Rad Tool Repair Manual

RAD TOOL REPAIR MANUAL
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
GENERAL INFORMATION
TABLE OF CONTENTS
1.
2.
3.
4.
General Information
Gearbox Repairs
2-Speed Repairs
Air Motor Repairs
TOOLS REQUIRED:
Part Number
Description
10551
Threaded Ring Removal Tool (NPW 120 Series Tools)
10552
Threaded Ring Removal Tool (NPW 180 Series Tools)
10552
Threaded Ring Removal Tool (NPW 200 Series Tools)
ALSO REQUIRED:
Manual Shop Press
#4 Bench Vise
Drill Bits
10 Ton Hydraulic Press
Drive Pin Punch Set
Power Drill
Hammer
Flathead Screwdriver
Mechanics Pick Set
Safety Glasses
RAD Tool Exploded Views
Solvent Based Parts Washer
Mechanics Magnet
Feeler Gauge
.001” Shim Stock
Aeroshell 22 Grease
Loctite White Lithium Grease
Lubriplate No.930-AA Grease
Royal Purple Synfilm 32
Loctite 242 & 686
Metric set of allen keys
*New World Technologies has customized jigs available for proper pressing during disassembly and reassembly. Please contact us at 1 800 983 0044 for further assistance.
LEGEND: FOLLOW THESE DIRECTIONS CAREFULLY:
Good
Look carefully
Do not attempt to operate/no good
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
GEAR BOX REPAIR PROCEDURES
Upon receiving a RAD tool that is in need for repair, it is necessary to carry out the following procedures:
DO NOT RUN THE TOOL!
•
•
Examine and record the condition of the tool judging by it's outward appearance.
Example- Deformed reaction arm, excessive denting and scarring and in odd cases, cracks in
the annulus housing.
Deformed Reaction Arm
To begin disassembly follow these procedures:
STEP 1:
Remove the four screws joining the gearbox to the air motor with the appropriate allen key size.
(see below)
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
GEAR BOX REPAIR PROCEDURES
STEP 2:
Remove the screws retaining the aluminum adapter plate and remove the adapter plate with the appropriate size allen key. (See fig 1)
FIG 1
FIG 2
STEP 3:
Remove the two indexing balls and springs with a magnet. (See fig 2)
STEP 4:
Mount the reaction arm into the bench vise (see figure 4) or use the supplied jig from New World
Technologies and insert the gearbox. Remove the threaded ring using the threaded ring removal tool.
(See fig 4.1)
FIG 4
FIG 4.1
STEP 5:
Remove the primary sun gear and the following stages below it along with the tools alignment pin and
the hardened washers. By holding the gearbox assembly upside down the internal stages should drop
out. (See fig 5 & 5.1)
FIG 5
FIG 5.1
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
GEAR BOX REPAIR PROCEDURES
STEP 6:
To remove the final stage, an internal snap ring must be pried out from the annulus housing with a snap
ring removal tool. Once the snap ring is removed, the final stage will slide out of the annulus housing.
(See fig 6 & 7) If there is considerable damage, the use of a shop press will be required.
FIG 6
FIG 7
STEP 7:
Upon complete disassembly of your RAD tool, each stage, the annulus housing and the adapter plate
must be de-greased using a parts washer. Thoroughly clean and then dry each part. Proper cleaning
will aid in checking for wear and failures. See examples of failures below.
EX 1:
Check teeth for
chips, burrs and
cracking.
EX 1
EX 2:
Check each
tooth for chips,
burrs and
cracking.
EX 2
EX 3:
Check parts for
minor cracks
and chips.
EX 4:
Check gears for
burrs, chips and
cracking.
EX 3
EX 4
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
GEAR BOX REPAIR PROCEDURES
STEP 8:
Remove the screws from each stage assembly with an allen wrench. (See fig 8 & 9)
FIG 8
FIG 9
STEP 9:
Separate the output carrier from the top plate using a press. (See fig 10)
FIG 10
FIG 11
STEP 10:
Once the stage assembly is apart, ensure that all needle bearings are accounted for and replace any
damaged components if required. Inspect everything very closely. (See fig 11 & 12)
Re-assemble in reverse order. Use Loctite 242
(removable strength) on all fasteners and
ensure all internal components are lubricated
using Aeroshell 22 Grease.
FIG 12
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
2-SPEED REPAIR PROCEDURES
Supplies (Fig 1)
1.) Lubriplate No.930-AA Multi Purpose Grease.
2.) LOCTITE White Lithium Grease
3.) Retaining Ring Compressor
FIG 1
FIG 2
STEP 1
Place the assembly into your press. With the retaining ring compressor, compress the retaining ring.
With the retaining ring compressed, lower the press compressing the internal spring and remove the
retaining ring. (See fig 2)
STEP 2
Once the retaining ring has been removed the
internal components of the 2-Speed body can be
removed. Thoroughly clean and degrease all
components and inspect.
FIG 3
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
2-SPEED FAILURE EXAMPLES
**The wear shown in Ex 1 & 2 are normal signs of wear and unless the 2-Speed is skipping, these
parts should not be replaced.**
Indents into the pockets of the solar pinion
can cause the 2-Speed mechanism to
“skip”.
Indents into the lobes of the 2-Speed body
can cause the 2-Speed mechanism to
“skip”.
EX 1
EX 2
Carefully inspect the front and back of the bearings inside the 2-Speed Mechanism. Excess load can cause the inner rim of the bearings to crack and break off.
EX 3 shows a bearing where the rim has completely worn off while EX 4 shows a
bearing in tact.
EX 3
EX 4
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
2-SPEED ASSEMBLY PROCEDURES
STEP 1
Before starting the assembly of the
2-Speed, print out the exploded view of the tool that you
are building for a guide and reference to the order of
assembly.
STEP 2
Layout all of the parts that are needed for the 2-Speed
assembly on a clean surface.
FIG 4
STEP 3
Press the bearing pins, gears and top plate into the 2-Speed body and fasten together. (see fig 5)
FIG 5
FIG 6
STEP 4
Press the permaglide bushing into the support. Later on we will fit this assembly over the output of the
solar pinion. (See fig 6)
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
2-SPEED ASSEMBLY PROCEDURES
STEP 5
Using Lubriplate No.930-AA Multi Purpose Grease, coat the inside of the 2-Speed body from the base to
the top of the lobes. (See fig 7)
FIG 7
FIG 8
STEP 6
Insert the axial rolling bearing into the base of the 2-Speed body and spray on a light coating of LOCTITE White Lithium Grease. (See fig 8)
STEP 7
Place “Disk A” in the bottom of the 2-Speed body so that it is covering the rolling bearing. Coat the surface with a light coating of LOCTITE White Lithium Grease. (See fig 9)
FIG 9
FIG 10
STEP 8
Check the fit of the ball actuator inside of the 2-Speed body. This should be able to slide freely up and
down without any catches.
Place the spring onto the base of the ball actuator and prepare to insert the two into the 2-Speed body.
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
2-SPEED ASSEMBLY PROCEDURES
STEP 9
After inserting the spring and ball actuator into the 2-Speed body, insert the internal
assembly into the body so that the fastener is pointing up. (See fig 11)
FIG 11
FIG 12
STEP 10
Take one of the balls and slide it back and forth from the bottom to the top of the
openings on the solar pinion to ensure there are no burrs or catches. If there are burrs, usually they will
be right at the stop of the openings and can easily be filed down. (See fig 12)
STEP 11
Take the (3) balls and place them in the lobes of the ball housing. Apply a significant amount of
LOCTITE White Lithium grease into the entire assembly. (See fig 13)
FIG 13
FIG 14
STEP 12
Coat the face and the underside of the solar pinion with Lubriplate No.930-AA Multi Purpose Grease.
(See fig 14)
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
2-SPEED ASSEMBLY PROCEDURES
STEP 13
Place the axial rolling bearing over the face of the solar pinion and coat with LOCTITE White Lithium
Grease. (See fig 15)
STEP 14
Place the support with the bushing over the solar pinion so that it rests on the rolling bearing.
(See fig 15)
FIG 15
FIG 16
STEP 15
Place the solar pinion onto the 2-Speed body so that the balls line up with the lobes on the bottom of the
solar pinion. (See fig 16)
STEP 16
Place the assembly into your press with the retaining ring over the output of the solar pinion. Here we
will need to compress the internal spring so that we can secure the retaining ring into its place.
(See fig 17)
STEP 17
Lower the press compressing the spring and using the
retaining ring compressor, fit the ring into the key.
Release the press and the assembly is complete.
(See fig 17)
STEP 18
Turn the solar pinion to ensure that it spins freely.
FIG 17
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
AIR MOTOR REPAIR PROCEDURES
**Always check the condition of the air motor components when servicing the tool.**
STEP 1:
Remove the 4 screws of the handle cap with an allen key and take off the cap and gasket.
STEP 2:
(UXR 2000) Using a punch inserted into the end of the rotor, carefully tap the rotor and end plate assembly and this assembly will pop out of the cylinder. (See fig. 13)
(NPW Series) Once the handle cap is removed from the back of the air motor, the internal components
will be able to slide out of the air motor. (See fig, 14)
FIG 13
FIG 14
STEP 3:
Remove all internal components of the air motor and thoroughly clean with a degreaser spray.
NOTE: Use a spray on degreaser such as CRC Chlor-Free Degreaser shown above. Inspect each part
very carefully, noting the shape and condition on the vanes, checking the endplate/rotor assembly for
scoring or burn marks. Clean the interior of the air motor housing and press out the cylinder assembly if
there is evidence of failure (burns on front plate, scoring/rust in cylinder).
NOTE: ONLY separate the rotor from the endplate if the endplate is damaged. The tolerance between
the two are very precise (.001” - .003”).
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
AIR MOTOR REPAIR PROCEDURES
STEP 4:
Re-assembly of the air motor consists of using a press to press fit the end plate onto the rotor. The
spacing between the rotor and the end plate is very critical and the clearance should be .001” to .003”.
The rotor must spin smoothly when held vertically and if there is any contact / friction between the plate
and the rotor, damage will occur. To check the tolerance manually, the rotor should spin free when held
vertical but stop when brought up horizontally. (See fig 16 & 17)
.004” to is too
much clearance
FIG 16
FIG 17
STEP 5:
Replace the vanes into the slots on the rotor and slide the cylinder over the rotor and onto the rear end
plate making sure that the spring pin is joining the end plate and the cylinder. (See fig 18 & 19)
FIG 18
FIG 19
STEP 6:
Place the front end plate onto the air motor cylinder aligning it with the front spring pin. Drop the
complete unit into the air motor handle with the hex side facing down into the face of the handle.
(See fig 20 & 21)
FIG 20
FIG 21
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
AIR MOTOR FAILURE EXAMPLES
EX 1
The face of the rotor will be damaged by
friction from the end plate in EX 3. If significant scoring can be felt or seen, lightly sand
the face of the rotor using a lathe and a very
fine grit of sand paper. Be sure to keep even
pressure across the face when sanding.
EX 2
Scoring of the cylinder will take place when
FOD enters the air motor. Using fine grit
sand paper, evenly re-finish the interior surface of the cylinder. If extensive damage has
occurred and the surface is not easily
re-finished, the part will need to be replaced.
EX 1
EX 2
EX 3
Scoring of the endplate will occur when FOD
enters the air motor. If aluminum, this end
plate cannot be re-finished and will need to
be replaced. If brass, evenly re-finish the
surface of the plate. If scoring or damage is
too deep to re-finish, the part will need to be
replaced. Do not skim these parts down.
Internal tolerances will be effected.
EX 3
EX 4
Example of new cylinder.
EX 4
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
GEARBOX GREASE SPEC SHEET
AEROSHELL 22 GREASE
LOCTITE WHITE LITHIUM GREASE
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
GEARBOX GREASE SPEC SHEET
LUBRIPLATE
930-AA
MULTI
PURPOSE
GREASE
Royal Purple
Synfilm 32
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
Trouble Shooting Guide
Air Motor:
Signs of Damage:
Burning Smell
Fluctuating RPM
Loss of Power
A burning smell will be detected when FOD enters into the air motor and is ground into the end
plates. This can cause a fluctuation in RPM and loss of power from the gun. Proceed to the Air Motor
Quick Fix on the following page for a detailed guide to complete this process. If performance does not
improve after these procedures, a tear down and inspection of the air motor will be necessary.
Gear Box:
Signs of Damage:
Excess Heat
Vibration
Excess Noise
Grinding
Loss of Power
All of the above situations can be caused by a number of different problems. Once the gear box
is separated from the air motor, try spinning the Primary Sun Gear. If the sun gear is difficult to turn or
you can feel small catches, the gear box should be disassembled, thoroughly cleaned and inspected.
The signs of damage noted above could be caused by bearing failure, FOD in the gear box, gear
damage, or failure of the internal components. Be sure to inspect EVERY component when servicing
your RAD gun.
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
Air Motor Quick Fix Guide
The below procedures will help restore lost power and RPM to your air motor by cleaning and
re-lubricating your air motor. After you have completed these procedures, if your air motor is still not
performing sufficiently, please contact your nearest RAD Repair Facility for further inspection and repair.
Step 1:
Remove the inlet bushing along with the
exhaust packing and O-Ring.
Step 2:
Once disassembled, lay out all of the parts that
have just been removed. *Note* make sure that
the throttle valve does not fall out of the air
motor once the inlet bushing has been removed.
Step 3:
Remove the exhaust packing from the parts that
are laid out and re-assemble the air motor.
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113
Air Motor Quick Fix Guide
Step 4:
Once re-assembled, spray a significant amount
of WD-40 into the inlet bushing of the gun.
Step 5:
Connect the gun into your airline, direct the face
of the motor and exhaust away from the operator and run the air motor until the RPM reaches
it’s peak and WD-40 is no longer being expelled.
Step 6:
Disconnect your air motor from your air line and
place a significant amount of *Royal Purple
Synfilm 32* (synthetic pneumatic oil) into the
inlet bushing. Repeat Step 5.
Once the RPM reaches it’s peak and oil is no
longer being expelled, disconnect the air line
and remove the inlet bushing. Install the
exhaust packing back into the housing and
assemble the air motor.
If the performance of your air motor is still poor,
please return the motor to an authorized RAD
Repair Facility for inspection.
WWW.RADTORQUE.COM
New World Technologies Inc.
Tel.: 604.852.0405
30580 Progressive Way
Fax: 604.852.0269
Abbotsford, BC, Canada, V2T 6Z2
E-mail: [email protected]
20113