PANDROL 02500 User manual

Partners in excellence
ENG_OMM_IMPACT_WRENCH_P01
09th November 2021
OPERATION AND MAINTENANCE
MANUAL
Impact
Wrench
MODEL 02500

1. Preface
2. Revision
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Thank you for choosing Impact Wrench!
You are now the owner of a quality product from Pandrol.
This manual aims to help you get to know your new Impact Wrench, to use it in the best way and to maintain it
properly for a long lifetime. It also presents important safety regulations and warnings.
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 specications, equipment, instructions and maintenance guidelines without
prior notice.
The manual contains instructions about the following topics:
1. Installation
2. Operation
3. Safety features and warnings
4. Maintenance and troubleshooting
(1) refers to a component in a gure/illustration.
IMPORTANT
This manual contains ordered actions, e.g.
1. Do this
2. ...and then this...
3. ...and nally this
These actions must be done in the numerical order presented.
Revision Date Comments
P01 2021-11-09 New Manual

Table of Contents
1. Preface 2
2. Revision 2
3. Safety Information 5
3.1. General 5
3.2. Safety actions 5
3.3. Personal/Safety equipment 6
3.4. Safety precautions 6
3.5. Qualiedpersonnel  7
4. Summary 8
5. Operation 9
5.1. Hammer installation 10
5.2 Coldweatheroperation  10
6. Troubleshootingguide  11
6.1. Repair troubleshooting 11
6.2. Torque/tensioncalibrationprocedure   12
6.3. Torque / tebsion calibration 13
7. Reviewofhydraulicprinciples  14
7.1. Hydraulicformulas  14
7.2. Backpressure  14
8. Maintenance 15
8.1. General 15
8.2. Warninglabelsandinformationsymbols 15
9. Limitedwarranty  16
9.1. Exclusionstolimitedwarranty  16
9.2. Limitation of liability 16
10. Customer information 18
11. Sealkitinformation  19
12. Assembly 20
12.1. Partsdiagram  20
12.2. Parts list 21
12.3. Partsdiagramandlist  22
13. Disclaimer 23
14. Contact 23
15. RecyclingandEnvironment  23
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3. Safety Information
3.1. General
• Tooloperatorsandmaintenancepersonnelmustalwayscomplywiththesafetyprecautionsgiveninthis
manual,andwithallstickersandtagsattachedtothetoolandhoses.
• 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e󰀩cientlywithoutendangering
themselvesorbystanders.
• Understandingoftheoperationandmaintenancemanualisessentialforanyoneusingormaintainingthetool.
• Warningsandsafetyprecautionsdescribedinthisdocumentshallonlybeconsideredasaminimum.National
conditions,standardsandregulationsoverrideconditions,standardsandregulationsdescribedinthis
document.
• Workwiththemachineisonlytobecarriedoutbyqualiedpersonnel,well-informedandeducatedingeneral
railwayworkmanshipandspecicallyintheconditions,standardsandregulationsonspecicrailtrack.
• Themachinemayonlybeusedforitsspeciedpurpose.
• Anyadjustmentsorserviceonthemachineisonlyallowedtobedonebyqualiedpersonnelthathaveread
andunderstoodthismanualandhavehadtrainingandinformationfromPandrol.
3.2. Safety actions
• Readandunderstandallsafetyregulationsandwarningsbeforeinstallation,operatingorperforming
maintenance on this machine.
• Donotoperatethetooluntilyouhavebeenthoroughlyandproperlytrainedorunderthesupervisionofan
instructor.
• Checkpowersourcedailytodetermineifcorrectowandpressureareavailable.Neverexceedowsor
pressuresforthetoolbeingused.Personalinjuryordamagetothetoolcanresult.
• Operatorsmustcleartheworkareaofnon-essentialpersonnel.Flyingdebriscancauseseriousinjury.
• Theoperatormustbefamiliarwithallprohibitedworkareassuchasunsafegrades,poorfootingareasand
overheadhazards.
• Usestandardsandregulations,accidentpreventionregulationsandregulationsconcerningspecialambient
conditions(e.g.areaspotentiallyendangeredbyexplosivematerials,heavypollutionorcorrosiveinuences).
• Maintainbalanceandproperfootingatalltimes.Neveroverreachtotheextentthatabrokenpartorsudden
movementofthetoolcancauseyoutoloseyourbalanceandfall,orcauseinjurytoyourselforsomeoneelse.
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• Donotoperatethetoolatexcessiveuidtemperaturesoperatordiscomfortandpotentialburnscanresultat
high oil temperatures.
• Donotcleaninspectorrepairthetoolwhileconnectedtothepowersource.Accidentalengagementofthetool
can cause serious personal injury.
• Oilinjectionhazardexistswiththistool.Oilinjectionisaconditionwherehydraulicoilisinjectedunderthe
skinfrompressureintheline.Alwayswearglovesandrepairanyleaksimmediately.Nevercarryatoolbythe
hoses.
• Donotusedamagedequipment.Immediatelyreplaceanydamagedhoses,ttings,orothercomponents
showingwirebraid,nicks,cuts,damageorabrasions.Failuretodosomayresultinequipmentdamageand/or
personalinjuryordeath.
• Cleanupanyoiloruidspillsimmediately.
3.3. Personal/Safety equipment
• 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workingpartsofthetools.Hydraulictoolsexerthightorqueandforceand
cancauseseriousinjuryordeathifimproperlyused.
• Whenworkingnearelectricalconductors,alwaysassumethattheconductorsareenergizedandthathosesand
clothingcanconductharmfulelectricity.Usehoseslabeledandcertiedasnonconductive.
• Alwayswearsafetyequipmentsuchasoilinjectionresistantworkgloves,safetyglasses,safetyboots,ear
protectionandothersafetyappareldictatedbyyoursupervisorapplicableforthejobyouaredoingandthetool
you are using.
• Theuseofancompressedair,whichmustbelessthan8BAR(116PSI),toblowpartscleanortoblowthem
dryafterbeingcleanedwithasolventwillcauseparticlesofdirtand/ordropletsofthecleaningsolventtobe
airborne.Theseconditionsmaycauseskinand/oreyeirritation.Whenusinganairjetdonotdirectittoward
anotherperson.Improperuseofairjetcouldresultinbodilyinjury.
3.4. Safety precautions
• Alwayswearprotectiveequipmentsuchasgloves,safetyglasses,earprotectionandsafetyshoes.
• 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.
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3.5. Qualied 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modied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.
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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e󰀩cient,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)
or
10GPM(38LPM)
2000PSI(140BAR) A-18”(45.7cm)
B-8”(20.3cm)
C-10”(25.4cm)
37lbs(16.8kg)
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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ttings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ow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.
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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tted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a󰀨ectedwhenthetemperaturedropsbelow50°F.Therefore,measuresshouldbe
takentopre-warmtoolsanduidsbeforeoperating.
NOTE!
• Refer to operating procedures of this manual before starting
Fig 4.
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6. Trouble shooting guide
6.1. Repair troubleshooting
Problem Remedy
Impact Wrench overheats • Operatewrenchon10GPM
Impact wrench spins but
won’t impact…
• Inspectfrontendforbrokenhammerpinsorotherbrokenparts.
Impact wrench only works in
one direction…
• Checkfrontendforbrokenparts
• Checkreversingvalvefortrashononeormorevalveparts
Impact wrench works slow
and has low power…
• •Checkthattorqueadjustmentvalveisscrewedinandnot
adjustedallthewayout.
• Checkthatowis10GPMandsystempressureissetat2000
PSI
Trigger sticks… • Checkfordirtorclearanceintriggerhousing
• Checkforreverseow(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
front end…
• Replacefrontshaftsealusingpartno.02598Shaftsealkit.
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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specication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
tra󰀩c.
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NOTE!
• Refer to the wrench calibration instructions on the previous page or follow
guidelines set forth by the railroad. If the torque setting of a particular
fastener type is critical, the wrench should be set as close to the desired
torque as possible and a calibrated torque wrench used to verify or check
the fastener torque periodically.
Size Wrench PSI Torque FT. LB Tension LB
3/4" 460 300 21,500
7/8" 500 485 29,500
1" 540 730 39,000
1 1/8" 565 900 46,000
1 3/8" 750 1700 69,000
Size Wrench PSI Torque FT. LB Tension LB
3/4" 470 400 28,000
7/8" 525 640 36,000
1" 600 960 50,000
1 1/8" 670 1360 63,000
1 3/8" 890 2500 95,000
6.3. Torque / Tension calibration
Grade 5 – track and frog bolts:
Grade 8 – Track and frog bolts:
WARNING!
• Over-torquing bolts will cause bolt failure under tra󰀩c.
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7. Review of hydraulic principles
Tool circuit
7.1. Hydraulic formulas
Example:HPrequiredtodeliver10GPMat1500PSI.
EstimatedHPdeliveredbypumporusedbytool
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e󰀨ected,butsealsmayblow.Thisiswhyitisveryimportanttodirecttheowintothetool
correctly.Reversingthehosestotestmayresultinblownseals,damagetothetool,andpersonalinjury.
GPM PSI
500 1000 1500 2000 2500 3000
31.03 2.06 3.09 4.12 5.15 6.18
51.72 3.43 5.15 6.86 8.58 10.30
10 3.43 6.86 10.30 13.70 17. 2 0 20.60
15 5.15 10.30 15.40 20.60 25.70 30.90
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8. Maintenance
8.1. General
Maintenance and overhaul is to be carried out by qualied 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.
Keep quick disconnect couplers clean and lubricated.
UsehydraulicuidsthatcomplywithHTMASpecication5.7,Thehydraulicuidshouldhaveaviscositybetween
100and400SSU(20-82centistokes)atthemaximumandminimumexpectedoperatingtemperatures.Petroleum
basedhydraulicuidswithanti-wearpropertiesandaviscosityindexofover140workforawiderangeof
operatingconditions.
Havetoolinspected,atleastannually,byPandroloraPandrolqualiedservicerepresentativetodetermineiftool
isinneedofsafetychangesorwornpartreplacement.
ContactPandrolonaperiodicbasis,atleastannually,forserviceBulletins,safetynotices,orotherimportant
information pertaining to this tool.
Other uids that meet or exceed this specication can be used.
* See cold weather operation hydraulic oil note.
WARNING!
• All adjustments work, overhaul and service must take place with the
machine turned o󰀨. Failure to do so could lead to fatal injury.
• It is of great importance that qualied personnel accomplish all service and
overhaul
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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.
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9. Limited warranty
Pandrol,INCwarrantstotheoriginalpurchaseofthisproductthattheproductwillbefreefromdefectsinmaterial
andworkmanshipfortheperiodofone(1)yearafterthedeliveryofsuchproducttothecustomer.Otherequipment
andpartsused,butnotmanufacturedbyPandrolarecovereddirectlybythewarrantyofthemanufacturerofthose
products.Proofofpurchasemustbedocumentedincludingreferencetoaserialnumberlocatedoneachtool.
Thepurchaser’sonlyremediesunderthislimitedwarrantyshallbelimitedatPandrol’ssoleoptiontothefollowing:
repair,replacementorrefundofthepurchasepriceofthedefectiveproducts.Eachoftheseremediesrequires
timelynoticationofthedefectintheproductandsubstantiationthattheproducthasbeenproperlystored,
maintainedandused.Pandrol’sobligationshereunderextendonlytothepurchaseroftheproductandnottoany
thirdparty.
AsaconditionprecedenttoPandrol’sobligationhereunder,thedefectiveproductmustnothavebeenalteredor
modied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tnessforaparticularpurpose.
Limitedwarrantydoesnotcovernormalwearandtearitemssuchaslters,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a󰀨ected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
o󰀩cerofPandrol,theremediessetforthhereinareexclusive.
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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
02900A–Diesel(1)10GPMor(2)5GPMcircuits(optionalcatalyticexhaust)
05500–Twinpowerdualcircuit(1)10GPMor(2)5GPMcircuits&5000wattgenerator
02050RM–Modularpowerunit(1)9GPM
03700A–Electricpower(1)10GPMor(2)5GPMcircuits
Grinders:
09200A–Precisionfroggrinder
06000–Prolegrinder
06950&06950A–Multi-purposegrinder
05900–Frog/prolegrinder(triggerversionavailable)
00700–Railsurfacingguide
04600–Straightstonegrindercwrotation(triggerversionavailable)
04700–Straightstonegrinderccwrotation(triggerversionavailable)
07500–Chamfertool
04800–6"Cupstonegrinder(triggerversionavailable)
00600–8"Cupstonegrinder
05400–Anglegrinder
09300-Headwashgrinder
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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
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11. Seal kit information
Sealkitformotorswithoutbearingmanufacturedafterapril2003
Without bearing
#02599 - Internal seal kit #02598 - 18mm shaft seal kit
Fig 5. Fig 6.
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12.Assembly
12.1. Parts diagram
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