Manual For The 63439 15 Amp 70 Lb. Pro Breaker Hammer
User Manual: Manual for the 63439 15 Amp 70 Lb. Pro Breaker Hammer 15 Amp 70 Lb. Pro Breaker Hammer
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Owner’s Manual & Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference. REV 16j Visit our website at: http://www.harborfreight.com Email our technical support at: productsupport@harborfreight.com When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please call 1-888-866-5797 as soon as possible. Copyright© 2016 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included. Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL. Table of contents SAFETy Safety ......................................................... 2 Specifications ............................................. 8 Setup .......................................................... 8 Operation ................................................... 10 Maintenance .............................................. 13 Parts List and Diagram .............................. 18 Warranty .................................................... 20 WARNING SyMBOLS AND DEFINITIONS SETUp This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Addresses practices not related to personal injury. OpERATION IMpORTANT SAFETy INFORMATION General power Tool Safety Warnings Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term ″power tool″ in the warnings refers to your mains-operated (corded) power tool. Work area safety MAINTENANcE 1. Keep work area clean and well lit. Cluttered or dark areas invite accidents. 2. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. Page 2 3. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. For technical questions, please call 1-888-866-5797. Item 63439 1. power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with grounded power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. 4. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. 2. Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded. 5. When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. 3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. 6. If operating a power tool in a damp location is unavoidable, use a Ground Fault circuit Interrupter (GFcI) protected supply. Use of a GFCI reduces the risk of electric shock. SAFETy Electrical safety 5. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. 2. Use personal protective equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. 6. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of these devices can reduce dust-related hazards. 3. prevent unintentional starting. Ensure the Trigger is in the off-position before connecting to power source, picking up or carrying the tool. Carrying power tools with your finger on the Trigger or energizing power tools that have the Trigger on invites accidents. 7. Only use safety equipment that has been approved by an appropriate standards agency. Unapproved safety equipment may not provide adequate protection. Eye protection must be ANSI-approved and breathing protection must be NIOSH-approved for the specific hazards in the work area. power tool use and care 1. Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. 2. Do not use the power tool if the Trigger does not turn it on and off. Any power tool that cannot be controlled with the Trigger is dangerous and must be repaired. 3. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. 4. Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. Item 63439 OpERATION 4. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. 5. Maintain power tools. check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. 6. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. 7. Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. For technical questions, please call 1-888-866-5797. Page 3 MAINTENANcE 1. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury. SETUp personal safety Service Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. SAFETy percussion Hammer Safety Warnings 1. Wear ear protectors. Exposure to noise can cause hearing loss. 2. Use auxiliary handles supplied with the tool. Loss of control can cause personal injury. 3. Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a ″live″ wire will make exposed metal parts of the tool ″live″ and shock the operator. 4. Keep clear of moving parts. SETUp 5. Unplug before inspecting, removing or installing chisel, or performing any service. 6. pull on chisel after installation and before use; chisel may move but MUST NOT slide out. 7. Wear steel-toed boots during use. 8. Do not operate this tool if you have back, neck, or wrist injuries, or other conditions that will be aggravated by the severe jerking forces that this tool exerts upon the operator. OpERATION 9. Maintain labels and nameplates on the tool. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 10. Avoid unintentional starting. Prepare to begin work before turning on the tool. 11. Do not lay the tool down until it has come to a complete stop. Moving parts can grab the surface and pull the tool out of your control. 12. When using a handheld power tool, maintain a firm grip on the tool with both hands to resist starting torque. 13. Do not leave the tool unattended when it is plugged into an electrical outlet. Turn off the tool, and unplug it from its electrical outlet before leaving. MAINTENANcE 14. This product is not a toy. Keep it out of reach of children. Page 4 15. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure. In addition, people with pacemakers should: • Avoid operating alone. • Properly maintain and inspect to avoid electrical shock. • Properly ground power cord. Ground Fault Circuit Interrupter (GFCI) should also be implemented – it prevents sustained electrical shock. 16. WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities, contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints • Crystalline silica from bricks and cement or other masonry products • Arsenic and chromium from chemically treated lumber Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. (California Health & Safety Code § 25249.5, et seq.) 17. WARNING: The cord of this product contains lead and/or di (2-ethylhexyl) phthalate (DEHP), chemicals known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5, et seq.) 18. The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. For technical questions, please call 1-888-866-5797. Item 63439 Vibration Safety 1. Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical check-ups to ensure medical problems are not being caused or worsened from use. Pregnant women or people who have impaired blood circulation to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud’s Disease should not use this tool. If you feel any symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible. 2. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury. 3. Wear suitable gloves to reduce the vibration effects on the user. SAFETy This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of vibration-related injury: 4. Use tools with the lowest vibration when there is a choice. 5. Include vibration-free periods each day of work. 6. Let the tool do the work. 7. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately. MAINTENANcE OpERATION SETUp SAVE THESE INSTRUcTIONS. Item 63439 For technical questions, please call 1-888-866-5797. Page 5 Grounding SAFETy TO pREVENT ELEcTRIc SHOcK AND DEATH FROM INcORREcT GROUNDING WIRE cONNEcTION: check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the power cord plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician. Grounded Tools: Tools with Three prong plugs SETUp 2. The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only wire connected to the tool’s grounding system and must never be attached to an electrically “live” terminal. (See 3-prong plug and Outlet.) 3-prong plug and Outlet OpERATION 1. Tools marked with “Grounding Required” have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet. If the tool should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user, reducing the risk of electric shock. (See 3-prong plug and Outlet.) 3. The tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in the preceding illustration. (See 3-prong plug and Outlet.) Double Insulated Tools: Tools with Two prong plugs MAINTENANcE 1. Tools marked “Double Insulated” do not require grounding. They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard Association, and the National Electrical Code. Outlets for 2-prong plug Page 6 2. Double insulated tools may be used in either of the 120 volt outlets shown in the preceding illustration. (See Outlets for 2-prong plug.) For technical questions, please call 1-888-866-5797. Item 63439 Extension cords 3. The smaller the gauge number of the wire, the greater the capacity of the cord. For example, a 14 gauge cord can carry a higher current than a 16 gauge cord. (See Table A.) 4. When using more than one extension cord to make up the total length, make sure each cord contains at least the minimum wire size required. (See Table A.) 5. If you are using one extension cord for more than one tool, add the nameplate amperes and use the sum to determine the required minimum cord size. (See Table A.) 6. If you are using an extension cord outdoors, make sure it is marked with the suffix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use. 8. Protect the extension cords from sharp objects, excessive heat, and damp or wet areas. TABLE A: REcOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION cORDS* (120/240 VOLT) NAMEpLATE AMpERES (at full load) SAFETy 2. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage. (See Table A.) 7. Make sure the extension cord is properly wired and in good electrical condition. Always replace a damaged extension cord or have it repaired by a qualified electrician before using it. EXTENSION cORD LENGTH 25´ 50´ 75´ 100´ 150´ 0 – 2.0 18 18 18 18 16 2.1 – 3.4 18 18 18 16 14 3.5 – 5.0 18 18 16 14 12 5.1 – 7.0 18 16 14 12 12 7.1 – 12.0 18 14 12 10 - 12.1 – 16.0 14 12 10 - - 16.1 – 20.0 12 10 - - - SETUp 1. Grounded tools require a three wire extension cord. Double Insulated tools can use either a two or three wire extension cord. * Based on limiting the line voltage drop to five volts at 150% of the rated amperes. Canadian Standards Association Underwriters Laboratories, Inc. V ~ A Volts Alternating Current Amperes n0 xxxx/min. No Load Revolutions per Minute (RPM) Item 63439 WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields. Read the manual before set-up and/or use. WARNING marking concerning Risk of Fire. Do not cover ventilation ducts. Keep flammable objects away. WARNING marking concerning Risk of Electric Shock. Properly connect power cord to appropriate outlet. WARNING marking concerning Risk of Hearing Loss. Wear hearing protection. For technical questions, please call 1-888-866-5797. MAINTENANcE Double Insulated OpERATION Symbology Page 7 Specifications SAFETy Electrical Rating 120VAC / 60Hz / 15A Blows Per Minute 950 BPM Included Chisels 1 Bull Point, 1 Flat 3156787 Setup - Before Use: Read the ENTIRE IMpORTANT SAFETy INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. SETUp TO pREVENT SERIOUS INJURy FROM AccIDENTAL OpERATION: Make sure that the Trigger is in the offposition and unplug the tool from its electrical outlet before performing any procedure in this section. Note: For additional information regarding the parts listed in the following pages, refer to Parts List and Diagram on page 18. Assembly The only assembly required for the Breaker Hammer is the installing of the Left Handle (82) to the side of the Gear Box (86) and the Spline Axle (91). Main Handle (51) Secondary Handle (82) OpERATION 1. First, slide Left Handle over the Spline Axle so that the end of the Spline Axle slides through the opening in the Left Handle. See Figure A. Gear Box (86) Figure B Spline Axle (91) 3. Thread Nut (40) over tip of Spline Axle. Use Wrench (not included) to fasten Nut, securing Left Handle in place. Periodically, check Nut for tightness. See Figure C. Secondary Handle (82) MAINTENANcE Figure A Secondary Handle (82) 2. With your other hand, hold and slightly twist Right Handle (51) while slowly manipulating Left Handle over the Spline Axle until the splines line up and it fits snug into place. See Figure B. Nut (40) Page 8 Spline Axle (91) Figure c For technical questions, please call 1-888-866-5797. Item 63439 SAFETy Functions chisel Socket SETUp Lock Lever OpERATION Main Handle Secondary Handle MAINTENANcE Trigger Item 63439 For technical questions, please call 1-888-866-5797. Page 9 Operating instructions Read the ENTIRE IMpORTANT SAFETy INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. SAFETy Tool Set Up TO pREVENT SERIOUS INJURy FROM AccIDENTAL OpERATION: Make sure that the Trigger is in the off-position and unplug the tool from its electrical outlet before performing any procedure in this section. Chisels come with or without collars. Figure D shows installation of a chisel without a collar (the included chisel is without a collar). Figure H shows installation of a chisel with a collar. Note: If the Chisel doesn’t slide in easily, apply grease to the loading end of the Chisel. Mounting chisels without a collar SETUp 1. Pull the Lock Lever to the side, just far enough to allow the Chisel to be inserted, as shown in Figure D. 2. Position the Lock Lever as shown in Figure D and Figure E. Insert Chisel with the Flat Notch facing the Lock Lever, as shown. 1 Lock Lever Flat Notch 2 OpERATION Figure E 3. Slide the Chisel in as far as it will go. Lock Lever 4. Pull the Lock Lever back until it touches the Spring, locking the Chisel into place. See Figure F. Figure D MAINTENANcE Note: Flat Notch on Collar-less Chisel must face the Lock Lever. Figure F Page 10 For technical questions, please call 1-888-866-5797. Item 63439 5. When the Chisel is installed, there will be approximately 1-3/4" of play along the Flat Notch of the shank. See Figure G. Physically check that the Chisel is secure before operating. SAFETy play Flat Notch Figure G Mounting chisels with a collar 1. Pull the Lock Lever open about 30-40° to the second engaging position as shown in Figure 2. 1 SETUp 2. Insert the collared Chisel. 3. Slide the Chisel in as far as it will go. 4. Return the Lock Lever to its original position to lock the Chisel in place. Physically check that the Chisel is secure before operating. The Chisel will have approximately 1-3/4″ of play, but should not come out when pulled. Retaining Ring OpERATION 2 Figure H 1. Designate a work area that is clean and well-lit. The work area must not allow access by children or pets to prevent distraction and injury. 2. Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing the power cord to possible damage. The power cord must reach the work area with enough extra length to allow free movement while working. 4. There must not be objects, such as utility lines, nearby that will present a hazard while working. If working in the ground or on a concrete slab on the earth, call local utility company to ensure that area is clear of utility lines. 5. Protect power cord from crushing, abrasion, and scraping by broken rock or concrete. 6. Keep power cord away from moving machines. 3. Secure loose work pieces using a vise or clamps (not included) to prevent movement while working. Item 63439 For technical questions, please call 1-888-866-5797. Page 11 MAINTENANcE Work piece and Work Area Set Up General Operating Instructions SAFETy TO pREVENT SERIOUS INJURy: Wear ANSI-approved safety goggles, ear protection, steel-toe boots, and dust mask during use. Keep feet clear of Breaker Hammer. Keep children and animals well clear of the work area. 1. Check Chisel for dullness, cracks, or other damage. 7. Push the tip forcibly down to begin striking material. NOTIcE: Running tool with no load or “empty blows” will damage the Breaker Hammer. cAUTION! Once activated, do not press, bear down, or thrust forcibly against the work surface. Allow the Breaker Hammer’s own weight to supply the needed force. SETUp cAUTION! Dull tipped chisels can cause unnecessary chisel movement, resulting in tool wear and possible injury. Use only sharp tipped chisels. 2. Clearly mark the work area. 3. Make sure that the Trigger is in the off-position, then plug the tool into an outlet on a circuit rated to 20 amps. 4. Set the bit against the work area. cAUTION! Keep power cord away from moving machines. 5. Place one hand on the Side Handle and the other hand around the Main Handle. 6. Press down on the Trigger. Note: Trigger does not lock. Keep pressure on the Trigger to keep running the tool. Note: If the Breaker Hammer has not been used for a long time or is being used in low temperatures, the tool may require 3-5 minutes to warm up. NOTE: Carbon Brushes will wear during use. The Breaker Hammer will stop working if the Brushes are worn. This does NOT mean Breaker Hammer is malfunctioning or broken, only that the worn Brushes will need to be replaced with the included Brushes by a qualified technician. 8. When work is complete, release the Trigger. The Trigger is spring-loaded and will return to the off position automatically. 9. To prevent accidents, turn off the tool and disconnect its power supply after use. 10. Clean, then store the tool indoors out of children’s reach. OpERATION MAINTENANcE Page 12 For technical questions, please call 1-888-866-5797. Item 63439 Maintenance and Servicing SAFETy procedures not specifically explained in this manual must be performed only by a qualified technician. TO pREVENT SERIOUS INJURy FROM AccIDENTAL OpERATION: Make sure that the Trigger is in the off-position and unplug the tool from its electrical outlet before performing any procedure in this section. TO pREVENT SERIOUS INJURy FROM TOOL FAILURE: Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use. cleaning, Maintenance, and Lubrication 4. WARNING! If the supply cord of this power tool is damaged, it must be replaced only by a qualified service technician. NOTE: The Breaker Hammer has airtight construction, allowing long periods of use (approximately six months of regular usage) before lubrication. SETUp 2. AFTER USE, wipe external surfaces of the tool with clean cloth. 3. Store in temperatures no lower than 50-60° F. MAINTENANcE OpERATION 1. BEFORE EAcH USE, inspect the general condition of the tool. Check for: • loose hardware, • misalignment or binding of moving parts, • damaged cord/electrical wiring, • dull or cracked Chisel, • cracked or broken parts, and • any other condition that may affect its safe operation. Item 63439 For technical questions, please call 1-888-866-5797. Page 13 Replacing carbon Brushes NOTE: The Breaker Hammer will cease operation once carbon Brushes are worn. check Brushes every 100 hours of use of use and replace when necessary. NOTIcE: When removing Left Handle, do not pull too far from Spline Axle (91) Only wiggle loose until partially off. See Figure L. SAFETy 1. Unplug the Breaker Hammer. 2. Set the Breaker Hammer down on a work bench with the spline axles closer to the top. Remove the four Bolts (97) fastening Cover (96) in place. See Figure I. Spline Axle (91) Left Handle (82) Bolts (97) cover (96) Figure L SETUp 5. Remove the four Bolts (5) from the side of the Gearbox (86). See Figure M. Figure I Bolts (5) 3. Slide Cover off top of Breaker Hammer. See Figure J. Gearbox (86) cover (96) OpERATION Figure M 6. Slide Gearbox open so that Wire Board (13) is visible. Remove Bolt (12) from Wire Fixing Board. See Figure N. Figure J 4. Use a Wrench to loosen the Nut (40) holding the Left Handle (82) in place. See Figure K. Left Handle (82) Wire Board (13) MAINTENANcE Nut (40) Bolt (12) Figure N Figure K Page 14 For technical questions, please call 1-888-866-5797. Item 63439 carbon Brush (15) Wire Board (13) 11. Once both Carbon Brushes have been replaced, slide Gearbox shut. SAFETy carbon Brush Holder Spring 10. To better access the second Carbon Brush, turn the Breaker Hammer over. Repeat Steps 6 to 9 to replace second Carbon Brush. NOTIcE: When closing Gearbox, make sure tab along rim of Gearbox aligns with the slot in the housing. See Figure P. Gearbox Tab Housing Slot SETUp 7. Remove the Wire Board, then use tip of flatedge screwdriver (not included) to carefully pop the Holder’s spring off the top of the Carbon Brush (15). See Figure O. Figure O cAUTION! The spring must be clear of the Holder lip to remove Carbon Brush. 8. Use the screwdriver to slide the Carbon Brush from the Holder. Then replace with new Carbon Brush. 12. Use the four screws to fasten the Gearbox back into place. Then replace Left Handle and fasten that into place against Gearbox. Replace Cover and fasten it into place using the Screws. MAINTENANcE OpERATION 9. Snap spring back into place and use Screw to replace Wire Board. Figure p Item 63439 For technical questions, please call 1-888-866-5797. Page 15 Greasing Gearbox Note: Due to the possibility of accidental damage and/or contamination, only a qualified technician should disassemble and lubricate this item. SAFETy 1. Loosen the 4 Socket Head Bolts (57) that connect the Cylinder Case (58) to the Crank Shaft Case (8). Disassemble the Cylinder Case, Ram (60) and Piston (61). See Figure Q. 4. Fill each of the 4 grooves inside the Cylinder Case with 0.5 ounces of synthetic high-temperature grease. 5. Slide the Ram back into the Cylinder Case and fill it with 0.5 ounces of tool oil. 2. Clean the Cylinder Case, Piston and Ram thoroughly, inside and out. 6. Carefully slide the Piston into Ram, making sure that the O-ring stays in place and is not damaged. 3. Check the condition of the O-ring (62). If the outside diameter (OD) of O-ring is less than the Piston’s OD, replace the O-ring. 7. Use the 4 Socket Head Bolts to connect the Cylinder Case to the Crank Shaft Case and tighten them securely. SETUp cylinder case (58) OpERATION Socket Head Bolt (57) Ram (60) piston (61) MAINTENANcE crank Shaft case (8) Figure Q Page 16 For technical questions, please call 1-888-866-5797. Item 63439 Troubleshooting 3. Tool’s thermal reset breaker tripped (if equipped). 4. Internal damage or wear. (Carbon brushes or Trigger, for example.) 1. Check that cord is plugged in. 2. Check power at outlet. If outlet is unpowered, turn off tool and check circuit breaker. If breaker is tripped, make sure circuit is right capacity for tool and circuit has no other loads. 3. Turn off tool and allow to cool. Press reset button on tool. 4. Have technician service tool. Tool operates slowly. Extension cord too long or wire size too small. Eliminate use of extension cord. If an extension cord is needed, use shorter/heavier gauge cord. See Extension Cords in GROUNDING section. Performance decreases over time. 1. Chisel dull or damaged. 2. Internal lubrication cold. 1. Keep cutting chisels sharp. Replace as needed. 2. Allow tool to operate with no load for 2 minutes before use. 3. Have qualified technician replace brushes. 3. Carbon brushes worn or damaged. SAFETy 1. Cord not connected. 2. No power at outlet. Likely Solutions SETUp Tool will not start. possible causes Excessive noise or rattling. Internal damage or wear. (Carbon brushes or bearings, for example.) Have technician service tool. Overheating. 1. Forcing tool to work too fast. 2. Chisel dull or damaged. 3. Blocked motor housing vents. 1. Allow tool to work at its own rate. 2. Keep cutting chisels sharp. Replace as needed. 3. Wear ANSI-approved safety goggles and NIOSH-approved dust mask/respirator while blowing dust out of motor using compressed air. 4. Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See Extension Cords in GROUNDING section. 4. Motor being strained by long or small diameter extension cord. Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect power supply before service. OpERATION problem THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO. Record product’s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead. Item 63439 Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. For technical questions, please call 1-888-866-5797. Page 17 MAINTENANcE pLEASE READ THE FOLLOWING cAREFULLy parts List and Diagram parts List SAFETy part SETUp OpERATION MAINTENANcE 1 2 3 4* 5 6 7 8 9 10 11 12 13 14 151 16 17 18 19 20 21 22 23 24 25** 26** 27* 28 29 30 31** 32 33 34 35** 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Description Top Cover Locking Bolt M12×1.25 Circlip Ø38 Deep Groove Ball Bearing 6301-2Z Bolt M8×35 Motor Bottom Cover Fan Crankshaft Case Motor Housing Stator Stator Holding Plate Tap Bolt ST4.8×60 Wire Board Rotor Carbon Brush Spring Washer Ø4 Bolt M4×12 Right Side Bottom Cover Tap Bolt ST3.5×9.5 Inductance Cover Inductance Stator Wiring Sheath Aire Baffle Assembly Inductance Holding Oil Seal Cover Seal Ring Bearing NA4904 Inner Ring Crankshaft Roller Bearing NU206EM Oil Seal Ø35× Ø52×8 Roller Circlip Ø52 Spline Cuff Bolt M8×20 Inductance Wiring Sheath Switch Cover Capacitance Switch HY87 Switch Chamber Locking Nut M10×1-6H Right Side Pendulum Tap Bolt ST4.2×19 Sheath Ring Pin B5×28 Tap Bolt ST4.2×16 Switch Chamber Cover Cable Nip Tap Bolt ST4.8×25 Bolt M6×55 Spring Washer Ø6 Qty part 1 1 1 1 9 1 1 1 1 1 2 2 2 1 2 2 4 1 2 1 1 1 1 1 1 1 2 1 1 1 1 2 2 4 1 1 1 1 1 2 1 2 1 1 2 1 1 2 4 4 51 52 53 54 55 56 57 58 59** 60 61 62** 63 64 65* 66 67 68 69** 70 71 72** 73 74 75 76 77 78** 79 80 81 82 83 84 85 86 87** 88 89 90* 91 92 93 94 95 96 97 98* 99** Description Right Handle Trigger Trigger Holding Tap Bolt ST4.2×13 Cord Sheath Plug Bolt M12×70 Cylinder Case O-Ring Ram Piston O-Ring Piston Pin Connector NA4904 Outer Ring Front Fixing Seal Ring Front Fixing Cover Spring Ø45 Orientation Sheath Second Striker O-Ring Ø45×Ø5 Spring Ø6.5 Saddle Gasket Pole Pin Ø8*55 Bolt M12×110 Locking Lever Pin Axis Urethane Ring Chisel Socket Left Side Pendulum Damping Plate Left Handle Bolt M6×30 Anti-Vibration Plate Nut M6 Gearbox Seal Washer Big Gear Adjustment Gasket Deep Groove Ball Bearing 6205 Spine Axle Medium Gear Needle Bearing K16×20×12.5 Medium Axis Felt Ring Seal Cover Bolt M6×20 Bearing Kit Seal Kit Qty 1 1 1 2 1 1 4 1 1 1 1 1 1 1 2 1 1 1 1 1 2 3 3 2 3 1 1 2 1 1 1 1 4 2 2 1 1 1 1 1 1 1 2 1 1 1 4 1 1 #151 - Two Carbon Brushes are installed; two replacement Brushes are included. Parts with one or two asterisks are not available individually. You must purchase the parts kits. #98* - Bearing Kit includes part numbers 65*, 90*, 4*, 27* #99** - Seal Kit includes part numbers 62**, 59**, 87**, 69**, 35**, 72**, 78**, 31**, 26**, 25** Page 18 For technical questions, please call 1-888-866-5797. Item 63439 MAINTENANcE OpERATION SETUp SAFETy Assembly Diagram Item 63439 For technical questions, please call 1-888-866-5797. Page 19 Limited 90 Day Warranty Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 3491 Mission Oaks Blvd. • pO Box 6009 • camarillo, cA 93011 • 1-888-866-5797
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