Utility Solutions LOAD-RANGER FLEX-LT Manuel utilisateur

LOAD-RANGER®FLEX-LT™

Maintenance Manual - Level 1

B-02383

(7-17-23)

(828) 323-8914 (828) 323-8410 sales@utilitysolutionsinc.com utilitysolutionsinc.com

101 33RD STREET DRIVE SE • HICKORY, NC 28602

(828) 323-8914 (828) 323-8410 sales@utilitysolutionsinc.com utilitysolutionsinc.com

101 33RD STREET DRIVE SE • HICKORY, NC 28602

LOAD-RANGER® FLEX-LT™ Maintenance Manual 1

INTRODUCTION

All Load-Ranger® FLEX-LT™ tools ship with an Inspection Reminder Sticker.

Load-Ranger® tools should be disassembled and inspected every 2 years in

accordance with the date stamped on the sticker.

The sticker should be replaced after inspection. To reorder, call Utility Solutions, Inc.

at 828-323-8914 and reference part number B-02373.

Utility Solutions, Inc. recommends the following procedure for disassembly and

inspection for all Load-Ranger® FLEX-LT™ tools to be performed every 2 years.

Prior to operating this tool, thoroughly read and fully understand the contents laid

out in the Operation Manual which is separate from this document and can be found

on our website, www.utilitysolutionsinc.com.

This manual is not intended to be a substitute for adequate training and experience

in safety procedures when operating this type of equipment. Where a discrepancy

exists, follow the procedures set forth by your employer.

SAFETY ALERT

MESSAGES

DISCLAIMER

INSPECTION

REMINDER STICKER

Carefully read and fully understand this manual prior to operating, maintaining

or testing this device. Improper operation, handling or maintenance of this

device can result in death, grievous personal injury and or equipment damage.

Only trained and qualiﬁed personnel should operate, inspect and maintain this

device.

LOAD-RANGER® FLEX-LT™ Maintenance Manual 2

FIELD INSPECTION

Utility Solutions, Inc. recommends performing the following Field Inspection Procedure prior to each use, as well as before and after teardown

and reassembly as per this manual.

For immediate assistance or help with this manual, please call Utility Solutions, Inc. at 828-323-8914.

1. Fully extend the tool.

2. Check for reset.

1. Inspect the yellow tube for

damage, cracks, or discoloration.

4. Activate the Flex Head by pivoting it

side to side. It should freely rotate

90 degrees in either direction and

return to the original position.

5. Activate the Clip Assembly

ensuring all components pivot

smoothly and fully return to their

original position. 6 . Activate the Arm Assembly by

pivoting it side to side, then front to

back. Ensure the components pivot

smoothly and fully return to their

original position.

2. Ensure the Black Gasket is fully tight.

3. Verify Upper and Lower Conductor paths are tight

and secure.

1. Reset the tool by pressing

the red Reset Trigger.

2. Pull on the Hook Loop to manually

extend the tool 2-3 inches and

release. The tool should rebound

quickly with felt spring pressure,

indicating proper reset.

3. Continuity should break when tool

is fully extended.

LOAD-RANGER® FLEX-LT™ Maintenance Manual 3

A - Rubber End Cap

Item # C-02218

B - 1/4”-20 x 3/8” Flat Head Screw

Item # B-02072

C - Guide Pin

Item # C-02194

D - 8-32 x 1/4” Socket Head Cap Screws

Item # B-02073

E - 1/4”-20 x 5/16” Button Head Screws

Item # B-02390

F - Lower Conductor Path

FLEX-1: Item # C-02188

FLEX-2: Item # C-02189

G - Arm Assembly

H - Black Tube Assembly

I - 10-24 x 7/16” Socket Head Cap Screws

Item # B-02071

J- Muﬄer Cap Assembly

Item # P-00843

K - Reset Trigger

L - Black External Gasket

M - Load Break Trigger

N - Yellow Tube Assembly

FLEX-1: Item # P-00842

FLEX-2: Item # P-00851

O - Female Contact

Item # C-02212

P - Arc Shim

Item # C-00509

Q - Pink Arc Snuﬀers

FLEX-1: Item # C-00554 (x2)

FLEX-2: Item # C-00554 (x4)

R - Plastic Spacer

FLEX-1: Item # C-00528

FLEX-2 : Item # C-00558

S - Probe Shaft Assembly

FLEX-1: Item # P-00841

FLEX-2: Item # P-00849

T - Loctite® Threadlocker Red 263

U - 9/64” Hex Wrench

V - 5/32” Hex Wrench

W - Load Break Tool Fiberglass

Cleaner / Wax

Item # B-00159

PART IDENTIFICATION

9/64”

5/32”

OPQR

Ensure all components remain clean and free of oils, greases, soot etc. If necessary, clean parts with warm soapy water.

LOAD-RANGER® FLEX-LT™ Maintenance Manual 4

DISASSEMBLY

INSTRUCTIONS

DISASSEMBLY INSTRUCTIONS

LOAD-RANGER® FLEX-LT™ Maintenance Manual 5

DISASSEMBLY INSTRUCTIONS

Step One Remove the Rubber End Cap.

Step Two Using the 5/32” hex wrench, remove the Lower Conductor Path.

Step Three Using the 5/32” hex wrench, remove the Probe Shaft Assembly fastener.

LOAD-RANGER® FLEX-LT™ Maintenance Manual 6

Step Five Unthread the Black External Gasket.

Note: additional force may be necessary as the threads are factory-sealed with thread sealant.

Step Six Pull the Yellow Tube Assembly from the Black Tube Assembly.

DISASSEMBLY INSTRUCTIONS

Step Four Using the 9/64” hex wrench, remove fasteners and the Guide Pin.

LOAD-RANGER® FLEX-LT™ Maintenance Manual 7

DISASSEMBLY INSTRUCTIONS

Step Eight 1) Pull the Probe Shaft Assembly from the Yellow Tube Assembly.

2) Inspect the Yellow Tube Assembly to ensure the ﬁberglass is not damaged, chipped, or discolored.

a. Verify the load break trigger pivots smoothly and springs back with spring pressure.

b. Ensure the white plastic Gasket Tube is not damaged or chipped.

3) Wax the ﬁberglass portion of the assembly using the Load Break Tool Fiberglass Cleaner / Wax. For best

results, follow the instructions on the bottle.

Step Seven Remove the Muﬄer Assembly using the 5/32” hex wrench.

LOAD-RANGER® FLEX-LT™ Maintenance Manual 8

DISASSEMBLY INSTRUCTIONS

Step Nine 1) Remove the Female Contact and inspect for excessive signs of pitting or damage. If surface soot deposits are

present, use mild soap and water or a very ﬁne nylon mesh sanding pad to remove the deposits.

a. Verify each ﬁnger on the Female Contact makes light contact with the brass & arc ring portion of the

Probe Shaft Assembly. Resize the ﬁngers on the Female Contact if necessary.

2) Remove the Arc Shim and and inspect for excessive signs of pitting or damage. If surface soot deposits are

present, use mild soap and water or a very ﬁne nylon mesh sanding pad to remove the deposits.

3) Remove and inspect the Pink Arc Snuﬀers and Plastic Spacer to verify they are not cracked, chipped, or

otherwise damaged.

a. FLEX-1 = Qty 2 Pink Arc Snuﬀers & Qty 1 single groove Plastic Spacer.

b. FLEX-2 = Qty 4 Pink Arc Snuﬀers & Qty 1 double groove Plastic Spacer.

4) Remove the Probe Shaft Assembly and inspect for excessive signs of pitting or damage. Replace if necessary.

a. KEY INSPECTION: expand the spring to verify there are no signs of fraying or damage to the

internal copper coils. This is a highly critical component in the load break tool, and a very

important step in the inspection process. Repair personnel should take great care to follow

these instructions carefully and to thoroughly inspect components.

b. Inspect the white and black plastic discs to verify they are not cracked, chipped, or otherwise damaged.

c. Inspect the arc ring and probe base for signs of excessive pitting or arcing. If surface soot deposits are

present a very ﬁne nylon mesh sanding pad can be used to remove the deposits.

d. Verify the probe base, arc ring, and white molded probe are not loose or show signs of damage.

Note: Be sure to keep the Probe Shaft free from dirt and oils when inspecting. If there is any uncertainty on the

extent of damage or repair needs, reach out to Utility Solutions, Inc. directly at 828-323-8914 or send pictures to

sales@utilitysolutionsinc.com.

1. 2. 3. 4.

LOAD-RANGER® FLEX-LT™ Maintenance Manual 9

REASSEMBLY

INSTRUCTIONS

REASSEMBLY INSTRUCTIONS

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