Stanley Black & Decker EP30 User Manual
EP30
ELECTRONIC
PIN BRAZING
Safety, OperatiOn and Maintenance
USer'S ManUaL
© 2011 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
69924 8/2013 Ver. 6
TABLE OF CONTENTS
WARNING
IMPORTANT
DECLARATION OF CONFORMITY ................................................................................................................................... 4
SAFETY SYMBOLS ...........................................................................................................................................................5
SAFETY PRECAUTIONS ................................................................................................................................................... 6
OPERATION ....................................................................................................................................................................... 7
GENERAL PROTECTION ..................................................................................................................................................7
CLEANING .........................................................................................................................................................................7
PREOPERATION PROCEDURES ..................................................................................................................................... 7
INITIAL SETUP AND BATTERY CHARGING.....................................................................................................................7
OPERATION ....................................................................................................................................................................... 8
CONNECTIONS ................................................................................................................................................................. 8
OPERATION ....................................................................................................................................................................... 8
PREPARE THE RAIL SURFACE ........................................................................................................................................ 8
PLACING THE GROUNDING CABLE ...............................................................................................................................8
SELECT PINS AND RINGS ............................................................................................................................................... 8
CHANGING PIN AND RING HOLDER ...............................................................................................................................8
LOADING PIN AND RING ..................................................................................................................................................9
ADJUSTING BRAZING PIN DISTANCE TO BRAZE SURFACE .......................................................................................9
SET CONTROL FOR PIN SIZE ..........................................................................................................................................9
EQUIPMENT MAINTENANCE & CARE ........................................................................................................................... 11
TROUBLESHOOTING .....................................................................................................................................................12
SPECIFICATIONS ............................................................................................................................................................ 13
ACCESSORIES................................................................................................................................................................13
EP30 PARTS ILLUSTRATION..........................................................................................................................................19
EP30 PARTS LIST............................................................................................................................................................20
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley
Hydraulic Tools recommends that servicing of hydraulic tools, other than routine maintenance, must be
performed by an authorized and certied dealer. Please read the following warning.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHO-
To ll out a Product Warranty Recording form, and for information on your warranty,
visit Stanleyhydraulic.com and select the Warranty tab.
(NOTE: The warranty recording form must be submitted to validate the warranty).
SERIOUS INJURY OR DEATH COULD RESULT FROM THE
IMPROPER REPAIR OR SERVICE OF THIS TOOL.
RIZED AND CERTIFIED DEALER.
3
DECLARATION OF CONFORMITY
Weisbeck, Andy
Directive/Standards
No.
Approved body
SS-EN
60974-10
Self
DECLARATION OF CONFORMITY
ÜBEREINSTIMMUNGS-ERKLARUNG
DECLARATION DE CONFORMITE CEE
DECLARACION DE CONFORMIDAD
DICHIARAZIONE DI CONFORMITA
________________ __________________________________ ____________________
I, the undersigned:
Ich, der Unterzeichnende:
Je soussigné:
El abajo firmante:
lo sottoscritto:
hereby declare that the equipment specified hereunder:
bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät:
déclare que l’équipement visé ci-dessous:
Por la presente declaro que el equipo se especifica a continuación:
Dichiaro che le apparecchiature specificate di seguito:
Surname and First names/Familiennname und Vornamen/Nom et pr énom/Nombre y apellido/Cognome e nom e
Hydraulic Tools
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Marke/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo: EP30 / EP60
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
Has been manufactured in conformity with
Wurde hergestellt in Übereinstimmung mit
Est fabriqué conformément
Ha sido fabricado de acuerdo con
E’ stata costruita in conformitá con
Richtlinie/Standards
Directives/Normes
Directriz/Los Normas
Direttiva/Norme
EMC Directive
Nr
Numéro
No
n.
2004/108/EC
Pin Braze / Safebond Unit (Product Group-Railroad)
Stanley Hydraulic Tools
All
Prüfung durch
Organisme agréé
Aprobado
Collaudato
Self
5. Special Provisions: None
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
6. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.
Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Signature/Unterschrift/Signature/Firma/Firma
Position/Position/Fonction/Cargo/Posizione Engineering Manager
Date/Datum/le/Fecha/Data 1-10-11
4
CAUTION
WARNING
DANGER
NOTICE
CAUTION
SAFETY SYMBOLS
IMPORTANT
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to
equipment.
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.
This safety alert and signal word indicate an imminently hazardous
situation which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
This signal word indicates a situation which, if not avoided, will result in
damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and
maintenance personnel.
5
SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always comply with the safety
precautions given in this manual and on the stickers and tags attached to the
tool and hose.
These safety precautions are given for your safety. Review them carefully before
operating the tool and before performing general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specic
work area and local safety regulations. If so, place the added precautions in the
space provided on page 5.
The EP30 Electronic Pin Brazing Units will provide safe and 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 before
operation. Failure to do so could result in personal injury or equipment damage.
• Operator must start in a work area without bystanders. The operator must be familiar with all prohibited work areas
such as excessive slopes, dangerous terrain conditions, and rail trafc.
• 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.
• Always wear safety equipment such as goggles, ear, head protection, and safety shoes at all times when operating the
tool.
• Do not inspect or clean the tool while the battery power source is connected. Accidental arcing can cause serious
injury.
• Do not load brazing pins or ceramic rings while the battery power source is connected. Accidental arcing can cause
serious injury.
• Do not use the tool while it is connected to a battery charger.
• Ensure battery charging is only done in a dry environment. Charging batteries in the rain or near standing water
resents an electrocution hazard. Read the safety and operation instructions provided with the battery charger before
using the battery charger.
• Do not operate a damaged, improperly adjusted, or incompletely assembled tools.
• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by
authorized and properly trained personnel.
• Do not exceed the rated limits of the tool or use the tool for applications beyond its design capacity.
• Always keep critical tool markings, such as labels and warning stickers legible.
• Always replace parts with replacement parts recommended by Stanley Hydraulic Tools.
6
OPERATION
GENERAL PROTECTION
Store the Electronic Pin Brazing Unit in a place where it is
protected from the elements, abrasive dust, and damage.
Use only recommended repair and replacement parts and
materials specied in the Parts List section of this manual.
Use only recommended accessories also specied in the
Parts List section of this manual.
Do not use the Electronic Pin Brazers for applications it was
not designed for.
WARNING
Make sure battery charging is only accomplished in a
well ventilated room. DO NOT PLACE THE CONTROL
BOX ON TOP OF THE BATTERIES. REMOVE THE
BATTERY BOX COVER. Battery charging produces
explosive gases. A battery explosion can cause serious
injuries. Avoid battery explosions by keeping cigarettes,
sparks, and ames away from batteries being charged.
Always wear safety glasses when working with
batteries.
Use the carrying handle to transport the unit from location
to location.
CLEANING
Establish a routine to keep the unit as free from dirt as possible – daily, or at each shift change, for example.
Pin Brazers exposed to rain, sand, or grit-laden air should be
cleaned prior to each use.
Keep tool labels and stickers legible.
PREOPERATION PROCEDURES
Before putting a new Pin Brazer into initial service, or after an
extended period of being unused, perform a visual inspection
for bent, broken, cracked, missing or worn components.
INITIAL SETUP AND BATTERY CHARGING
WARNING
1. The three batteries furnished are sealed, maintenance
free batteries.
Sealed, maintenance free batteries do not contain cell caps
and are already lled with battery acid. They will require
charging before use.
NOTICE
Use only battery charger specially made for pin brazing
units (36V dc) approved by Stanley.
2. Locate the four battery cables and connect them to the
terminals on the batteries and the battery box as shown in
gure 1. Do not replace the lid on the battery box at this
time.
+Pos.
-Neg.
Failure to follow the instructions in the battery charger
operation manual can result in battery explosion and
serious bodily injury. To reduce the risk of battery explosion, read and understand the safety and operation
instructions in the battery charger operation manual,
the instructions published by the battery manufacturer,
and the instructions in this manual before attempting to
charge the batteries.
Figure 1. Battery cable and terminals
3. Insert the enclosed foam-rubber spacers between each
battery and at both ends between the battery and the unit.
4. Connect the battery charger to the grinder outlet on the
unit, then to the mains. When removing the charger remove
the main rst, the remove the plug from the unit.
7
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