaining ring, .437", external ........................................... 1
43 40168 50401682 Shaft, idler ......................................................................... 1
44 41593 50415930 Drive pin with square head................................................ 1
45 41624 50416242 Dowel pin, .250 x .625" .................................................... 2
46* 41595 50415950 Gasket ............................................................................... 1
47 40412 50404124 Motor cap (includes item 48)............................................. 1
48 41591 50415911 Needle bearing, .439 x .625 x .500".................................. 2

H8500A Hydraulic Impact Wrench, Drill and Screwdriver
Parts List (cont’d)
49 41616 50416162 Screw, cap, 1/4–20 x 1.00", socket head.......................... 8
50 43817 50438174 Hook, lift ............................................................................ 1
51 40408 50404083 Pinion, carrier .................................................................... 1
52 40418 50404182 Gear and bearing assembly (includes Item 53) ................. 2
53 43483 50434837 Bearing, roller .................................................................... 2
54 41624 50416242 Dowel pin, .250 x .625" ..................................................... 2
55 41731 50417312 Hammer............................................................................. 1
56 41506 50415062 Bearing, thrust ................................................................... 1
57 41732 50417321 Race, bearing .................................................................... 2
58 40043 50400434 Spring, compression ......................................................... 1
59 41295 50412951 Ball, .250", stainless steel.................................................. 2
60 41241 50412413 Anvil................................................................................... 1
61 41734 50417341 Bearing, thrust ................................................................... 1
62 41794 50417941 Race, thrust ....................................................................... 2
63 40586 50405861 Case assembly (includes Items 64 and 65)....................... 1
64 41736 50417361 Bearing, roller .................................................................... 1
65* 41737 50417371 Seal.................................................................................... 1
66* 40134 50401344 Gasket ............................................................................... 1
67 41616 50416162 Screw, cap, 1/4–20 x 1.00", socket head.......................... 4
68 41284 50412842 Ball, .281", steel ................................................................ 3
69 40160 50401604 Sleeve................................................................................ 1
70 40045 50400454 Spring, compression ......................................................... 1
71 40161 50401613 Ring ................................................................................... 1
72 41514 50415142 Lock ring............................................................................ 1
73 50493140 Hex adapter assembly ...................................................... 1
74+ 52000733 Plug, non-adjustable torque (optional)
See plug kit........................................................................ 1
75 43093 50430939 Washer, .451 x .640 x .080"............................................... 1
Repair Kits
* 41195 50411951 Packing kit (includes items marked with an asterisk)........ 1
+ 41194 50411942 Plug kit, non-adjustable torque
(includes items marked with plus sign) ............................. 1
40407 50404073 Hammer assembly (includes 51–59).................................. 1
UPC No.
Key 78-3310- Part No. Description Qty
USA 800-435-0786 Fax: [phone]
815-397-7070 Fax: [phone]
Canada 800-435-0786 Fax: [phone]
International [phone] Fax: [phone]
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 Printed in USA