Matweld 02500 User manual

632South3rdStreet
P.O.Box2816•Paducah,KY42002
270-444-0085
Fax:[phone]
Website:www.matweld.com
Email:[email protected]
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 09/09
FLOW
5 gpm (19 lpm)
or
10 gpm (38 lpm)
PRESSURE
2000 psi
(140 bar)
DIMENSIONS
A - 18” (457mm)
B - 8” (203mm)
C - 10” (254mm)
WEIGHT
36 lbs
(16.36 kg)
AB
C
The 1” Impact wrench is capable of
handling the toughest jobs. Crossing,
frog or track bolts are no problem for
thisruggedtool.Anti-vibration design
and optional handle provide an efficient,
safe and ergonomic work position for
the task at hand. Atorque adjustment
knob “dials in” torque from 0-3500 ft lb.
Designed for 5 or 10 gpm.
02500 10 GPM
1” IMPACT WRENCH

MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 09/09
2

MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 09/09
3
GENERAL SAFETY PRECAUTIONS:
TOOLOPERATORSAND MAINTENANCE PERSONNELMUSTALWAYS COMPLY WITHTHE SAFETY
PRECAUTIONSGIVENINTHIS MANUAL,ANDWITHALLSTICKERSANDTAGSATTACHEDTOTHE
TOOLAND HOSE.ALL SAFETYPRECAUTIONSARE GIVEN FOR YOUR SAFETY. READ TO UNDER-
STANDAND FOLLOWALLSAFETY, MAINTENANCEAND OPERATION INSTRUCTIONS BEFORE YOU
USEOR MAINTAINTHETOOL.REVIEW THE MANUALDAILYBEFORE USINGTHETOOL. INADDITION,
FOLLOWALL SAFETYGUIDELINES GIVEN TO YOU BYYOUR SUPERVISOR. DO NOT USE THE
TOOLIF YOU HAVEANY QUESTIONSABOUTTHE OPERATION, SAFETY OR MAINTENANCE OFTHIS
TOOL. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR
EQUIPMENTDAMAGE.
MATWELD HAS NO CONTROL OVER TOOL USE OR OPERATION ONCE IT LEAVES THE MATWELD
PLANT. MATWELD HAS NO CONTROLOVER OPERATOR OR MAINTAINER SELECTION. THE CUS-
TOMER MUSTASSUME RESPONSIBILITYFOR THE TOOL’S SUITABILITY FORAPARTICULAR FUNC-
TION, FORANYONE USING THETOOLOR MAINTAINING THETOOLREGARDING THEIR FITNESS TO
USE THE TOOL OR REPAIR THE TOOL, UNDERSTANDING OF THE OPERATIONAND SAFETYAND
MAINTENANCEMANUAL, INTELLIGENCE TO USE GOOD JUDGMENT IS NECESSARY TO WORK
SAFELYANDEFFICIENTLYWITHOUTENDANGERING THEMSELVES OR BYSTANDERS INTHE
WORK AREA.
• DO NOT OPERATE THE TOOLUNTILYOU HAVE BEEN THOROUGHLYAND PROPERLY TRAINED
OR UNDER THE SUPERVISION OFAN INSTRUCTOR.
• CHECK POWER SOURCE DAILY TO DETERMINE IF CORRECT FLOW AND PRESSURE ARE
AVAILABLE. NEVER EXCEED FLOWS OR PRESSURES FOR THE TOOL BEING USED. PER-
SONALINJURY OR DAMAGE TO THE TOOLCAN RESULT.
• OPERATORS MUST CLEAR THE WORK AREA OF NONESSENTIAL PERSONNEL. FLYING DEBRIS
CANCAUSESERIOUS INJURY.
• THE OPERATOR MUST BE FAMILIAR WITHALL PROHIBITED WORKAREAS SUCHAS UNSAFE
GRADES, POOR FOOTINGAREASAND OVERHEAD HAZARDS.
• MAINTAIN BALANCEAND PROPERFOOTINGATALLTIMES. NEVER OVERREACH TOTHE EX-
TENT THATA BROKEN PART OR SUDDEN MOVEMENT OF THE TOOLCAN CAUSE YOU TO
LOSE YOUR BALANCEAND FALL, OR CAUSE INJURY TO YOUR SELF OR SOMEONE ELSE.

MATWELD, INC. PHONE:[phone] FAX:[phone]
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• WHEN WORKING NEAR ELECTRICAL CONDUCTORS,ALWAYS ASSUME THATTHE CONDUC-
TORSARE ENERGIZEDAND THAT HOSESAND CLOTHING CAN CONDUCT HARMFULELECTRIC-
ITY. USE HOSES LABELEDAND CERTIFIEDAS NONCONDUCTIVE.
• DO NOT OPERATE THE TOOLAT EXCESSIVE FLUID TEMPERATURES OPERATOR DISCOM-
FORTAND POTENTIALBURNS CAN RESULTAT HIGH OILTEMPERATURES.
• NEVER WEAR LOOSE CLOTHING THAT CAN GET ENTANGLED IN THE WORKING PARTS OF THE
TOOLS OR BE CARELESS WITH HANDS, FEET OR OTHER BODY PARTS AROUND THE WORK-
ING PARTS OF THE TOOLS. HYDRAULIC TOOLS EXERT HIGH TORQUEAND FORCE AND CAN
CAUSE SERIOUS INJURYOR DEATH IF IMPROPERLY USED.
• TOAVOID PERSONALINJURYOR EQUIPMENTDAMAGE,ALLTOOLREPAIR, MAINTENANCE OR
SERVICE MUST ONLY BE PERFORMED BYAUTHORIZEDAND PROPERLY TRAINED PERSON-
NEL.
• ALWAYS WEAR SAFETY EQUIPMENTSUCHAS OILINJECTION RESISTANT WORK GLOVES,
SAFETY GLASSES, SAFETY BOOTS, EAR PROTECTIONAND OTHER SAFETYAPPAREL DIC-
TATED BY YOUR SUPERVISORAPPLICABLE FOR THE JOB YOU ARE DOINGAND THE TOOL
YOUARE USING.
• DO NOT CLEAN INSPECT OR REPAIR THE TOOL WHILE CONNECTED TO THE POWER
SOURCE.ACCIDENTALENGAGEMENT OFTHE TOOL CAN CAUSE SERIOUS PERSONALINJURY.
• OILINJECTION HAZARD EXISTS WITHTHISTOOL.OILINJECTION ISACONDITION WHERE
HYDRAULIC OILIS INJECTED UNDER THE SKIN FROM PRESSURE INTHE LINE.ALWAYS WEAR
GLOVESAND REPAIRANY LEAKS IMMEDIATELY. NEVER CARRYATOOLBYTHE HOSES.
• DONOTUSEDAMAGEDEQUIPMENT. IMMEDIATELYREPLACEANYDAMAGED HOSES, FITTINGS,
OR OTHER COMPONENTS SHOWING WIRE BRAID, NICKS, CUTS, DAMAGE ORABRASIONS.
FAILURE TO DO SO MAY RESULT IN EQUIPMENTDAMAGEAND / OR PERSONAL INJURY OR
DEATH.
• CLEANUPANYOILORFLUIDSPILLSIMMEDIATELY.

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5
HAVE SUPERVISORADDADDITIONALPRECAUTIONS RELATINGTO THE SPECIFIC
WORK AREAAND LOCAL SAFETY REGULATIONS BELOW:
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MATWELD, INC. PHONE:[phone] FAX:[phone]
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6
02500 IMPACT WRENCH
SAFETY PRECAUTIONS:
1. ALWAYS WEAR PROTECTIVE EQUIPMENT SUCHAS GLOVES, SAFETY GLASSES, EAR PRO-
TECTIONAND SAFETY SHOES.
2. DO NOT WEAR CLOTHING WHICH MAY BECOME ENTANGLED IN THE TOOL.
3. ALWAYS KEEP WORKAREA FREE OF TOOLS OR ANY OTHER OBJECTS WHICH MAY IMPAIR
SOUND FOOTING.
4. CAUTION -OILINJECTION HAZARD EXISTSWITHTHISTOOL.OILINJECTIONISACONDITION
WHERE THE HYDRAULIC OIL IS FORCED UNDER THE SKIN THROUGH PRESSURE IN THE LINE.
ALWAYS WEAR GLOVESANDREPAIR LEAKS IMMEDIATELY.
5. DO NOT CARRY THE TOOL BY THE PIGTAIL HOSES.
6. DO NOT OVER TORQUE TRACK AND FROG BOLTS.
7. DO NOT USE DEFECTIVE SOCKETS OR THOSE NOT MANUFACTURED FOR IMPACT
WRENCHES.
8. DO NOT ATTEMPT TO LOOSEN LOCKED UP WRENCH WITH ANY HAND TOOL. DISCONNECT
FROM POWER SOURCE AND THEN REPAIR WRENCH.
9. USEASOCKET RETAINING RING TO KEEP SOCKET ON THEANVIL.

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02500 IMPACT WRENCH
FLOW: 10 GPM (38 LPM)
PRESSURE: 2000 PSI (140 BAR)
BACK PRESSURE: MAX150PSI
OPERATION:
1. 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 WORKAREA IN SUCH A WAY TO RELIEVE STRESS ON THE HOSEAND QUICK DIS-
CONNECT FITTINGS WHILE WORKING. BEAWARE OF HOSE LOCATIONATALLTIMES.
2. CONNECT THE TOOL TO THE POWER SOURCE.
3. TURN THE POWER SOURCE “ON” TO SUPPLY 10 GPM TO TOOL.
4. TO TIGHTEN BOLTS, PUSH THE LEVER HANDLE (LOCATED ON BOTH SIDES OF IMPACT
WRENCH MANIFOLD) FORWARD. TO LOOSEN BOLT, PULL LEVER HANDLE BACK.
5. PULL THE TRIGGER UP TO START THE WRENCH.
6. NEVER OPERATE THE TOOL ONANY HIGHER FLOW THAN 10 GPM. THE TOOL IS DE-
SIGNED TOACCEPT ONLY THE RECOMMENDED 10 GPMAND WILLMALFUNCTIONAND
OVERHEAT THE OILIF USED OTHERWISE.
7. TURN THE POWER SOURCE “OFF” BEFORE DISCONNECTING WRENCH.

MATWELD, INC. PHONE:[phone] FAX:[phone]
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8
02500 IMPACT WRENCH
MAINTENANCE
1. CHECK TOOL DAILY FOR PROPER OPERATION, LEAKS, OR DAMAGE.
2. INSPECT HOSES DAILY. REPLACE CUT, BURNED, OR OTHERWISE DAMAGED HOSES.
3. KEEP QUICK DISCONNECT COUPLERS CLEAN AND LUBRICATED.
4. USEHYDRAULIC FLUIDSTHATCOMPLYWITH HTMASPECIFICATION 5.7,THE HYDRAULICFLUID
SHOULD HAVEAVISCOSITY BETWEEN 100AND 400 SSU (20-82 CENTISTOKES)ATTHE MAXI-
MUMAND MINIMUM EXPECTEDOPERATINGTEMPERATURES.PETROLEUMBASED HYDRAULIC
FLUIDS WITHANTI-WEAR PROPERTIESANDA VISCOSITY INDEX OF 140 WORK FORAWIDE
RANGEOFOPERATING CONDITIONS.
THE FOLLOWING OILS MEET HTMA SPECIFICATION 5.7:
AMOCORYKONMV CITGOA/WALLTEMP
SUNVIS706 MOBILD.T.E. 13
CHEVRONEP-MV TEXACO “RANDO” HDAZ
OTHER FLUIDS THAT MEET OR EXCEED THIS SPECIFICATION CAN BE USED.
*SEE COLD WEATHER OPERATION HYDRAULIC OIL NOTE.
5. HAVE TOOL INSPECTED,AT LEASTANNUALLY, BY MATWELD ORAMATWELD QUALIFIED SER-
VICE REPRESENTATIVE TO DETERMINE IF TOOLIS IN NEED OF SAFETY CHANGES OR WORN
PARTREPLACEMENT.
6. CONTACT MATWELD ONAPERIODIC BASIS,AT LEASTANNUALLY, FOR SERVICE BULLETINS,
SAFETY NOTICES, OR OTHER IMPORTANT INFORMATION PERTAINING TO THIS TOOL.
7. THE IMPACTASSEMBLY MUSTBE REPACKED WITH GREASE ONAREGULAR BASIS.
A GOOD RULE OF THUMB IS:
CASUALUSAGE REPACK EVERY 60 DAYS
HEAVY USAGE REPACK EVERY30 DAYS
8. THE HAMMERING MECHANISM SHOULD BE ROUTINELY INSPECTED FOR WEARAND PROPER
LUBRICATION.THISASSEMBLY IS EASILYACCESSED BY REMOVINGTHE (4) SOCKET HEAD
CAP SCREWS THATATTACH THE HAMMER HOUSING TO THE TOOLBODY.
PACKGREASEINTOTHE HAMMER FRAMEASSURINGTHATALLPARTSARE LIBERALLY
COATED. USEAHIGHTEMPERATURE, MOLYBDENUM BASE,AND LITHIUM COMPOUND GREASE.
REINSTALL USING A REMOVABLE THREAD LOCKER ON THE (4) SCREWSAND TORQUE TO 25
FT LBS.
COLD WEATHER OPERATION:
HYDRAULIC SYSTEM PERFORMANCE ISAFFECTED WHEN THE TEMPERATURE DROP BELOW 50
F. THEREFORE MEASURES SHOULD BE TAKEN TO PRE-WARM TOOLS AND FLUIDS BEFORE
OPERATING.

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02500 IMPACT WRENCH
HAMMER INSTALLATION:
ALTHOUGHTHE HAMMERSARE IDENTICALPARTS,THEYMUSTBE INSTALLED IN OPPOSING POSI-
TIONS FOR PROPER OPERATION.
THE RELIEF CUT SIDES WILLFACE EACH OTHER WHEN PROPERLY FITTED INSIDETHE HAMMER
FRAME, BUTTHE HAMMER PIN NOTCH WILL BEASSEMBLED 180oAPART WITH (1)ATTHE 12:00
POSITIONAND THE OTHERATTHE 6:00 POSITION.
REPAIR TROUBLESHOOTING:
1. IMPACT WRENCH OVERHEATS…
•OPERATE WRENCH ON 10 GPM
2. IMPACT WRENCH SPINS BUT WON’TIMPACT…
•INSPECT FRONT END FOR BROKEN HAMMER PINS OR OTHER BROKEN PARTS.
3. IMPACT WRENCH ONLYWORKS IN ONE DIRECTION…
•CHECK FRONT END FOR BROKEN PARTS
•CHECK REVERSING VALVE FOR TRASH ON ONE OR MORE VALVE PARTS
4. IMPACT WRENCH WORKS SLOW AND HAS LOW POWER…
•CHECK THAT TORQUEADJUSTMENT VALVE IS SCREWED IN AND NOTADJUSTEDALLTHE
WAYOUT.
•CHECK THAT FLOW IS 10 GPM AND SYSTEM PRESSURE IS SETAT 2000 PSI
5. 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).
6. HYDRAULICOIL RUNNING OUT OF FRONT END…
•REPLACE FRONT SHAFTSEALUSING PART NO. 01612 SHAFTSEALKIT.
HAMMERPINNOTCH@6:00
RELIEF
CUT
HAMMERPINNOTCH@12:00
PROPERHAMMERORIENTATION
RELIEF
CUT
ASSEMBLYFACETOFACE

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02500 IMPACT WRENCH
TORQUE / TENSION CALIBRATION PROCEDURE:
(USING MATWELD PART #01650 – TORQUE GAUGE)
1. INSTALL TEST GAUGE IN PRESSURE LINEAT TOOLAND CONNECT TO POWER SOURCE SUP-
PLY HOSES – 5 GPM.
2. REFER TO BOLT TIGHTENING CHART SPECIFICATION REQUIRED FOR THE GRADEAND SIZE
BOLT BEING USED. (ALWAYS FOLLOW MANUFACTURER’S RECOMMENDATIONS.)
3. LOOSEN LOCK COLLAR ON TORQUE ADJUSTMENT KNOB.
4. IFTORQUEADJUSTMENT KNOB ISTURNEDALLTHE WAY IN, BACKADJUSTMENT KNOB OUT
ONE AND A HALF TURNS COUNTERCLOCKWISE TO DECREASE INITIAL TORQUE.
5. BEGIN TIGHTENING BOLT, KEEPINGA CLOSE WATCH ON THE TORQUE GAUGE. TURN THE
ADJUSTMENT KNOB IN CLOCKWISE INCREASINGTHE PRESSURE UNTILTHE DESIRED SET-
TINGIS REACHED.
6. LOOSENAND RETIGHTEN THE TEST BOLTA COUPLE OF TIMES TO VERIFY THE SETTING.
7. RETIGHTEN THE LOCK COLLAR.
8. TORQUE GAUGE MAY BE REMOVED ONCE DESIRED TORQUE IS SET.