user manual - PolarTools
Contents
1. ted tool as recommended in the instruction hand book to prevent an unnecessary increase in vibra tion levels Sleeve fittings should be used where practicable Support the weight of the tool in a stand tensioner or balancer if possible Hold the tool with a light but safe grip taking account of the required hand reaction forces because the risk from vibration is generally greater when the grip force is higher ADDITIONAL SAFETY INSTRUCTIONS FOR PNEUMATIC POWER TOOLS 1 J Always shut of air supply drain hose of air pressure and disconnecttoolfromairsupplywhennotinuse before changing accessories or when making repairs Never direct air at yourself or anyone else Whipping hoses can cause severe injury Always check for damaged or loose hoses and fittings Cold air shall be directed away from the hands Do not use quick disconnect couplings at tool inlet for impact and air hydraulic impulse wrenches Use hardened steel or material with comparable shock resistance threaded hose fittings Whenever universal twist couplings claw coup lings are used lock pins shall be installed and whip check safety cables shall be used to safeguard against possible hose to tool and hose and hose connection failure Do not exceed the maximum air pressure stated on the tool For torque control and continuous rotation tools the air pressure has a safety critical effect on per formance Therefore requirements for length and diameter o2. Bearing Cylinder Spring Pin Rotor Blade 6 Rotor Rear Plate Ball Bearing Rear Gasket O Rear Cover Screw 4 O Ring Steel Ball Spring Reverse Valve Trigger O Ring Muffler Retainer Valve Stem Spring Exhaust Deflector O Ring O Washer Hose Adaptor 18NPT Service Kit O Rebuilt Kit TECHNICAL SPECIFICATION PRODUCT TYPE 1 2 professional composite impact wrench MODEL 6100 1012 RPM R MIN 6500 10 WEIGHT 2 02kg 4 45 Ibs AIR PRESSURE 6 3 bar 90 PSI RECOMMENDED MAXIMUM HOSE LENGTH 50 ft 10m RECOMMENDED MINIMUM HOSE BORE 3 8 10mm DIAMETER NOISE LEVEL LOAD NO LOAD SOUND PRESSURE 96 1 91 6 dB A LEVEL SOUND POWER 107 1 108 6 dB A LEVEL MEASUREMENT UNCERTAINTY K 3dB Tested in accordance with EN ISO 15744 RECOMMENDED PERSONAL SAFETY EQUIPMENT VIBRATION LEVEL 9 44 m sec MEASUREMENT UNCERTAINTY K 1 5 m sec Tested in accordance with EN ISO 28927 2 OTHER DATA AIR INLET 1 4 6 3 mm BOLT CAPACITY 5 8 16mm TORQUE 900 ft lb 125 kg m 1220 Nm AVERAGE AIR 140 L min CONSUMPTION 4 8 cfm OVERALL LENGTH 6 50 122 mm OVERALL WIDTH 2 88 64 mm OVERALL HEIGHT 8 27 198 mm SQUARE DRIVE 1 2 CLUTCH TYPE Twin hammer USE Safety glasses and ear protectors PARTS NO P6100 1012 01 P6100 1012 02 P6100 1012 03 P6100 1012 04 P6100 1012 05 P6100 1012 06 P6100 1012 07 P6100 1012 08 P6100 1012 09 P61
3. firm grip and footing and be aware that when loosening fasteners the tool can move quite quickly away from the fastener being undone An allowance must always be made for this rearward movement so as to avoid the possibility of hand arm body entrapment 1 Do not connect a quick connect coupling directly to the tool but use a whip or a leader hose of say approxi mately 12 inches 300 mm length Do not connect the tool to the airline system without incorporating an easy to reach and operate air shut off valve The air supply should be lubricated It is strongly re commended that an air filter regulator lubricator FRL is used as shown in Figure 1 as this will supply clean lubricated air at the correct pressure to the tool Details of such equipment can be obtained from your supplier If such equipment is nit used then the tool should be lubricated by shutting off the air supply to the tool depressurizing the line by pressing the trigger on the tool Disconnect the air line and pour into the intake bushing a teaspoonful 5 ml of a suitable pneumatic motor lubricating oil preferably incorporating a rust in hibitor Reconnect tool to air supply and run tool slow ly for a few seconds to allow air to circulate the oil If tool is used frequently lubricate on daily basis and if tool starts to slow or lose power When lubricating also ensure that screen in intake bushing is clean It is recommended that the air pressure at the tool whi
4. 00 1012 10 P6100 1012 11 P6100 1012 12 P6100 1012 13 P6100 1012 14 P6100 1012 15 P6100 1012 16 P6100 1012 17 P6100 1012 18 P6100 1012 19 P6100 1012 20 P6100 1012 21 P6100 1012 22 P6100 1012 23A P6100 1012 24 P6100 1012 25 P6100 1012 26 P6100 1012 27 P6100 1012 28 P6100 1012 29 P6100 1012 30 P6100 1012 31 P6100 1012 32 P6100 1012 33 P6100 1012 34 P6100 1012 35 P6100 1012 36 P6100 1012 37 P6100 1012 38 P6100 1012 39 P6100 1012 40 P6100 1012 41 DESCRIPTION Oil Seal Hammer Case Bushing Anvil Collar O Ring Anvil Hammer Cage Hammer Pin 2 O Hammer Dog 2 Washer Front Gasket Motor Housing O Ring Steel Ball Spring Reverse Valve Retainer Valve Stem Spring Exhaust Deflector O Ring O Washer Hose Adaptor 18NPT Muffler Regulator Knob Trigger O Ring O Ring Ball Bearing Oil Seal Cylinder Spring Pin Rotor Blade 6 Rotor Rear Plate Ball Bearing Rear Gasket 9 Rear Cover Screw 4 Service Kit O Rebuilt Kit
5. 105 2 100 1 dB A LEVEL MEASUREMENT UNCERTAINTY K 3dB Tested in accordance with EN ISO 15744 RECOMMENDED PERSONAL SAFETY EQUIPMENT LOAD NO LOAD SOUND PRESSURE 94 2 89 1 dB A VIBRATION LEVEL 9 69 m sec MEASUREMENT UNCERTAINTY K 1 5 m sec Tested in accordance with EN ISO 28927 2 OTHER DATA AIR INLET 1 4 6 3 mm BOLT CAPACITY l J 2 15mm TORQUE 450 ft lb 62 kg m 610 Nm AVERAGE AIR 120 L min CONSUMPTION 4 2 cfm OVERALL LENGTH 4 81 122 mm OVERALL WIDTH 2 52 64 mm OVERALL HEIGHT 7 80 198 mm SQUARE DRIVE 1 2 CLUTCH TYPE Twin hammer USE Safety glasses and ear protectors PARTS NO P6100 0012 01 P6100 0012 02 P6100 0012 03 P6100 0012 04 P6100 0012 05 P6100 0012 06 P6100 0012 07 P6100 0012 08 P6100 0012 09 P6100 0012 10 P6100 0012 1 1 P6100 0012 12 P6100 0012 13 P6100 0012 14 P6100 0012 15 P6100 0012 16 P6100 0012 17 P6100 0012 18 P6100 0012 19 P6100 0012 20 P6100 0012 21 P6100 0012 22 P6100 0012 23 P6100 0012 24 P6100 0012 25 P6100 0012 26 P6100 0012 27 P6100 0012 28 P6100 0012 29 P6100 0012 30 P6100 0012 31 P6100 0012 32 P6100 0012 33 P6100 0012 34 P6100 0012 35 P6100 0012 36 P6100 0012 37 P6100 0012 38A P6100 0012 40 P6100 0012 41 DESCRIPTION Oil Seal Regulator Knob Hammer Case Bushing Anvil Collar O Ring Anvil 1 2 DR Hammer Pin 2 O Hammer Dog 2 Hammer Cage Front Gasket 9 Motor Housing O Ring Washer Ball
6. CE EC DECLARATION OF CONFORMITY WE POLAR TOOLS APS Soldalen 9 DK 7100 Vejle Denmark Declare in sole responsibility that the equipment EQUIPMENT AIR IMPACT WRENCH MODEL SERIAL NO 6100 0012 6100 1012 to which this declaration applies complies with these normative documents MACHINERY DIRECTIVE 2006 42 EC and conforms to the following EN standards EN ISO 12100 2010 EN ISO 11148 6 2010 Authorized representative established within the EU if applicable Company Name Polar Tools Aps Company Address Person responsible for compiling the technical file established within the EU Name Surname _ Mikael Linde Address Note This declaration becomes invalid if technical or operational Jens Gr ns Vej 1 DK 7100 Vejle Denmark Read the operator s instructions before operating the tool Wear eye protection device Soldalen 9 DK 7100 Vejle Denmark Wear ear protection device modifications are introduced without the manufacturers consent Name and Signature Position Title Mikael Linde Owner Date and place Denmark December 12 2012 nalar SERENAN OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Includes foreseen use work stations putting into service operating dismantling assembly and safety rules IMPORTANT PRODUCT TYPE 1 2 PROFESSIONAL COMPOSITE IMPACT WRENCH MODEL 6100 0012 6100 1012 Read these instructions carefully before i
7. ced gloves 4 Do not wear loose fitting gloves or gloves with cut or frayed fingers 5 Never hold the drive socket or drive extension 6 Keep hands sway from rotating drives SAFETY PRECAUTIONS FOR OPERATING HAZARDS 1 The use of the tool can expose the operator s hands to hazards including crushing impacts cuts and abrasions and heat Wear suitable gloves to protect hands 2 Operators and maintenance personnel shall be physically able to handle the bulk weight and power of the tool 3 Hold the tool correctly be ready to counteract normal or sudden movements and have both hands available ly Maintain a balanced body position and secure footing Release the start and stop device in the case of an interruption of the energy supply Use only lubricants recommended by the manufacturer Do not use in confined spaces and beware of crushing hands between tool and workpiece espe cially when unscrewing SAFETY PRECAUTIONS FOR REPETITIVE MOTIONS HAZARDS 1 When using a power tool for the operator can experience discomfort in the hands arms shoulders neck or other parts of the body While using an assembly power tool for threaded fasteners the operator should adopt a comfortable posture whilst maintaining secure footing and avoiding awkward or off balanced postures The operator should change posture during extended tasks which can help avoid discomfort and fatigue If the operator experiences symptoms such as p
8. e a hazard if damaged by use of the tool SAFETY PRECAUTIONS FOR DUST AND FUME HAZARDS 1 Dust and fumes generated when using assembly power tools for threaded fasteners can cause ill health for example cancer birth defects asthma and or dermatitis risk assessment and implementation of appropriate controls for these hazards are essential Risk assessment should include dust created by the use of the tool and the potential for disturbing existing dust Direct the exhaust so as to minimize disturbance of dust in a dust filled environment Where dust or fumes are created the priority shall be to control them at the point of emission All integral features or accessories for the collection extraction or suppression of airborne dust or fumes should be correctly used and maintained in accor dance with the manufacturer s instructions Use respiratory protection in accordance with employer s instructions and as required by occupa tional health and safety regulations SAFETY PRECAUTIONS FOR NOISE HAZARDS 1 Unprotected exposure to high noise levels can cause permanent disabling hearing loss and other pro blems such as tinnitus ringing bussing whistling or humming in the ears Risk assessment and implementation of appropriate controls for these hazards are essential Appropriate controls to reduce the risk may include actions such as damping materials to prevent work pieces from ringing Use hear
9. ear approved safety goggles if work in dusty This also applies to other persons in the near by vicinity 13 Do not wear loose clothing or jewelry They can be caught in moving parts Rubber gloves and non skid foot wear are recommended when working out doors Wear protective hair covering to contain long hair 14 Keep proper footing and balance at all times 15 Use clamps or a vice to hold work piece It is safer than using your hand and free both hands to operate the air tool 16 When not use before performing service or chan ging accessories please disconnect tool from air compressor 17 Do not carry plugged in air tool with your finger on the switch trigger Be sure switch is in the OFF position when connecting to air supply 18 Watch what you are doing 19 Use common sense even unsafe situation or un balanced positions particularly when you are tired 20 Air powered tools can vibrate in use Vibration repetitive motions or uncomfortable positions may be harmful to your hands or arms Stop using any tool if discomfort tingling feeling or pain occurs Seek medical advice before resuming use 21 For multiple hazards read and understand the safety instructions before installing operating repairing maintaining changing accessories on or working near the assembly power tool for threaded fasteners Failure to do so can result in serious bodily injury 22 Only qualified and trained operators should install adj
10. ersistent or recurring discomfort pain throbbing aching tingling numbness burning sensations or stiffness these warning signs should not be ignored The operator should tell the employer and consult a qualified health professional SAFETY PRECAUTIONS FOR ACCESSORY HAZARDS il Disconnect the assembly power tool for threaded fasteners from the energy supply before changing the inserted tool or accessory Do not touch sockets or accessories during impac ting as this increases the risk of cuts burns or vibration injuries Use only sizes and types of accessories and consum ables that are recommended by the assembly power tool for threaded fasteners manufacturer Use only impact wrench rated sockets in good condition as poor condition or hand sockets and accessories used with impact wrenches can shatter and become a projectile SAFETY PRECAUTIONS FOR WORKPLACE HAZARDS i Slips trips and falls are major causes of workplace injury Be aware of slippery surfaces caused by the use of the tool and also of trip hazards caused by the air line or hydraulic hose Proceedwithcarein unfamiliar surroundings Hidden hazards such as electricity or other utility lines can exist The assembly power tool for threaded fasteners is not intended for use in potentially explosive atmos pheres and is not insulated against coming into contact with electric power Make sure there are no electrical cables gas pipes etc that can caus
11. ersonal accessories from closing to the moving part to reduce the risk of being caught trapped or drawn in the rotating spindle MAINTENANCE INSTRUCTION iL 2 Dry the filter and the air inlet of the tool Lubricate the quick connect coupling to prevent blocking Air tool require lubrication throughout the life of the tool The air motor and bearing uses compres sed air to start the tool The moisture in compres sed air will rust the air motor you must lubricate the motor daily Avoid storing the tool in a location subject to high humidity If the tool is left as it is used the residual moisture inside the tool can cause rust Before storage lubricate tool and run it for a few seconds Regular inspection of spindles threads and clam ping devices in respect of wear and tolerances for location of abrasive products If the tool is too seriously damage to be used any more recycle raw material instead of disposing as waste The machine accessories and packaging should be sorted for environmental friendly recyc ling Check with your local authority or retailer for recycling advice 6100 0012 1 2 STUBBY COMPOSITE IMPACT WRENCH 6100 1012 1 2 COMPOSITE IMPACT WRENCH TECHNICAL SPECIFICATION PRODUCT TYPE 1 2 stubby professional composite impact wrench MODEL 6100 0012 RECOMMENDED MAXIMUM HOSE LENGTH RECOMMENDED MINIMUM HOSE BORE 35 8 10mm DIAMETER NOISE LEVEL LEVEL SOUND PowER
12. ety instructions in the user s manual GENERAL SAFETY RULES 1 Watch the tool at all times when in use 2 People under the influence of alcohol or drugs are not allowed to use repair or maintain the tools 3 Keep unqualified persons children etc away from the tool 4 Keep work area clean and with sufficient daylight or artificiallighting Theworkareaonwhichthemachine is used must be cleaned up Disorder is potential cause of accidents 5 Danger of explosion Never use oxygen and combus tible gas as an air supply for the tool which many be ignited by spark and cause fire or explosion 6 Never use gasoline or other flammable liquids to clean the tool 7 Do not use air tools in potentially explosive atmos oheres such as in the presence of flammable liquids cleaning solvents fluid energy or stored gases 8 Do not expose air tools to rain Do not use air tools in damp or wet locations 9 When a fault or failure is detected the tool must immediately be disconnected from the air supply and returned for repair 10 It is not permitted to modify the tool in any way 11 When notin use keep tools in a dry place either loc ked up ori a high place out of the reach of children Do not force small air tools to do the job of a heavy duty task Do not use air tool for purpose of which was not intended 12 Wear suitable ear protection at environment noise level gt 80db A and safety spectacles when using the tool Always w
13. f the hose shall be specified Never carry an air tool by the hose WARNING 1 The tool shall not be used in explosive atmospheres unless specially designed for that purpose The tool is not electrically insulated Do not use where there is a possibility of coming into contact with live electricity Unexpected tool movement due to reaction forces or breakage of inserted tool or reaction bar may cause injuries Preferably shut off the air supply before changing socket or at least ensure that the hands are well clear of the operating trigger Be aware of the risk of crushing by torque between a reaction bar and the workplace When loosening fasteners first ensure that there is sufficient clearance behind the tool to avoid hand entrapment The tool will move away from the threaded joint as the nut bolt etc is loosened and rides up the thread moving the tool with it There is a risk of being injured specially when unscrewing in confined work place if hands are not kept away from the reaction bar Keep hands sway from the nut runner socket In case of nut runner socket failure it may danger to person from high speed splinters being emitted from impact wrench Be aware of the whipping compressed air hose Always ensure that the reverse valves is in the correct position before operating the tool Do not run the tool unless the socket is first located on the joint Prevent the loose clothes long hair or any other p
14. ing protection in accordance with emplo yer s instructions and as required by occupational health and safety regulations Operate and maintain the assembly power tool for threaded fasteners as recommended in the instruc tion handbook to prevent an unnecessary increase in noise levels If the assembly power tool for threaded fasteners has a silencer always ensure it is in place and in good working order when the assembly power tool for threaded fasteners is operating Select maintain and replace the consumable inser ted tool as recommended in the instruction hand book to prevent an unnecessary increase in noise SAFETY PRECAUTIONS FOR VIBRATION HAZARDS 1 Exposure to vibration can cause disabling damage to the nerves and blood supply of the hands and arms Keep the hands away from the sockets Wear warm clothing when working in cold condi tions and keep your hands warm and dry If you experience numbness tingling pain or white ning of the skin in your fingers or hands stop using 10 the assembly power tool for threaded fasteners tell your employer and consult a physician Operate and maintain the assembly power tool for threaded fasteners as recommended in the instruc tion handbook to prevent an unnecessary increase in vibration levels Do not use worn or ill fitting sockets or extensions as this is likely to cause a substantial increase in vibration Select maintain and replace the consumable inser
15. lst the tool is running at 90 psi 6 3 bar The tool can run at lower and higher pressure with the maximum permitted working air pressure of 100 psi 7 0 bar For a lower air pressure the tool will give a lower output for a given setting of the sir regulator set for 90 psi 6 3 bar operation and increased output for higher pres sure Hence it is possible that changes in supply pres sure can give situation where the fastener is under over tightened For changes in pressure the regulator posi tion and application should be reassessed It is recom mended that joint tightness of the threaded fastener assembly be checked with suitable measuring equip ment Follow the national legislation of waste disposal PUTTING INTO SERVICE AIR SUPPLY Use a clean lubricated air supply that will give a mea sured air pressure at the tool of 90 psi 6 3 bar when the tool is running with the trigger fully depressed And the air regulator in its maximum opening flow position Use recommended hose size and length It is recom mended that the tool is connected to the air supply as shown in figure 1 FIGURE 1 All pipe and fitting N A should be 1 2 or larger 7 Compressor with sufficient capacity to maintain recommended working pressure at each tool outlet Take air from top Low Easy to reach and spot operate shut off valve Va Air tool Air regulator set at recommended working air pressure Drain daily Reco
16. mmended air supply system OPERATING The output of the impact wrench in prime working condition is governed by mainly three factors a The input air pressure b The time the impact wrench is operated on joint Normal time for joints of average tension requirement 3 to 5 seconds c The setting of air regulator for a given joint at a given pressure operated for a given time The air regulator can be used to the regulate the out put of the impact wrench if no other control means is available It is strongly recommended that an external pressure regulator ideally as part of a fitter regulator lubricator FRL is used to control air inlet pressure so that the pressure can be set to help control the tension required to be applied to the threaded fastener joint There is no consistent reliable torque adjustment on an impact wrench of this type However the air regulator can be used to adjust torque to the approximate tight ness of known threaded joint To set the tool to the de sired torque select an nut or screw of known tightness of the same size thread pitch and thread condition as those on the job Turn air regulator to low position ap ply wrench to nut and gradually increase power turn regulator to admit more air until nut moves slightly in the direction it was originally set The tool is now set to duplicate that tightness note regulator setting for future use When tightness nuts not requiring critical torque values
17. nstalling operating servicing or repairing this tool Keep these instructions in a safe accessible place MANUFACTURER SUPPLIER Polar Tools ApS Soldalen 9 DK 7100 Vejle Denmark Tel 45 7584 1122 Fax 45 6980 4374 E mail info polartools com www polartools com ORIGINAL INSTRUCTION FORESEEN USE OF TOOL The impact wrench is designed for the tightening and loosening of threaded fasteners within the range as specified by manufacturer It should only be used in conjunction with suitable impact type 1 2 13 mm square female driver nut running sockets Only use sockets which are of the impact type It is allowed to use suitable extension bars universal joints and socket adaptors between the square out out driver of the impact wrench and the square female drive of the socket Do not use the tool for any other purpose than that specified without consulting the manufacturer or the manufacturer s authorized suppli er To do so may be dangerous Never use an impact wrench as hammer to dislodge or straighten cross threaded fasteners Never attempt to modify the tool for other uses and never modify the tool for even its recommended use as a nut runner CE WORK STATIONS The tool should only be used as a handheld hand ope rated tool It is always recommended that the tool is used when standing on the solid floor It can be in other positions but before any such use the operator must be in a secure position having a
18. run nut up flush and then tighten an ad ditional one quarter to one half turn slight additional turning is necessary if gaskets are being clamped For additional power needed on disassembly work turn regulator to its fully open position This impact wrench is rated a bolt size please refer technical specification of tool Rating must be down graded for spring U bolts tie bolts long cap screws double depth nuts badly rusted conditions and spring fasteners as they absorb much of the impact power When possible clamp or wedge the bolt to prevent spring back Soak rusted nuts in penetrating oil and break rust seal before removing with impact wrench If nut does not start to move in three to five seconds use a large size impact wrench Do not use impact wrench beyond ra ted capacity as this will drastically reduce tool life Note Actual torque on a fastener is directly related to ee joint hardness tool speed condition of socket and the time the tool is allowed to impact Use the simplest possible tool to socket hook up Every connection absorbs energy and reduces power SAFE RULES WHEN USING AN IMPACT WRENCH Read all these safety instructions before operating this product and save these instructions The tool has been manufactured in conformity with the instruction of EU machine directive The EU mark will be considered void in the event of inexpert repairs the use of non original parts and in case of non obser vance of the saf
19. ust or use the assembly power tool for threaded fasteners 23 Donot modify this assembly power tool for threaded fasteners Modifications can reduce the effective ness of safety measures and increase the risks to the operator 24 Do not discard the safety instructions give them to the operator 25 Do not use the assembly power tool for threaded fasteners if it has been damaged 26 Tools shall be inspected periodically to verify that the ratings and markings required by this part of EN ISO 11148 are legibly marked on the tool The employer user shall contact the manufacturer to obtain replacement marking labels when necessary SAFETY PRECAUTIONS FOR PROJECTILE HAZARDS 1 Failure of the workpiece of accessories or even of the inserted tool itself can generate high velocity projectiles 2 Always wear impact resistant eye protection during the operation of the assembly power tool for threa ded fasteners The grade of protection required should be assessed for each use 3 Ensure that the workpiece is securely fixed SAFETY PRECAUTIONS FOR ENTANGLEMENT HAZARD 1 Entanglement hazards can result in choking scal ping and or lacerations if loose clothing personal jewelry neckwear hair or gloves are not kept away from the tool and accessories 2 Gloves can be become entangled with the rotating drive causing severed or broken fingers 3 Rotating drive sockets and drive extensions can easily entangle rubber coated or metal reinfor
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