SM-253 — Right Angle Tube Roller 909 Series
Contents
1. After the tool is completely assembled the right angle square drive spindle should turn freely using a small hand wrench If the spindle does not turn freely the motor should be checked for proper spacing Do not run the tool until the spindle turns freely Failure to do this could result in damage to motor compo nents Ist REDUCTION GEAR TRAIN REASSEMBLY 2 Gear Train 13 Tooth Spider 21 Tooth idler gears on inner set of gear pins 3 Gear Train 19 Tooth Spider 21 Tooth idler gears on inner set of gear pins Clutch Reassembly The clutch is reassembled in the reverse order of disassembly The torque spring bearing No 909 2160 must be assembled so that the solid side of the ball separa tor is facing the torque spring plate No 909 2156 17 SM 253 DISASSEMBLY 16 DISASSEMBLY General Clamp the flats of the handle in a vise with the tool in a vertical position Using a suitable wrench loosen left hand threads the clamp nut No 909 2117 and remove the angle head assembly Unscrew and remove the clutch housing and gear case assemblies Clamp the gear case in the vise and unscrew the clutch housing Slip the motor unit out the front of the handle It may be necessary to bump the handle on the work bench to loosen the motor Right Angle Head Remove the bearing cap lock screw 1 16 hex No 909 2112 and unscrew left hand threads the bearing cap Clamp the square drive in the vise and use a soft mallet to drive2. Dirty air inlet screen Clean Rotor blades worn chipped or broken Replace Broken throttle valve spring Replace Valve ball does not seal Replace or rework valve seat 19 SM 253 DISASSEMBLY 18 Right Angle Head When installing needle bearings press only on the bearing s stamped end The pinion needle bearing should be slipped on the pinion gear and pressed into the housing to the following depth 230 Right Angle Head 3 3 16 81 mm 110 Right Angle Head 3 76 2 mm The pinion bearing retainer No 909 2116 should be securely tightened to ensure proper gear make up The driven gear bearing cap should be torqued to 100 110 ft Ib 1 35 1 49Nm and the bearing cap lock screw torqued to 10 in lb 1 1 52cmkg mini mum NOTE When assembling the angle head to the complete tool the clamp nut No 909 2117 left hand threads must be torqued to 100 110 ft 1bs 1351 149Nm Trip Rod Sizing During reassembly of the tools the trip rod must be ground flush 0 1 32 0 0 793mm with the end of the rotor Hold the motor firmly in the handle at the time the trip rod is being sized to length Safety Check After repair or replacement of parts tools equipped with an automatic shutoff device should be tested to verify that they are functioning properly CAUTION To prevent hand entrapment from torque reaction the square drive should be positioned from the throttle as shown below SM 25
3. the angle head off Press the spindle out of the driven gear and then press the spindle out of the ball bearing Unscrew and remove the bearing retainer No 909 2116 and grease plug No 909 2111 Use a suitable driver to drive the pinion gear out of the housing Clutch CAUTION The adjustment cover No 909 2168 retains the ball spring No 909 2169 and steel ball No 24031 0000 and care should be exercised to prevent their loss Use a 5 32 3 96mm diameter pin to lower the clutch adjustment This will al low the clutch retainer ring No 909 2170 to be removed from the clutch housing Remove the clutch assembly from the housing Use a suitable bearing puller to remove ball bearing No 909 2154 Remove retainer ring No 909 2153 drive shaft washer No 909 2155 trip sleeve spring No 909 2159 and trip sleeve No 909 2157 from the drive shaft No 909 2165 NOTE Trip Plunger No 909 2166 trip plunger spring No 909 2158 and two 2 balls No 909 2151 should also be removed at this time Use a sharp pointed instrument to remove the cam retainer ring No 909 2171 from the ball retainer No 909 2164 Slip the drive shaft No 909 2165 and clutch cam No 909 2163 out the rear of the ball re tainer No 909 2164 Gear Case Slip the entire gear train out the rear of the gear case The 2nd reduction idler gears may be removed for inspection by driving the idler gear pins No 6637 0000 out the rear of the spider
4. 3 OPERATION Always operate inspect and maintain this tool in accordance with American National Standards Institute Safety Code for Portable Air Tools ANSI B186 1 and any other applicable safety codes and regulations FOR TOP PERFORMANCE AND MAXIMUM DURABILITY OF PARTS OPER ATE THIS TOOL AT 90 psig 6 2bar 620kPa AIR PRESSURE WITH 13mm DIAMETER HOSE WARNING Always turn off the air supply and disconnect the air supply hose before installing removing or adjusting any accessory on this tool or before performing any maintenance on this tool Failure to do could result in injury Air powered tools can vibrate in use Repetitive motions uncomfortable positions vibrations can cause injury to hands fingers wrists of some persons Stop using any tool if discomfort tingling felling or pain occurs Seek medical advice before resum ing use HOSE AND HOSE CONNECTIONS Use 1 2 13mm hose or hose fitting with a Male Hose Nipple 1 2 hose to 1 2 male pipe for attaching it to the tube Roller A smaller hose or hose fitting will reduce the power and efficiency of the Tube Roller LUBRICATION After each two or three hours of operation unless an Air Line Lubricator is used dis connect the air hose and pour into the inlet about 3cc of SAE No 10 or Wilsolub Pneumatic motor oil Cat No 9047 The use of an Air Line Lubricator is recom mended with any air operated tool Install a Wilson automatic lubricator Cat No 8
5. 597 as close to the tool as possible Gearing and Right Angle Assembly should be grease lubricated approximately every 160 hours of operation Inject bearing type grease 1 to 2 strokes through grease fitting in housing HIGH TORQUE TOOL ALWAYS USE PROPER REACTION BAR IMPORTANT The reaction bracket No 909 2103 must fully engage the spline on the right angle head Position the bracket forward on the small diameter of the head and then move it rearward to engage the spline Securely tighten reaction bar with pipe wrench screws and jam nuts USE ONLY SOCKETS APPROVED FOR POWER TOOL SERVICE ALWAYS WEAR APPROVED EYE PROTECTION See the latest edition of ANSI Z87 1 Ameri can National Standard for Occupational and Educational Eye and Face Protection READ UNDERSTAND AND PRACTICE the requirements of ANSI B186 1 Safety Code for portable air tools SM 253 OPERATION Cont 909 2000 amp 2100 TUBE ROLLER The Model 909 2100 Tube Roller is designed to operate on 90 PSIG air pressure but does not depend on controlled air pressure to maintain accurate torque Accurate torque is achieved by setting the clutch to the desired torque on the application The tool will shut off automatically at this torque Releasing the throttle will allow the tool to reset for the next cycle Clutch Adjustment Rotate the adjustment cover until the adjustment slot is uncovered With the angle head end of the tool facing away use the 909 2127 adjusting t
6. GEAR ASS Y 909 2250 S SET SCREW P0006 0000 NOTE z On 909 1900 Model the trip rod No 909 2199 and shut off valve No 909 2198 is removed from the throttle assembly and the set screw No 20006 0000 is assembled in place on the rotor No 909 2186 DESCRIPTION PART NO tv LEVER THROTTLE amp MOTOR ASS Y CLUTCH ASSY 309 2260 _ 1 GEAR ASSY 9909 2250 o 1 i NG TOO KEY DESCRIPTION PART NO 5 5 n 5 14 7 PARTS LIST 909 2280 SM 253 ITEM PART NO DESCRIPTION st perso sa a pes sas KAN e vi mm Fa aioe 1 ADoser cover o we sm SM 253 13 PARTS LIST 909 2260 12 SM 253 SM 253 DESCRIPTION CYCLINDER PIN AIR INLET SCREEN ROTOR BEARING 80 909 2180 1 THROTTLE VALVE SPRING ROTOR LOCK NUT REVERSING VALVE SCREW MOTOR ALIGNMNET PIN Pas 9092236 ROTOR ASSEMBLY CYLINDER INCL PIN ROTOR BLADE 90 909 2190 1 REAR BEARING PLATE THROTTLE VALVE SEAT THROTTLE VALVE INLET BUSHING THROTTLE LEVER 96 909 2196 10 EXHAUST DEFLECTOR Cog 9092198 SHUT OFF VALVE MOTOR SPACER REVERSING VALVE REVERSING RING DEFLECTOR SPACER SM 253 SM 253 PARTS LIST 909 2240 PARTS LIST 909 2250 ITEM PART NO DESCRIPTION 909 2101 SPINDLE 909 2106 SPINDLE BEARING e ea ns SPINDLE BEARING 909 223 I 909 211 p N ON 909 212 Oo Ke N oO
7. Motor Use a soft faced mallet to drive the rotor out of the front rotor bearing No 909 2154 This will allow the removal of the front bearing plate No 909 2185 cylin der and five 5 rotor blades No 909 2188 from the rotor No 909 2186 Clamp the rotor lightly in the vise and unscrew the rotor lock nut No 909 2181 Rest the rear bearing plate on the vise jaws and use a soft faced mallet to drive the rotor out of the rear rotor bearing SM 253 OPERATION Cont 909 1900 TUBE ROLLER The 1900 Stall Type Model Tube Roller is designed to develop max torque at 90 PSIG air pressure and it doesn t have clutch adjustment Torque output can be con trolled by a pressure regulator installed in the air supply line MAINTENANCE WARNING Always turn off the air supply and disconnect the air supply hose before in stalling removing or adjusting any accessory on this tool or before perform ing any maintenance on this tool Failure to do could result in injury Air tools are made of precision parts and should be handled with reasonable care when servicing Excessive pressure exerted by a holding device may cause distortion of a part Ap ply pressure evenly when disassembling or assembling parts which have a press fit When removing or installing bearing apply pressure to the bearing race that will be the press fit to mating part if this is not practiced Brinelling of the bearing race may occur making replacement necessary I
8. SM 253 SPECIFICATIONS Model no 909 1900 909 2000 909 2100 Type Roll Throttle Lever Throttle Roll Throttle Stall Type Torque Control Torque Control Free Speed RPM 90 90 90 Min Torque Ft Lb 150 150 150 Max Torque Ft Lb 305 305 305 Air Pressure psi 90 90 90 Air Inlet 1 2 NPT 1 2 NPT 1 2 NPT muse 1 2 LD 1 2 LD 1 2 LD Air Flow Free 90 CEM 90 CFM 90 CFM Speed Spindle 3 4 square 3 4 square 3 4 square Weight 20 18 5 Lb 8 8kg 18 5 Lb 8 8kg Thomas C Wilson Inc 21 11 44th Avenue Long Island City New York 11101 Tel 718 729 3360 Fax 718 361 2872 http www tewilson com E mail tevvilson Qtcvvilson com 18 5 Lb 8 8kg SM 253 909 1900 Smarter Tools for 909 2000 Smarter Work 909 2100 SERIES 909 RIGH ANGLE TUBE ROLLER OPERATING INSTRUCTIONS amp SERVICE MANUAL Rev A 2 23 2007 Thomas C Wilson Inc 21 11 44th Avenue Long Island City New York 11101 Tel 718 729 3360 Fax 718 361 2872 http www tcwilson com E mail tevvilson Qtcvvilson com SM 253 SAFETY INSTRUCTIONS AN WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in accident fire and or personal injury SAVE THESE INSTRUCTIONS Do not allow corrosive gases or foreign material to enter the unit Moisture oil based contaminants or other liquids must be filtered out Eye protection 1s always require
9. d when running motor Hearing protection is recommended when in close proximity to all operating air motors Dust mask non skid safety shoes hard hat gloves and other personal safety equip ment must be used Stay alert watch what you are doing and use common sense when operating a power tool Dress properly Do not wear loose clothing or jewelry Keep your work area clean and well lit Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Disconnect the tool from the air supply before installing making any adjustment changing accessories servicing or storing tool SM 253 TROUBLE SHOOTING PROBLEM Motor will not run CAUSE amp REMEDY Insufficient air supply Check 90 psi and 90 CFM air supply Clogged air inlet screen Replace or Clean Broken or severely worn rotor blades Replace Rust due to improper storage of tool Disassemble and clean Refer to Disassembly procedure Broken throttle valve pin or lever Motor will not reach RPM Motor stalls at high torque Motor fails to stop Insufficient air volume Check 90 CFM supply Dirty air inlet screen Clean Worn rotor blades Replace Air supply hose chocked or too small See Operating Procedure recommended hose Rotor Assembled incorrectly Re assemble referring to assembly procedure Insufficient air pressure Check 90 psi supply
10. ool or a 5 32 diameter pin to rotate the adjusting nut clockwise to in crease the torque setting and counterclockwise to decrease the setting After adjustment rotate the cover over the slot to lock the nut in place CAUTION If the clutch is adjusted over the maximum 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 motor power and the tool will function like a stall type tool Operational Check Grip tool securely and be prepared to counteract stall torque in case clutch is improperly adjusted Use proper reaction bar Torque Setting By looking into the clutch adjustment access hole markings can be seen on the adjusting nut NOTE The marking centered in the access slot is the one to read Five revolutions of the adjusting nut covers the complete torque range of the tool The mark ings start at A 1 lowest torque setting and go thru A 8 on the first revolution of the nut The second revolution starts with B 1 the third starts with C 1 etc The fifth revolution ends with E 8 highest torque setting NOTE The torque setting marks are for reference only and do not relate to a specific amount of torque SM 253 DISASSEMBLY Handle Unscrew the inlet bushing No 909 2194 for inspection of the throttle compo nents The ai
11. r inlet screen No 909 2175 should be washed in a solvent and blown out in the reverse of normal airflow Replace if damaged or clogged Reassembly The tool is reassembled in the reverse order of disassembly Clean all parts thor oughly in a solvent and inspect for damage or wear Check all bearings for wear which can be detected by excessive endplay and or roughness that would indicate a brinelled condition The rotor blades should be replaced if they measure less than 3 8 9 5mm at either end All gear teeth bearings and pins should receive a close inspection and be replaced if necessary All gears and open bearings should receive a generous amount of No 2 Moly grease during reassembly Motor Reassembly To assemble the motor install the rear rotor bearing into the rear bearing plate Make sure the outer bearing race is firmly seated in the bearing plate Clamp the rotor body lightly in the vise with the threaded end up and slip the rear bearing plate assembly onto the rotor shaft far enough for the bearing lock nut to start Tighten the lock nut until there is approximately 001 001 5 0 025 0 038mm clearance between the rotor and bearing plate The outer bearing race should be firmly seated and the rotor bumped forward when checking this clearance Pack both rotor bearings with a good grade of No 2 Moly grease after assembly of the motor unit IMPORTANT During reassembly of the complete tool it is important that the motor be free
12. t is important that the correct tools and fixtures are used when servicing this tool Disassembly should be done on a clean work bench with a clean cloth spread to prevent the loss of small parts After disassembly is completed all parts should be thoroughly washed in a clean solvent blown dry with air and inspected for wear levels abuse and contamination Double sealed or shielded bearings should never be placed in solvent unless a good method of re lubricating the bearing is available Open bearings may be washed but should not be allowed to spin while being blown dry When replacement parts are necessary consult drawing containing the parts for identification Before reassembling lubricate parts where required Use bearing grade grease in bearings When assembling O ring care must be exercised to prevent damage to the rubber sealing surfaces A small amount of grease will usually hold steel balls and small parts in place while assembling When ordering parts be sure to list PART NUMBER PART NAME MODEL NUMBER AND SERIAL NUMBER OF TOOL USE ONLY GENIUE RE PLACEMENT PARTS SM 253 SM 253 909 1900 Ts 3002236 1 ROTORASSENBLY ___ 90 sopzioo REAR BEARINGRLATE __ 909 2000 4 S Loctite In Place bt SERI l es Sl 909 2230 THROTTLE SLEEVE 909 2231 THROTTLE RETURN SPRING SM 253 SM 253 PARTS LIST 909 2270 1 ROLL THROTTLE 8 MOTOR ASS 909 2770 2 STALL RING 909 1920 SST 3
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