Stanley Black & Decker EPX10 User Manual
EPX10
PIN BRAZING UNIT
Safety, OperatiOn and Maintenance
USer ManUaL
© 2013 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
73157 2-2015 Ver-6
DECLARATION OF CONFORMITY
Weisbeck, Andy
Directive/Standards
No.
Approved body
IEC
EMC Directive
950: 1991
89/336/EEC, 89/392/EEG, 91/368/EEG
Safetrack Baavhammar AB
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 prénom /Nombre y apellido/Cognome e nome
Hydraulic Tools
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Marke/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo: EPX10 ECONECT (Digital Pin Braze unit)
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
EN
EMC : EN
EN
IEC
EN
Low Voltage Directive
Nr
Numéro
No
n.
60950: 1988, 60204-1
50082-2: 1995
55022: 1988 Class B/CISPR 22: 1985 class B
801-2: 1991
55101-2: 1990, 8kV CD, 15kVAD
73/23/EEC
Digital Pin Braze / ECONECT Unit (Product Group-Railroad)
Stanley Hydraulic Tools
All
Prüfung durch
Organisme agréé
Aprobado
Collaudato
L. Mölleberga
245 93 Staffanstorp
Sweden
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 Director of Product Development
2 ► EPX10 User Manual
Date/Datum/le/Fecha/Data 2-12-2013
TABLE OF CONTENTS
DECLARATION OF CONFORMITY .......................................................................................................................... 2
SAFETY SYMBOLS ..................................................................................................................................................4
SAFETY PRECAUTIONS .......................................................................................................................................... 5
CHARGING THE BATTERY ...................................................................................................................................... 6
PREOPERATION ...................................................................................................................................................... 7
OPERATION .............................................................................................................................................................. 8
SPECIFICATIONS ................................................................................................................................................... 10
MAINTENANCE ...................................................................................................................................................... 11
TROUBLESHOOTING ............................................................................................................................................15
ACCESSORIES.......................................................................................................................................................16
PARTS ILLUSTRATION ..........................................................................................................................................20
PARTS LIST ............................................................................................................................................................21
ELECTRICAL DIAGRAM .........................................................................................................................................22
REPLACING THE BATTERY (applies only to units S/N 1215090 and below) ........................................................ 23
IMPORTANT
To ll out a Product Warranty Validation form, and for information on your warranty,
visit Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty Validation record must be submitted to validate the warranty).
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic Tools
recommends that servicing of the ECONECT unit, other than routine maintenance, must be performed by an autho-
rized and certied dealer. Please read the following warning.
WARNING
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR
SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN
AUTHORIZED AND CERTIFIED DEALER.
For the nearest authorized and certied dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
EPX10 User Manual ◄ 3
DANGER
WARNING
CAUTION
NOTICE
IMPORTANT
SAFETY SYMBOLS
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, could result in death or serious injury.
CAUTION
Always observe safety symbols. They are included for your safety and for the protection of the tool.
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.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
4 ► EPX10 User Manual
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 pre-
cautions relating to the specic work area and local
safety regulations. If so, place the added precautions in
the space provided in this manual.
This tool 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.
• 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.
• Charging the battery can only be carried out between
0°C to +45°C (32°F to 113°F).
• 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 con-
ditions, 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 respiratory protection 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 presents an electrocution hazard. Read the safety and operation instructions provided with the battery
charger before using the battery charger.
EPX10 User Manual ◄ 5
CHARGING THE BATTERY
Connect the charger to the “grinder / charging” outlet on the unit then plug in the power cord.
The battery is fully charged after about 4 hours (if completely discharged).
NOTICE
CHARGING THE BATTERY CAN ONLY BE
CARRIED OUT BETWEEN 0°C to +45°C
LED
LED
CAUTION
If the batteries are left uncharged, they
may be damaged.
Battery charging
The battery 95% charged.
The battery 100% charged
The battery temperature below 0 or above 45C°.
Battery temperature OK.
6 ► EPX10 User Manual
PREOPERATION
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 this manual.
Use only recommended accessories also specied in the
this manual.
Do not use the Electronic Pin Brazer for applications it was
not designed for.
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 ECONECT Pin Brazing unit 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
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.
EPX10 User Manual ◄ 7
OPERATION
PREPARE THE RAIL SURFACE
Select the type and length of bonding cable to use for the
bond and use it as a guide to determine where brazing points
on the rail will be required.
Before brazing, the rail must be cleaned of rust, corrosion,
paint, pits, or other contamination at the points where the brazing is going to be done and on an area close to the brazing for
placement of the grounding cable. Cleaning is accomplished
with a grinder to ensure clean, bare metal.
CAUTION
Always use eye protection when grinding and brazing.
b. The pin holder is threaded onto a threaded shaft in the gun
and locked in place with a nut. Place an open end wrench
over the nut and an open end wrench over the ats on the
pin holder. While holding the nut in place, unscrew the pin
holder counter clockwise.
Pin Holder
Nut
Figure 3. Pin and Ring Holder
c. Install the correct pin holder and tighten it securely against
the nut.
Ring Holder
1. Grind the surface of the rail where brazing is going to be
done, until the surface shows shiny metal, free of rust, corrosion, pits, or other contamination. When grinding, use the
edge of the grinding wheel - not the face of the wheel.
2. Grind the surface of the rail where the grounding cable
will be placed to ensure a good ground. The grounding cable
should be placed in close proximity to the brazing area. If using a magnet ground try to attach the magnet within 0.5m/20
in. of brazing area. Ground should be on same work piece
where pin brazing is taking place.
PLACING THE GROUNDING CABLE
3. When nished grinding the rail for placement of the grounding cable, place the grounding cable on the cleaned surface
and then insert the other end into the twist lock receptacle in
the Econect unit marked "GROUND" and twist to lock.
SELECT PINS AND RINGS
4. Select brazing pins and ceramic rings to match the speci-
cations of the bonding cable you selected.
IMPORTANT
Warning! Never rotate the shaft when mounting the pin
holder, it can damage the gun.
d. Install the correct ring holder by placing it over the pin holder
and into the circular groove in the gun, and nally, pushing
on it to seat it in place.
LOADING PIN AND RING
6. Insert the brazing pin into the pin holder. The rounded tip
should be facing away from the gun.
7. Insert the ceramic ring into the ring holder. The serrated
edge should be facing away from the gun. See gure 4.
Ceramic Ring
CHANGING PIN AND RING HOLDER
5. Check that the pin holder and ring holder on the gun are
the correct sizes for the brazing pins and ceramic rings you
selected. If the sizes are incorrect, the pin holder and ring
holder can be changed as follows:
a. The ring holder is a "push t" to the gun. To remove it from
the gun, simply pull it away from the gun.
8 ► EPX10 User Manual
Brazing Pin
Figure 4. Loading pin and ring
OPERATION
• Connect the brazing gun, power and trigger cable to the unit.
• Connect the ground device to the unit, if not already connected.
• Press on/off button and select the right pin type by pressing the ”setting” button.
The unit will remember what setting was used last.
• Load the gun with brazing pin and ferrule, if not already loaded.
Selected setting
ON / OFF
Error Indication
Battery Indicator
Pin setting
Fuse for electronics
Fuse for grinding
/ charge
Make sure to braze in the top of the hole when
brazing to a vertical surface.
PIN BRAZE
• Hold the gun rmly with both hands against the work
piece and pull the trigger just once.
• The electronic unit will by itself nish the brazing process.
Gun power
Gun control
Grinding / charging
Ground
NOTE:
If the brazing is aborted to early “ERROR” will turn on.
The brazing should be redone for a good result.
The error lamp will turn off after 8 seconds
Use a new ceramic ring for each new pin braze.
• Hold the gun in place for 3-4 seconds after the brazing is complete to allow for cooling.
• Remove the gun straight backwards without pulling
the trigger!
• Knock off the shank of the brazing pin with a hammer.
• The brazing is completed.
NOTICE
The battery indicator “LOW BATT” ashes when
the batteries are almost discharged,
when the “LOW BATT” is constantly lit the batter-
ies are discharged and you can’t do
any more pin brazing. Charge the battery.
EPX10 User Manual ◄ 9
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