# EP5PTI13 HR42-MT-L

## Impulse Nutrunner

# Product Information

# General Information

WARNING

Risk of Property Damage or Severe Injury

Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.

- Read all Safety Information delivered together with the different parts of the system.

- Read all Product Instructions for installation, operation and maintenance of the different parts of the system.

- Read all locally legislated safety regulations regarding the system and parts thereof.

- Save all Safety Information and instructions for future reference.

In this Section

- Safety Signal Words
- Warranty
- Website
- ServAid
- Safety Data Sheets MSDS/SDS
- Special Precaution
- Country of Origin
- Dimensional Drawings

# Safety Signal Words

The safety signal words Danger, Warning, Caution, and Notice have the following meanings:

DANGER | DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING | WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION | CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE | NOTICE is used to address practices not related to personal injury.

# Warranty

- Product warranty will expire in 12+1 months after dispatch from Atlas Copco's Distribution Center.

- Normal wear and tear on parts is not included within the warranty.

  - Normal wear and tear is that which requires a part change or other adjustment/overhaul during standard tool maintenance typical for that period (expressed in time, operation hours or otherwise).

- The product warranty relies on the correct use, maintenance, and repair of the tool and its component parts.

- Damage to parts that occurs as a result of inadequate maintenance or performed by parties other than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the warranty.

- To avoid damage or destruction of tool parts, service the tool according to the recommended maintenance schedules and follow the correct instructions.

- Warranty repairs are performed only in Atlas Copco workshops or by Certified Service Partners.

Atlas Copco offers extended warranty and state-of-the-art preventive maintenance through its ToolCover contracts. For further information, contact your local Service representative.

For electrical motors:

- Warranty will apply, only when the electric motor has not been opened.

# Website

Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on the Atlas Copco website.

Please visit: www.atlascopco.com.

# ServAid

ServAid is a portal that is continuously updated and contains Technical Information, such as:

- Regulatory and Safety Information

- Technical Data

- Installation, Operation and Service Instructions

- Spare Parts Lists

- Accessories

- Dimensional Drawings

Please visit: https://servaid.atlascopco.com.

For further Technical Information, please contact your local Atlas Copco representative.

# Safety Data Sheets MSDS/SDS

The Safety Data Sheets describe the chemical products sold by Atlas Copco.

Please consult the Atlas Copco website for more information www.atlascopco.com/sds.

# Special Precaution

- Check that the power socket is properly fastened.

- Replace the square drive retainer or socket if worn.

- Avoid unnecessary idling.

- When using a suspension yoke, make sure that it is in good condition and correctly fastened.

In this Section

- PTFE

# PTFE

WARNING

Polymer Hazard

The vanes in this product contain PTFE (a synthetic fluoropolymer). Due to wear, there might be PTFE particles inside the product. Heated PTFE can produce fumes which may cause polymer fume fever with flu-like symptoms, especially when smoking contaminated tobacco.

Health and Safety recommendations for PTFE must be followed when handling vanes and other components:

- Do not smoke when servicing this product

- PTFE-particles must not come in contact with open fire, glow or heat

- Motor components must be washed with cleaning fluid and not blown clear with an air line

- Wash your hands before starting any other activity

# Country of Origin

For the Country of Origin, please refer to the information on the product label.

# Dimensional Drawings

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.

Please visit: https://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

# Overview

# Applications

This pneumatic shout-off impulse tool can be used for various applications where reaction free tightening and/or high productivity is needed.

# Technical Product Data

Technical Product Data can be found on either ServAid, or the Atlas Copco website.

Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

# Installation

# Installation Requirements

# Air Quality

- For optimum performance and maximum product life we recommend the use of compressed air with a maximum dew point of +10°C (50°F). We also recommend to install an Atlas Copco refrigeration type air dryer.

- Use a separate air filter which removes solid particles larger than 30 microns and more than 90% of liquid water. Install the filter as close as possible to the product and prior to any other air preparation units to avoid pressure drop.

For impulse/impact tools make sure to use lubricators adjusted for these tools. Regular lubricators will add too much oil and therefore decrease the tool performance due to too much oil in the motor.

Make sure that the hose and couplings are clean and free from dust before connecting to the tool.

Both lubricated and lubrication free products will benefit from a small quantity of oil supplied from a lubricator.

# Air Lubrication Guide

Recommended air lubricators:

- Atlas Copco Optimizer (1 liter) 9090 0000 04

- Q8 Chopin 46

- Q8 Chopin 32

- Shell Air Tool Oil S2 A 320

- Mobil SHC Cibus 32

# Compressed Air Connection

WARNING

Risk of severe injury

Air under pressure can cause injury.

- Always shut off the air supply when not in use or before any adjustments.

- Drain the hose of air pressure and disconnect the tool from air supply when not in use or before any adjustments.

- Always use the correct hose size and air pressure for the tool.

WARNING

Compressed Air

High air pressure can cause severe damage and bodily injury.

- Do not exceed maximum air pressure.

- Make sure that there are no damaged or loose hoses or fittings.

For correct air pressure and hose size, see the Technical Product Data on - https://servaid.atlascopco.com or www.atlascopco.com.

Make sure that the hose and couplings are clean and free from dust before connecting to the tool.

# Air Pressure Regulation

Make sure to adjust the regulator to the lowest expected pressure on the line.

Adjusting the air pressure will have the following consequences:

- Decreasing the air pressure will result in a slower but more accurate tool.

- Increasing the air pressure will result in a faster but less accurate tool.

If the pressure from the airline is below five bar, a tool from the EP L-series (designed for low pressure installations) is recommended.

# Installation Instructions

# Recommended hose sizes

Make sure that all connections, adapters and couplings exceed the recommended minimum inner diameter, corresponding to the recommended hose size of the tool. Refer to the examples in the table. Recommended hose size for a specific tool is found in "Technical specifications" in https://servaid.atlascopco.com

Recommended hose size | Minimum inner diameter for all couplings and adapters
--- | ---
8 mm | 7 mm
10 mm | 7 mm
13 mm | 9.4 mm

# Installation of Flexible Hose

To prevent tool vibrations use a flexible hose for compressed air with a minimum length of 300 mm (12") between the tool and the quick coupling.

# Initial Setting of Torque

To minimize the risk of damage to the actual joint we recommend to set the torque slightly lower on the test joint than the torque wanted for the application. Make sure to use the same equipment, such as for example extensions, sockets and air pressure on the test joint as will be used on the actual joint.

A | Torque transducer IRTT
B | Test joint
C | ST Analyzer

Make sure to always verify the torque settings on your actual joint.

# Operation

# Ergonomic Guidelines

Consider your workstation as you read through this list of general ergonomic guidelines and see if you can identify areas for improvement in posture, component placement, or work environment.

- Take frequent breaks and change work positions frequently.

- Adapt the work area to your needs and the work task.

  - Adjust for convenient reach range by determining where parts or tools should be located to avoid static load.

  - Use workstation equipment such as tables and chairs appropriate for the work task.

- Avoid work positions above shoulder level or with static holding during assembly operations.

  - When working above shoulder level, reduce the load on the static muscles by reducing the weight of the load. You can also reduce the load on the static muscles by holding the load close to the body.

  - Make sure to take frequent breaks.

  - Avoid extreme arm or wrist postures, particularly for operations requiring a degree of force.

- Adjust for convenient field of vision by minimizing movement of the eyes and head during the work task.

- Use the appropriate lighting for the work task.

- Use ear protection equipment in noisy environments.

- Use dust extraction system or mouth protection mask in dusty environments.

# Operating Instructions

# Air Pressure Monitoring, RE-signal

It is possible to connect the tool to a pressure monitoring equipment to monitor the tightening. The pressure signal from the tool (differential pressure over the motor) can be used to detect:

- Missed fasteners

- Trigger release before set torque is reached

- Stripped threads

- Cross-threading

- Re-hits

- Drop in air supply

To connect the tool to a pressure monitoring equipment we recommend using a Reporting Connection Kit, see Accessories https://servaid.atlascopco.com.

The pressure monitoring equipment does not measure torque.

## Assembly of the Reporting Connection Kit

## Air Pressure Signal Diagram

# Optimizing the Tool Performance

It is not recommended to use extensions with pulse tools. Extensions cause vibrations, which in turn may cause wear on the tool, longer tightening time, limited accuracy and difficulty reaching maximum torque. If an extension is necessary due to accessibility constraints, it should be as short as possible. Guided sockets or extensions are strongly recommended.

## Recommended number of pulses

The pulse tool shall reach the target torque, with shut off, within 5-20 pulses. Measure the number of pulses to reach the target torque with an analyzer. The tightening time can also be used as a guide, to know if the tool is set correctly:

- ≤ 1 second for tools up to 30 Nm

- ≈ 1 second for tools up to 80 Nm

- ≈ 2 seconds for tools up to 150 Nm

- ≈ 5 seconds for tools up to 450 Nm

- ≤ 10 seconds for tools up to 850 Nm

If the target torque is reached within less than 5 pulses (= short tightening time), the torque scatter will increase and it can be difficult to adjust to the right level, especially on hard joints.

If the target torque is reached after more than 20 pulses (= too long tightening time) the wear will increase and more frequent oil filling and service will be required. Too long tightening time, in combination with high production rate, may also result in excessive heating of the oil. In that case the power will decrease with longer tightening time and sometimes no shut off.

If the target torque is reached within less than 5 pulses, adjust it by:

- Decreasing the air pressure.

- Reducing the speed with the AutoTrim or Trim valve.

- If the above is not possible or does not give the wanted results, a smaller tool may be a better choice.

If the target torque is reached with more than 20 pulses, adjust it by:

- Increasing the dynamic air pressure to 6-7 bar for standard EP tools, or up to 5 bar for low pressure EP L-tools.

- Adjusting the AutoTrim or Trim valve to give maximum power/speed.

- If the above is not possible or does not give the wanted results, a bigger tool may be a better choice.

When changing the air pressure, measure the target torque again and adjust it if needed.

# MultiTrim Function

The design of PTI-MT tools combines the advantage of both AutoTrim and Trim function - MultiTrim - in the same tool. The tools are factory set at AutoTrim function and can easily be change to Trim function when suitable for the application.

# When to Use AutoTrim Valve or Trim Valve

## AutoTrim Valve

- For applications where the tool is used to tighten both hard and soft joints.

## Trim Valve

- For applications where the tool is used for tightening joints with similar characteristics.

## Position of the Set Screw with AutoTrim or Trim Setting

Relevant Information

- Switching to AutoTrim Function
- Switching to Trim Function

# Switching to Trim Function

When the tool has been used with AutoTrim function:

1. Switch to Trim function as per illustration.

2. Check that the tool works properly.

Relevant Information

- Setting of Tightening Torque When Using Trim Function

# Adjusting the Trim Valve

# Switching to AutoTrim Function

When the tool has been used with Trim function:

1. Switch to AutoTrim function as per illustration.

2. Check that the tool works properly.

Relevant Information

- Setting of Tightening Torque When Using AutoTrim Function

# Adjusting the AutoTrim Valve

Regularly check the function of the AutoTrim valve.

The AutoTrim valve gives a reduced speed during rundown and will automatically switch to full speed/power after 1-2 pulses. If this is not the case, follow steps 1-3.

1. Make sure that the AutoTrim function is activated correctly.

2. Check the recommended reduced (free) speed, according to the table AutoTrim Settings for Regular Pressure Tools or AutoTrim Settings for Low Pressure Tools. Adjust if needed.

   Adjusting the Reduced (free) Speed

3. Adjust the switching point valve.

   Adjusting the Switching Point Valve

- If the valve is too closed, the AutoTrim will not shift to full speed and power when pulsing starts. Turn the valve counter clockwise 90 degrees to find the correct switching point. Repeat until correct switching point is reached.

- If the valve is too open, the AutoTrim will shift to full speed and power too quickly (during rundown). Turn the valve clockwise 90 degrees to find the correct switching point. Repeat until correct switching point is reached.

## Re-setting the Switching Point of the AutoTrim Valve

1. Close the switching valve completely, by turning it clockwise, until it stops.

2. Open the valve counter clockwise 6.5 turns with an Allen key.

3. If needed, turn the valve 90 degrees at a time to find the correct switching point, as described above.

4. If correct switching cannot be achieved with 5-8 turns, from fully closed, then service may be needed, see Service section.

## AutoTrim Settings for Regular Pressure Tools

Model | Reduced (free) speed (rpm)
--- | ---
EP4PTI9 HR10-MT / HR42-MT | 3100-3400
EP5PTI19 HR10-MT / EP5PTI17 HR42-MT | 3100-3400
EP6PTI32 HR10-MT / EP6PTI28 HR42-MT | 2900-3200
EP7PTI55 HR10-MT | 2875-3125
EP8PTI70 HR10-MT | 2675-2925
EP9PTI80 HR13-MT | 2725-2975
EP11PTI100 HR13-MT | 2325-2525
EP13PTI150 HR13-MT | 2225-2475

## AutoTrim Settings for Low Pressure Tools

Model | Reduced (free) speed (rpm)
--- | ---
EP5PTI15 HR10-MT-L / HR42-MT-L | 2600-3100
EP6PTI25 HR10-MT-L / HR42-MT-L | 2600-3100
EP7PTI35 HR10-MT-L | 2650-3050
EP8PTI45 HR10-MT-L | 2650-3050
EP9PTI65 HR13-MT-L | 2450-2850
EP11PTI80 HR13-MT-L | 2300-2600
EP13PTI110 HR13-MT-L | 2150-2550

Improper AutoTrim function may result in:

- Increased scatter (wrong torque).

- Longer tightening time.

- No shut-off.

Relevant Information

- Switching to AutoTrim Function

# Setting of the Tightening Torque

To use the tool at a higher torque than recommended maximum torque may result in incorrect function and faster wear.

Always do a control of the tightening torque on the actual joint.

1. Remove the slotted cover plug at the front of the tool.

2. Turn the pulse unit until you see the adjusting screw in the hole.

3. Start at a low torque and increase it until you reach the wanted torque level.

# Torque Check - Residual Torque Measurement on Actual Joint

1. Make sure to use the same equipment, such as extensions, sockets and air pressure during the tightening, as will be used on the actual tightening application.

2. When performing a torque check on the actual joint we recommend using an ST Wrench with residual torque measurement* setting.

* Torque required to cause the threads of the fastener (including its head) on which torque is applied, to move relative to the mating thread.

A | The actual joint
B | Torque wrench with monitoring

1. Perform a tightening.

2. Measure the result with the Torque wrench with monitoring.

# Setting of Tightening Torque When Using AutoTrim Function

When using a tool with AutoTrim function make sure that it is correctly adjusted. When correctly adjusted the AutoTrim reduces the speed during rundown and will automatically switch to full speed/power after approximately 1-2 pulses.

Relevant Information

- Adjusting the AutoTrim Valve

# Setting of Tightening Torque When Using Trim Function

When using the tool with Trim function make sure that it is adjusted correctly. The Trim valve can be used to reduce the speed to improve the accuracy, especially on low torque settings on hard joints.

Relevant Information

- Adjusting the Trim Valve

# Service

# General Service Information

If the tool is not working properly, take it out of operation for inspection. Preventive maintenance is recommended at regular intervals. See detailed information on Preventive Maintenance.

- Make sure to use the service tools, service kits and spare parts recommended by Atlas Copco.

- Make sure to follow the Service instructions provided by Atlas Copco.

Make sure to work in a clean environment and that all parts are cleaned before re-assembling. Foreign particles, even small fibers from paper tissue, may affect the service life of the Pulse unit.

# Maintenance Instructions

# Daily Inspection

- Make sure that the tool is in good condition, no visual damage.

- Make sure that the air connection and air installation is done correctly. Listen for any air leakage.

- Make sure that sockets and extensions have no visual damage.

- Make sure to have the correct air pressure.

- Listen to make sure that there is no unexpected noise when running the tool.

# Preventive Maintenance

There are several criteria that affect the need for service on EP-tools such as; type of joint, torque level and tightening duration, production rate, air pressure and air quality. Recommendations are based on Reference Tightening, as listed in table. The service intervals and service solutions are based on experience and internal testing.

## Reference Tightening

Tool size | Torque level of max torque | Tightening time | Production rate tightening/hour
--- | --- | --- | ---
EP 5-6 PTI | 70-80 % | 1 second | 600
EP 7-8 PTI | 70-80 % | 1 second | 600
EP 9 PTI | 70-80 % | 1,5 seconds | 500
EP 11 PTI | 70-80 % | 1,5 seconds | 500
EP 13 PTI | 70-80 % | 1,5 seconds | 400

The air installation and air quality for the Reference Tightening should be according to recommendations in the Product Instructions. Deviations from above conditions may affect the service intervals.

# Preventive Maintenance Level 1

Carry out maintenance after 200 000 - 250 000 tightening, see table Reference Tightening, or once a year whichever comes first.

For maximum tool performance follow below instructions and use recommended service tools and service kits from Atlas Copco. Always use tightening torque and lubrications as recommended by Atlas Copco.

## Tool Handle

- Make a visual inspection for any damage.

- Inspect the yoke and suspension points.

- Inspect the bushing in the Pulse unit casing and the surface of the anvil.

- Clean the inlet strainer.

## Air Motor

- Make a visual inspection for any damage.

- Change the vanes.

- Change the bearings if needed.

## AutoTrim / Trim

- Open and inspect the parts for damage, wear or blockage.

- Clean the needle valve (only AutoTrim).

- Change the sealing if needed (only AutoTrim).

- Assemble and adjust according to instructions.

## Trigger and Reversing Valve

- Look for any leakage and make sure that it works correctly.

- Inspect the O-rings and washer, replace if needed.

## Silencer

- Open and inspect the parts for damage, replace if needed.

- Change the filter.

## Pulse Unit

- Inspect the shut-off mechanism.

- Inspect the square drive and hex drive for any cracks or wear.

- Make sure that the torque adjustment screw has enough friction to prevent the setting from accidently changing during operation.

- Change the oil accordingly.

- Make sure that the pulsing frequency is within limits, as per the Tool Condition Test.

Relevant Information

- Oil Filling and Changing Instruction for Pulse Unit
- Preventive Maintenance
- Tool Condition Test

# Preventive Maintenance Level 2

Carry out maintenance after 400 000 - 500 000 tightenings, see table Reference Tightening, or every second year whichever comes first.

For maximum tool performance follow below instructions and use recommended service tools and service kits from Atlas Copco. Always use tightening torque and lubrications as recommended by Atlas Copco.

Same as level 1 with additional Pulse unit maintenance below:

## Pulse Unit

- Drain all the oil completely from the Pulse unit.

- Disassemble the Pulse unit.

- Clean and inspect all parts and surfaces thoroughly for any wear or damage.

- Inspect the shut-off mechanism and replace damaged or worn parts.

- Clean the magnets from any metal particles.

- If replacing the rollers we strongly recommend replacing the pistons as well.

- Change all O-rings and Diaphragms.

- Replace the anvil sealing. Make sure that the cylinder front piece is clean and dry on the inside with no lubrication before assembling the new sealing.

- Make sure that the anvil surface is smooth, clean and lubricated with pulse oil to prevent damages to the anvil sealing during assembly.

- Make sure to assemble the Pulse unit in the right way. It is important that the camshaft and the separator washer pin is lined up with the groove in the cylinder front piece. If not, the cylinder end piece will not be correctly fastened and the Pulse unit will not function correctly.

- Fill the Pulse unit to the right oil level.

Relevant Information

- Oil Filling and Changing Instruction for Pulse Unit
- Preventive Maintenance

# Assembling the Pulse Unit

Make sure to assemble all parts of the Pulse unit in the right order.

It is important that the camshaft and the separator washer pin is lined up with the groove in the cylinder front piece. If not, the cylinder end piece will not be correctly fastened, and the Pulse unit will not function properly.

# Assembling the AutoTrim Valve

When re-assembling the AutoTrim after inspection or service, make sure to protect the piston sealing from the housing thread.

# Assembling Motor in Housing

* For correct tightening torque, see Spare Parts https://servaid.atlascopco.com.

# Position of the Stop Pin in Pulse Unit

The position of the stop pin is correctly set at the factory. If the position has to be reset or adjusted due to service or replacement of spare parts, follow the instructions below.

In this Section

- Adjusting the Position of the Stop Pin

# Adjusting the Position of the Stop Pin

The position of the stop pin is correctly set at the factory. If the position has to be reset or adjusted due to service or replacement of spare parts, follow the instructions below.

Measurement D is the opening diameter for the gauge.

D = 1.8 mm

1. Fit a 2.5 mm Allen key in the adjustment screw.

2. Hold the Pulse unit with both stop surface of inertia body and anvil in horizontal position and the Allen key pointing downwards.

3. Press the inertia body to open the hole for the gauge.

4. Place a gauge, for instance a drill bit, with the correct diameter of D in the hole.

5. Adjust the opening by turning the adjustment screw 45 degrees at the time until the gauge is in line with the pulse unit.

   Avoid unnecessary turning of the adjustment screw.

   - Turn the screw anti-clockwise to raise the gauge.

   - Turn the screw clockwise to lower the gauge.

6. Check that the gauge is correctly inserted by repeatedly pressing and releasing the inertia body. The gauge should return to the correct position in line with the Pulse unit.

7. Apply Loctite 290 to the adjustment screw.

# Lubrication Instructions

# Rust Protection and Cleaning

Water in the compressed air can cause rust. To prevent rust we strongly recommend to install an air dryer.

Water and particles can cause sticking of vanes and valves. This can be prevented by installing an air filter close to the product to avoid pressure drop.

Before longer stand stills always protect your tool by adding a few drops of air motor oil into the air inlet. Run the tool for 5–10 seconds and absorb any excess oil at the air outlet in a cloth.

# Lubrication Guide

Brand | General purpose, Bearings and Gears
--- | ---
BP | Energrease LS-EP2
Castrol | Optileb GR UF 1
Esso | Beacon EP2
Q8 | Rembrandt EP2
Mobil | Mobilegrease XHP 222 NLGI2
Klüber Lub. | Klübersynth UH 1 14-151
Texaco | Multifak EP2
Molykote | BR2 Plus
Shell | Gadus S2

Brand | Pulse unit hexagon
--- | ---
Klüber Lub. | Microlube GL 261

# Oil Level in the Pulse Unit

The right oil level in the Pulse unit is important for the tool to work correctly.

The need to add oil to the Pulse unit will vary depending mainly on the number of tightening, torque level and number of pulses (tightening time).

Operating the tool on a low oil level will result in faster wear of the parts in the Pulse unit. It will also affect the tool performance and accuracy.

Always check the tightening torque after filling the oil.

## Detect Low Oil Level in the Pulse Unit

- Longer tightening time

- Very high pulse frequency, especially when the tool has not been used for a while.

- Low torque or abnormal torque changes (increased scatter).

- No shut-off.

To measure the pulse frequency use a static torque transducer or an inline transducer connected to torque testing equipment, as per the Tool Condition Test.

Relevant Information

- Tool Condition Test
- Torque Check - Residual Torque Measurement on Actual Joint

# Oil Filling and Changing Instruction for Pulse Unit

Required equipment for oil filling and oil changing:

- Atlas Copco Pulse unit oil.

- Atlas Copco Pulse unit Oil Filling Kit.

  For ordering number for Spare Parts, see https://servaid.atlascopco.com.

Oil Filling Equipment Kit

- 2 x Adapter M3

- 2 x Adapter M4

- 4 x Hose length 540 mm

- 2 x Hose length 50 mm

- 1 x Hose length 120 mm

- 1 x Syringe 50 ml

- 1 x Syringe 1 ml

- 4 x Plug

- 5 x Connection

- 2 x Connection

- 2 x Can

- 2 x Cover

1. Place the Pulse unit in a vise at an angle so that the outlet hole is at the highest point.

2. Remove the screw covering the inlet opening. Make sure that the o-ring is on the screw and not left in the Pulse unit. Attach the filling hose by hand, with the hose connector end to the Pulse unit.

3. Fill the large syringe with oil to maximum capacity from the oil can.

   Always use new Atlas Copco Pulse unit oil.

4. Remove the stop plug from the filling hose and then attach the syringe to the hose.

5. Remove the screw covering the outlet opening of the Pulse unit. Make sure that the o-ring is on the screw and not left in the Pulse unit. Attach the return hose to the Pulse unit.

6. Remove the stop plug from the return hose and then attach it to the oil can.

7. Start filling oil into the Pulse unit from the large syringe. When filling oil into the Pulse unit, there will be air bubbles exiting.

8. Rotate the anvil back and forth while filling the oil until no more bubbles are coming out of the Pulse unit.

9. Spin the complete Pulse unit around while filling the oil, to make sure that there are no air bubbles left inside of the Pulse unit.

10. Remove the return hose from the oil can and attach the stop plug to the return hose end.

11. Remove the return hose from the outlet opening of the Pulse unit. Put the screw covering the outlet opening back in position.

12. Now position the Pulse unit in the vise with the inlet opening facing upwards.

13. Remove the syringe from the filling hose and attach the stop plug to the filling hose.

14. Remove the oil filling hose from the Pulse unit.

15. Use the small syringe to extract the right amount of oil accordingly, see table Oil Filling.

16. Put the screw covering the inlet opening back in position.

## Oil Filling

Oil reduction (X) from 100% full Pulse unit | Approximate oil volume in Pulse unit
--- | ---
0.4 ± 0.05 ml | 6 ml

# Inspection and Lubrication of the Pulse Unit

# Recommended Oil for the Pulse Unit

The recommended oil for the pulse unit is Atlas Copco Pulse Unit Oil.

A bottle of Atlas Copco Pulse Unit Oil and the required syringe or syringes are orderable as kits. Please see Service Kits for ordering numbers.

# Dismantling/Assembling Instructions

# Assembling Motor in Housing

* For correct tightening torque, see Spare Parts https://servaid.atlascopco.com.

# Tightening of Threaded Connections

The tightening torque indicated in the exploded views (see Spare parts section in https://servaid.atlascopco.com) will give the right clamping force and prevent parts from loosening. It is important not to exceed the clamping force, these parts must be able to open up without being damaged at service. After some time of operation and in special circumstances, depending on application and usage, the parts may however loosen somewhat. The tightening torque can then be increased by 10-20% and some type of low or medium thread locking fluid can be applied.

# Torque Check - Residual Torque Measurement on Actual Joint

1. Make sure to use the same equipment, such as extensions, sockets and air pressure during the tightening, as will be used on the actual tightening application.

2. When performing a torque check on the actual joint we recommend using an ST Wrench with residual torque measurement* setting.

* Torque required to cause the threads of the fastener (including its head) on which torque is applied, to move relative to the mating thread.

A | The actual joint
B | Torque wrench with monitoring

1. Perform a tightening.

2. Measure the result with the Torque wrench with monitoring.

# Tool Condition Test

## Test Conditions

Temperature Pulse unit: approximately 20° C.

Dynamic air pressure: 4 bar (58 psi).

Hose size: Ø 8 mm Hose length: 3 m

A | Static Torque transducer SRTT
B | ST Analyzer (set at 850 Hz)

1. Test the free speed in the forward direction with the tachometer.

   Make sure that the tool runs on full speed regardless of AutoTrim or Trim setting. If the tool is used with AutoTrim, also test the AutoTrim function.

2. Test the maximum torque and pulse frequency by setting the filter frequency in ST Analyzer to 850 Hz.

   Test the max torque and pulse frequency in reverse direction using an SRTT static torque transducer. Tightening time approximately 1 second.

3. Check the shut-off mechanism.

   Perform some tightenings to make sure that the tool shuts off correctly.

A tool in good condition should achieve the following values:

Model | Free speed (rpm) | Pulse frequency CCW static (Hz) | Max Torque CCW static (minimum) (Nm)
--- | --- | --- | ---
EP5PTI13 HR42-MT-L | 6900 -10%/+25% | 17-29 | 15

Correct pulse frequency indicates that the air motor and the Pulse unit are in good condition. If the pulse frequency is too high - add more oil. If the pulse frequency is too low - reduce the oil level.

# Tests and Adjustments after Service

Perform a tool condition test to make sure that the tool is working properly.

In this Section

- Test Method - Static or Dynamic
- Tool Condition Test
- Torque Check - Residual Torque Measurement on Actual Joint
- Adjusting the Position of the Stop Pin

# Test Method - Static or Dynamic

A static torque measurement is recommended for the ErgoPulse machines.

If dynamic torque measurement with an electronic inline torque transducer is used, always verify your measurement result by a static check with a torque wrench (electronic).

For more information, refer to Atlas Copco "Pocket Guide to Pulse Tools". Ordering No. 9833 1225 01.

# Tool Condition Test

## Test Conditions

Temperature Pulse unit: approximately 20° C.

Dynamic air pressure: 4 bar (58 psi).

Hose size: Ø 8 mm Hose length: 3 m

A | Static Torque transducer SRTT
B | ST Analyzer (set at 850 Hz)

1. Test the free speed in the forward direction with the tachometer.

   Make sure that the tool runs on full speed regardless of AutoTrim or Trim setting. If the tool is used with AutoTrim, also test the AutoTrim function.

2. Test the maximum torque and pulse frequency by setting the filter frequency in ST Analyzer to 850 Hz.

   Test the max torque and pulse frequency in reverse direction using an SRTT static torque transducer. Tightening time approximately 1 second.

3. Check the shut-off mechanism.

   Perform some tightenings to make sure that the tool shuts off correctly.

A tool in good condition should achieve the following values:

Model | Free speed (rpm) | Pulse frequency CCW static (Hz) | Max Torque CCW static (minimum) (Nm)
--- | --- | --- | ---
EP5PTI13 HR42-MT-L | 6900 -10%/+25% | 17-29 | 15

Correct pulse frequency indicates that the air motor and the Pulse unit are in good condition. If the pulse frequency is too high - add more oil. If the pulse frequency is too low - reduce the oil level.

# Torque Check - Residual Torque Measurement on Actual Joint

1. Make sure to use the same equipment, such as extensions, sockets and air pressure during the tightening, as will be used on the actual tightening application.

2. When performing a torque check on the actual joint we recommend using an ST Wrench with residual torque measurement* setting.

* Torque required to cause the threads of the fastener (including its head) on which torque is applied, to move relative to the mating thread.

A | The actual joint
B | Torque wrench with monitoring

1. Perform a tightening.

2. Measure the result with the Torque wrench with monitoring.

# Adjusting the Position of the Stop Pin

The position of the stop pin is correctly set at the factory. If the position has to be reset or adjusted due to service or replacement of spare parts, follow the instructions below.

Measurement D is the opening diameter for the gauge.

D = 1.8 mm

1. Fit a 2.5 mm Allen key in the adjustment screw.

2. Hold the Pulse unit with both stop surface of inertia body and anvil in horizontal position and the Allen key pointing downwards.

3. Press the inertia body to open the hole for the gauge.

4. Place a gauge, for instance a drill bit, with the correct diameter of D in the hole.

5. Adjust the opening by turning the adjustment screw 45 degrees at the time until the gauge is in line with the pulse unit.

   Avoid unnecessary turning of the adjustment screw.

   - Turn the screw anti-clockwise to raise the gauge.

   - Turn the screw clockwise to lower the gauge.

6. Check that the gauge is correctly inserted by repeatedly pressing and releasing the inertia body. The gauge should return to the correct position in line with the Pulse unit.

7. Apply Loctite 290 to the adjustment screw.

# Troubleshooting

# Troubleshooting Guide

Problem | Reason | Action
--- | --- | ---
The tool does not shut off, or the tightening time is too long. | Target torque close to maximum torque of the tool. | Chose a bigger tool with more power.
| Low dynamic air pressure. | Check the dimensions of the hose and couplings. Increase the air pressure.
| Low rotation speed. | See problem "The rotation speed is too low".
| The extension is too long. | Check the extension.
| Worn extension or socket/bits. | Check the extension and socket/bits.
| Torque setting screw is turned too much. | Adjust the torque setting screw CCW until tool shuts off.
| The stop pin in the shut off mechanism is incorrectly adjusted. | Check with a gauge.
| Incorrect oil level in the Pulse unit. | Adjust the oil level or refill the oil.
| The joint is too soft for the tool. | Chose a bigger tool with more power.
| Worn parts in the Pulse unit. | Inspect and replace any worn parts, see https://servaid.atlascopco.com.
| Malfunctioning AutoTrim. | Check the AutoTrim function.
| The yield point of the joint is reached. | Check the joint specification.
The pulse frequency is too high or too low. | Incorrect oil level in the Pulse unit. | Adjust the oil level or refill the oil.
Inconsistent shut off or insufficient accuracy | The target torque is not within the tool specification. | Change to a different tool size.
| Not enough pulses (hard joint and low torque setting). | See section Optimizing the Performance of Your ErgoPulse Tool.
| Extension is too long. | Check the extension.
| Worn extension or socket/bits. | Check the extension and socket/bits.
| Pressure fluctuations in the air supply. | Use a pressure regulator (for each tool) to get a consistent air supply.
| Incorrect oil level in the Pulse unit. | Adjust the oil level or refill the oil.
| Friction is too low on the Torque setting screw. | Replace with new screw.
| Worn parts in the Shut off mechanism. | Inspect and replace any worn parts.
| Stop pin in the Shut off mechanism is not correctly adjusted. | Check with a gauge.
| Malfunctioning AutoTrim. | Check the AutoTrim function.
| The joint is too soft and max torque setting. | Reduce the torque setting slightly, or use a bigger tool with more power.
The rotation speed is too low. | Not enough air pressure. | Check the dimensions of the hose and couplings. Increase the air pressure.
| Wrong Trim valve setting | Adjust the Trim valve.
| Dirt in the Inlet or the Silencer. | Clean or replace the air Inlet strainer and the Silencer filter if needed.
| Worn parts in the motor. | Inspect and service the motor.
| Wrong or damaged trigger valve. | Inspect the trigger valve.
AutoTrim does not work properly | Set screw in tool handle is set to Trim mode. | Set the Set screw to AutoTrim mode.
| Dirt in the silencer filter. | Replace the silence filter.
| Wrong adjustments or settings. | See section Adjusting the AutoTrim Valve.
| Dirt or damaged parts in the AutoTrim. | Inspect and replace any worn parts.
| The wrong auto-trim part has been used. | Check Spare Part for to use, see https://servaid.atlascopco.com.

# Recycling

# Environmental Regulations

When a product has served its purpose it has to be recycled properly. Dismantle the product and recycle the components in accordance with local legislation.

Batteries shall be taken care of by your national battery recovery organization.

# Recycling Instruction

Pos | Part | Remarks | Recycle as
--- | --- | --- | ---
1 | Pulse unit casing |  | Metal, aluminum
2 | Bushing |  | Metal, aluminum bronze
3 | Pulse unit |  | Metal, steel
4 | Screw ring |  | Metal, steel
5 | Sleeve |  | Metal, steel
6 | Ball bearing |  | Metal, steel
7 | End plate |  | Metal, aluminum
8 | Cylinder |  | Metal, aluminum
9 | Rotor |  | Metal, steel
10 | 7 vanes |  | Plastics, other, POM
11 | 7 plugs |  | Plastics, other, POM
12 | End plate |  | Metal, aluminum
13 | Ball bearing |  | Metal, steel
14 | Support washer |  | Metal, aluminum
15 | Inlet washer |  | Metal, aluminum
16 | Trigger |  | Metal, steel
17 | Motor casing |  | Metal, aluminum
18 | Valve |  | Metal, brass
19 | Silencer |  | Metal, steel
20 | Adapter |  | Metal, aluminum/steel
21 | Protective cover |  | Plastics, other, PUR