Mueller H-603 Troubleshooting guide

OPERATION
AND MAINTENANCE
INSTRUCTIONS
MUELLER®
H-603 and H-604
POWER OPERATORS
CAUTION - Should the equipment that the power
operator is connected to suddenly stop turning or
stall, the torque transmitted through the handle of the
power operator may be sufficient to cause the person
holding it to be thrown off balance. Before starting
the power operator, the person operating should
assume a stable, well braced and balanced position
on solid ground so this torque can be controlled, DO
NOT USE WIRE, TAPE OR ANY OTHER MEANS
TO HOLD THE POWER OPERATOR SWITCH
OR THROTTLE LEVER IN THE “ON” OR “RUN”
POSITION. DOING SO MAY PREVENT THE
POWER OPERATOR FROM SHUTTING OFF IN
THE EVENT THE PERSON OPERATING LETS
GO OF THE HANDLE.
WARNING - Do not use the power operator in an
explosive atmosphere or around flammable materials.
Do not remove or deface the warning tag, form 8933,
attached to the unit.
CAUTION - Do not suspend the power operator by
the power cord, or use the cord to lift or lower the
unit. Doing so may cause the cord to separate or
compromise the electrical connection inside the unit,
making the unit inoperable or posing an electrical
shock hazard. Use of the power operator with a
damaged electrical cord or compromised electrical
connection could result in serious injury or death.
H-603 Electric Operator
CAUTION
CAUTION WARNING
Electrical connection: Only operate the H-603
unit from a power source rated at 120VAC or DC,10
AMPS with a minimum capacity of 1500 watts to
accommodate peak load requirements.
When connected to an AC source– To help prevent
electrical shock or possible electrocution, always use
the supplied Ground Fault Current Interrupter (GFCI)
in series with this unit and a 3-prong grounding type
receptacle, which is installed in accordance with the
National Electrical Code. The GFCI is for use ONLY
with 1201, 60Hz Alternating Current (AC). DO NOT
use the GFCI on Direct Current (DC). See instructions
supplied with the GFCI for additional information.
Extension cords must have a continuous rated capacity of
10 AMPS at 120 volts and include a properly connected
grounding circuit. DO NOT connect the ground wire
(normally green) to the neutral wire (normally white).
DO NOT remove or in any way disable the grounding
lug on the plug of the unit of GFCI,
Replacement GFCI units are available by contacting
Mueller Customer Service at 800-423-1323.
Before each use of the unit, check to be sure the
electric motor is securely attached to the handle and
that all mounting screws are in place and tight. Also,
inspect the gear case for leakage. The gear

OPERATION
AND MAINTENANCE
INSTRUCTIONS
MUELLER®
H-603 and H-604
POWER OPERATORS
case (3/4 pint capacity) is filled with the proper lubricant
at the factory and requires no periodic service. However,
if leakage has occurred or the gear case requires repair,
contact Mueller Co. Customer Service at 1-800-423-1323
for return instructions.
After approximately every forty tapping operations,
check the brushes in the electric motor by removing
the plastic screws, located one on each side of the
electric motor. When removing the brushes, observe
the relationship of the curvature at the end of each
brush and reinstall the brushes with the curvature in the
same position. Replacement brushes are available from
Mueller Co. Customer Service at 1-800-423-1323.
NOTE: If the electric motor does not turn on when the
switch trigger is pulled, small debris particles may be
in the brushes/ armature area of the motor. To correct
this situation, unplug the unit from the power source,
remove and wipe the electric brushes clean. Then spray
the brush contact area with electric contact cleaner, re-
install the brushes and continue operations.
Install an air line lubricator as close to the inlet of
the unit as practical. The proper use of an air line
lubricator is required to maintain operator warranty.
Adjust the lubricator to produce a slight oil mist in the
exhaust air. Use a good quality oil intended for use with
an in-line lubricator.
Maintain 55 cubic feet of free air at 90 psig, measured
at the unit. Use of a pressure gauge mounted as near
the unit as possible is
recommended. Blow moisture and debris from the
air hose before connecting it to the H-604 operator.
Before each use of the unit, inspect the gear case
for leakage. The gear case (3/4 pint capacity) is filled
with the proper lubricant at the factory and requires no
periodic service. However, if leakage has occurred or the
gear case requires repair, contact Mueller Co. Customer
Service at 1-800-423-1323 for return instructions.
After approximately every forty hours of operation,
lubricate the air motor using a quality lube grease by
applying two or three pumps of the grease gun to each
of the grease fittings.
In the event of noticeable power loss (see PC. TPA1512),
remove the Throttle Handle Assembly (Item 1) by
unscrewing it counter-clockwise from Throttle Connector
(Item 13). Remove the Strainer Retaining Spring (Item
15) and Air Strainer (Item 14), and thoroughly clean
both parts. If necessary, clean and lubricate the Throttle
Valve Assembly (Items 3 thru 12). Carefully reassemble
the Throttle Valve, Strainer and Strainer Spring to the
Throttle Handle Assembly. Reinstall the Throttle Handle
Assembly to the Throttle Connector,
DO NOT operate the air motor without the Strainer and
Strainer Spring in place.
H-604 Air Power Operator
MAIN OFFICE - Chattanooga, TN [phone]
CANADA - Mueller Canada Inc., Milton Ontario [phone]
11758-rev5/14-1M-1 ©1995 Mueller Co. Printed in U.S.A.