Stanley Hydraulic Impact Wrench Instructions

IW12 Hydraulic Impact Wrench Safety, Operation & Maintenance

66023 User Manual 12/2020 Ver. 22

IW12 Impact Mechanism Illustration – Detail E

ITEM

| P/N|

DESCRIPTION

1| 02764| Cap Screw
2| 11207| Circuit Type “D” Decal
3| 28788| “Read the Manual” Decal
4| 29087| Hammer Case
5| 81439| Sound Power Decal
6| 00149| O-ring
7| 35445| Bushing
8| 20262| Retaining Ring
9| 21408| Thrust Bearing Race
10| 09878| Thrust Bearing
11| 20259| Retainer
12| 22728| Anvil
13| 08069| Hammer Pin
14| 20257| Hammer Frame
15| 08067| Hammer
16| 28323| CE Decal
17| 36004| Spacer – Model IW1234001
18| 02764| Cap Screw
| 02449| Cap Screw – Model IW1234001
19| 12285| Trigger Guard – Model IW1234001
20| 07724| Nut – Model IW1234001
21| 12470| Cap Screw – Model IW1234001
22| 35451| Impact Mechanism Assembly
23| 08073| IW12 Seal Kit (not shown) – * In seal kit

IW12 Hydraulic Motor Illustration – Detail F

ITEM

| P/N|

DESCRIPTION

1| 08019| Thrust Washer
2| 08020| Thrust Bearing
3| 00166| Retaining Ring
4| 07987| Backup Washer
5| 09396| Backup Ring
6| 08017| O-ring
7| 372055| Dowel Pin
8| 08014| Bushing
9| 08001| Main Shaft
10| 08023| O-ring
11| 07997| Motor Cap Assembly (Includes 372055)
12| 73683| Tool Name Tag
13| 01870| Cap Screw
14| 09277| Nut
15| 19453| Relief Adjustment Screw
16| 07989| Idler Gear Assembly
17| 07991| Idler Shaft
18| 07995| Insert
19| 03252| O-ring
20| 00717| O-ring
21| 08073| IW12 Seal Kit (not shown) – * In seal kit

IW12 Trigger & Spool Assembly- Detail G

ITEM

| P/N|

DESCRIPTION

1| 00786| Cap Screw
2| 07724| Nut
3| 07996| Trigger
| 28536| Trigger – Models IW1214001 & IW12140AX
4| 01851| Roll Pin – Models IW1214001 & IW12140AX
5| 27441| Thumb Latch – Models IW1214001 & IW12140AX
6| 27445| Spring – Models IW1214001 & IW12140AX
7| 22064| Rod Wiper
8| 22063| Spool Cap
9| 06533| O-ring
10| 00026| O-ring
11| 23678| Headed Push Pin
12| 73046| On/Off Spool
13| 07986| Relief Seat
14| 07993| Relief Poppet
15| 07985| Spring
16| 07982| Spring Rest
17| 07988| Spring
18| 29083| Rotation Direction Decal
19| 08016| Retaining Ring
20| 73311| Main Housing
| 73313| Main Housing – Model IW12140AX
21| 08002| Reversing Spool
22| 08015| Backup Ring
23| 01211| O-ring
24| 00580| Set Screw
25| 04939| Lever
26| 00936| Adapter
27| 03973| Male Coupler
28| 03972| Female Coupler
29| 08073| IW12 Seal Kit (not shown) – In seal kit

Safety Precautions

The Safety Alert Symbol alerts you to potential personal injury hazards. Obey all safety messages that follow to avoid possible injury or death.

Indicates an imminently hazardous situation which will result in death or serious injury.

Indicates a potentially hazardous situation which could result in death or serious injury.

Indicates a potentially hazardous situation which could result in property damage.

Always observe safety symbols. They are included for your safety and for the protection of the tool.

WARNING: Read all safety warnings and instructions. Failure to follow warnings and instructions may result in tool damage and/or serious injury.
WARNING: To reduce the risk of injury, read the instruction manual.

General

• Do not discard safety instructions. Give to the operator.
• This tool will provide dependable service if operated in accordance with the instructions given in this manual. Read and understand this manual and any stickers and tags attached to the tool and hoses before operation. Failure to do so could result in personal injury or equipment damage.
• Inspect the tool before each use and ensure all decals are legible. Contact STANLEY if replacements are needed.
• Establish a training program for all operators to ensure safe operation. Do not operate the tool unless thoroughly trained or under the supervision of an instructor. Keep out of the reach of children.
• Operators and maintenance personnel shall be able to physically handle the bulk, weight and power of the tool.
• Avoid unsuitable postures as these positions do not allow for counteracting of normal or unexpected movement of the tool, such as a sudden break of the tool bit. Change postures during extended tasks to help avoid discomfort or fatigue.
• Do not operate a damaged, improperly adjusted, modified or incompletely assembled tool.
• Do not operate the tool 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.
• Provide adequate ventilation in closed areas when operating a gas or diesel hydraulic power source.
• Do not inspect, carry, clean, change accessories or perform maintenance on the tool while the power source is connected. Accidental engagement of the tool can cause serious injury.
• Ensure work piece is securely fixed. Be aware that failure of the work piece or accessories may generate high velocity projectiles.
• Stay alert, watch what you are doing and use common sense when operating a hydraulic tool. Do not operate this tool if you are tired or under the influence of drugs or alcohol. A moment of inattention while operating hydraulic tools may result in serious injury.
• Assess risks to others around you before operating the tool.
• During operation, do not contact mechanisms, accessories or hardware as they can become very hot; use your Personal Protection Equipment (PPE).
• Use and maintain the tool as stated in this manual. Misuse of this tool is forbidden. Misuse of the tool can cause serious injury. Do not modify the tool in any way.
• Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations.
• Never operate the tool if you cannot be sure that underground utilities are not present, such as electrical cables, gas pipes, etc. These can cause a hazard if damaged with the tool.
• The tool is not insulated against coming into contact with electric power. Use hose certified as non-conductive.
• Do not overreach. Maintain proper footing and balance at all times when using the tool.
• Slips, trips and falls are major causes of workplace injury. Be observant of hoses lying about the work area, as they can be a tripping hazard.
• Operator must start in a work area without bystanders and must assess the risk to bystanders, including the risk of serious injury or death caused by the tool or accessories dropped from an elevated height.
• Operators must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.
• Only use clean hydraulic fluid and lubricants that have been recommended by STANLEY.
• Ensure tools are working properly and safely by performing preventative maintenance (PM) procedures.
• Repair and service of this tool must only be performed by an authorized and certified dealer.
• Use only replacement parts recommended by STANLEY.
• Do not force the tool to do the work of a larger tool. Use the correct tool for your application.
• Use only hoses and hose couplings that are rated for a minimum working pressure of 2500 PSI (172 BAR).
• Keep hands away from rotating chuck, drill bits or drives.
• Rotating drive sockets and drive extensions can easily entangle rubber-coated gloves or metal reinforced gloves. Never hold the drive, sockets, drive extensions or other accessories.
• Do not use in confined spaces. Beware of crushing hazards between the tool and the workpiece, especially when unscrewing or reversing the tool.
• Keep the work area well lit.
• 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.
• In spite of the application of relevant safety regulations and the implementation of safety devices, certain residual risks cannot be avoided. These risks are: repetitive strain injury due to incorrect posture and risk of pinching fingers when changing tool bit or pressing trigger.

Dust and Fumes

• 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, birth defects or other reproductive harm. Some examples of these chemicals are:

  • Lead from lead-based paints,
  • crystalline silica from bricks and cement and other masonry products, and
  • 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.
    Protect yourself and those around you. Research and understand the materials you are drilling. Follow correct safety procedures and comply with all applicable national, state or provisional health and safety regulations relating to them, including, if appropriate arranging for the safe disposal of the materials by a qualified person.

• When dust or fumes are created, control them at the point of emission. Direct tool exhaust to minimize disturbance of dust.

• Operate and maintain the tool as recommended in this manual to minimize dust.

• Use respiratory protection in accordance with employers instruction or as required by occupational health and safety regulations.

• Avoid prolonged contact with dust. Allowing dust to get into your mouth, eyes or lay on the skin may promote absorption of harmful chemicals.

• Select and replace tool bits as recommended in order to prevent an unnecessary increase in dust or fumes.

• Keep tool handles dry, clean and free from oil and grease. This will enable better control of the tool.

PPE

• Always wear safety equipment such as impact resistant goggles, ear protection, head protection, breathing protection and safety shoes at all times when operating the tool.
• Hands may be exposed to hazards, impacts, cuts, abrasions and heat. Wear gloves.
• Wear a hardhat if performing overhead work. · Use PPE that conforms to standards ANSI Z87.1 (Eye and Face Protection), ANSI Z89.1 (Head Protection), ANSI Z41.1 (Foot Protection) and ANSI S12.6 (S3.19) (Hearing Protection).
• Do not wear loose fitting clothing, jewelry or gloves with cut or frayed fingers when operating the tool. Entanglement, choking, scalping and laceration can occur if loose clothing, personal jewelry, neck wear, hair or gloves are not kept away from the rotating tool and it’s accessories. Gloves can become entangled with the rotation drive, causing severed or broken fingers.

Sound

• Exposure to high noise levels can cause permanent, disabling hearing loss and other problems, such as tinnitus (ringing, buzzing, whistling or humming in the ears). Use hearing protection in accordance with employer’s instructions and as required by occupational health and safety regulations. Appropriate controls to reduce the risk can include actions such as damping materials to prevent work pieces from “ringing”.
• Use and maintain as recommended in the manual to prevent an unnecessary increase in noise levels.

Vibration

• When using a rotary or percussive tool to perform work related activities, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of the body.
• If you experience numbness, tingling, pain or whitening of the skin in your fingers or hands, stop using the tool. Tell your employer and consult a physician.
• Wear warm clothing when working in cold conditions and keep your hands warm and dry.
• Exposure to vibration can cause disabling damage to the nerves and blood supply of the hands and arms.
• Do not use worn or ill-fitting sockets or extensions, as this is likely to cause a substantial increase in vibration.
• Do not touch sockets or accessories during impacting. This increases the risk of cuts, burns or vibration injuries.
• Use and maintain as recommended in the manual to prevent an unnecessary increase in vibration.
• Check the vibration level after each service. If higher than normal, contact your STANLEY dealer.

Hydraulic

• Warning: Hydraulic fluid under pressure could cause skin injection injury. Do not check for leaks with your hands. If you are injured by hydraulic fluid, get medical attention immediately.
• Do not let hydraulic oil get on the skin. Hydraulic oil is hot. Wear Personal Protection Equipment (PPE) at all times.
• If exposed to hydraulic fluid, wash hands immediately.
• Do not exceed the maximum relief valve setting stated on the tool.
• Inspect and clean couplers before use, daily. Replace damaged couplers immediately.
• Hydraulic circuit control valve must be OFF before coupling or uncoupling tools. Failure to do so may damage the couplers and cause overheating of the hydraulic system.
• Ensure the couplers are properly connected and are tight.
• Do not operate the tool at fluid temperatures above 140°F (60°C). Higher temperatures can cause operator discomfort and damage to the tool.
• Do not exceed the rated flow and pressure as stated on the tool. Rapid failure of the internal seals may result.

What is the IW12 Hydraulic Impact Wrench?

IW12 is a medium duty impact wrench designed for bolting, drilling and underwater applications. IW12 requires an external hydraulic power supply capable of supplying 4-12 GPM (15-45 LPM) @ 1000-2000 PSI (70-140 BAR).

Specifications

Pressure| 1000-2000 PSI (70-140 BAR)
Flow| 4-12 GPM (15-45 LPM)
Hydraulic Circuit Type| Open Center
Max. Relief Pressure| 2100 PSI (145 BAR)
Recommended Back

Pressure

| 250 PSI (17 BAR) – Can be used with higher back pressures with reduced seal life.
Couplers| 3/8 inch NPT Flush Face
Port Size| -8 SAE O-ring
Min. Hose Pressure Rating| 2500 PSI (172 BAR)
Max. Hydraulic Oil Temperature| 140°F (60°C)
HTMA/EHTMA Category| Type II, Category D
Drive| 3/4 inch Square Drive
RPM| 1385 @ 5 GPM (19 LPM)
Torque| 250-1200 ft. lbs. (360-1632 Nm)
Tool Weight| 21 lbs.
Tool Size| 9.5 inches x 4 inches x 14 inches
Underwater Tool Max. Depth| 1000 feet (305 M)

Recommended Hose Diameters for Underwater Applications

Depth| 8 GPM (30 LPM)| 12 GPM (45 LPM)
100 feet (31 Meters)| 5/8 inches (16 mm)| 5/8 inches (16 mm)
300 feet (91 Meters)| 3/4 inches (19 mm)| 1 inch (25.4 mm)
600 feet (183 Meters)| 1 inch (25.4 mm)| 1 inch (25.4 mm)
1000 feet (305 Meters)| 1 inch (25.4 mm)| 1 1/4 inches (32 mm)

Sound & Vibration Declaration

Measured A-Weighted sound power level| 102.4 dBA
Measured A-Weighted Sound Pressure| 94.4 dBA
Uncertainty, Kpa, in decibels| 3.39 dBA
Values determined according to noise test code given in ISO 15744, 11203 and 3744.
Declared vibration emission value in accordance with EN ISO 28927-2.
Declared Vibration Emission Value (Main Handle):| 10.9 m/sec²
Declared Vibration Emission Value (Support Handle):| 11.3 m/sec²
Uncertainty| 2.15 m/sec²

Parts of an IW12 – Detail A

Tool Setup – Detail C

Do not install or change tool accessories while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury. Disconnect the hydraulic power source before installing or changing accessories.

1. Disconnect the tool from the hydraulic power source.

Select Rotation Direction

2. Turn the rotation direction lever in the upward position for clockwise rotation – OR – turn the lever in the downward position for counter clockwise rotation.

Install Socket

U se only impact-rated sockets and accessories. Do not use standard sockets or accessories, or sockets that are in poor condition. These can crack or fracture during operation and can become a projectile.

3. Push a 3/4 inch, square drive, impact rated socket onto the anvil. Note: Choose sockets designed for high impact (800-5500 ft. lbs. (10857457 Nm)).

Tool Operation – Detail E

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.

Connect to a Hydraulic Power Source

1. Using a calibrated flow and pressure gauge, check the output of the hydraulic power source. Ensure it matches the flow and pressure in “Specifications” on page 7. Hydraulic fluid must be 50°F or above. Preheat if necessary.

2. Ensure that the hydraulic power source is equipped with a relief valve set to open at the maximum relief pressure. See “Specifications” on page 7.

3. Wipe hose couplers with a clean, lint free cloth.

4. Connect the return hose to the tool port marked “Out”.

5. Connect the pressure hose to the tool port marked “In”.

6. Ensure couplers are undamaged, properly connected and are tight.

Using the Tool

Bolt Types for Use with IW12

Bolt Grade

| Thread Sizes

SAE Grade 2

|

1 – 1 1/2 inch

SAE Grade 5|

3/4 – 1 1/4 inch

SAE Grade 8|

5/8 – 1 inch

Note: Only use the sizes and types of accessories and consumables that are recommended by STANLEY for threaded fasteners. Do not use other types or sizes of accessories and consumables.

8. Hold the main tool handle with your dominant hand.

9. Place the socket or accessory on the fastener being driven.

10. Flip the trigger lock and squeeze the trigger.

Note: Hold the tool correctly and be ready to counteract normal or sudden movements. Have both hands available. High reaction torque can develop if the tool stalls, which can be caused by excessive loads being applied to the tool.

11. Release the trigger to stop the tool. Note: If you encounter a breakdown or the tool stops for any reason, release the trigger and power down the hydraulic power source.

Tool Use Tips

• To more accurately tighten bolts, lubricate threads and check bolts with a torque wrench. Duplicate time of impacting for bolts of the same length and thread.
• Heavy, loose or multiple adapters can dissipate the intensity of impact. Use as few adapters as possible and ensure they fit tightly. Loose fitting accessories will increase vibration.
• Hold the tool with a light, but safe grip. Risk from vibration is greater with higher grip force.
• Maximum torque can be obtained by continuously impacting for 10 seconds.
• Hydraulic flow and pressure from the hydraulic power source will dramatically influence the tool impact force and speed. Regularly check the hydraulic power source. See “Specifications” on page 7.

Tool Maintenance

Daily Maintenance

1. Remove hydraulic power from the tool.
2. Check all hydraulic connections and hoses for damage. Replace damaged parts before operating the tool.
3. Remove the hammer case and inspect the impact mechanism. If the mechanism is not well lubricated, or if the grease is burned, see “Grease the Impact Mechanism” on page 8.
4. Inspect tool to ensure all decals are legible. Contact STANLEY if replacements are needed.
5. Using a calibrated flow and pressure gauge, check the output of the hydraulic power source. Ensure it matches the flow and pressure in “Specifications” on page 7. Proper flow and pressure maintain proper tool speed.

Underwater Tool Maintenance

Perform maintenance on underwater models after each use.

1. Remove hydraulic power from the tool.
2. Clean and grease the impact mechanism with a waterproof grease. See “Grease the Impact Mechanism” on page 8.
3. Using a water displacing oil, spray into the trigger.
4. Spray or dip the entire tool.

Grease the Impact Mechanism

STANLEY Recommended Grease

Energy Release G-200
Kendall Super-Blu L-427
Texaco Starplex 2
Lubrication Engineers Almagard 3752

STANLEY Recommended Grease

Mobil Delvac Xreme Service

1. Remove and clean the impact mechanism.
2. Inspect all parts for damage. Replace damaged parts before using the tool.
3. Lubricate the inside of the hammer frame, the thrust bearing and thrust races with a STANLEY recommended grease.
4. Reassemble the impact mechanism and reattach it to the tool.
5. Torque the four cap screws that hold the impact mechanism to the tool
   to 13-15 ft. lbs. (17-20 Nm).

Tool Storage & Transport

Drain the tool of hydraulic fluid and plug open hydraulic ports. Collect all hydraulic fluid for recycling (See “Tool Disposal” on page 8). Clean the tool and store in a clean, dry space that is safe from damage. Ensure the tool is secured and will not move during transport. An unsecured tool could cause personal injury or damage to the tool.

Tool Disposal

Hydraulic Oil

Hydraulic oil can contaminate the air, ground and water if not properly recycled. Recycle hydraulic oil in accordance with all State, Federal and local laws, at your local oil recycling facility.

Hydraulic Hoses

Hang hydraulic hoses to drain. Collect the oil for recycling. Contact your local municipal recycling authorities for an approved hydraulic hose recycling site.

Tool Body

Drain hydraulic oil from the tool, making sure to collect the oil for recycling. Disassemble the tool and dispose of all non-metal parts. Recycle the metal components. Contact your local municipal recycling authorities for recycling instructions.

Accessories

IW12 Accessories

Description| Part Number
3/4 inch Square Anvil to 3/4 inch Jacobs Chuck,

Adapter

| 01857
5/8 inch Hex Shank x 1/2 inch Square Male,

Adapter

| 05080
3/4 inch Square Anvil to 5/8 inch Hex Quick

Change Adapter

| 06790
Lineman’s Style Auger Drill Bits (Use with adapter 06790)
5/8 inch, Hex Pole Bit, 9/16 inch x 21 inch x 24 inch Overall Length| 27845
5/8 inch, Hex Pole Bit, 13/16 inch x 21 inch x 24 inch Overall Length| 27847

Troubleshooting

“Specifications” on page 7. Proper flow and pressure maintain proper tool speed. Check regularly.
Incorrect sockets or accessories.| Stop using the tool immediately. Only use impact rated sockets or accessories that fit tightly.
Impact mechanism needs to be lubricated.| See “Grease the Impact Mechanism” on page 8.
Impact mechanism is worn or damaged.| Contact your STANLEY dealer for service.
Tool runs too fast.| Hydraulic power source is not running properly.| Ensure the power source is delivering proper flow and pressure. See “Specifications” on page 7. Proper flow and pressure maintain proper tool speed. Check regularly.
Pressure and return hoses are reversed.| See “Connect to a Hydraulic Power

Source” on page 7.

Tool Failure.| Contact your STANLEY dealer for service.
Grease is leaking from the impact mechanism.| Hard use and heat forcing out grease.| This is normal. Follow proper maintenance.

See “Tool

Maintenance” on page 8.

Tool is leaking hydraulic oil.| Hydraulic fluid is too hot.| Ensure hydraulic fluid temperature does not exceed the value in “Specifications” on page 7.
Tool damage or failure.| Contact your STANLEY dealer for service.

STANLEY Infrastructure
6430 SE Lake Road, Portland, Oregon 97222 USA
503-659-5660 / Fax 503-652-1780
www.stanleyinfrastructure.com
© 2014 Stanley Black&Decker, Inc.
New Britain, CT 06053 USA

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