Operation and Maintenance User Manual Models 400, 800, 1800
Contents
1. SPOOLVALVEASSEMBLY 5 32 STEEL BALL HOUSNGBACKFORNOPCB mso 3 8 NPT MULTI FLEX SWIVEL 440332 SOCKETSETSCREW PLENUM SEAL 3 O O AM3 1 UPPERREARMUFHER O _ AMa SPOOLVALVEWASHER O zm 2 25 92005416 2 2 M amp XO70XeMMBUTONHEADCAPSCREW Ca 3 5 5 050 10 LONG SOCKET HEAD SCREW 30 085550 4 LONG LOW SOCKET HEAD CAP SCREW o ams 1 3787 0 300051 2 OTA 5 5 MSX080X8MM LONG LOW SOCKET HEAD CAP SCREW 534 AFREARDEAN Ol BICOL PO OI DNI on 5 cof 2 2 LOCTITE INSTANT GASKET BLACK GASKET SEALANT 5463K731 1 16 1 0 HOSE BARB FITTING PLUG 1 8 X 1 16 D ANTISTATIC WHITE TUBING n 2 See Page 21 for ATM 1 PCB Parts Call out and Parts List Page 19 of 25 gt BOLT TECH GS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date2. gt MANNINGS The of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Operation and Maintenance User Manual Models 400 800 1800 3000 Bolttech Mannings Corporate Headquarters 501 Mosside Blvd North Versailles PA 15137 www bolttechmannings com Page 1 of 25 BOLT TECH NINGS The Perfect Union of People Products and Ser Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 INDEX PAGE L Salc InfoEmatiOl 3 Ze 4 3 General Tool Layout ccesccscscccrcccccscccscssesccscccscsccssccees 5 3 1 Basic Tool 5 sA CONIO 5 4 Operating Instructions 6 7 5 Routine Care and Maintenance 8 6 Control Unit Breakdown and Parts List 9 7 Troubleshooting I EORR 10 8 PCB Battery 22 24 2 25 2BOLT TECH NINGS The met hae Products and Ser Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Bolttech Mannings has designed this tool to be safe ergonomic and functional Use of pro
3. GRIP INTERNAL SNAP RING EXTERNAL SNAP RING DU BEARING 8 32 X 1 5 8 LONG SHCS 1 3 4 NEEDLE ROLLER BEARING 1 EY THRUST WASHER 20 AT300 RBG L 2 24 a Lm cem 28 L 38 30 mE 3 33 WHM 162N NTA 3244N AT3000 O RING ARM SEAL 999 X 2 051 X 0 098 AT3000 DR RING 1 REMOVABLE DRIVE SEAL LOCTITE 242 E Wu 8 Gm N A DOW CORNING G2001 GREASE AT3000M DECAL 05008091645 M5 X 8 MM SET SCREW NYLON PATCH 10 32 5 1655 10 32 X 5 16 LONG SET SCREW 18 25 2BOLT TECH MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 ITEM BOLTTECH MANNINGS PART NUMBER pon DESCRIPTION e 4 NNERBALBEARNGRACE LEFT MOTOR HOUSING ASSEMBLY 7 RMGHrMOTORHOUSNG ASSEMBLY HREADEDHOUSNGCAP O VAWESPRNGRETANER O o MOTOR CELL i ams 2 080 8 LONG SOCKET SHOULDER SCREW AIR INLET FITTING 14 881449 387 DA 9 16 LONG DOWEL PIN 15 9595 1 1 8 DIA X 1 000 LONG DOWEL PIN 16
4. 6 A AT1800 S2A 1800 STAGE 2 ARM 7 amosa 1 1800 STAGE 3 ARM 8 amosa 1 1800 STAGE 4 ARM 9 ATI800 S2IP_ 1 1800STAGE 2 INPUT PINION 10 1800 531 1 1800 5 3 INPUT PINION Lu am 22 a 2 1800 52 1800 5 2 1800 53 1800 5 3 14 1800 54 1800 5 4 2215 1800 F3 1800 RING GEAR 16 1800 3 1800 INPUT PINION e e e 17 AT800RD 1 __ 1800 REMOVABLE DRIVE 18 ATI800OR 1 1800 BEARING OUTER RACE 19 __ 1 1800 REACTIONBAR 20 ATIS0CRBG 1 ___ 1800 REACTION BAR GRIP 21 1 INTERNALSNAPRING 22 WSM2SN 1 EXTERNAL SNAP RING 23 1 CU BEARING e l l 91251 203 8 32 X 1 1 2 LONG 5 5 24 25 NTA284N 2 13 4 NEEDLE ROLLER BEARING 26 4 1 3 4 THRUST WASHER 40923 1 PNIONSEAL O 28 AT1800 DR RING 1 REMOVABLE DRIVE SEAL 29 AT1800 O RING ARM SEAL 1 749 X 1 853 X 0 098 30 LOCTITE242 BLUETHREADSEALER 31 62001 N A DOW CORNING G2001 GREASE 32 1 MULTIPLIER DECAL 33 05008091645 1 5 8 SET SCREW NYLON PATCH 10 32 5 1655 1 10 32 X 5 16 LONG S
5. STAGE 3 PLANET 400 STAGE 1 ARM AT400 S2IP 400 STAGE 2 INPUT PINION 400 52 STAGE 2 ARM AT400 S3A STAGE 3 ARM 400 REMOVABLE DRIVE 00 51 400 5 1 400 52 5 2 400 53 STAGE 3 AXLE 400 INPUT PINION RING GEAR 400 BEARING OUTER RACE 400 REACTION BAR INTRNAL SNAP RING EXTERNAL SNAP RING 18 1 19 AT400 O RING ARM SEAL 1374 X 1478 0 098 20 REMOVABLE DRIVE SEAL 21 C 40923 L 22 LOCTITE 242 23 DOW CORNING G2001 GREASE 24 AT400M DECAL errr oc 2 05008091645 MS 8 MM SET SCREW NYLON PATCH 10 32 5 1655 10 32 X 5 16 LONG SET SCREW n A Page 12 of 25 MANNINGS The Perfect Union of People Products Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 AT800 ee 262272 2477 77 4 13 13 25 2BOLT TECH 5MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 800 BOLTTECH MANNINGS PART NUMBER AT amp 00 51P 800 52 AT800 53P 800 521 AT800 352A 00 5 00 51 800 52 800 53 DESCRIPTION 800 STAGE 1 PLANET 800 STAGE 2 PLANET 800 STAGE 3 PLANET 800 STAGE 1 ARM 800 STAGE 2 INPUT PINION 800 STAGE 2 ARM STAGE
6. in the proper direction shown on the printed circuit board Page 23 of 25 BOLT TECH The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Place cover on the Tighten cap screws 1 a cross pattern Tighten to 17 1 165 of torque Page 24 of 25 2BOLT TECH MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Revision History Approved Description of Revision Revised Page s By Updated to new format Added to Routine Care and Maintenance The first reservoir is for collection Motor Housings to a qty of 1 as a set Fixed 12 7 31 2013 19 Matt R EMT plenum seal part number ATM 32 to 34 11 27 2013 Updated Parts Lists to match Discovery 12 14 16 18 19 04 01 2014 Added PCB battery replacement procedure 2 5 2015 Implemented Handle Conversion to bolts 19 20 Page 25 of 25
7. the final air pressure the regulator can be locked by depressing the knob until it clicks this will ensure the pressure remains at the set point for the required torque value NOTE Refer to the certificate of calibration for the particular model and Serial number of the tool Verify that the test date 1s within the previous 12 months Exceeding maximum torque value will result in tool failure and void tool warranty Page 6 of 25 gt BOLT TECH SMANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 5 For tightening the stall point and torque is achieved by depressing the trigger 1 times after the nut has stopped rotating while the pneumatic torque tool is on the nut of the application Some models may be supplied with a digital readout The digital readout is used to display the air pressure and the torque being applied to the drive of the tool To activate the digital readout push the power button once The display should turn on At this point you will get to choose whether you want to see PSI ft Ibs or bar N m To switch between the two the button must be pushed and held for two seconds The light will switch to the other side To switch between PSI and ft lbs or bar and N m push the button once while the display is on NOTE After pushing the power button the display will remain ON for 10 seconds If you push the button
8. with in 10 seconds it will stay on for an additional 10 seconds The digital readout 15 factory programmed during tool calibration using the USB interface Page 7 of 25 2BOLT TECH NINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Routine Care and Maintenance The filter lubricator reservoir must be kept filled with air tool oil This 15 accomplished by removing the air tool oil fill cap shown on page 4 Failure to keep the reservoir filled will result in permanent damage to the Tool and void factory warranty The Auto Oiler is factory pre set ANY adjustment will void warranty The oiler 15 factory pre set for 1 drop of oil every 3 5 seconds while running the tool wide open at 90 psi Recommended Oil Conoco Turbine Oil 32 or Equal Regulator filter 15 located after the air inlet and is 20 microns which should be replaced regularly The first reservoir is for the collection of water removed from the inlet air If the reservoir becomes filled with water 1t can be expelled by loosening of the drain plug on the bottom of the reservoir Caution Reservoir is pressurized when connected to the air line The drain plug should be opened slowly to avoid spray Your tool needs to be calibrated on a yearly basis as a minimum to ensure correct torque values are being generated Contact your Bolttech Mannings representative to sc
9. 02 05 2015 gt p s INSTRUCTIONS FOR INTENDED USE ENLARGED FOR CLARITY 1 NUMBERS 35 38 37 38 AND 39 SEE ASSEMBLY Y NOTE Page 20 25 MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 BOLTTECH MANNIN GS PART NUMBER ATM 10N REAR HOUSING CAP FOR PCB PRINTED CIRCUIT BOARD AAA LITHIUM 1 5V BATTERY DESCRIPTION 2 AT PCBN 3 0 50 10MM LONG SOCKET HEAD CAP SCREW 1 16 TO 1 8 BARBED TUBE FITTING 1 4 O D X 1 8 1 0 ANTISTATIC WHITE TUBING Page 21 of 25 gt BOLT TECH NINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 PCB Battery Replacement Procedure Tool needed 2 5mm Hex T Handle Wrench Recommended batteries 2 AAA Energizer Advanced Lithium Use T handle to remove the 3 screws that hold the rear cover on the tool Page 22 of 25 gt BOLT TECH 4 NINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Carefully remove batteries with your fingers Do not use any conductive items to pry the Lo as RN Insert new batteries
10. 3 ARM 800 REMOVABLE DRIVE 800 STAGE 1 AXLE 800 STAGE 2 AXLE 800 STAGE 3 AXLE 800 RING GEAR 500 BEARING OUTER RACE 800 REACTION BAR INTRNAL SNAP RING EXTERNAL SNAP RING ARM SEAL 1 500 X 1 604 X 0 098 AT800 DR RING REMOVABLE DRIVE SEAL LOCTITE 242 BLUE THREAD SEALER N A DOW CORNING G2001 GREASE M05008D91645 M5 X 8 MM SET SCREW NYLON PATCH TRA 2233N 1 3 8 THRUST WASHER 10 32 5 1655 10 32 5 16 LONG SET SCREW 800 40923 lt Page 14 of 25 Revision Date 02 05 2015 The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 NE A 4 uud SS N 2 1800 UN ON NE ONG MN NN EE NN i 5 EN SSA S SS MSS REA SSS SS gt mi ewes ON ISN D Page 15 of 25 2BOLT TECH 5MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 A T1800 BOLTTECH MANNINGS ITEM NO QTY DESCRIPTION PART NUMBER 1 0 aAtigoo sip 2 1800 5 1 2 ___ 2 1800 5 2 __3 180053 4 ata sc a
11. E REACTION BAR DRIVE RETAINING RETAINING RING RING SAFETY PIN REMOVABLE DRIVE MULTIPLIER IMPACT SOCKET NY PIN RETAINER TOGGLE TRIGGER REACTION BAR SWIVEL FITTING 3 2 Basic Control Unit Layout Cage Air Inlet Air Pressure Regulator Knob Air Tool Oil Fill Cap Air Pressure Gauge Air Outlet Page 5 of 25 2BOLT TECH gt MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Operating Instructions 1 Connect the control unit air inlet to a gt dia Air supply hose NOTE An air source of at least 45 CFM 90 psi MAX pressure is required Failure to provide at least 45 CFM can result in deviations from the calibration report 2 Using the torque certification supplied set the regulator to the desired pressure without depressing the trigger on the pneumatic wrench 3 This model 15 supplied with a toggle trigger The direction Tighten or Loosen 1s controlled by which direction the trigger is depressed Refer to the diagram below for which direction to change the rotation of the drive LOOSEN counter clockwise TIGHTEN clockwise 4 The final air pressure must be set after the tool has stalled on the first bolt with the trigger depressed The stall point 15 reached when there 15 no longer any movement of the nut and there 15 a constant flow of air through the motor After setting
12. ET SCREW 16 25 BOLT TECH Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 AT3000 2 222 5 9 7 Sp one o lt Veale i ESAE SM 95 Saas vas D IN NF NIE YE MEL AT T M HN e S o TTN OO gt Page 17 25 2BOLT TECH 5MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 A T3000 BOLTTECH MANNINGS DESCRIPTION PART NUMBER 000 51 3000 5 1 AT3000 52P 3000 STAGE 2 PLANET AT3000 S3P 3000 STAGE 3 PLANET 3000 STAGE 4 PLANET AT3000 S1A 3000 STAGE 1 ARM AT3000 S2A 3000 STAGE 2 ARM AT3000 53A 3000 STAGE 3 ARM 3000 STAGE 4 ARM 3000 STAGE 2 INPUT PINION ars000s 3 3000 STAGE 1 AXLE 12 AT300S9X 2 3000 STAGE 2 AXLE 13 AT300053X 4 3000 STAGE 3 AXLE 14 AT3000 S4X 4 3000 5 4 15 0 1 3000 RING GEAR 16 AT300P 1 3000 INPUT PINION B AT3000 RD X 3000 REMOVABLE DRIVE 18 AT3000 OR 1 3000 BEARING OUTER RACE 19 AT3000 RB 3000 3000 REACTION
13. hedule a calibration service Note Any disassembling of the Multiplier OR Motor Assembly other than to replace the removable drive will void warranty Page 8 of 25 BOLT TECH MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Control Unit Breakdown and Parts List Pressure Gauge Splitter Fittin Chicago Fitting Air Outlet Fitting Filter Regulator Lubricator FLR Pop Off Valve Unit Hose Hose Strain Relief Strap clip Male Hose Fitting Female Hose Fitting Filter Regulator Lubricator FLR CU2N Chicago Fitting CU3N Hose CU4N 1 Female Hose Fitting CUSN Male Hose Fitting CU6N Spacer Fitting CU7N 160 250 NGFN 1 Splitter Fitting Air Outlet Fitting CU10N Pop off Valve CU11N Cage Strap Strap Clip Hose Strain Relief CUN 2 Page 9 of 25 2BOLT TECH gt MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Troubleshooting 1 Supply if the control unit is not getting at least 45 CFM the tool will not produce optimal torque values Be aware that multiple feeds on a compressor will cause a drain on its volume output 2 Back nut secure if the back nut turns then you will not obtain optimal torque values The use of a back up wrench on the back nut will solve this 3 Chase pa
14. per protective safety gear such as protective clothing gloves and safety glasses 1s recommended while using this tool FAILURE TO FOLLOW THESE RECOMMENDATIONS COULD RESULT IN SERIOUS BODILY INJURY The reaction arm will turn until it hits a stationary reaction point typically an adjacent nut or housing structure The reaction arm must be secure and stationary KEEP ALL HANDS FEET AND CLOTHING AWAY FROM THE REACTION ARM SERIOUS CRUSHING INJURIES CAN OCCUR This tool should only be used with impact sockets Page 3 of 25 2BOLT TECH IMANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 Introduction e tis important to follow all guidelines laid out in this manual Failure to do so can result injury voiding the warranty and damage to the tool and or surrounding equipment Each tool is accompanied by a certified calibration report Refer to the report to determine the air pressure setting for the required torque e Due to variances in things such as compressed air supplies joint characteristics and other application related variables deviations from the calibration report may occur e Any modification to the reaction arm can affect torque output The reaction arm supplied with the tool is designed to fit most industrial applications ANSI B16 5 API DIN and British Flanges Your tool can be fitted
15. ttern if the nuts are not being torqued in a viable chase pattern uneven loading will occur effecting the torque values 4 Socket size minimizing the length of the socket used ensures more torque is being delivered to the nut 5 Nut is seated to achieve correct preload the nut must come to a complete stop during the torque process 6 If the water reservoir becomes full it can affect tool operation Periodic draining of the water reservoir may be necessary See routine care and maintenance Digital readout only 7 If the digital readout should stop working you may replace the batteries located under the rear housing cap The suggested batteries are AAA Energizer Lithium Ion However any AAA battery will work 2 Batteries are required If the device still does not work it must be repaired by a Bolttech Mannings service technician Page 10 of 25 t 3 MANNINGS MANNINGS Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 aN cs BB 22424 47722222 Med Page 11 of 25 2BOLT TECH SMANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 AT400 BOLTTECH MANNINGS QTY DESCRIPTION PART NUMBER 400 51 400 5 1 AT400 S2P 400 STAGE 2 PLANET AT400 S3P 400
16. with a custom reaction arm for specific applications however deviations from the standard reaction arm will affect torque output Increasing dimension X will result in minimal torque deviation from the torque certificate supplied with the tool This is shown in the cross hatched Area 1 Decreasing dimension X will result in minimal deviation from the torque certificate however it will increase the amount of side load exerted on the tool which can result in premature failure of the output drive Increasing dimension Y will result in a decrease in torque from the torque certification supplied with the tool This is shown in the cross hatched Area 2 Decreasing dimension Y will result in an increase in torque from the torque certification supplied with the tool MAXIMUM TORQUE STANDARD RBAR LENGTH MINIMUM TORQUE Where it is necessary to use an extension drive between the output square drive of the tool and the socket you must provide a balanced reaction A double sided reaction arm with both sides taking equal load serves this purpose To ensure proper performance it is recommended to have Bolttech Mannings design manufacture and calibrate the custom reaction arm to fit your needs Page 4 of 25 BOLT TECH 5MANNINGS The Perfect Union of People Products and Services Documentation Standards Document Control Revision No 15 Revision Date 02 05 2015 General Tool Layout 3 1 Basic Tool Configuration REMOVABL
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