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RAMSET TRAKFAST Repair Manual

Other manuals for TRAKFAST: Repair Manual

Summary of TRAKFAST

  • Page 1

    Trakfast repair manual tool repair manual trakfast repair manual.

  • Page 2: Trakfast Repair Manual

    Trakfast repair manual 1 rev. 09/07 table of contents safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 tool operation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 3: Trakfast Repair Manual

    Trakfast repair manual 2 rev. 09/07 • 5/32” hex key • inside snap ring pliers • outside snap ring pliers • #2 phillips screwdriver • t15 torx screwdriver • t25 torx screwdriver • t7 torx screwdriver • flat blade screwdriver • needle nose pliers • lubricating oil • loctite #343 blue • rtv silicone • ...

  • Page 4: Trakfast Repair Manual

    Trakfast repair manual 3 rev. 09/07 failure to follow all instructions may result in severe per- sonal injury or substantial damage to tool and/or personal property. The following safety instructions have been included to provide you with information necessary for safe operation of the trakfast tool...

  • Page 5: Trakfast Repair Manual

    Trakfast repair manual 4 rev. 09/07 safety instructions always wear eye and ear safety gear when working with or in the vicinity of the trakfast tool. 1. Wear eye and ear protection. 2. Always assume the tool is “loaded”. 3. Don’t treat the trakfast tool as a toy. The trakfast tool is not a toy — it...

  • Page 6: Trakfast Repair Manual

    Trakfast repair manual 5 rev. 09/07 safety instructions 15. Fuel cell storage 16. Always store the tool with the fuel cell removed. 17. Keep the tool clean. 18. Keep your hands clear of the work area surface. Battery cell and charger 1. Keep the battery charger upright for proper opera- tion. 2. Onl...

  • Page 7: Trakfast Repair Manual

    Trakfast repair manual 6 rev. 09/07 tool operation overview magazine assembly the magazine assembly has two functions. Its primary func- tion is to store and feed fasteners into the nose of the tool. Its secondary function is to house the battery and battery contact assembly. Motor assembly the moto...

  • Page 8: Trakfast Repair Manual

    Trakfast repair manual 7 rev. 09/07 tool operation start and pre-combustion when lower probe (e) is pressed against the work surface, cage (f) is forced against the spring (g). Combustion chamber (h) is raised up against cylinder head (i), and o-rings (j & m) seal off the combustion chamber, creatin...

  • Page 9: Trakfast Repair Manual

    Trakfast repair manual 8 rev. 09/07 combustion depressing the trigger activates the ignition circuit. This causes a spark (n) to jump the gap between the spark element and cylinder head, igniting the fuel/air mixture in the combustion chamber. Pis- ton assembly (o) is forced downward driving the fas...

  • Page 10: Trakfast Repair Manual

    Trakfast repair manual 9 rev. 09/07 tool operation power/exhaust downward movement of the piston assembly, past exhaust ports (p), allows exhaust gases to exit. The pressure of the exhaust gases against the flat washer compresses the wave washers, allowing the gases to flow through the mid-check area ...

  • Page 11: Trakfast Repair Manual

    Trakfast repair manual 10 rev. 09/07 tool operation return reduced pressure within the combustion chamber allows wave washers (t) to reseal the combustion chamber. Rapid cooling of gases trapped in the combustion chamber (u) creates vacuum. This vacuum is strong enough to lift and hold the pis- ton ...

  • Page 12: Trakfast Repair Manual

    Trakfast repair manual 11 rev. 09/07 tool operation purging the combustion chamber drops when the tool is lifted from the work surface and the trigger is re- leased. This opens the seal between the combustion chamber and cylinder head o-ring (w) and sleeve o-ring (x). The fan is now able to circulat...

  • Page 13: Trakfast Repair Manual

    Trakfast repair manual 12 rev. 09/07 troubleshooting symptom possible problems service battery cell doesn’t appear to ac- cept charge — green charger light does not come on — red charger light comes on when battery cell is inserted in charger. Inoperative indicator lights on char- ger. Try battery c...

  • Page 14: Trakfast Repair Manual

    Trakfast repair manual 13 rev. 09/07 tool disassembly danger always take the following precautions before any service or routing maintenance is performed: • remove fasteners • remove fuel cell • remove battery remove the magazine assembly loosen and remove knob (part #801124). Slide the magazine bac...

  • Page 15: Trakfast Repair Manual

    Trakfast repair manual 14 rev. 09/07 tool disassembly remove handle assembly (part 1) lift off cap, grill and filter with screw driver. Loosen four screws using a 5/32” hex key (part # 7405061). Lift off cap assembly (part # 401365)..

  • Page 16: Trakfast Repair Manual

    Trakfast repair manual 15 rev. 09/07 remove screw at bottom of handle assembly (part # 7405065). Remove cam bushing.(part # 401397). Push cam bushing out of handle from side where the screw was removed. Remove handle assembly (part 1).

  • Page 17: Trakfast Repair Manual

    Trakfast repair manual 16 rev. 09/07 tool disassembly remove motor assembly pull handle assembly away from motor assembly until fan clears combustion chamber assembly. Do not scratch combustion chamber walls with fan blades. Set handle assembly down carefully so that fan blades are not damaged and f...

  • Page 18: Trakfast Repair Manual

    Trakfast repair manual 17 rev. 09/07 tool disassembly motor/cylinder head assembly torque head switch to 5-10 in-lbs. Torque spark plug to 20-25 in-lbs. Install stem adapter as illustrated. Notice the difference between one end of the sleeve to the other. One side of the sleeve has a rib. The other ...

  • Page 19: Trakfast Repair Manual

    Trakfast repair manual 18 rev. 09/07 apply a small amount of oil or lubricant to the inside of the bore where the fan motor is positioned. Insert motor assembly as illustrated. The motor sleeve orientation will determine how well the spacing will be around the shaft. Make sure that it is equally spa...

  • Page 20: Trakfast Repair Manual

    Trakfast repair manual 19 rev. 09/07 tool disassembly make sure the “flat” side of the shaft is where the set screw on the fan blade will be tightened. Position the fan blade approximately .120” away from the bottom of the cylinder head. Feeler gages or an 1/8” drill bit works well as a spacer. Caref...

  • Page 21: Trakfast Repair Manual

    Trakfast repair manual 20 rev. 09/07 tool disassembly cylinder head assembly key part no. Description 1 401365 cap, grill & filter assembly 3 7505018 foam filter only 4 901065a screw kit, #10-24 x 1-1/4” sems (pkg. 4) 8 900271 p.C board assembly 8a 7405090 p.C board screw & washer, #8-32 x 1/2” (pkg. ...

  • Page 22: Trakfast Repair Manual

    Trakfast repair manual 21 rev. 09/07 tool disassembly handle assembly (part 2) remove trigger cam (part #401396). Remove belt hook and screw. (screw, part #7405065) (belt hook, part #401495) remove (3) screws (part #7405067). Remove (1) screw (part #7405066). Lift off handle half. Remove actuator as...

  • Page 23: Trakfast Repair Manual

    Trakfast repair manual 22 rev. 09/07 remove trigger and spring from handle. (trigger, part #401394a) (spring, part #401395) remove trigger switch with screw driver. Undo the two screws and lift out. Unplug from the spark unit. (trigger switch, part #404990) (trigger screws, part #7405091) tool disas...

  • Page 24: Trakfast Repair Manual

    Trakfast repair manual 23 rev. 09/07 tool disassembly lift up spark plug wire and remove from handle half (part #7505166). Tool disassembly handle assembly - part 2 (cont’d) unplug spark wires from spark unit. Lift up with screw driver to remove spark unit (part #7405163). Note: msu spark units are ...

  • Page 25: Trakfast Repair Manual

    Trakfast repair manual 24 rev. 09/07 remove fan blade set screw (requires #t-7). (fan blade part #403167 with screw) with phillips screw driver remove (3) screws (part #7405090) holding p.C. Board. Unplug fan connector. Pull out red stem adapter (part #401340). Tool disassembly handle assembly - par...

  • Page 26: Trakfast Repair Manual

    Trakfast repair manual 25 rev. 09/07 remove spark plug (part #7505164). Fan motor kit (part #900525a). See inserts for motor/cylinder assembly. Tool disassembly handle assembly - part 2 (cont’d).

  • Page 27: Trakfast Repair Manual

    Trakfast repair manual 26 rev. 09/07 tool disassembly handle assembly key part no. Description 52 7405163 spark unit (msu) 52a 7505166 red wire and boot only (msu) (for tools after serial no. 398091440) 53 900012 wire cover plate 54 404619 insulator (under trigger switch) 55 404490 trigger switch 56...

  • Page 28: Trakfast Repair Manual

    Trakfast repair manual 27 rev. 09/07 tool disassembly magazine assembly remove (2) screws holding foot (part #7505146). Remove foot (part #801113). Pull off magazine. Remove lower rail (part #801110). Pull and slide out rear of magazine. Remove (3) screws from magazine (part #7405070). Remove (1) sc...

  • Page 29: Trakfast Repair Manual

    Trakfast repair manual 28 rev. 09/07 tool disassembly magazine assembly (cont’d) remove (2) screws from shear block (part #7405147). Remove magazine halves (part #7405149). Remove upper rail (part #801112). Inspect upper rail for heavy burrs. Remove cover plate (part #7506006)..

  • Page 30: Trakfast Repair Manual

    Trakfast repair manual 29 rev. 09/07 tool disassembly magazine assembly (cont’d) remove battery contact (part #7505017). Inspect battery contact for bent or broken terminals. Replace contact assembly if these conditions exist. Remove shear block. Take out (2) screws (part #7405147). Shear block (par...

  • Page 31: Trakfast Repair Manual

    Trakfast repair manual 30 rev. 09/07 tool disassembly magazine assembly (cont’d) remove lockout bracket screw (part #801122). Remove lockout bracket (part #801106). Remove carrier assembly from magazine half. Hold carrier firmly and slide forward to front of magazine towards the post and lift constan...

  • Page 32: Trakfast Repair Manual

    Trakfast repair manual 31 rev. 09/07 tool disassembly magazine assembly (cont’d) remove pin from spring carrier/follower assembly (part #7405168). Remove spring from carrier (part #7405168)..

  • Page 33: Trakfast Repair Manual

    Trakfast repair manual 32 322 32 rev. 09/ r rev ev. V. 09/07 09/ 9//07 7 07 tool disassembly magazin ma mag ag i a mb mbl bly ly key k key ey part no. Pa part no rt no. Iption ptio ipt ption n 14 14 070 07 07 70 )) 071 07 71 071 1 )) 146 14 46 1 13 26 2 26 epiece tools) epiece to oolss) 18 18 g g 93...

  • Page 34: Trakfast Repair Manual

    Trakfast repair manual 33 rev. 09/07 tool disassembly housing assembly remove (3) screws (part #7405060). Lift off dust shield (part #7505013). Lift off housing (part #7505148). Lift off nosepiece assembly (part #801130a)..

  • Page 35: Trakfast Repair Manual

    Trakfast repair manual 34 rev. 09/07 remove piston stop retaining ring (part #401328), using snap ring pliers (part #401333). Make sure when you reassemble that retaining ring ends are not positioned in the vertical notches in the sleeve. Slide piston out of mid-check assembly (part #7502000). Lift ...

  • Page 36: Trakfast Repair Manual

    Trakfast repair manual 35 rev. 09/07 slide off cage and spring. (part #7405144 only comes as an assembly) (spring, part #401488) lift out mid-check retaining ring (part #401322). Remove with snap ring pliers (part #401333). Remove 2 wave washers and 1 seal washer (part #7405056). Housing assembly (c...

  • Page 37: Trakfast Repair Manual

    Trakfast repair manual 36 rev. 09/07 lift off piston rings (part #7405055). Always make sure the piston ring end gaps are opposite each other. Housing assembly (cont’d) tool disassembly lift off o-ring (part #404482)..

  • Page 38: Trakfast Repair Manual

    Trakfast repair manual 37 rev. 09/07 remove (2) screws (part #7405059). Lift off stop plate (part #801127). Lift off lock-out probe (part #801128). Lift off work contact element (part #801129). Inspect work contact element for burring or damage. Replace if burring or damage is noted. Nose assembly t...

  • Page 39: Trakfast Repair Manual

    Trakfast repair manual 38 rev. 09/07 remove (2) screws (part #7405059). Lift off guide block (part #801131). Slide out upper probe (part #801132). Inspect rubber grommet for damage. Replace upper probe if grommet is damaged. Nose assembly (cont’d) tool disassembly.

  • Page 40: Trakfast Repair Manual

    Trakfast repair manual 39 rev. 09/07 original nosepiece tool reassembly key part no. Description 24 401313 air dam 25 7405171 combustion chamber (w/air dam) 25a 900234 cage 26 401330 chamber lockout bar 27 401328 piston stop retaining ring 28 7502000 piston assembly (with piston rings) 29 7405055 pi...

  • Page 41: Trakfast Repair Manual

    Trakfast repair manual 40 rev. 09/07 tool reassembly telescoping nosepiece key part no. Description 24 401313 air dam 25 7405171 combustion chamber (w/air dam & cage) 25a 900234 cage 26 401330 chamber lockout bar 27 401328 piston stop retaining ring 28 7502000 piston assembly (with piston rings) 29 ...

  • Page 42: Trakfast Repair Manual

    Trakfast repair manual 41 rev. 09/07 tool reassembly magazine assembly place shear block in magazine assembly (part #7405145). Secure with screws (part #7405147). Check shear block for any damage. Place battery clip in magazine half (part #401422). Secure with screw (part #401423). Check for any dam...

  • Page 43: Trakfast Repair Manual

    Trakfast repair manual 42 rev. 09/07 place cover plate in magazine assembly (part #7506006). Notice position of notch. It should be placed toward the bottom/ rear of magazine. Place upper rail in magazine half (part #801112). Check for any damage. Check ends of rail for any burrs and check to see if...

  • Page 44: Trakfast Repair Manual

    Trakfast repair manual 43 rev. 09/07 slide carrier all the way back to the lock position (part #7405168). Place magazine halves together (part #7405149). Secure with screws . (part #7405070, 3 each) (part #7405071, 1 each) (shear block screws, part #7405147) slide lower rail into magazine halves (pa...

  • Page 45: Trakfast Repair Manual

    Trakfast repair manual 44 rev. 09/07 tool reassembly place handle assembly on to the magazine assembly. Screw on the knob. This will hold the handle on the magazine. Place battery in magazine. You will have a green light. If you have a red light, you will need to check the battery or the battery con...

  • Page 46: Trakfast Repair Manual

    Trakfast repair manual 45 rev. 09/07 tool reassembly handle assembly - part 2 spark unit (part #7405163). Remove any silicone residue from handle. Place new silicone in handle. Press spark unit into handle. Replace the unit if it does not spark. Push red wire into spark unit and route the wires into...

  • Page 47: Trakfast Repair Manual

    Trakfast repair manual 46 rev. 09/07 tool reassembly handle assembly - part 2 place plastic wire cover over wires. Make sure all wires are seated properly in handle.Vva place trigger switch on top of the wire cover. Secure with screws. Check for any damage. Press button to make sure it is not sticki...

  • Page 48: Trakfast Repair Manual

    Trakfast repair manual 47 rev. 09/07 tool reassembly handle assembly - part 2 replace screw if damaged, or if washers are missing. If washers are missing the fuel cell will not sit in handle properly, causing a misfire. Replace cylinder head if cracked or broken. Replace o-ring after cleaning, worn o...

  • Page 49: Trakfast Repair Manual

    Trakfast repair manual 48 rev. 09/07 tool reassembly handle assembly - part 2 place actuator inside the handle. Note the position of the handle. Replace if broken or damaged. Check all wires before placing handle half. Secure with screws. Pull trigger to make sure it is in correct position. Place be...

  • Page 50: Trakfast Repair Manual

    Trakfast repair manual 49 rev. 09/07 tool reassembly handle assembly - part 2 place handle half on magazine assembly. Place battery in magazine. For testing, push head switch then pull trigger. This will activate the fan motor and spark unit. Keep fingers away from fan! Caution.

  • Page 51: Trakfast Repair Manual

    Trakfast repair manual 50 rev. 09/07 tool reassembly housing assembly place bumper inside chamber. If bumper is loose inside the chamber, replace with new one. The bumper is marked “top”. It should be oriented so the word “top” is visible. Replace o-ring if it has been pinched, worn or after cleanin...

  • Page 52: Trakfast Repair Manual

    Trakfast repair manual 51 rev. 09/07 tool reassembly housing assembly - (cont’d) slide the combustion chamber on to sleeve mid-check assembly. Check for any damage on parts. Lubricate sealing surfaces on combustion chamber with trakfast or paslode oil prior to assembling the sleeve. Place lockout br...

  • Page 53: Trakfast Repair Manual

    Trakfast repair manual 52 rev. 09/07 tool reassembly housing assembly - (cont’d) check piston to see if it is bent or tip is worn. Check piston rings for damage. Clean inside the grooves. Check to make sure piston is not too short. If length is too short, the tool will not shoot overhead or drive fa...

  • Page 54: Trakfast Repair Manual

    Trakfast repair manual 53 rev. 09/07 tool reassembly housing assembly - (cont’d) place nosepiece assembly on mid-check assembly. Note how parts line up. Slide housing over nosepiece and mid-check assembly. Note the position of the lockout bar. Slide dust shield over nosepiece. Secure with screws. Re...

  • Page 55: Trakfast Repair Manual

    Trakfast repair manual 54 rev. 09/07 tool reassembly housing assembly - (cont’d) slide handle assembly into housing. Keep handle assembly straight so that the fan does not hit the inside of chamber. Line up cam with housing. Place cam bushing inside the cam and housing. Note position of cam in housi...

  • Page 56: Trakfast Repair Manual

    Trakfast repair manual 55 rev. 09/07 tool reassembly housing assembly - (cont’d) place grill on cap assembly. Slide in and tap down. Place shear block into nosepiece. Slide magazine onto handle/housing assembly. Secure magazine assembly and housing together with knob. Place battery in tool. Slide ca...

  • Page 57: Trakfast Repair Manual

    Trakfast repair manual 56 rev. 09/07 tool reassembly nosepiece assembly — original nose original nose piece (part #801114a). Roll pins (part #7405058). Check for any damage. Replace roll pins if loose. Slide lower probe in nosepiece (part #7505057). Replace probe if bent or grommet is worn or missin...

  • Page 58: Trakfast Repair Manual

    Trakfast repair manual 57 rev. 09/07 tool reassembly nosepiece assembly — telescoping nose telescoping nosepiece assembly (part #801130a). Check for any damage. Nose and flange should be tight and without movement. Slide lower probe into nosepiece. Replace probe if bent or grommet is worn or missing...

  • Page 59: Trakfast Repair Manual

    Trakfast repair manual 58 rev. 09/07 tool reassembly nosepiece assembly — telescoping nose slide lockout probe onto work element. Check for any damage. If the work element is burred, the fasteners will not flow into the firing position. Slide lockout probe and work element onto the nosepiece. Place st...

  • Page 60: Trakfast Repair Manual

    Trakfast repair manual 59 rev. 09/07 service bulletin issue date: december 4, 2001 subject: trakfast tool (tf1100) nose changes revision: all tf1100 tools built since august 2001 (serial #301080281) are equipped with a new style “telescoping nosepiece”. Tools built before august 2001 use what is ref...

  • Page 61: Trakfast Repair Manual

    Trakfast repair manual 60 rev. 09/07 troubleshooting guide problem solution fan motor does not run. • check battery • check for solid green light • red light — check battery contact (7505017) • check fan motor and head switch connectors • check fan motor (7405164) • check head switch (404601) fan ru...

  • Page 62: Trakfast Repair Manual

    Trakfast repair manual 61 rev. 09/07 troubleshooting guide the troubleshooting charts on the following pages have been developed to provide a systematic approach to handling problems. The charts provide troubleshooting information for each phase of tool operation, and list the suggested cor- rective...

  • Page 63: Trakfast Repair Manual

    Trakfast repair manual 62 rev. 09/07 troubleshooting guide symptom possible problems service fasteners do not slide freely into magazine; strip does not advance into nose of tool. Pin or pins not properly collated. Use strip with proper collation. Damaged strip. Discard the damaged strip burr(s) in ...

  • Page 64: Trakfast Repair Manual

    Trakfast repair manual 63 rev. 09/07 troubleshooting guide symptom possible problems service battery cell doesn’t appear to accept charge – green charger light does not come on – red charger light comes on or charger flashes red/green lights. Inoperative indicator lights on charger. Try battery cell ...

  • Page 65: Trakfast Repair Manual

    Trakfast repair manual 64 rev. 09/07 symptom possible problems service fan not running – tool led is off. Battery cell not charged. Charge battery cell according to owner’s manual. Magazine is loose, preventing current flow from magazine to handle and cylinder head. Make sure magazine is tight to nos...

  • Page 66: Trakfast Repair Manual

    Trakfast repair manual 65 rev. 09/07 pre-combustion/combustion stage of operation symptom possible problems service work contact element (wce) doesn’t go down all the way – tool does not operate. Wce is bent or build-up of dirt in track restricts operation. Remove and inspect wce. Replace wce as req...

  • Page 67: Trakfast Repair Manual

    Trakfast repair manual 66 rev. 09/07 troubleshooting guide power/exhaust stage of operation symptom possible problems service tool works properly, but pins won’t drive fully. Check application. Check application. Fuel cell is low. Check fuel cell according to owner’s manual. Tool works properly, but...

  • Page 68: Trakfast Repair Manual

    Trakfast repair manual 67 rev. 09/07 symptom possible problems service tool cycles with a “poof” sound – no pin is driven. Piston rings are damaged or not seated properly in piston ring grooves. Check piston rings and service as required. Piston retaining ring is damaged, missing, or not seated prop...