Reliable Equipment REL-425C Manual

1
RELREL
RELREL
REL-425C425C
425C425C
425C
DISTRIBUTED BY
OPERATORS’ GUIDE
WARNING
All information found in this guide
must be read and understood before
use or testing of this tool. Failure
to read and understand these warnings
and safe handling instructions could result
in severe personal injury and or death.
HYDRAULIC
IMPACT WRENCH
with 7/16” quick change chuck
REL-425CManual 03-09
Shown with optional
7/16” hex X 1/2” square drive impact adapter
and low pressure hydraulic couplers

2
CAUTION
The information in this manual is intended to guide the user in the
use and application of this tool. It is not intended as a substitute
for proper training and experience in safe work practices for this
typeofequipment.
Consult your supervisor or safety personnel if you have any
questions regarding the safe operation of this tool.
DISTRIBUTED BY
REGISTRATION
UPON RECEIPT OF THIS TOOL, COMPLETE THE REGISTRATION BELOW.
COMPANY ______________________________________________________
ADDRESS ______________________________________________________
_______________________________________________________________
PHONE____________________ FAX _______________________________
SERIAL NUMBER ________________________________________________
DATE OF PURCHASE ____________________________________________
DEALER NAME__________________________________________________
THIS SYMBOL INDICATES ITEMS OF EXTREME IMPORTANCE.
Safety of user and others may be in jeopardy if these instructions
are not read and understood.

3
TABLE OF CONTENTS
DESCRIPTION.............................................................................3
TOOL SPECIFICATIONS ...........................................................4
SOURCE SPECIFICATIONS......................................................4
GENERAL SAFETY INFORMATION..................................... 5-7
HOSES- Fittings,Connectctions,Installation .................................8
HOSES AND FITTINGS (General Information) .............................9
OPERATIONAL SAFETY ......................................................... 10
OPERATING INSTRUCTIONS................................................ 11
MAINTENANCE........................................................................ 12
DISASSEMBLY ....................................................................13-14
ASSEMBLY...........................................................................15-19
PARTS DIAGRAM REL-425 .................................................... 20
PARTS LIST FOR REL-425..................................................... 21
PARTS LIST FOR PRESSURE CONTROL SPOOL ................... 22
INTRODUCTION & SPECIFICATIONS FOR REL-425C...... 23
PARTS DIAGRAM REL-425C ................................................. 24
PARTS LIST FOR REL-425C.................................................. 25
PARTS LIST REL-425C O/C CONTROL SPOOL....................... 26
USING REL-425TS (TEST STAND) ........................................ 27
MAINTENANCE RECORD ...................................................... 28
DESCRIPTION
The REL-425C is a user friendly hydraulic impact tool that has broad applications for
the utility and construction industries. Delivering 425 ft.lbs. of torque at 6 gpm, this
tool is great for drilling, loosening rusted hardwear, or tightening lag bolts with ease.
The tool is well balanced to feel comfortable and secure. The trigger is designed to
be responsive in a heavily gloved hand enabling the user smooth, easily controlled
operation. The dual system actuating spool can be switched from open center to
closed center by simply turning the selector knob completely. A readily accessible
reversing spool allows unconstrained direction control. The handle is coated with a
heat protecting material which aids in handling the tool in adverse conditions.
The REL-425 comes with the standard 7/16” hex in the nose with an E-Z grip quick-
release chuck to readily change from square adapters for sockets to various tools
such as drills and augers.

4
TOOL SPECIFICATIONS
Length....................................................................................... 8.6" (21.8cm)
Width .......................................................................................... 2.7" (6.8 cm)
Height....................................................................................... 8.8" (21.8 cm)
Weight .....................................................................................6.3 lb. (2.8 kg)
Output Torque ............................... 425 ft lb. @ 5-6 gpm (recommended)
NOTE: TORQUEMAYVARYWITH TRUCK PRESSUREAND HYDRAULICFLOW
Pressure Port .............................................................. 9/16-18 SAE Thread
Return Port .................................................................... 3/4-16 SAE Thread
Drive.....................................7/16 Hex Socket (Removable 1/2" Sq. Drive)
Hyd. System Type .......................................E-Z Open and Closed Center
SPECIFICATIONS
Hydraulic Power Source
Flow: Min......................................................................4 gpm (5.1 lpm)
Recommended..........................................5-8 gpm (19-30 lpm)
Flow Range................................................4-8 gpm (15-45 lpm)
Optimum Flow...............................................6 gpm* (12.7 lpm)
RPM ........................................................................................3,600 @ 6 gpm
Operating Pressure Min............................................... 1,300 psi (69 bar)
Operating Pressure Max............................................. 2,000 psi (138 bar)
Pressure Relief Setting...................................... 2,000 psi Max. (138 bar)
Back Pressure...................................................................200 psi (13.8bar)
Filtration .............................................................................10 microns Max.
Hydraulic System........................E-Z Select for Open or Closed Center
Fluid Temperature, Max.......................................................140OF (60OC)
* Checked with Flowmeter on Pressure Line
Relief Valve not to exceed 2000 psi
Flow not to exceed 8 gpm
WARNING

5
WARNING
BEFORE USING THIS TOOL, READ THE WARNINGS
and the recommended practices described in this manual.
Failure by the operator to read and fully understand these
warnings will leave this person unqualified to use and
operate this tool. Property damage, severe personal injury,
and/or death could result by not following these warnings.
Eye
Protection
These warnings will appear in appropriate locations when they are pertinent to the
particular subject being shown. Read each one carefully and follow them strictly.
WARNING
Always wear eye protection to avoid
injury from flying debris or hydraulic
oil leaks. Failure to do so can result
in serious personal injury.
Hard Hat
WARNING
Alwayswear a hard hat toavoid injury
from falling debris. Failure to do so
can result in serious personal injury.
Hearing
Protection
WARNING
Always wear hearing protection,
to avoid hearing loss due to long
term exposure to high noise levels.
Foot
Protection
WARNING
Always wear foot protection.
Failure to do so can result in serious
personal injury.
Dust Mask
WARNING
Always wear a dust mask. Failure to
observe this warning may result
in serious health issues and/or
breathing difficulty.
WARNING
Protective
Gloves
Always wear protective gloves
Failure to do so can result in serious
personal injury.

6
WARNING
Safety
DO NOT attempt to make any changes to any of the component
parts or accessories when connected to the power source.
DO NOT adjust, inspect, or clean tool while the tool is connected
to the power source. The tool could accidentally start up
and cause serious injury.
DO NOT lock the tool in the On Position. In an emergency,
serious damage or injury could occur during the time
required to stop the tool.
Safe Operation & Care
USE THIS TOOL FOR ITS INTENDED PURPOSE ONLY
Any other use can result in injury or property damage.
INSPECT TOOL BEFORE USE. Replace any worn, damaged or
missing parts. A damaged or improperly assembled tool may
malfunction, injuring operator and/or nearby personnel.
INSPECT HYDRAULIC HOSES AND COUPLINGS before
each use. Repair or replace if any cracking, leakage, wear or
damage is is found. Worn or damaged hoses may fail resulting
in personal injury or property damage.
CLEAR WORK AREA of all bystanders and unnecessary
personnel before operating this tool.
KEEP ALL PARTS OF THE BODY AWAY FROM MOVING PARTS.
Failure to observe this warning could result in serious injury.
WARNING
Oil Injection Injury
Hydraulic oil or fluid under the skin is a serious injury. Oil
under pressure can penetrate the skin and may cause
dismemberment or loss of life. Seek medical assistance
immediately if such an injury should occur.
Always wear safety gloves, eye protection and all required
safety equipment when operating or handling this tool.
DO NOT use fingers or hands to attempt to locate a leak.
DO NOT handle hoses or couplers while system is pressurized.
NEVER open or service the system before depressurizing.
WARNING

7
Safe Handling
HYDRAULIC FLUID MAYCAUSE SKIN IRRITATION.
Prevent hydraulic fluid from making contact with skin.
IN THE EVENT OF SKIN CONTACT immediately wash thoroughly.
Failure to observe this warning could result in injury.
CAUTION
Vibration Hazard
Apply just enough pressure to control the tool operation.
Applying excess pressure to the tool may cause operator
discomfort or temporary numbness.
Failure to observe this warning could result in serious injury.
CAUTION
Electrical Shock Hazard
Use only certified nonconductive hoses and fittings. Always
wear and use the necessary clothing, equipment and safety
practices to protect against electrical shock. Failure to follow
these rules can result in serious personal injury or death.
WARNING
CAUTION
General Safety
Ensure that all fellow employees and bystanders are clear
and protected from possible injury caused by this tool or the
operations being performed. Persons in close proximity could
be injured and property damaged if the tool were to malfunction.
This tool should always be used within the limits and purposes
stated by the product manufacturer. Abuse or usage beyond
the manufacturers’ intended purposes could cause damage to
the tool and severe injury to the operator.
Burn Hazard
Do Not connect or disconnect tool, hoses or fittings while
power source is running or while hydraulic fluid is hot.
Hot hydraulic fluid may cause serious burns.
Failure to observe this warning could result in serious injury.
WARNING

8
HOSES AND FITTINGS
There exists the potential for shock in using anything other
than certified nonconductive hoses and hydraulic oil with
dielectric properties, when using system components near
energized electrical lines. Failure to recognize these conditions
could cause electrocution.
Hoses and fittings used with this tool must comply with S.A.E. J1273 which
covers recommended practice for selection, installation, and maintenance of hose
and hose assemblies. The correct hoses and fittings are available from your supplier.
WARNING: Failure to comply with these warnings could result in severe bodily injury.
WARNING
UNIT/HOSE CONNECTIONS
ALWAYS SHUT OFF pump/power source and move flow selector
to OFF before connecting or disconnecting system components.
ALWAYS DEPRESSURIZE hydraulic system before slowly
disconnecting this unit or any of the systems components.
ALWAYS TIGHTEN couplings completely. Loose or improperly
tightened couplings will not allow fluid to pass through the
hose creating a blockage in the supply or return line.
ALWAYS INSPECT HOSES AND CONNECTORS before
connection to tool. Replace or repair if any leakage is evident.
Leakage is a sign of deterioration in component parts. Worn or
leaking parts must be repaired or replaced, or tool damage or
severe injury could result.
WARNING
HOSE INSTALLATION
Care must be taken to assure the correct connection of
the hoses to the pressure and return ports.
Connect the return hose to the return port on the power
source, then to the return port on the tool.
Connect the pressure hose to the pressure port on the
tool, then to the pressure port on the power source.
Operation with hydraulic flow reversed can cause malfunction.
Failure to fully comply can result in severe injury or death.
CAUTION

9
HOSES AND FITTINGS
Care must be exercised in the use of hose and fittings for use on hydraulic tools, especially in
confined areas. Any obstruction or abrasive surrounding could damage the hose and cause a
serious accident. Always use the recommended hose for the tool that is being used. Always consult
the dealer or distributor for the correct hoses and purchase from him to ensure, from a safety
standpoint that the materials used in the manufacture of the hoses is to the correct specification
for the application. Fittings must meet the standards established by the industry to adequately
assure safety. Poor quality or low rated fittings are not to be used. They invite a serious accident.
Length: Hose must be the correct length for the general use of the tool or for the specific
function it is to provide. Pressure surge is an important factor in the selection of hoses. The
hose should be rated above the expected surge pressure to ensure adequate safety. Hoses
that are too long will have a tendency to coil, kink, or move in multiple directions creating a
safety hazard. Hoses that are too long will rub or chafe against the ground or projecting
objects, seriously shortening the life of the hose. It may be advisable to carefully restrain a
hose which is temporarily too long for the current application. Pressure surge can cause
whipping, and seriously damage the hose. Always keep the hose length as short as possible
for the operation which is it intended.
Size: The hose must be large enough to carry the pressurized flow of fluid to the end
application without creating undue heat generation or excessive turbulence. These factors
could cause excessive wear to the hose from any or all of the above reasons.
Pressure: Hose selection must be made so that the recommended maximum operating
pressure is greater than the system pressure. A surge or sudden drop in pressure will cause
the hose to deteriorate faster if the maximum pressure of the hose is significantly below the
surge pressure. A hose with a top rate of pressure as the line pressure of the installation is
not an accepted safety practice. Always err on the side of safety.
Temperature: Hose can be seriously damaged by passing over or near hot objects. Avoid
any situation that will heat the hose. Serious damage and/or failure will occur.
Unusual Applications: Careful thought and research should precede installation of hoses. Thorough
and protected testing, with appropriate safety guards, must be done to avoid injury before general use.
Connections: Hoses must have the proper end fittings in order to mate correctly with
connectors. Worn or damaged connectors and worn end fittings on the ends of the hose
can cause a failure. Pressure surge can cause a slow or sudden failure at the connection
causing serious damage or injury.
Safety Check: Before using any installation, perform a thorough checkout to determine if
any of the above or unforeseen problems occur. Initial testing with safety guards is an
invaluable safety precaution.
Always consult the distributor or manufacturer for the correct specifications regarding any of the
items discussed above. The correct hoses and fitting are available from your supplier.
There exists the potential for SHOCK in using anything other than certified
non-conductive hoses and hydraulic oil with dielectric properties when using
system components near ENERGIZIZED ELECTRICAL LINES. Failure to
recognize these conditions could cause ELECTROCUTION.
Hoses and fittings used with this tool must comply with S.A.E. J1273
recommended practice for selection, installation, and maintenance
of hose assemblies.
FAILURE TO COMPLY WITH THESE WARNINGS COULD RESULT IN SEVERE BODILY INJURY.
WARNING

10
OPERATIONAL SAFETY WARNINGS
SHOCK, ELECTRICAL: This is a non-insulated tool. The need for keeping the tool
dry and cleen is imperative. Using this tool in an energized electrical environment
could be dangerous to the user. Failure to take this into account could result in electrocution.
NEVER CONNECT components or fittings to this unit unless power/pump source is
turned off or disconnected.
ALWAYS INSPECT hydraulic hoses and fittings for wear or deterioration every day.
Replace all parts that show signs of leaking, wear, or damage.
KEEPALL PARTS OF THE BODYAWAY from moving parts of the tool when connected
to the power source for the tool.
MAKE SURE there is no person in close proximity to you or the tool who could be
injured by any operation being performed with the tool.
DO NOT overextend your position by overreaching or unbalancing the footing
necessary to maintain physical control of your body.
ALWAYS MAINTAIN a firm grip on the tool to avoid having the tool slip out of the
hands during an operation, causing a serious injury.
DO NOT side load or apply any type of indirect force.
Socket, bit, or adapter may be damaged creating a potentially dangerous situation.
DEPRESSURIZE THE UNIT before attempting to disassemble, connect, or disconnect
any of the components. Check oil temperature before disconnecting or disassembling
this unit. A serious burn could result from this exposure.
SEE A DOCTOR IMMEDIATELY, if a hot oil injury should occure.
SEE A DOCTOR IMMEDIATELY, if a pressurized oil injury should occure. Infection or
serious reaction could result from any hydraulic pressure injury.
USE THIS TOOLFOR THE MANUFACTURERS’INTENDED PURPOSE ONLY.
USEALLAPPROPRIATEANDAPPLICABLEPERSONALSAFETYEQUIPMENT as required by the
operating company.
OBSERVECLOSELYALL SAFETYRULES FORAPARTICULAR JOB CLASS
THE PURCHASER/OWNER of this unit must be certain that allthe users of this unit are properly
trained in it’s use and in compliance with all appropriate industrial codes and/or practices.
FAILURE TO HEED THESE WARNINGS COULD RESULT IN
SERIOUS PERSONAL INJURY AND/OR PROPERTY DAMAGE.
WARNING
Operation/Safety methods may vary in accordance
with the working guidelines established by each utility
or contractor.
For your own safety, ensure that you fully comply with
all safe operation guidelines required by your employer.

11
OPERATING INSTRUCTIONS
Correctly install fittings
1. Although the tool will work with the pressure and return lines backwards, the tool’s
performance will be adversely affected and this may create an unsafe condition in
certain hydraulic systems. The pressure inlet is the smaller forward port.A9/16–18 SAE
fitting (Parker #6) is required. The return outlet requires a 3/4-18 SAE fitting (Parker #8.)
2. At this point, it is important to ensure that any couplers used are the correct type,
and the flow is going in the right direction.
Select Open-Center or Closed-Center NEW O/C SPOOL DESIGN
IMPORTANT! Theoperator of the tool MUSTknow the typeof hydraulic system onwhich the
tool is being used. Failure to observe all warnings and instructions could result in property
damage, severe personal injury, and/or death.
The O/C knob has been engraved with an arrow indicating the direction for the
appropriate OPEN/Closed Center setting.
The O/C spool has been pre-set to an OPEN CENTER configuration at the factory.
To Change spool setting for CLOSED CENTER operation:Turn O/C knob in the Clockwise
direction. (Turn O/C knob completely) HAND TIGHTEN ONLY
NOTE: While using the tool, the operator should check the OC/CC alignment frequently
in the event it becomes inadvertently disoriented.
Installing a driver or drill into the chuck
1. Ensurethepowersupplyisdisconnected.Squeezethetriggertorelieveanyinternalpressure.
2. Pull the chuck away from the front end of the REL-425 as far as it will go.
3. Slide the bit into the anvil. Wear protective gloves: drill bits may cause injury.
4. Release the chuck and ensure it snaps back into position. Check that the bit is being
held securely in place. Using the REL-425
1. Before placing a load on the tool, squeeze the trigger a few times to ensure the
wrench will start and stop correctly and the bit is turning in the right direction.
2. If the inlet and outlet lines are correct and the reversing spool is pushed toward
the right, the anvil should turn clockwise. Check to be sure that the reversing
spool is all the way toward the right or left as needed.
3. The trigger is designed to make it easy to “feather” the REL-425. For safest operation,
squeeze and release the trigger slowly.
4. When the tool is not in use, remove it from the power source.
WARNING
USE ONLYIMPACT STYLE BITS, SOCKETS AND ACCESSORIES
APPROVED FOR IMPACT USE. Bits, sockets, and accessories not
designed for impact applications can break and cause severe injury.
INSPECT BITS, SOCKETS AND ACCESSORIES BEFORE USE.
Discard damaged items. Damaged items can break and cause severe injury.

12
MAINTENANCE
The life, reliability, and safety of the tool is dependent on proper maintenance.
DAILY MAINTENANCE
Clean all surfaces including handle, trigger, chuck, main spool, reversing spool,
fittings, and hoses.
Inspect tool for wear and damage.
Worn or damaged parts can cause malfunction during operation.
Inspect for cracked hoses and leaking fittings.
Check fluid level of the power source reservoir frequently.
All the above items must be replaced with new parts if signs of wear are evident.
FLUID CONTAMINATION: Cover the ends of fittings with a dust cap when disconnected.
This will help keep the fluid from contamination.
MONTHLY MAINTENANCE: Inspect per Appendix A, SAE Standard J1273, 5/86 for
hose or fitting damage such as wear, cracks or leakage, replace the necessary parts.
NOTE: Keep Label Set clean and legible. Replace decals when necessary. Part #RL13100
BEFORE USING THIS PRODUCT
READ THE SAFETY WARNINGS
and recommended practices described
in the manual. Failure by the operator to
read and fully understand the warnings
will leave this person unqualified to use
and operate the tool.
Failure to observe all warnings and instructions could result
in property damage, severe personal injury, and/or death.
ELECTROCUTION
HAZARD
The user should be properly
trained in the correct procedures
required for work on or around
electrical lines.
REL-SM
WARNING
HYDRAULIC FLUIDS
All hydraulic fluids that meet these listed specifications or the listed HTMA
specifications may be used for this tool.
S. U. S.
@ 100OF (38OC)....................................................................... 140 TO 225
@ 210OF (99OC)..................................................................... 40 minimum
FLASH POINT .................................................. 340OF min. (170O C min.)
POUR POINT.. ..................................................... -30OF min. (-34OC min.)
SPECIFICATIONS
Chuck: 7/16 quick change
System: open or closed center
Flow Range: 4 - 8 gpm
(optimum 6 gpm)
Operating Pressure: 1000-2000 psi
REL-425B-SL

13
DISASSEMBLING THE REL-425
ALWAYS WEAR EYE PROTECTION!
Before beginning any repair, the tool must be removed from the power
source and the internal oil pressure must be relieved. Gloves and face
protection should be worn. Carefully remove the inlet and outlet fittings.
Squeeze the trigger and hold for a few seconds, then switch the reversing
spool to the other direction and hold the trigger open again.
NOTE: Complete disassembly should be preformed by factory authorized personnel only!
Refer to the parts drawing while following these instructions.
REMOVING THE TRIGGER
1. Place a solid support under the trigger while driving the two pins (37) out from
the trigger nuts. CAUTION: Failing to properly support the trigger may break the
body casting or bend the main spool (14.)
2. Remove the trigger nuts (5.)
REMOVING THE CHUCK
1. Remove the front ring clip (66) from the anvil. CAUTION: the ring clip may fly off
and strike you or someone standing nearby, and the cap (65) and spring (64) will
want to shoot out when released. Take precautions to prevent these parts from
becoming projectiles.
2. As you slide the nose piece (63) off the anvil, the two bearings (67) may drop out.
If required, for further repair, remove the inner ring clip.
3. Examine the parts carefully and replace any worn or damaged parts. Ensure the
ring clips were not deformed during removal. If in doubt, replace them.
Disassembling the Impact Housing
1. Disassemble on a clean flat surface. Remove the three socket head screws (26.)
Pull the shell (60) away from the body being careful not to loose any parts that
may fall out. The cage (61) with the two hammers (50) and hammer pins (69) will
drop off of the anvil. Take note of how the two identical hammers are set in the
opposite direction of each other. During re-assembly it will not matter which way
they go as long as they are 180° apart.
2. The large pin washer (68), spacer (44), and the thrust washers (10) and bearing
(11) can be removed from the body.
WARNING

14
Removing the Reversing Spool
Note: The spool can be installed or removed from either side.
1. Remove both adjusting caps (82) from the reversing spool. CAUTION: do not use pliers.
to hold the spool while loosening a screw.
2. Push the spool into one side of the body until the O-ring is exposed on the other side.
3. Remove the exposed O-ring.
4. Push the spool back in the opposite direction all the way out of the body. Do not
attempt to push an O-ring all the way through the body.
Disassembling the Motor
NOTE: Oil will run out when the cap is loosened.
1. Remove the eight socket head screws (28) from the back of the motor cap.
2. Pull the cap back just enough to drain the oil into a proper receptacle.
3. Pull the cap all the way off taking care not to lose any of the parts that may fall out.
4. Remove the idler shaft (40), pin (41), and lower gear.
5. Remove the circle clip (13) and upper gear.
6. The drive shaft can be pushed out through the front of the tool. Do not attempt to
pull the drive shaft back through the motor end.
7. Examine the five needle bearings (30) in the body and cap. If the bearings in the
cap are damaged, replace the cap. A new cap is supplied with bearings pressed in.
If the bearings in the body are damaged, return it to the factory for repair or
replace the body with the bearings already pressed in.
Disassembling the Main Spool
Caution: The main spool is spring loaded. Wear proper protection to prevent injury
in the event you lose control of the parts.
1. Drive out the coiled spring pin (37) and remove the OC/CC knob (17).
2. Pull the spool back which will compress the spring and secure it. This can be done by
sliding a thin O-ring pick through the hole where the coiled spring pin came out of and
wedging it over the ear on the back of the body.
3. Remove the spring clip (16) and washer (17) from the trigger end.
4. Carefully release the main spool and allow the spring to decompress.
5. Remove the spring clip (16) and washer (17) from the back end.
NOTE: It is difficult to remove the two spring clips without damaging them. We
recommend replacing the spring clips every time they are removed.
6. Pull the main spool out the back end of the tool. Do not pull the spool out the trigger end.

15
3
2567
8
10
11
14
15
12
Spool Assembly
REASSEMBLING THE REL-425C
NOTE: Before reassembling the REL-425C, inspect all parts for damage or excessive
wear. Nicks or burrs on the corners of the shafts or spools can be fatal to tool life. All old
grease should be removed and the parts should be clean and free of foreign particles.
Itis recommended to replacethe O-rings, thecircle clip, and,most importantly,the two spring
clips (16) on each end of the main spool each time the unit is reassembled.
REASSEMBLING THE MAIN SPOOL (AS REVISED 06/08)
1. ReplacetheO-ringinside the hand body. (Notshownindiagrambelow.See pg 22)
2. ReplacetheO-ring on the main spool.
3. ReplacetheO-ring on the spool stem.
4. Pre-lubricate the passageway where the spool resides and all spool components
with petroleum jelly or hydraulic oil.
5. Reinstallbrass pintle.
6. Threadstem intospoolbodycompletely.(Handtighten only)
7. Insertretainingclip into main spool body
8. Insertflatwasher and retaining ring into triggersideofhandlebody.
9. Slide the spool into the back of the unit so that the narrow end
with roll pin hole protrudes out of the front where the trigger attaches.
10. Inserttriggerspring, support washer and retaining ring. Correct order is important.
11. Re-connect trigger using long roll pin before installing O/C knob.
12. Turn spool stem out until retaining clip stops progress.
13. Squeeze trigger fully and secure with roll pin hole exposed.
14. Install knob onto end of spool stem.Allign roll pin hole with hole in the stem.
(O/C marking orientation is not critical)
15. UsingblueLoctiteRinstall the set screws into OC/CC Knob.
Align set screws with holes in spool body and tighten completely. (Do NOT over tighten)
NOTE: O/C Spool is now in the OPEN CENTER configuration. Adjust accordingly

16
Reassembling the Motor
1. Replace the O-ring (35).
2. Apply petroleum jelly to the drive shaft to help it
slide through the O-ring. Install the drive shaft.
It will only go one way.
3. Install the Key (12). Petroleum jelly will keep it in
place while installing the gear.
4. Install the upper gear (3).
5. Install the circle clip (13).
6. Assemble the lower gear (3), idler shaft (40),
and it’s pin (41) in their place.
7. Install the two dowel pins (31).
8. Install a new gasket (7).
9. Install the motor cap (6).
10. Install the eight socket head screws (28) as shown
with their lockwashers (29).
Replace any screw or lockwasher that appears defective.
A service removable liquid thread adhesive (e.g. blue Loctite®) is recommended.
First snug all screws, then torque in the sequence shown below to 80 in-lbs.
Reassemble the Trigger
1. Install the two trigger nuts (5). Screw the nuts all the way in, then back off
approximately one turn.
2. Lay the unit on its side. Position the trigger over the nuts and place a support
under the trigger.
3. Drive in the two coiled spring pins (37).

17
Reassembling the Impact Housing
NOTE: Use a high quality lithium grease that is rated for at least 250° F. An HP or EP
grease with an NGLI #2 rating is recommend.
1. Thoroughly grease the drive shaft (8).
2. Clean and inspect the thrust bearing (11) and two thrust washers (10) to ensure they
roll freely. If in doubt, replace them. Repack the bearing with grease.
3. Installwith the bearing betweenthetwowashers as shown inthepartslist drawing by
droppingthewasher-bearing-washer over the drive shaftand into the pocket inthebody.
4. Grease the inside of the spacer (44) and drop over the drive shaft.
5. Drop the pin washer (68) over the drive shaft so the raised boss is towards the spacer.
Apply a light coating of grease to the face of the pin washer.
Set the body aside.
6. Thoroughly grease the inside of the anvil bushing (60)
inside the shell (60), and install the anvil (62).
Install adapter flange (70) into body (2) and work O-ring (71)
into positionaround flange.
7. Reassemble the hammers (50) into the cage (61)
using a light coating of grease over entire mechanism.
NOTE: The hammers must be turned 180° from each other.
It does not matter which hammer points up or down as long
as they are opposite. (Refer to illustration shown at right)
8. Install the long pins (69).
9. Apply a coating of grease to the anvil and insert into cage and hammer assembly.
10. Carefully add anvil and hammer assembly to body assembly. (Support hammer pins)
Coat all moving parts liberally with recommended grease.
DO NOT PACK NOSE ASSEMBLYWITH GREASE. This can cause heat build up.
11. Install the shell over the hammer mechanism and onto the body.
12. Install and snug the three screws (26) and lockwashers (27). Use a removable liquid
thread locking compound (e.g.: blue Loctite®).
HAMMERS
R-425C-IM
WASHER,PIN
13169
ADAPTER,
FLANGERING
13193
O-RING
13194
HAMMER,PIN
13168
HAMMER
13150
CAGE
13161
ANVIL
.811INMW/ 1CLIPGROOVE
13172
SHELLW/BUSHING
13192
(3) 9/32”
DRIVEBALL
13191
CHUCK
13173
SPRING
13174
CAP,SPRING
13150
RINGCLIP
13178
68 70 71 69 50 61 62 60 67 63 64 65 66

18
Reassembling the Chuck
1. Install the drive balls (67).
Filling the holes where the drive balls
go with grease will hold them in place.
2. Wipe a thin film of grease over all the end
of the anvil and install the chuck.
3. Insert the anvil spring (64).
4. Insert the spring cap (65) with the flat
side toward the spring (see figure below).
5. Install the forward ring clip (66).
WARNING: Wear face protection.
64
66
65
SPRING

19
Item # Description Part Number # Req.
81 SPOOL,REVERSING 13181 1
82 ADJUSTINGCAP 13182 2
83 PLUG,ADJUSTING 13183 2
84 * O-RING, PLUG (incl. in sealkit) 13184 2
85 PINTLE 13185 2
86 ADJUSTING SCREW,5/16-24FLAT POINT 13186 2
87 LOCK SCREW, 8-32 X 1/4 BRASS TIP 13187 2
88 * O-RING,SPOOL (incl. in seal kit) 13188 2
89 SPRING 13189 2
PRESSURE CONTROLPRESSURE CONTROL
PRESSURE CONTROLPRESSURE CONTROL
PRESSURE CONTROL
SPOOLSPOOL
SPOOLSPOOL
SPOOL ASSEMBLASSEMBL
ASSEMBLASSEMBL
ASSEMBLYY
YY
Y
Assemble the control spool as shown.
Begin with left or right assembly.
NOTE: Do not install adjusting Cap (82)
InsertspooluntillO-ringgroove(A)isseen.
InstallappropriateO-ring,and centerspool.
Assemble opposing side of spool.
InstallAdjusting Caps.(to24 ft. lb.torque)
Test action and torque prior to use in field.
PRESSURE CONTROL SPOOL KIT. - PART # 13179
A
NOTICE: Removalorimproper
repacementof adjustingscrew
(C) may affect torque setting.
C
If torque setting is compromised wrench
relief valve pressure must be reset and
tested by a certified factory technician.
Failureto observe thiswarning can result
in tool failure and serious personal injury.
B

20
REL-425CREL-425C
REL-425CREL-425C
REL-425C
PP
PP
PARAR
ARAR
ARTS DRATS DRA
TS DRATS DRA
TS DRAWINGWING
WINGWING
WING
PRESSURE CONTROL SPOOL
Refer to Page 22