Vessel GT-3500GE Assembly instructions

GT-3500GENEWMODEL
OPERATOR,S INSTRUCTION MANUAL
PORTABLE IMPACT WRENCH
・SPEC TYPE (Documents Included)
・ USA GAS EMISSION CONTROLVERSION(EPA PHASE/CARB Tier1)
・INTERNATIONAL SPEC MODEL
2001 Edition
Tools since 1916
R
99093030.02 Printed in Japan.
Product of Japan
No. 17-25, Fukae Kita 2-chome, Higashinariku, Osaka 537-0001 Japan
Tel :[phone] Fax :[phone]
Manufactured by:
® SPEC TYPE
Email:[email protected] URL http://www.vessel.co.jp/exp/
Copyright VESSEL CO., INC. 2001
C

TECHNICAL DATA -----------------------------------------------------
WARNINGS & SAFETY INSTRUCTIONS ------------------------
OPERATING INSTRUCTION----------------------------------------
TROUBLE SHOOTING ------------------------------------------------
MAINTENANCE INSTRUCTION ------------------------------------
EXPLODED VIEWS AND SPAREPARTS LISTS ---------------
Engine - Exploded Diagram Drawing -------------------------------
Engine - Parts List ------------------------------------------------------
Engine components - Exploded Diagram Drawing -------------
Engine components - Parts List -------------------------------------
Recoil Starter - Exploded Diagram Drawing & Parts List ------
Carburetor - Exploded Diagram Drawing & Parts List ---------
Impact Mechanism - Exploded Diagram Drawing ---------------
Impact Mechanism - Parts List---------------------------------------
1
2〜3
4〜5
6〜8
9〜11
12
13
14
15
16
17
18
19
20
PAGE No.
GASOLINE ENGINE IMPACT WRENCH
OPERATORS MANUAL
& SPAREPARTS LISTS
"PHANTOM" moves quickly!
PORTABLE
PORTABLE
INDEX
CHAPTER 1.
CHAPTER 2.
CHAPTER 3.
CHAPTER 4.
CHAPTER 5.
CHAPTER 6.

TECHNICAL DATA
Note: To improve the performance, the specifications are subject to change without notice.
CHAPTER 1.
INTRODUCTION
Engine Type
Displacement
Fuel Tank Capacity
Fuel Mixture Ratio
Revolution(idling)
Revolution(loaded, impact)
Revolution(non loaded, max)
Maximum Output
Maximum Torque
Compression Rate
Fuel Consumption Rate
:Two Stroke, Forced, Air Cooled, Single Cylinder
: 46.5cc, Φ43x32mm(Inner bore size x stroke)
: 1 liter
: 25:1(gasoline : 2 cycle oil)
: 2700 rpm ±250
: 7120 rpm
: 9880 rpm
: 2.3 Ps/7500 rpm
: 0.34 kg-m/5500 rpm
: 7.1 : 1
: 380 g/Ps.h
Ignition Type
Spark Plug Type : Electronic : NGK BPMR6A
Vibration Unloaded
Loaded : 4m/S2 : 19m/S2
Noise Idle
Loaded : 78dBA : 100dBA
Carburetor Type : Diaphragm
Impact Square Drive Size
Fastening Torque Range
Free Speed
: 25.4 mm(1")
: 1030Nm(Full Throttle : 760ft. lbf)
800Nm(Half Throttle : 590ft. lbf)
: 1200 rpm
Capacity Bolt Diameter : 32 mm (1 1/4")
Weight Without fuel : 19.50 kg (42.99 lbs.)
Overall Dimensions Length
Height
Width
: 700mm (28")
: 330mm (13")
: 390mm (15")
Accessories Hex Key Wrench
Spark Plug Wrench
Spanner
4mm 1pc.
5mm 1pc.
6mm 1pc.
1pc.
10-13mm 1pc.
GT-3500GE GASOLINE ENGINE IMPACT WRENCH is ahigh quality tool with self-contained
heavy duty and high power two cycle engine as power source. And its unique designof impact
mechanism withVESSEL pneumatic V-Hammer ultra light weight impact wrench series,even
small engine (46.5 cc) can create higher fastening torque with enormous light weight only
19.50kg (42.99 lbs.)
Because of self-contained high power two cycle engine, it is veryeasily mobile to carry by one
man to any construction sites in the rain forest, hill or desertsuch remote areas where electricity
supply or air compressor, generator are not available.
The capacityof this tool is 32mm (1 1/4") bolt size and ideal for fastening and loosening bolts
of wood sleepers at railroad construction and many more applications.
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WARNINGS AND SAFETY INSTRUCTIONS
CHAPTER 2.
Read these instructions carefully before operating, maintaining or servicing this tool.
Please keep these instructions in a safe accessible place.
Read to fully understand and
observe the following safety
precautions and warnings.
Careless or improper use of
tool may cause serious or fatal
injury.
WARNING!
Indicates instant possibility of
severe personal injury or loss
of life, if instructions are not
followed.
Always wear eye, head and
ear protectors when using this
tool.
CAUTION!
Indicates apossibility of per-
sonal injury or equipment dam-
age, if instructions are not
followed.
Always wear a safety face shield or goggles.
Always wear heavy, long pants, boots and
gloves. Do not wear loose clothing, jewellery,
short pants, sandals or go barefoot. Secure
hair so it is above shoulder length.
Do not operate that tool when you are tired,
ill or under the influence of alcohol,drugs or
medication.
Never let achild or inexperienced person
operate the machine.
Wear hearing protection.
Never start or run the engine inside a closed
room or building. Breathing exhaust fumes
can kill.
Keep handles free of oil and fuel.
Keep hands away from anvil.
Do not grab or hold the unit by rotating anvil.
Hold the handles firmly with both hands and
make sure to stand on the firm base or ground.
Do not touch spark plug, high voltage cord du-
ring operation as it may cause electric shock.
To avoid burn do not touch those places like
engine, muffler, exhaust where get very hot
during in use or even after stop engine until
it gets cool for the time being.
When operation is prolonged, take abreak
from time to time so that you may avoid pos-
sible whitefingerdiseasewhich is caused
by vibration.
Operator safetyInspectthe entire tool before each use. Re-
place damaged parts. Check for fuel leaks and
make sure all fasteners are in place and se-
curely fastened.
Replace parts that are cracked, chipped or
damaged in any way before using the tool.
Keep others away when making carburetor
adjustments.
Use only accessories as recommended for this
tools by the manufacturer.
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Tool safety
Never modify the tool in any way. Do not use
your tool for any job except that for which it is
intended.
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Fuel safety
Mix and pour fuel outdoors and where there
are no sparks or flames.
Use a container approved for fuel.
Do not smoke or allow smoking near fuel or
the tool or while using the tool.
When filling up fuel, stop engine and make
sure engine is cool and choose the places
where no flamables and well ventulation.
Wipe up all fuel spills before starting engine.
WARNING!

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Maintain the tool according to recommended
procedures.
Disconnect the spark plug before performing
maintenance except for carburetor adjust-
ments.
Keep others away when makingcarburetor
adjustments.
Use only genuine replacement parts as rec-
ommended by the manufacturer.
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Maintenance safety
Carry the tool by hand with the engine stopp-
ed and the muffler away from your body.
Allow the engine to cool, empty the fuel tank,
and secure the tool before storing or trans-
porting in a vehicle.
Empty the fuel tank before storing the tool. It
is recommended that the fuel be emptied
after each use. If fuel is left in the tank, store
so fuel will not leak.
Store tool out of the reach of children.
Clean the unit carefully and store it in a dry
place.
Make sure engine switch is off when trans-
porting or storing.
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Transport and storage
If situations occur which are not covered in this
manual, take care and have a good judgement.
Contact your dealer if you need assistance.
Move at least 3m away from fueling site before
starting engine.
Stop engine before removing fuel cap.
Empty the fuel tank before storing the tool. It is
recommended that the fuel be emptied after
each use. If fuel is left in the tank, store so fuel
will not leak.
Store tool and fuel in area where fuel vapors
cannot reach sparks or open flames from
water heaters, electric motors or switches,
furnances, etc.
Antivibration systems do not guaranteethat
you will not sustain whitefinger disease or car-
pal tunnel syndrome.Therefore, continual
and regular users should monitor closely the
condition of their hands and fingers. If any of
the above symptoms appear, seek medical
advice immediately.

WARNING!
(7)
(8)
(9)
( 10 )
OPERATING INSTRUCTION
CHAPTER 3.
Use only quality two cycle oil with gasoline at mixture ratio of 25:1
(Gasoline : Two cycle oil) (FIG. 3)
1.FUEL
*Never use by gasoline only as engine will burn.
(1)
(2)
(3)
(4)
(5)
(6)
Place the tool on a firm stand or solid floor.
Set gear change lever to neutral (N) position. (FIG. 3-2)
Press priming bulb several times so that fuel flows through bulb
into carburetor. (FIG.3-3)
Turn choke lever to closed position. (FIG. 3-4)
Pull throttle lever,and then press the support button.
then the throttle lever is stayed there in the state of half-throttle,
and won't be back to the original location. (FIG.3-5)
Pull recoil starter handle strongly, taking care to keep the handle
in your grasp and not allow to withdraw rope until the end. (FIG.3-6)
After initial fires, engine will continue to run, return choke lever
slowly to open position.
If engine will stop after a few fires by procedure of (7), return choke
lever to open position and pull recoil starter handle strongly again.
If engine does not start by procedure of (8), repeat procedures
from (4).
After starting engine, return throttle lever to idle positionfor
slow engine. Then allow the engine about2〜3minutes to
warm up before in use.
2.START UP ENGINE
WARNING!
CAUTION!
Do not smoke and keep all other fire away from fuel tank during
filling fuel as it causes fire or burn yourself. (FIG .3-1)
*Once starting the engine, do not leave tool alone. Always hold han-
dle tightly so that tool will not move around on the stand or floor.
*Before and during operation, always take a firm stance and keep
safety position from slipping of falling down.
Wipe up all fuel spills before starting engine.
CAUTION!
Return recoil starter rope gently to its original position.
Fill up fuel after well mixed fuel and oil in a separate clean container.
WARNING!
25 1
GASOLINE TWO CYCLE OIL
GEAR CHANGE LEVER
(FIG.3)
(FIG.3-1)
OIL POT PORT
(FIG.3-2)
PRIMING BULB
CLOSED
OPEN
CHOKE LEVER
(FIG.3-3)
(FIG.3-6)
(FIG.3-4)
PRESS
(FIG.3-5)

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6
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5
OPEPATING INSTRUCTION
CHAPTER 3.
(1)
(2)
(3)
(4)
Select R(for clockwise direction) or L(counter clockwise di-
rection) gear for fastening or loosening bolts and nuts.
Always release throttle lever to allow slow engine for idling and
turn gear change lever and do not change gear when engine is
accelerating.
This new model has implemented an adjustment button in order
to operate two different torque values.
A.FULL THROTTLE(MAXIMUM TORQUE)1030 Nm
If you squeeze the throttle lever fully, the machine shows the
maximum torque,1030Nm.
B.HALF THROTTLE(MEDIUM TORQUE) about 800Nm
1.Press the adjustment button.
2.Squeeze the throttle lever and the adjustment valve will
prevent the throttle lever from moving further more. In other
words, the throttle lever would hit at the adjustment valve
and would not create further torque. (FIG.3-8)
Fine tune might be required by turning adjustment button from
number 1 to 3. The number should be set at the yellow sign area.
(FIG.3-9)
Once bolts or nuts fastened, release throttle lever for idling and
not allow driving shaft turn and remove socket from bolts or nuts.
3.OPERATION.
(1)
(2)
(3)
Release throttle lever to decrease engine speed.
Push stop switch to stop engine. (FIG. 3-10)
Place the tool on firm stand or solid floor and turn gear change
lever to N (neutral) position.
4.STOPPING ENGINE
TROUBLE SHOOTING - 1
CHAPTER 4.
ENGINE DOES NOT START Fill up fuel at mixture ratio 25 gasoline : 1 two cycle oil
1. Remove spark plug 2. Exhaust exceeded fuel by pulling recoil starter handle 5-6 times 3. Install spark plug 4. Turn choke lever to open position and pull recoil starter handle Repair Air leak from carburetor Incorrect carburetor adjustment Bad diaphragm in carburetor Incorrect carburetor valve hinge height adjustment
<Fuel System>
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Empty fuel or shortage Wet spark plug due to too much intake of fuel Bent or disconnection of fuel pipe Poor function of carburetor
<Electrical system>
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Ignition stop switch in stop position No spark Short circuit of stop switch lead wire Dirty plug Wider spark plug gap Poor connection of high voltage cord in ig- nition with spark plug Bad ignition coil
CORRECTIVE ACTIONPROBABLE CAUSESYMPTOM
Turn to on position 1. Bad connection/Ignition coil 2. Incorrect air gap/Ignition coil 3. Bad ignition coil Repair or replace Clean up or replace Adjust correct gap to 0.6 mm Correct connection Replace
CROSS SECTION SKETCH
Adjustment button
Throttle lever
move
move
PRESS
Throttle lever
ADJUSTMENT BUTTON
2
3
2
1
Yellow Sign
STOP SWITCH
(FIG.3-8)
(FIG.3-9)
(FIG.3-10)

TROUBLE SHOOTING - 2
CHAPTER 4.
ENGINE INSTALLED
SOON AFTER
STARTING OR IS
LIKELY TO STOP
Fill up fuel at mixture ratio of 25 gasoline : 1 two cycle oil
Turn to open position
Check if cracks are found on pipe or connector and pipe is securely
fixed
Air leak from carburetor
Incorrect carburetor adjustment
Bad diaphragm in carburetor
Incorrect carburetor valve hinge height adjustment
<Fuel System>
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Shortage of fuel
Choke lever in closed position
Air goes through to fuel system
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Poor function of carburetor
<Electrical system>
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Bad spark plug
Bad ignition coil
CORRECTIVE ACTIONPROBABLE CAUSESYMPTOM
Replace
Replace
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7
CHAPTER 4.
ENGINE
OVERHEATS ●
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TROUBLE SHOOTING - 3
Bad mixture ratio fuel
Wrong selection of spark plug
Clogged cylinder with dirt
Clogged cooling duct with dirt
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Gear change lever in neutral position

Worn out of drum shoe on clutch arm
Fill up correct mixture ratio fuel at 25 gasoline : 1 two cycle oil
Replace. Use pure and instructed parts only
Clean up
Clean up
Turn to R(clockwise direction) or L(counter clockwise direction)
position
Replace
NON-REVOLUTION
OF ANVIL SHAFT
CORRECTIVE ACTIONPROBABLE CAUSESYMPTOM
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Dirty air cleaner element
Carbon deposits in muffler, exhaust port on
cylinder
Poor cylinder pressure due to worn out of
piston, piston ring, cylinder
Worn out of anvil
Worn out of clutch
Worn out of cam plate
Worn out of hammer
Broken of return spring
Clean up
Clean up

Replace

Replace
Replace
Replace
Replace
Replace
OUTPUT POWER
REDUCTION

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9  10
MAINTENANCE INSTRUCTION
CHAPTER 5.
It is recommended to practice regular check-up and maintenance in accordance with usage
frequency to keep your tool better condition and long life and eventually it reduces total run-
ning costs.
This practice also protects you from serious injuries.
* Rinse the fuel tank with gasoline.
* Clean the exterior of the carburetor and the space around it.
* Clean the fan and the space around it.
(1)
(2)
(3)
When the engine is test run at the factory, the carburetor is properly adjusted, do not try to
touch it.
When idle speed is higher(when the anvil is rotating) or lower(engine will stop), adjust to
correct speed by idle adjustment screw.
How to adjust L adjustment screw(lower speed fuel adjust-
ment) and H adjustment(higher speed fuel adjustment)
1. CARBURETOR ADJUSTMENT
MAINTENANCE/CHECK-UP/REPAIRING
Daily Check-Up
* Check all nuts and screws are securely tightened.
* Check fuel level, and when filling up fresh fuel, wipe up spill and clean fuel tank.
* Check oil level of gear box through window. Oil level should be center of window and if
lower than this level, add oil to this level.
Weekly Maintenance
* Check the starter, especially cord and return spring.
* Clean the exterior of the spark plug.
* Remove spark plug and check the electrode gap. Adjust it to 0.6 mm, or change the
spark plug.
* Clean the cooling fins on the cylinder and check that the air intake at the starter is not
clogged.
* Clean the air filter.
Monthly Maintenance
Turn to clockwise for higher idle
Turn to anti clockwise for lower idle (FIG. 5-1)
①
②
③
Under idle condition, turn L adjustment screw to right or
left to look for the peak of idle speed. And from this position,
return adjustment screw to the left 1/8-1/4 turn.
Full open throttlelever and turn H adjustment screw to
right or left and follow the same procedures as L adjust-
ment screw explained.
Standard return screw degrees are :
L adjustment screw : 1 1/8 return from full closed
H adjustment screw : 1 1/8 return from full closed
(1)Remove spark plug and touch it to metal part except spark plug mounting thread.
(2)Pull recoil starter handle.
2. CHECK-UP SPARK CONDITION
* Never touch spark plug to the area at spark plug mounting
thread since remaining gas might be exploded.
* When pulling recoil starter handle, do not touch the metal part
of spark plug or you will get electric shock.
* After wipe and clean up fuel around the place where spark plug
to touch and  make sure no fire possibility and check spark plug.
(3)When in normal condition, you see spark.
(1)Use recommended type of spark plug.
(2)In a best operation condition, electrodes on the spark plug show dark brown and keep dry.
If the spark plug is dirty, clean it and check the electrode gap. If readjustment is necessary,
the correct gap is 0.6mm.
The spark plug condition is influenced by the following factors ;
* An incorrect carburetor setting.
* Wrong fuel mixture (too much oil in the gasoline).
* A dirty air filter.
* Hard running conditions (under cold weather operation).
The spark plug should be replaced after about 100 operation hours or earlier if the electro-
des are badly eroded.
3. SPARK PLUG (FIG. 5-2)
(1)When the air filter gets dirty and closed with dust, it will cause various troubles :
* Carburetor malfunctions.
* Starting problems.
* Engine power reduction.
* Unnecessary wear on the engine parts.
* Abnormal fuel consumption.
(2)Cleaning the air filter
Air filter must be cleaned from dust and dirt regularly and
damaged filter must be replaced with a new one.
* Remove the air filter cover and the filter.
* Rinse it in warm soap suds and wring tight and dry it before
re-assembly.
* Damaged air filter must be replaced with a new one.
4. AIR FILTER (FIG. 5-3)
WARNING!
WARNING!
IDLE ADJUSTMENT SCREW
(FIG.5-1)
(FIG.5-2)
REMOVE CARBON
(FIG.5-3)
AIR FILTER
(CLEANER SPONGE)
0.6mm

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11   12
(1) 5. FUEL FILTER (FIG. 5-4) If fuel filter is clogged with impurities in the fuel,
fuel will not flow into carburetor and it will make
engine malfunction. Regular check-up is recom-
mended.
* Drain all fuel from fuel tank and pull out fuel
filter line from tank.
* Pull filter element out of holder assembly and
rinse element in warm water with detergent.
* Rinse thoroughly until all traces of detergent
are eliminated.
* Squeeze, but do not wring and keep dry.
* If element is too dirty, replace it.
(1) Engine power reduction maybe cause by a lot of
carbon accumulated around exhaust port on
cylinder, muffler inlet or outlet in the long use.
Regular clean-up is recommended.
* Remove the muffler and clean up any excess
carbon from the exhaust port or muffler inlet
every 100 hours of operation.
* When cleaning up, remove carbon carefully not
to hurt piston, cylinder and do not let carbon
into crank case.
6. MUFFLER (FIG. 5-5)
(1) When contact places of anvil and hammer become worn-out to be dull by percussion, the tool
becomes output power reduction and due to extra longer percussion than normal condition
it will cause damage and earlier broken of parts.
* Empty all oil in the gear box and remove hammer housing completeand check the degree
of worn-out of anvil and hammer at least once every month. And give grease around hitting
area.
7. IMPACT MECHANISM
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Clean each part and apply two cycle oil on the metal part to prevent from corrosion.
To keep tool for a long time(more than 3 weeks), drain fuel from fuel tank and keep running
engine without load until the engine will stop and exhaust all remaining fuel in the carburetor.
Remove spark plug and pure two cycle oil into cylinder and pull recoil starter handle several
times to spread oil.
Stop the recoil starter handle when you feel engagement.
Damaged parts should be repaired before storage.
Keep the tool where the place without dust, humidity also the temperature below 50 ℃.
Store tool out of the reach of children.
Keep fuel into safety container in the cool room or place where no flammable. And do not
use stale fuel as it causes engine troubles.
8. STORAGE
1.
2.
3.
4.
5.
6.
When order for spareparts, please indicate index number, part name
and quantity.
Quantity as number required here is for one unit.
V marks indicate over-size shims for precise adjustment.
Minimum order is 10 pcs. or more for such small items like screws,
nuts and washers.
Each spareparts for engine is not supplied but as assembly or com-
plete set only except spark plug.
Specifications are subject to change without notice.
EXPLODED VIEWS AND SPAREPARTS LISTS
CHAPTER 6.
SPAREPARTS ORDER
=
NOTE
=
(FIG.5-4)
(FIG.5-5)