PortaCo DI-05-76-O User manual

ORIGINAL OPERATION MANUAL
IMPACT DRILL DI-05-76-O

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
Change overview
Auditing
Date
Comment, including chapter
changed by
01
11-26-2018
Creation
Jesse Bunn

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
1About this manual................................................................................................................................................. 5
2General ................................................................................................................................................................. 6
2.1 General information...............................................................................................................................................................6
2.2 Designated use.......................................................................................................................................................................6
2.3 Unintended use......................................................................................................................................................................6
2.4 Environment requirements....................................................................................................................................................6
2.4.1 Operating requirements...........................................................................................................................................6
2.4.2 Emissions ..................................................................................................................................................................6
3Safety.................................................................................................................................................................... 8
3.1 Basics .....................................................................................................................................................................................8
3.2 Important safety information ................................................................................................................................................9
3.3 Qualification of the operating and maintenance personnel ................................................................................................13
3.4 Emergency information / safety devices..............................................................................................................................13
3.5 Safety signs ..........................................................................................................................................................................14
4Design and function .............................................................................................................................................15
4.1 Design ..................................................................................................................................................................................15
4.2 Specification.........................................................................................................................................................................15
4.2.1 Hydraulic fluid ........................................................................................................................................................15
4.2.2 Supply, interfaces and connections........................................................................................................................16
4.3 Function ...............................................................................................................................................................................17
4.4 Boundaries and interfaces ...................................................................................................................................................17
4.5 Drill Bits................................................................................................................................................................................17
5Transport, assembly and dismantling...................................................................................................................18
6Commissioning and operation..............................................................................................................................18
6.1 General information for start-up .........................................................................................................................................18
6.1.1 Testing procedure ..................................................................................................................................................19
6.1.2 Specification of the hydraulic system.....................................................................................................................20
6.2 Power source specifications.................................................................................................................................................21
6.3 Tool Connecting Procedures ................................................................................................................................................22
6.4 Connecting Hoses.................................................................................................................................................................22
6.5 Tool attachment installation and removal ...........................................................................................................................23
6.6 Operation.............................................................................................................................................................................23
6.7 Disconnecting Hoses ............................................................................................................................................................24
6.8 Cold weather operation .......................................................................................................................................................24

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
7Maintenance ........................................................................................................................................................25
7.1 Change of hydraulic fluid .....................................................................................................................................................25
8Troubleshooting...................................................................................................................................................26
8.1 General information for troubleshooting and repairs .........................................................................................................26
8.2 Troubleshooting and repairs................................................................................................................................................26
9Shutdown and re-commissioning .........................................................................................................................28
10 Storage.................................................................................................................................................................28
11 Dismantling and disposal .....................................................................................................................................28
Publisher: PortaCo Inc.
1805 2nd Ave N, Moorhead, MN 56560
Phone [phone], Fax [phone]
[email protected], www.portaco.com/
Date of publication: 12-01-2018
Documentation version: 1.0
Document / order number: 6600-OOP

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
1About this manual
This document is the original operation manual for the Impact Drill DI-05-76-O of PortaCo Inc., 1805 2nd Ave N, Moorhead, MN
56560
The operation manual is intended to enable the operator to safely operate the system as intended and warn them of foreseeable
misuse. The manual is intended for the operating company´s specialized staff. In addition to the operation manual, the spare parts
catalogue and the maintenance manual of the manufacturers of the individual components are to be observed.
WARNING
Operating errors using the device, e.g. by instruction errors, may lead to personal injury or damage to the
device.
-The instruction for use must be accessible to operators and maintenance personnel at all times!
-A copy of the technical documentation including the instruction for use must be kept in a suitable and
accessible place.
The explanation of the hazard pictograms is contained in chapter safety.
This document is to be treated as confidential. No portion of the document may be disseminated to another party or reproduced
without written permission from PortaCo Inc. All rights reserved.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
2General
This chapter contains basic information about the machine and is intended to provide an initial overview.
2.1 General information
The Impact Drills are designed for numerous maintenance functions in the utility, municipal, and construction fields.
The tool is hydraulically powered. The hydraulic energy is provided by a hydraulic unit. The hydraulic unit is not part of the scope of
delivery. We recommend the Hydraulic Power Units D-23, E-15, G-18, G-21, G-23 or G-31.
Further design information is shown and described in chapter 4.
Regarding ergonomics, the stresses and strains resulting from the device are typical for a device in the construction industry.
2.2 Designated use
The Impact Drills are designed for numerous maintenance functions in the utility, municipal, and construction fields.
To use the tool as intended, all persons who use the device must adhere to the guidelines in this operation manual.
2.3 Unintended use
-Do not allow others to be near the tool when starting it or while operating. Keep bystanders and animals out of the work area.
-Do not operate the tool near energized transmission lines.
-Be sure to keep hands and other body parts clear and free from all moving parts.
-Always connect hydraulic hoses to the tool before activating the hydraulic circuit on your power unit. Check that hydraulic
couplers are secure before activating the circuit.
-Make sure the tool’s socket was stopped turning before setting down tool.
-At the work site, never carry the tool with the socket rotating.
-Never operate a tool that is damaged, improperly adjusted, or not completely and securely assembled.
-Never carry or pick this tool up by the hydraulic hose.
-Connecting to power source which exceeds the required flow and pressure rating
-Atmosphere temperature below -20°C/-4°F or above 45°C/113°F
-Hydraulic oil temperature below 10°C/50°F or above 82°C/180°F
2.4 Environment requirements
2.4.1 Operating requirements
The machine is designed for use on construction sites outdoors. It can be used at temperatures between
-20 °C to 45 °C (-4°F to 113°F). The temperature of the hydraulic fluid should be at least 10 °C (50°F).
When working in tunnels, the country-specific safety regulations must be observed.
2.4.2 Emissions
In technically perfect condition, the A-weighted emission sound level at the work place is lower than 70 dB(A). Hearing protectors is
not required.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
Other emissions do not occur during regular device operation.
In the event of damage, hydraulic fluid may leak. Should this be the case, eliminate the leak and remove any fluid which has leaked
with the intended binders.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
3Safety
3.1 Basics
The machine corresponds to the generally recognized standards of technology and practice. Nevertheless, knowledge of the
residual risks as well as general knowledge of the device is required to ensure safe and accident-free work.
The safety information is understood to be in addition to the existing accident prevention regulations and laws. The information is
intended to warn operating personnel about foreseeable misuse. Existing safety prevention measures and laws must be followed at
all costs!
The operation manual must be read and understood by all persons who work on the device. Introduction to the device is to be
documented in writing.
CAUTION
Hazards from the operational environment of the device can lead to injuries of persons.
-No alterations to the device may be made which lead to a change in function.
-All hazards from the environment or from unforeseeable operating conditions of the device cannot be
captured and depicted within this manual.
Modifications to the machine must be made by the distributing company. In this case this manual will also be
adapted.
The chapter on safety regulations serves to:
-explain the depiction of the safety regulations and symbols
-inform users about dangers, residual risks and measures for reducing risks
-specify the minimum requirements of the operating personnel

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
Symbol
Meaning
DANGER
DANGER indicates a hazard with a high degree of risk, which when it is not avoided results in death or
serious injury.
WARNING
WARNING indicates a hazard with a medium degree of risk, which when it is not avoided may result in
death or serious injury.
CAUTION
CAUTION indicates a hazard with a low degree of risk, which when it is not avoided may result in minor
or moderate injury.
NOTICE
NOTE, non-compliance may result in environmental or material damage
Attention risk of injury!
General note for helpful tips and additions.
Read the safety information before using the machine. Non-compliance may result in injuries and
damage to property.
Table 1: Signal words and Symbols
3.2 Important safety information
Read this chapter and observe the safety information before using.
The safety regulations are to be observed by all persons who work on the device. The regulations and instructions for accident
prevention valid at the place of operation are to be observed. Instruction of the operating and maintenance personnel in system
safety is to be documented.
Please pay particular attention to this chapter to avoid accidents!
PortaCo Inc. is not liable for injury to persons or property which results from misuse of the machine.
DANGER
There is a danger of crushing in the area where the tool is working.
-Do not reach or step into the working area of the device during the turning process.
Use personal safety equipment.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
DANGER
The bursting of hydraulic components and uncontrolled whipping of the hydraulic hoses is possible.
-Only use the machine within the prescribed limits.
-Before disconnecting the hydraulic couplings, make sure that the pressure is relieved.
-The machine must be maintained at regular intervals, the intervals are specified by the operator's risk
assessment.
DANGER
Contact with live parts results in the worker sustaining a lethal electric shock.
-In the case of railway tracks with live rails, the busbar must be shorted or switched off by the control
room of the transport company.
-Check that no voltage is present in the rail system continuously!
DANGER
The operator inhales aerosol of hydraulic oil.
-Only use the device within the prescribed limits.
-The device must be maintained at regular intervals, the intervals are specified by the operator's risk
assessment.
-In the event of leaks switch the device to a safe state.
DANGER
If an employee is hit by a train or car, severe or fatal injuries may result.
-Pay attention to your own safety!
-Wear work clothing with reflectors and a safety vest!
-The foreman must ensure that the line being worked on has been closed.
-Place a track marshal with a horn on the opposite track.
DANGER
Employees may be severely or fatally injured by lightening during a thunderstorm.
Stop work during thunderstorms!
WARNING
In case of poor weather conditions (rain, snow) there is a risk of injury due to poor visibility or slippery
standing surfaces.
-Stop work if standing surfaces are slippery.
-Stop work if visibility is poor.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
WARNING
In case of leakage, there is a risk of slipping on the oil film.
-Remove spilled hydraulic oil with the prescribed absorbent material.
-Put on S3 safety shoes.
WARNING
Improper maintenance or maintenance not carried out on time may result in damage to the machine or
injury to persons.
-Maintenance intervals are to be determined by the operator within the scope of their risk assessment.
-Observe the maintenance intervals and maintenance instructions of the manufacturer and existing
directives.
-Components may only be replaced with identical spare parts. It is imperative that the specifications of
the component manufacturer be followed when mounting the component.
WARNING
Spilled hydraulic oil can lead to an increased risk of fire and environmental pollution.
-Remove spilled hydraulic oil with the prescribed absorbent material.
WARNING
Operating errors using the device, e.g. by instruction errors, may lead to personal injury or damage to the
device.
-The instruction for use must be accessible to operators and maintenance personnel at all times!
-A copy of the technical documentation including the instruction for use must be kept in a suitable and
accessible place.
CAUTION
The hydraulic oil heats up during operation. Leaking hydraulic oil can easily burn the operator.
-Wear safety clothing.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
CAUTION
Noise emissions occur during operation of the hydraulic unit.
-Wear ear protection
-Switch the device off if unusual noises occur
CAUTION
High noise pollution occurs during operation as a result of the striking mechanism.
-Wear ear protection
-Switch the device off if unusual noises occur.
CAUTION
Vibrations occur in the device during operation as a result of the striking mechanism.
-Wear appropriate work gloves.
-Only use the device with the handles provided for this purpose.
NOTE
Inadequate lighting may result in incorrect switching operations or mix-ups.
Adhere to the break and recovery times prescribed by law.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
3.3 Qualification of the operating and maintenance personnel
The intended circle of users for the machine includes the operators and maintenance personnel.
Anyone who carries out work on the device must be familiar with the functions and dangers of the machine. Introduction to the
machine is to be documented in writing.
All operators as well as employees that regularly enter the area of the machine should at least be instructed on the following
topics:
-Basic device functions (operators)
-instruction for use (operators)
-Conduct in work area (all)
-Location of safety devices (operators)
-Personal protective equipment (all)
Furthermore, operators should possess the necessary physical and mental capacities which are required to operate and service the
machine.
The operating personnel must wear personal protective equipment according to the job at hand and dangers of the environment.
The operational procedures as well as the professional association guidelines and safety data sheets are to be observed.
3.4 Emergency information / safety devices
The specification of the Working Conditions Act must be observed when working with the machine. Persons who work with the
machine are required to use their personal protective equipment as intended. In this case that means:
-work gloves
-safety glasses or safety mask
-safety shoes S3
-hearing protection

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
3.5 Safety signs
Safety sign
Meaning
Mandatory sign “Wear hearing protection”: indicates that while working with the machine hearing
protection must be worn by all persons near to the machine.
Mandatory sign “Wear safety glasses”: indicates that while working the machine safety glasses must
be worn by the operator.
Mandatory sign “Wear protective shoes”: indicates that while working the machine protective shoes
must be worn by the operator.
Mandatory sign “Wear protective gloves”: indicates that while working the machine protective gloves
must be worn by the operator.
Mandatory sign “Wear protective clothing”: indicates that while working the machine protective
clothing must be worn by the operator.
Table 2: Safety signs

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
4Design and function
[KE/G1]
4.1 Design
Figure 1. Overall design
No.
Description
1
7/16 Hex quick chuck
2
Rotation direction selector
3
On/off lever
4
Port, “IN” pressure
5
Port, “OUT” return
4.2 Specification
Criteria
Value
Length
230 mm / 9.0 inch
Width
95 mm / 3.75 inch
Height
260mm/ 10.25 inch
Weight (dry)
4.3 kg / 9.5 lb
Table 3: Specifications
4.2.1 Hydraulic fluid
The hydraulic fluid should meet the following requirements.
1
2
3
4
5

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
Criteria
Value
Viscosity (at 10 °C)
95 cSt
Viscosity (at 38 °C)
27-42 cSt
Viscosity (at 60 °C)
16,5 cSt
Pour point
-10 °C
Viscosity index (ASTM-D2220)
min. 140
Flash point (ASTM-D92)
min. 171 °C
Pump wear test (ASTM-D2882)
max. 60 mg
Demulsibility (ASTM-D1401)
max. 30 minutes
Table 4: Hydraulic fluid data
The following hydraulic fluids or equivalent are suitable for use.
Manufacturer
Type
Chevron
Clarity AW ISO 32
Mobil
Univis J32
Gulf
Harmony AW-HVI-150-32
Shell
Tellus T32
Table 5: Suitable hydraulic fluids
4.2.2 Supply, interfaces and connections
The machine is powered by a hydraulic unit. There are quick couplings (3/8" flat face) for connecting the hydraulic unit.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
4.3 Function
The PortaCo, Inc. DI-05-76-0 hydraulic Impact Drill is designed for numerous maintenance functions in the utility, municipal and
construction fields. Several innovative features have been incorporated into the design of these tools to provide lightweight, quiet
and efficient use.
The dual spool enable operation of the tool on both open and closed center, systems, and also comes equipped with a reversing
spool which allows the wrench to be operated in forward or reverse.
The PortaCo, Inc. Impact Drill operates by automatically supplying fluid in such a way that it turns the drive shaft of the assembly.
As the trigger is depressed, it moves the spool to close off the flow of oil to the return port and directs the flow of oil through the
tool circuit.
The flow of oil through the directional spools causes the shaft in the motor to turn and rotate the drive assembly. With no or
minimal resistance, the anvil and hammer turn in unison. As greater resistance is encountered during use of the wrench, the force
of the resistance causes the hammer to slip and strike the anvil resulting in the impact action. The impact action continues until
the resistance is reduced or the work completed.
The drill operates in a similar manner as above but the motor turns the drive shaft which then rotates a gear reduction system to
drive the industrial grade chuck... The hydraulic energy is provided by a hydraulic unit. The hydraulic unit is not part of the scope of
delivery. We recommend the Hydraulic Power Units D-23, E-15, G-18, G-21, G-23 or G-31.
4.4 Boundaries and interfaces
The Impact Drill consists of the parts pictured in chapter Design. The battery limit is the connection to the hydraulic unit. Power and
auxiliary materials are not part of PortaCo Inc´s scope of service. Other parts which are not directly part of the machine are also
excluded.
4.5 Drill Bits
PortaCo, Inc. offers a full line of impact drill bits, sockets, and adapters. Contact PortaCo, at 218-263-0223 for a complete list.
The standard Impact Drill is all that is available at this time.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
5Transport, assembly and dismantling
The machine must be disconnected from the hydraulic unit for transport. For this purpose, the hydraulic unit must be switched off
and the system depressurized. After that the hydraulic hose couplings can be detached. Then the machine can be transported fully
assembled without being taken apart.
6Commissioning and operation
6.1 General information for start-up
DANGER
Incorrect operation of the machine or disregard of safety instructions may lead to
endangerment of persons or damage to the machine.
-Familiarize yourself with the complete instruction for use before beginning work on the
machine. Pay particular attention to chapter 3!
NOTE
A thorough, visual inspection of the machine is to be carried out by the operator before start-up.
Start-up of the machine may only be carried out by qualified specialist personnel. The start-up engineer must be acquainted with
the machine. Requirements for start-up are:
If the tool is used in cold weather, preheat the hydraulic fluid by running power source at low engine speed. Fluid
temperature should be at or above 50° F/10° C (400-ssu/82 centistokes) before use, when using recommended fluids. Using
too thick of fluid may result in tool damage
All detachable connections have been checked and tightened if necessary
Check for loose nuts and bolts, keep all fasteners tight to prevent parts from separating and causing unsafe conditions
Check hydraulic fittings and hoses for leaks or damage. Keep all hydraulic components in good condition to prevent tool
failure and for operator safety
CAUTION
Do not search for leaks with bare hands. Pressurized fluid escaping from a damaged hose
or fitting can penetrate the skin and be injected in the body causing injury or death.
-Wear appropriate work gloves.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
6.1.1Testing procedure
WARNING
Never stick foreign objects, fingers, or other extremities into moving mechanisms. Failure to follow these
instructions may lead to severe personal injury or tool damage.
Before operating the Impact Drill it is important to inspect the trigger linkage mechanism for obstructions. Make sure all drill bits or
sockets are securely mounted. Follow all safety precautions when inspecting tool.
1. Connect the tool to the power source follow the procedures in section 2.6 of this manual.
2. Verify that the pressure and return hoses are connected properly to the tool and hydraulic power source ports.
3. The hydraulic power source reservoir must be filled to full level with hydraulic fluid.
4. After verifying the above, start the power source flow. All power source shut-off devices must be engaged or opened
(clutch engaged, separate ON/OFF valves open, etc.)
5. Check the tool to see if it operates.
NOTE
If the tool does not operate, it will be necessary to determine where the problem exists (i.e., in the tool, hoses, or hydraulic power
source).
Determining the problem area
1. Stop the power source. Depressurize the system and allow to cool. Disconnect the existing tool from the hoses and power
source. See action on hose connections in this manual for proper procedures.
2. Connect a known, properly operating tool to the hoses and power source. See the tool’s operator manual for the correct
hook-up procedure. Start the power source flow.
If the known, properly operating tool operates, the problem is in the disconnected tool. See the troubleshooting charts in
this operator’s manual.
If the known, properly operating tool does not operate, the problem is likely to be in the hoses or the power source. Proceed
to Step 3
3. Stop the power source flow. Disconnect the existing hoses from the known, properly operating tool and power source. See
the tool’s operator manual for the correct disconnect procedure.
4. Connect a different set of hoses to the known, properly operating tool and power source. Start the power source flow.
A) If the known, properly operating tool operates with the different set of hoses, the problem is in the disconnected hoses.
B) If the known, properly operating tool does not operate, the problem is in the power source. See your power source
operator’s manual for troubleshooting.
If, after following all steps in the Troubleshooting section, it has been determined that the problem lies with the tool,
proceed to the Troubleshooting Guide. Use of the Troubleshooting Guide will help you identify and determine the cause of
the problem.

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Impact Drill DI-05-76-O ORIGINAL OPERATION MANUAL
NOTE
It is not recommended that the end-user attempt to perform repairs, as special tools and procedures are required. We cannot be
responsible for the heat generated through any combination of pump inefficiencies, oil bypassing over relief valves, pre-existing
flow controls, or unusual restrictions in the system. Where these and other possible inefficiencies exist, substantially larger
reservoirs and/or coolers may be required.
Should you have any problems or questions with your Hydraulic Tooling, please do not hesitate to contact Customer & Technical
Service Department at PortaCo, Inc.
6.1.2Specification of the hydraulic system
The hydraulic unit should ensure a flow of at least 20 lpm (5 gpm) at a pressure of 138 bar (2,002 psi). The pressure must be limited
to 150 bar (2,176 psi). Measurements must be carried out at the minimum operating temperature by 10 °C (50 °F) of the hydraulic
fluid. Warm the hydraulic fluid if necessary.
The temperature of the hydraulic fluid must be limited to 60 °C (140°F).
We recommend the use of the hydraulic units D-23, E-15, G-18, G-21, G-23 or G-31 from PortaCo Inc.
Hose requirements
It is not often necessary or advisable to use long hoses. All hoses must have an oil resistant inner surface and an abrasion resistant
outer surface. Each hose must have male pipe ends for most applications. Longer hoses can be used when necessary, but can
affect the operation of the engine due to resistance in the hose.
If small diameter or long hoses are used, or if restrictive fittings are connected to the supply and return ports, the pressure required
to, push the fluid through the system and back to the tank will be higher. This will reduce tool power.
NOTE
Oil should always flow from the male coupler through the female coupler.
NOTE
The pressure increase in uncoupled hoses left in the sun may make them difficult to connect. When possible after use, connect
the free ends of the operating hoses together.
Hose types
Hydraulic hose types authorized for use by PortaCo, Inc. is as follows:
1. Labeled and certified non-conductive
2. Wire braided (conductive)
3. Fabric braided (not certified or labeled non-conductive)
Hose type 1: Listed above is the only hose authorized for use near electrical conductors.
Hose type 2 and 3: Listed above are conductive and must never be used near electrical conductors.