40 Series Nutrunners
Contents
1. 008 865723 004 Stall Tools Only gt 842366 202198 202266 L DA a 847853 1 4 SQ DR am 844014 3 8 SQ DR l 864964 555987 11 4 SQ DR 202986 1 4 SQ DR 844016 13 8 SQ DR 844013 3 8 SQ DR f VA 4 202268 1 4 SQ DR 202199 202201 202197 202267 13 8 SQ DR 202303 842980 202310 813446 f 8 a 1 4 INTERN FLUSH SOCKET SPINDLE MAGNETIC SPINDLE SIZE SPINDLE CONVERSION PART NO KIT PART NO Tomm 202298 201004 13mm 202299 201005 15mm 202300 201006 1 2 202301 201007 g te 202302 201008 Conversion kit contains all parts needed to convert a K right angle head to flush socket operation PARTS LIST K RIGHT ANGLE HEAD PART NO NAME OF PART PART NO NAME OF PART 201004 10mm Conversion Kit 202310 1 4 Hex Magnetic Spindle 201005 13mm Conversion Kit 202317 Felt Ring 201006 15mm Conversion Kit 202986 Lock Pin Retiner Plug 1 4 201007 1 2 Conversion Kit 202987 Socket Lock Pin 1 4 201008 9 16 Conversion Kit 813446 Collar incl 844305 202196 Spindle Bearing Cap 842366 Plug 202197 Spindle Ball Bearing 842980 3 32 Steel Ball 202198 Spindle Needle Bearing 844013 Lock Pin Retainer Plug 3 8 202199 Spindle Lock Nut 844014 Lock Pin Spring 3 8 202200 Pinion 8T 844016 Socket Lock Pi2. 203478 Inlet Bushing 863454 O Ring 9 16 x 11 16 foe NG eh E eh ve ve Te IN JE a The complete backhead assembly can be purchased as a subassembly using these part number 201426 Parts included in backhead assembly Tool Components Tightening Techniques for 40 Series Right Angle Nutrunners 10 20 8 30 Gear Trains Clamp angle head with bushing in vise Tighten all other components before posi tioning angle head relationship to throttle lever Place spanner wrench in adjustment slot of clutch housing and tighten clutch hous ing to angle head to 40ft Ibs 54Nm Tighten gear case to clutch housing to 40ft Ibs 54Nm Tighten motor housing to gear case to 40ft Ibs 54Nm while holding gear case with other wrench Tighten backhead to motor housing securely Tool is equipped with the M or K head All components must be tightened Then the angle head must be loosened and shimmed for alignment Left Hand Left Hand Threads Threads Use wrench to tighten motor housing to gear case while still holding gear case with other wrench 40 ft Ibs 54Nm Vise Jaws 4 BACKHEAD CLUTCH MOTOR HOUSING HOUSING suae Right Hand Threads Right Hand Threads _ Use wrench A to tighten TA Extension gear case to clutch Use wrench to tighten for mp housing 40 ft Ibs 54Nm backhead to motor Place Spanner Wrench i in G leverage i housing 40 ft Ibs 54Nm adjustment slot of clutch
3. 842517 and driven gear by clamping the spindle in a vise and driving the right angle housing No 869048 away from the spindle using a soft faced mallet The ball bearing can now be removed by pressing the larger end of the spindle through the bearing I D Press the smaller end of the spindle through the gear to remove the driven gear The pinion bearing retainer No 863564 may be removed by utilizing a 5 8 hex nut and a 5 8 deep socket Engage the hex in the bearing retainer and unscrew the retainer using the 5 8 deep socket The pinion and bearings may now be removed by lightly tapping angle head on a soft surface P Right Angle Head Using a suitable wrench unscrew left hand threads the bearing cap No 203250 Remove the square drive spindle No 203249 or No 203439 ball bearing No 842517 and driven gear No 203251 by clamping the square drive in the vise Drive the right angle housing No 203441 away from the square drive using a soft faced mallet Remove the spindle retainer nut No 203248 with a 1 2 12 7mm wrench The ball bearing can now be removed by pressing the threaded end of the spindle through the gear to remove the driven gear Remove the housing set screw No 867546 and using a punch drive the pinion gear No 203440 and bearings No 203253 and 202197 out the angle head CLUTCH DISASSEMBLY 104P 204P amp 304P Models Unscrew the adjustment nut No 202755 This will allow the adjustment plate No 2027
4. DR aj TW UI j IK 7 0325 203439 13 8 SA DR 847272 203248 842517 203249 1 2 SA DR OD FLUSH SOCKET SPINDLE SIZE SPINDLE CONVERSION 203772 PART NO KIT PART NO 10mm 203766 201512 1imm 203767 201513 13mm 203768 201514 Conversion kit contains all 14mm 203769 201515 parts needed to convert a 15mm 203770 201516 P right angle head to flush 15mm 204225 NONE socket operation 15mm 204315 NONE 16mm 203962 201569 17mm 203771 201517 9 16 203807 201528 PARTS LIST 40 SERIES P RIGHT ANGLE HEAD PART NO NAME OF PART PART NO NAME OF PART 201512 10mm Conversion Kit 203251 Driven Gear 201513 11mm Conversion Kit 203253 Pinion Needle Bearing 201514 13mm Conversion Kit 203437 Pinion Bearing Retainer 201515 14mm Conversion Kit 203438 Housing Lock Nut 201516 15mm Conversion Kit 203439 3 8 Sg Dr Spindle 844016 844014 844013 201517 17mm Conversion Kit 203440 Pinion Gear 201528 9 16 Conversion Kit 203441 Housing 201569 16mm Conversion Kit 203443 Housing Clamp Ring 203766 10mm Flush Socket Spindle 204225 15mm Extended Socket Spindle 203766 10mm Flush Socket Spindle length 19 82 15mm 203767 11mm Flush Socket Spindle 204315 15mm Extended Socket Spindle 203768 13mm Flush Socket Spindle ength 29 32 23mm 203769 14mm Flush Socket Spindle 842517 Spindle Ball Bearing 203770 15mm Flush Socket Spindle 842980 Ball 203771 17mm Flush Socket Spindle 84401
5. related components in the head and securely tighten left hand threads the bearing cap No 203250 Press the pinion needle bearing No 203253 press on the bearing s stamped end into the head along with pinion No 203440 to a depth of 1 250 31 75mm Install ball bearing No 202197 Retighten housing lock nut with proper wrench to 20 ft Ibs MOTOR REASSEMBLY Assemble the rear rotor bearing and rear bearing plate press on the bearing s inner race onto the rear rotor shaft until there is approximately 0015 038mm clearance between the plate and rotor T a 0015 038mm A 4 i Clearance i Assemble the rear rotor bearing and rear bearing plate press on the bearing s inner race onto the rear rotor shaft until there is approximately 0015 clearance be tween the plate and rotor Assemble the five 5 ro tor blades cylinder front bearing plate and front rotor bearing press on the bearing s inner race to the rotor assembly Af terfinal assembly the cyl inder should be held firmly but not tightly be tween the two 2 bearing plates and the rotor should turn freely and not rub either bearing plate BACKHEAD REASSEMBLY During reassembly all O rings should be lubricated with a good O ring lubricant CLUTCH SPACING 10 20 amp 30 Assemble the tool completely less clutch assembly and trip rod Position the right angle head in relation to the th
6. steps to prevent further occur rences These steps might include but are not limited to reposition ing the workpiece or redesigning the workstation reassigning work ers to other jobs rotating jobs changing work pace and or changing the type of tool used so as to minimize stress on the operator Some tasks may require more than one type of tool to obtain the optimum operator tool task relationship The following suggestions will help reduce or moderate the effects of repetitive work motions and or extended vibration exposure e Use a minimum hand grip force consistent with proper control and safe operation e Keep body and hands warm and dry cold weather is reported to be a major factor contributing to Raynaud s Syndrome e Avoid anything that inhibits blood circulation Smoking Tobacco another contributing factor Cold Temperatures Certain Drugs Avoid OK N Extension Avoid d Flexion Avoid OK Z L Neutral Ulnar Deviation Neutral Radial Deviation e Tasks should be performed in such a manner that the wrists are maintained in a neutral position which is not flexed hvperextended or turned side to side e Stressful postures should be avoided select a tool appropriate for the job and work location e Avoid highiv repetitive movements of hands and wrists and con tinuous vibration exposure after each period of operation exer cise to increase blood circulation e Keep tool well main
7. warning labels when missing or when the information can no longer be read Replacement labels can be ordered as any spare part READ OPERATING INSTRUCTIONS 203185 4 203185 Do notremove this tag until the operator of this tool has read these safety precautions 203289 OPERATING AND SERVICE INSTRUCTIONS FOR YOUR SAFETY AND THE SAFETY OF OTHERS READ AND UNDERSTAND THE SAFETY RECOMMENDATIONS ON PAGES 2thru 4 BEFORE OPERATING A NUTRUNNER CLECOMATIC MODELS Tools eguipped with the CLECOMATIC clutch are designed to tighten the fastener to a predetermined torque and shut off automaticallv Releasing the throttle lever will allow the tool to reset for the next cvcle CLUTCH ADJUSTMENT Shut off air supplv to the tool and rotate the adjustment cover No 202829 180 to uncover the adjustment slot in the clutch housing Rotate the spindle until the hole in the adjustment nut is visible in the slot Use a 1 8 8mm diameter pin to hold the nut Use a suitable tool to turn the spindle in a coun terclockwise direction to increase torque or clock wise to decrease torque Return the adjustment cover to its closed position after every ad justment A CAUTION mum power output of the tool the clutch will not function and the tool will operate like a stall type tool Also if the tool is being operated at its upper torque limits a drop in air pressure could cause the clutch not to function due to a loss of mo
8. 1 1 2 Sq Dr Socket Lock Pin 203772 Spindle Bearing Cap 844013 Spring Retainer 203807 9 16 Flush Socket Spindle 844014 1 2 amp 3 8 Sq Dr Spring 203962 16mm Flush Socket Spindle 844016 3 8 Sq Dr Socket Lock Pin 202197 Pinion Ball Bearing 847272 O Ring 5 8 x 3 4 203248 Spindle Lock Nut 847445 O Ring 1 16 X 15 16 203249 1 2 Sq Dr Spindle incl 844011 844014 844013 864105 Housing Needle Bearing 203250 Spindle Bearing Cap 867546 Housing Set Screw The complete right angle head can be purchased as a subassembly using these part numbers 3 8 sq dr 201417 1 2 sq dr 201418 40 SERIES 2ND REDUCTION GEAR TRAIN FOR 104P 204P 8 304P 203748 203749 203749 203750 203747 203451 PARTS LIST 40 SERIES 2ND REDUCTION GEAR TRAIN FOR 104P 204P amp 304P 203451 203453 203747 Spider 203748 203749 203750 Gear Case 45T Retainer Ring Idler Gear incl 2 203749 Idler Gear Bearing Idler Gear Pin The complete 2nd reduction gear train can be purchased as a subassembly using part number 201521 1ST REDUCTION 104P 8 10M GEAR TRAIN 203781 203784 203793 203782 867902 203783 F 3 JT 869584 844364 867907 203785 203786 PARTS LIST 104P amp 10M GEAR TRAINS 203749 1st Red Gear Bearing 203781 2nd Red Gear incl 203749 203782 1st Red Gear 15T incl 203749 203783 2nd Red Gear Pin 203784 2nd Red Gear Bearing 203785 2nd Red Spider 203
9. 2 if needed housing and tighten to angle head 40 ft Ibs 54Nm tee f l Spanner Wrench 2 Adjustable Wrench 5c AN Bushing Tool Components Tightening Techniques for 40 Series Right Angle Nutrunners 104 204 8 304 Gear Trains Clamp angle head with bushing in vise Tighten all other components before posi tioning and tightening housing lock nut on angle head Place spanner wrench in adjustment slot of clutch housing and tighten clutch hous ing to second reduction gear case to 40ft Ibs 54Nm Tighten first reduction gear case to clutch housing to 40ft Ibs 54Nm Tighten motor housing to first reduction gear case to 40ft Ibs 54Nm while holding first reduction gear case with another wrench Tighten backhead to motor housing securely The P angle head has a spline for positioning the head to the throttle lever Once alignment is achieved the housing lock nut should be torgued to 20 ft Ibs Extension for leverage ua if needed Place Spanner Wrench in b Left Hand adjustment slot of clutch AN Threads housing and tighten to i A A second reduction i Use wrench to tighten gear case 40 ft Ibs 54Nm li motor housing to gear case while still holding Left Hand jum gear case with other wrench 40 ft Ibs 54Nm Vise Jaws eas BACKHEAD CLUTCH MOTOR HOUSING HOUSING FL Ji Right Hand ka Lai
10. 54 thrust bearing No 847596 thrust race No 202753 torque spring release spring No 202752 release sleeve No 203271 three 3 steel balls No 842161 ball retainer No 203272 and five 5 steel balls No 844077 to be removed from the clutch spindle assembly Wash the spindle assembly in a solvent and rotate the cam No 203270 to remove as much grease as possible Remove the retainer ring No 202749 ball plug No 202748 and twelve 12 steel balls No 842161 from the cam This will allow the trip plunger No 202745 reset spring No 202763 and pin No 843231 to be removed from the rear of the clutch spindle No 203456 10M 20M 20K amp 30K Models Unscrew the adjustment nut No 202824 This will allow the adjustment plate No 202754 thrust bearing No 847596 thrust race No 202753 torque spring release spring No 202752 release sleeve No 203271 three 3 steel balls No 842161 ball retainer No 203272 and five 5 steel balls No 844077 to be removed from the clutch spindle assembly Wash the spindle assembly in a solvent and rotate the cam No 203270 to remove as much grease as possible Remove the retainer ring No 202749 ball plug No 202748 and twelve 12 steel balls No 842161 from the cam This will allow the trip plunger No 202745 reset spring No 202763 and pin No 843231 to be removed from the rear of the clutch spindle No 202848 2ND REDUCTION GEAR TRAIN DISASSEMBLY 104P 204P amp 304P Gear
11. 6 Non Rev Grip Sleeve Only 867922 503466 Rev 203634 Non Rev 863454 B 202697 844265 203459 203637 ASSEMBLY S BACKHEAD l OPTIONAL MUFFLING KIT ASSEMBLV 201632 EXISTING PARTS EA NA 203479 AA Grip Sleeve Only i KA 203479 204152 203474 203476 a as s AC 944309 L Ia AA F 203481 203481 A H0 U PINGAR 640 204157 203481 204156 203475 20347 847272 Poe 203480 203481 PARTS LIST 40 SERIES MOTOR HOUSING 8 BACKHEAD ASSEMBLY FOR 10M 20M 20K 30K 104P 204P amp 304P PART NO NAME OF PART PART NO NAME OF PART 202410 Lever Pin 203479 Exhaust Deflector 202697 Spring 203480 Strainer 203457 Finger Spring Spacer 203481 Muffler 203459 Motor Housing incl 202967 844265 8 203794 203557 Throttle Lever 203465 Reversing Valve 203634 Dummy Ring 203466 Reversing Valve Ring 203636 Valve Block 203470 Trip Rod Guide 203637 Motor Housing Non Rev incl 203794 203471 Shut off Valve 203794 Grip Sleeve 203472 Shut off Valve Spring 204152 Grip Sleeve 203473 Backhead incl 203474 619999 Retainer Ring 203474 Throttle Valve Seat 844265 Ball 203475 Throttle Valve 844309 O Ring 7 16 x 5 8 203476 Throttle Valve Spring 847272 O Ring 5 8 x 3 4 203477 Throttle Valve Pin 863009 O Ring 3 4 x 7 8 Non Rev Qty 1
12. 786 1st Red Spider incl 203793 203793 1st Red Gear Pin 844364 Retainer Ring 847147 Ball Bearing 867902 Rotor Pinion 15T 867907 Gear Case 869584 Pinion Spacer BAU nwa WwWwWwWw Denotes parts not included in subassembly The complete gear case can be purchased as a subassembly using Part No 201522 1ST REDUCTION 20M 20K 204P 30K amp 304P GEAR TRAINS 867871 867921 847147 867922 090 844364 204 8 20 304 8 30 869182 204 8 20 867866 304 8 30 869181 PARTS LIST 20M 20K 204P 30K 8 304P GEAR TRAINS PART NO 844364 Bearing Retainer Ring 847147 Spider Bearing 867866 204 amp 20 Idler Gear 18T incl 867921 867871 Gear Case 867872 204 amp 20 Spider incl 867922 867921 204 20 304 amp 30 Idler Gear Bearing 867922 Idler Gear Pin 869181 304 amp 30 Idler Gear 16T incl 867921 869182 304 amp 30 Spider incl 867922 The complete gear cases can be purchased as a subassembly using Part No 204 20M amp 20K 861573 30K amp 304 861680 40 SERIES CLECOMATIC CLUTCH FOR 104P 204P 8 304P 202749 1 O RINGS 2027 203456 pais a 843231 8421 61 844077 203270 203271 104 Only 843791 ii 203285 304 amp 204 an 304P 202822 White 204P 203590 Yellow 104P 869306 PARTS LIST 40 SERIES 104P 204P 8 304P CLECOMATIC CLUTCH PART NO NAME OF PART
13. 9 Operation amp Service Manual GOOPER Tools 823181 2 01 Cleco 40 Series Nutrunners jojxinjajij jxxixxi B TX Series Output Drive 40 2 1 4 3 3 8 Rotation 4 1 2 Non Reversible Q Quick Change R Reversible M 25 Magnetic Nutrunner S Built in Socket Specify Size Clutch Designation T Threaded Spindle A Clecomatic Handle Generation 5 aali B Second Gear Train Designation Angle Terminations 10 30 204 20 104 304 M P For additional product information visit our website at http www clecotools com NORTH AMERICA EUROPE CooperTools Cooper Power Tools GmbH amp Co P O Box 1410 Postfach 30 Lexington SC 29071 D 73461 Westhausen Safetv Recommendations For your safety and the safety of others read and understand the safety recommendations and operating instructions before operat ing a nutrunner Always wear protective eguipment WARNING Impact resistant eve protection must be worn while operating or working near this tool For additional information on eve protection and face protection refer to Federal OSHA Regulations 29 Code of Federal Regula tions Section 1910 133 Eve and Face Protection and American National Standards Institute ANSI Z87 1 Occupational and Educa tional Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 11 West 42nd Street New Vork NV 10036 CAUTION Personal hearing protection is recommended when oper
14. Conversion kit contains all parts needed to convert a M right angle head to flush socket operation PARTS LIST M RIGHT ANGLE HEAD PART NO NAME OF PART PART NO NAME OF PART 201102 10mm Conversion Kit 863360 Pinion Needle Bearing 201103 13mm Conversion Kit 863564 Pinion Bearing Retainer 201104 15mm Conversion Kit 863698 Head Positioning Shim 008 201214 11mm Conversion Kit 864076 Driven Gear 202566 10mm Flush Socket Spindle 864396 Spindle Bearing Cap 202567 13mm Flush Socket Spindle 865723 Head Positioning Shim 004 202568 15mm Flush Socket Spindle 867641 Lock Pin Retainer Plug 202569 Bearing Cap 867642 Socket Lock Pin 202725 11mm Flush Socket Spindle 867643 3 8 Sq Dr Spindle incl 847219 867641 842517 Spindle Ball Bearing 867642 842980 3 32 Steel Ball 869034 Angle Head Adapter 843589 Grease Fitting 869048 Right Angle Head incl 843589 847219 Lock Pin Spring 869049 Pinion 847710 O Ring 1 2 x 5 8 869050 Bearing Spacer 847846 Pinion Ball Bearing 882629 Spindle Needle Bearing ah ok ee ee ee ee l e coe cre Gee Ce Number of spacers required is variable The complete M Right Angle Head can be purchased as a subassembly Denotes parts not included in subassemblies listed below 3 8 Square Drive Spindle 861637 40 SERIES P 202197 203437 203438 RIGHT ANGLE HEAD 203443 864105 867546 i 203441 844014 3 8 SQ DR 844014 1 2 SQ DR 844016 3 8 SQ DR E 844011 1 2 SQ
15. PART NO NAME OF PART 202745 Trip Plunger N Clutch Housing 202748 Ball Plug Clutch Spindle 15T 202749 Retainer Ring Torgue Spring White 202752 Release Spring O ring 202753 Thrust Race 3 16 Steel Ball 202754 Adjustment Plate i Ball Bearing 202755 Adjustment Nut Reset Pin 202763 Reset Spring Retainer Ring 202822 Torque Spring Green 5 16 Steel Ball 202829 Adjustment Cover O ring 203270 Clutch Cam id Retainer Ring 203271 Release Sleeve 104 Thrust Bearing 203272 Ball Retainer Torgue Spring Yellow 203285 Release Sleeve 304 8 204 pasa one A ages The complete clutch can be purchased as a subassembly using these part numbers 104P 201422 204P 201441 amp 304P 201423 Denotes parts not included in subassembly 40 SERIES CLECOMATIC CLUTCH FOR 10M 20M 20K 8 30K 202749 6 ha S 202748 O 842161 843231 sends De ma EJ iii r N O 842161 202763 844077 203271 869434 202754 202753 203285 202824 847596 202752 202829 869305 10M Red 203590 20M amp 20K White 202822 30K Green PART NO NAME OF PART 202745 Trip Plunger Clutch Cam 202748 Ball Plug Release Sleeve 0 amp 0 202749 Retainer Ring Ball Retainer 202752 Release Spring Release Sleeve 0 202753 Thrust Race Torque Spring White 202754 Adjustment Plate 3 16 Steel Ball 202762 Clutch Housing Reset Pin 202763 Reset Spring 5 16 Steel Ball 202822 Torque
16. Spring Green Thrust Bearing 202824 Adjustment Nut Torque Spring Red 202829 Adjustment Cover Steel Spacer 030 035 202848 Clutch Spindle Spacer 090 097 The complete clutch can be purchased as a subassembly using these part numbers 10M 201387 20M amp 20K 201442 amp 30K 201388 Denotes parts not included in subassembly Number of spacers required is variable 40 SERIES MOTORS FOR 10M 20M 20K 30K 104P 204P 8 304P 203464 Rev 203635 Non Rev 869583 10M 104P 203461 204P 8 20 304P amp 30K 203462 10M 8104P 203468 20 204P 8 304P 8 30K 203469 203460 _ Rev 203638 _ Non Rev PARTS LIST 40 SERIES 10M 20M 20K 30K 104P 204P amp 304P MOTORS PART NO NAME OF PART PART NO NAME OF PART 202704 Front Bearing Plate 203488 Rear Bearing 203460 Cylinder 203489 Front Bearing 203461 10M 104P 204P amp 20 Rotor 6T 203630 Rotor Blade 203462 304P amp 30K Rotor 9T 203635 Rear Bering Plate Non Rev 203464 Rear Bearing Plate 203638 Cylinder Non Rev 203468 10M amp 104P Trip Rod 812165 Cylinder Pin 062 Dia x 73 16 Lg 869583 Motor Spacer 203469 204P 20 304P amp 30K Trip Rod 062 Dia x 7 16 Lg 40 SERIES MOTOR HOUSING PARTS 8 BACKHEAD ASSEMBLY FOR 10M 20M 20K 30K 104P 204P 8 304P MOTOR HOUSING PARTS Not included in Backhead Assembly 203465 Rev Reversible Only 20363
17. T Threads Right Hand Threads Right Hand y u reads i E Use wrench i H to tighten viseJaws i G gear case to clutch Use wrench to tighten housing 40 ft Ibs 54Nm backhead to motor While holding clutch housing housing to U HU with spanner wrench 40 ft Ibs 54Nm aa Extension for leverage if needed oe Spanner Wrench 2 Adjustable Wrench E ANN Bushing g COOPER Tools CooperTools 670 Industrial Drive Lexington SC 29072 Phone 803 359 1200 Fax 803 359 2013 www clecotools com
18. Trains Remove the spider No 203747 out the rear of gear case No 203451 If replacement of idler gears are necessary the idler gear pins No 203750 can be driven out the rear of the spider with a punch Idler gear bearings No 203749 can be pressed out of the idler gears No 203748 1ST REDUCTION GEAR TRAIN DISASSEMBLY Single Reduction 204P 304P 20M amp 20K Gear Trains The spider No 867872 or No 869182 should be pressed out the bearing toward the rear of the gear case No 867871 Remove the retainer ring No 844364 and press the bearing No 847147 out the front of the gear case DISASSEMBLY Continued If replacement of the idler gear pins is necessarv thev should be pressed out the rear of the spider See Fig 1 for replacement pin height 5 20 agu 255 will lt Rear Fig 1 Single Reduction Spider Double Reduction 104P amp 10M Gear Trains Both spiders should be removed from the rear of gear case No 867907 Remove the retainer ring No 844364 and press the bearing No 847147 out the front of the gear case If replacement of the idler gear pins is necessary they should be pressed out the rear of the spider See Fig 2 for replacement pin height 104P 8 10M 1st Reduction Spider Fig 2 Double Reduction Spiders MOTOR HOUSING DISASSEMBLY Clamp backhead No 203473 in vise and unscrew motor housing No 203459 Reversing valve ring No 203466 and pin No 867922 may be removed at thi
19. ating or working near this tool Hearing protection is recommended in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant structures can substantially contribute to and increase the noise level in the area Excessive air pressure above 90 PSIG and worn motor components can also increase sound level emitted by tool Proper hearing conservation measures including annual audiograms and training in the use and fit of hearing protection devices may be necessary For additional information on hearing protection refer to Federal Regulations Section 1910 95 Occupational Noise Exposure and American National Standards Institute ANSI S12 6 Hearing Protec tors Cleco nutrunners are designed to operate on 90 psig 6 2 bar maximum air pressure If the tool is properly sized and applied higher air pressure is unnecessary Excessive air pressure in creases the loads and stresses on the tool parts sockets and fasteners and may result in breakage Installation of a filter regula tor lubricator in the air supply line ahead of the tool is recommended Before the tool is connected to the air supply check the throttle for proper operation i e throttle moves freely and returns to closed position Being careful not to endanger adjacent personnel clear the air hose of accumulated dust and moisture Before connecting a tool to the air hose or removing a tool f
20. ccumulated dirt and moisture then one 1 teaspoonful of 10W machine oil should be poured into the tool s air inlet before connecting the hose to the tool LUBRICATION An automatic in line filter regulator lubricator is recommended as it increases tool life and keeps the tool in sustained operation The in line lubricator should be regularly checked and filled with a good grade of 10W machine oil Proper adjustment of the in line lubricator is performed by placing a sheet of paper next to the exhaust ports and holding the throttle open approximately 30 seconds The lubricator is properly set when a light stain of oil collects on the paper Excessive amounts of oil should be avoided Application of the tool should govern how frequently it is greased It is recommended that the idler gears and right angle gears receive a generous amount of NLGI 2 EP grease through the grease fittings every 40 hours of operation STORAGE In the event that it becomes necessary to store the tool for an extended period of time overnight weekend etc it should receive a generous amount of lubrication at that time and again when returned to service The tool should be stored in a clean and dry environment DISASSEMBLY GENERAL 40RNALOM 20M 20K amp 30K Unscrew left hand threads and remove the angle head Unscrew left hand threads and remove the clutch housing and clutch Unscrew and remove the gear case assembly The trip rod should be remov
21. ed at this time to prevent its being lost or misplaced The motor unit may now be removed from the motor housing See the following paragraphs for complete disassembly instructions on the various sub assemblies AORNALOAP 204P amp 304P With tool mounted vertically in vise unscrew housing lock nut No 203438 lift up and remove the angle head Unscrew and remove the second reduction gear train Unscrew left hand threads and remove the clutch housing and clutch Note Do not lose finger spring spacer No 203457 Unscrew and remove the gear case assembly The trip rod should be removed at this time to prevent its being lost or misplaced The motor unit may now be removed from the motor housing See the following paragraphs for com plete disassembly instructions on the various sub assemblies RIGHT ANGLE HEAD DISASSEMBLY K Right Angle Head To disassemble the right angle head unscrew the spindle bearing cap This will permit the removal of the spindle assembly The pinion bearing retainer No 863564 may be removed by utilizing a 5 8 hex nut and a 5 8 deep socket Drop the hex nut over the pinion shaft and engage the hex in the bearing retainer and unscrew the retainer using the deep socket Using a suitable driver drive the pinion No 202200 and related bearings out of the angle head M Right Angle Head Using a suitable spanner wrench unscrew left hand threads the bearing cap No 864396 Remove the spindle ball bearing No
22. n 3 8 202201 Driven Gear 12T 844305 1 4 x 3 8 O Ring 202266 Angle Head incl 864964 847411 11 16 x 13 16 O Ring 202267 3 8 Sq Dr Spindle incl 844013 847846 Pinion Ball Bearing 844016 844014 847853 Lock Pin Spring 1 4 202268 1 4 Sq Dr Spindle incl 202987 863564 Pinion Ball Ring Retainer 847853 202986 863698 008 Spacer 202298 10mm Flush Socket Spindle 864964 Grease Plug 202299 13mm Flush Socket Spindle 865723 004 Spacer 202300 15mm Flush Socket Spindle 869034 Angle Head Adapter 202301 1 2 Flush Socket Spindle 869864 Pinion Needle Bearing 202302 9 16 Flush Socket Spindle 202303 Bearing Cap oe ee Gee Geen Ce rinda ob a a Number of spacers required is variable The complete K Right Angle Head can be purchased as a subassembly Denotes parts not included in subassemblies listed below 1 4 Square Drive 861146 3 8 Square Drive 861147 M RIGHT ANGLE HEAD 869034 863698 865723 847846 m 863360 869050 863564 ANGLE HEAD ADAPTER Stall Tools Only FA E z 1 882629 e JE DAS og Y 869048 867642 TI r 867641 mi Ea D 864396 864076 867643 FLUSH SOCKET SPINDLE 869051 SIZE SPINDLE CONVERSION PART NO KIT PART NO 10mm 202566 6 201102 11mm 202725 8 201214 3 8 24 Drill Spindle 13mm 202567 4 201103 14mm 15mm 202568 2 201104
23. oid anything that inhibits blood circulation Avoid continuous vibration exposure Keep wrists straight Avoid repeated bending of wrists and hands Some individuals may be susceptible to disorders of the hands and arms when performing tasks consisting of highly repetitive motions and or exposure to extended vibration Cumulative trauma disorders such as carpal tunnel syndrome and tendonitis may be caused or aggravated by repetitious forceful exertions of the hands and arms Vibration may contribute to a condition called Raynaud s Syndrome These disorders develop gradually over periods of weeks months and years It is presently unknown to what extent exposure to vibrations or repetitive motions may contribute to the disorders Hereditary factors vasculatory or circulatory problems exposure to cold and dampness diet smoking and work practices are thought to contribute to the conditions Any tool operator should be aware ofthe following warning signs and symptoms so that a problem can be addressed before itbecomes a debilitating injury Any user suffering prolonged symptoms of tin gling numbness blanching of fingers clumsiness or weakened grip nocturnal pain in the hand or any other disorder of the shoulders arms wrists or fingers is advised to consult a physician If it is determined that the symptoms are job related or aggravated by movements and postures dictated by the job design it may be necessary for the employer to take
24. rom service or changing sockets make sure the air line is shut off and drained of air This will prevent the tool from operating if the throttle is accidently engaged CAUTION When using right angle nutrunners be sure the throttle is positioned relative to the angle head so that the throttle will not become wedged against an adjacent object in the ON position due to torque reaction The angle head may be repositioned with respect to the lever to accommodate proper location for task If tool is to be reversed locate throttle lever in a neutral position that will prevent entrapment Refer to operating instructions for additional informa tion It is essential for safe operation that any operator of a nutrunner use good balance sure footing and proper posture in anticipation of a torque reaction Tools with clutches can stall rather than shut off if adjusted over maximum power output of tool or if there is a drop in air pressure Operator must then resist stall torque until throttle is released Sy Spindle Rotation Torque Reaction Tool balance arms are available to absorb the torque reaction of the tool while balancing the weight of the tool for improved ergonomic applications D Safetv Recommendations A WARNING Repetitive work motions and or vibration may cause injury to hands and arms Use minimum hand grip force consistent with proper control and safe operation Keep body and hands warm and dry Av
25. rottle lever Use spacers No 863698 to position head Break assembly apart at the clutch housing and gear case left hand threads and install the spacers No 869434 five 5 spacers No 869423 and clutch assembly Reassemble the tool Measure gap between the clutch housing and gear case Remove the appropriate number of spacers No 869423 to allow clutch housing and gear case to make up tight NOTE Spacers are 030 76mm thick If there is not a gap add spacers No 869423 to achieve one The total amount of spacers removed must be equal to or greater than the gap EXAMPLE Gap is 048 1 22mm Remove two 2 030 76mm thick spacers 060 1 52mm total CLUTCH SPACING 104 204 amp 304 The O rings No 844306 070 1 8mm and No 813449 103 2 6mm are used to restrict the movement of the clutch in the clutch housing The O ring should be chosen that restricts the movement but does not become compressed to tightiv TRIP ROD SIZING Install trip rod Screw clutch housing down until tool begins to start Continue to screw the housing down 3 4 to turns Measure the gap between the clutch housing and gear case Cut this amount off the trip rod SAFETV CHECK After repair or replacement of parts all tools should be tested to verifv that the Clecomatic automatic shut off device is functioning properiv K RIGHT ANGLE HEAD 869034 B 847846 ANGLE HEAD ADAPTER 869864 863564 N iff 863698
26. s time Tapping motor housing on soft surface should remove reversing valve No 203465 The shut off valve No 203471 and shut off valve spring No 203472 can be removed from backhead at this time to prevent loss The throttle rod guide can be pressed out and replaced if necessary BACKHEAD DISASSEMBLY Unscrew and remove the inlet bushing No 203478 for inspection and cleaning of the strainer No 203480 exhaust deflector No 203479 and mufflers 203481 Replace any parts if clogged or torn The porous bronze deflector can be washed in solvent and reverse blown with compressed air to clean it The throttle valve No 203475 and throttle valve spring No 203476 may be removed The throttle valve seat No 203474 can be pressed out and replaced if necessary REASSEMBLV GENERAL All parts should be washed in a solvent and inspected for damage or wear Particular attention should be given to all bearings gears gear pins and rotor blades as failure of these parts could cause damage to more expensive parts Rotor blades should be replaced at everv repair cvcle or if thev measure less than 3 16 4 7mm on either end A NOTE Refer to pages 18 and 19 for proper tightening techniques for all components Must be replaced if less than 3 16 4 7mm on either end Inspect and replace any O rings or seals that show signs of wear or deterioration All gears gear pins and open bearings should receive a generous amount of NLGI 2 EP grea
27. se during reassembly During reassembly of the clutch all parts should receive a thin coating of a mixture of 1OW machine oil and NLGI 2 EP grease Reassembly of all of the various sub assemblies is in the reverse order of disassembly however the following paragraphs list some of the more important reassembly proce dures RIGHT ANGLE HEAD REASSEMBLY K Right Angle Head Slip pinion needle bearing No 869864 unstamped end first on the pinion No 202200 and press press on the bearing s stamped end the bearing to a depth of 7 8 22mm from the face of the bearing bore Install pinion ball bearing No 847846 and bearing retainer No 863564 in the head and tighten retainer securely using the 5 8 16mm hex nut and 5 8 16mm deep socket Using a suitable driver through the hole in the top of the head drive the pinion back to make sure it is seated properly in the head M Right Angle Head Assemble the spindle and related components in the head and securely tighten left hand threads the bearing cap No 864396 Use bearing spacer No 869050 to press the pinion needle bearing No 863360 press on the bearing s stamped end in the head Install ball bearing No 847846 and bearing retainer No 863564 in the head and tighten retainer securely using the 5 8 hex nut and 5 8 deep socket Retighten head to tool with proper wrench to a torque higher than the torque rating of the tool P Right Angle Head Assemble the spindle and
28. tained and replace worn parts Work gloves with vibration reducing liners and wrist supports are available from some manufacturers of industrial work gloves Tool wraps and grips are also available from a number of different manufacturers These gloves wraps and wrist supports are de signed to reduce and moderate the effects of extended vibration exposure and repetitive wrist trauma Since thev varv widelv in design material thickness vibration reduction and wrist support qualities itis recommended that the glove tool wrap orwrist support manufacturer be consulted for items designed for vour specific application WARNING Proper fit of gloves is important Improp erlv fitted gloves mav restrict blood flow to the fingers and can substantially reduce grip strength Safetv Recommendations ADDITIONAL SAFETY RECOMMENDATIONS FOR USE OF RIGHT ANGLE DRILLS Do not wear loose fitting clothes long hair gloves ties or jewelry Follow good machine shop practices Rotating shafts and moving components can entangle and entrap and can result in serious injuries Never wear long hair loose fitting clothes gloves ties or jewelry when working with or near a drill of any type A WARNING Wear respirator where necessary Drilling or other use of this tool may produce hazardous fumes and or dust To avoid adverse health effects utilize adequate ventilation and or a respirator Read the material safety data sheet of any cut
29. ting fluids or materials involved in the drilling process A CAUTION e Drill bits are sharp Handle them carefully to avoid injury e The cutting tool maximum speed rating must equal or exceed the rated speed of the tool e Use the appropriate size chuck key to securely tighten a drill bit in the chuck e Use precautions when drilling because of the possibility of the cutting tool bending or breaking e High reaction torque may be experienced by the operator with any drill at breakthrough e Drill bits or accessories not centered properly in the chuck can cause excessive wobble or vibration For more information on the safe use of portable air tools see the latest edition of ANSI B186 1 Safety Code for Portable Air Tools available from the American National Standards Institute Inc 11 West 42nd Street New York NY 10036 This information is a compilation of general safety practices obtained from various sources available at the date of production However our company does not represent that every acceptable safety practice is offered herein or that abnormal or unusual circum stances may not warrant or require additional procedures Your work may require additional specific safety procedures Follow these procedures as required by your company Warning Labels The warning labels found on these tools are an essential part of this product Labels should not be removed Labels should be checked periodically for legibility Replace
30. tor power and the tool will function like a stall type tool If tool stalls operator must resist stall torque until the throttle is released If the clutch is adjusted over the maxi Operational check Grip tool securely and be prepared to coun teract stall torque in case clutch is improperly adjusted THIS IS A HIGH TORQUE TOOL THROTTLE POSITION K 8 M Right Angle Head Both the K 8 M heads are threaded to the gear case Throttle positioning is accomplished by using shims between the head and the gear case as required to properly position the throttle lever with respect to the head to prevent hand entrapment See Torque Reaction page2 Retighten head with proper wrench to a torque higher than the torque rating of the tool P Right Angle Head The throttle lever may be repositioned to accomodate proper location for task and to avoid hand entrapment The P head is splined to the gear case Repositioning of the angle head is done by loosening housing lock nut No 203438 left hand threads and lifting angle head enough to disengage the spline and turning to position desired Retighten housing lock nut with proper wrench to 20 ft Ibs AIR SUPPLY For maximum performance use a 3 8 I D air hose no longer than 8 in length If additional length is required the next larger hose should be connected to the 3 8 hose Being careful to avoid endangering adjacent personnel or your self the air hose should be cleared of a
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