45 Series Pistol Reaction Bar Nutrunners
Contents
1. No Part No Model 844774 2 867526 2 844774 867526 3 844774 867523 844774 867523 204809 203107 203106 203107 832125 865576 PL 844774 Part No 203336 861525 203337 861485 203336 861484 203337 861486 7 TOC 869758 3 8 Sq Dr 869767 202324 869759 3 8 Sq Dr 3 Ext 869761 Incl in 202502 202502 Ingan 202802 869756 1 2 Sq Dr 869757 1 2 Sq Dr 3 Ext 844016 3 8 REACTION BAR 1844011 11 2 Material Complete Reaction Head Pin 844017 3 8 Reaction Bar Bar Only Only 844014 1 1 2 Aluminum 869769 202009 202007 1884126 844013 3 8 Steel 869770 202008 202007 884126 844013 1 2 PARTS LIST 45 amp 55 GEAR TRAINS PART NO NAME OF PART PART NO NAME OF PART 202007 Reaction Bar Head 861486 6 1st Red Spider 19T incl Pin 202008 Reaction Bar Steel 1 861525 2 1st Red Spider 13T incl Pin 202009 Reaction Bar Aluminum 867523 4 6 1st Red Gear 17T incl 844774 202324 Spindle Bushing 867524 4 6 Rotor Pinion 6T 202502 Gear Case incl 869767 amp 202324 867526 2 3 1st Red Gear 21T incl 844774 203106 2 2nd Red Gear 18T incl 844774 869756 1 2 Sq Dr Spindle inci Ret Pin 203107 3 6 2nd Red Gear 152. 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 Safety Recommendations 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 Keep body and hands warm and dry cold weather is reported to be a major factor contributing to Raynaud s Syndrome Avoid anything that inhibits blood circulation Smoking Tobacco another contributing factor Cold Temperatures Certain Drugs Avoid OK Avoid Avoid OK Avoid 17 3 N LH I Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation e Tasks should be performed in such a manner that the wrists are maintained in a neutral position which is not flexed hyperextended or turned side to side e Stressful postures should be avoided select a tool appropriate for the job and work location Avoid highly repetitive movements of hands and wrists and continuous vibration exposure after each period of operation exercise to increase blood circu lation Keep tool well maintained and replace worn parts 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 Standar
3. 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 0015 clearance between the rotor and bearing plate The outer bearing race should be firmly seated and the rotor bumped forward when checking this clearance as shown in drawing below t iiy 4 EL ER 4 i Clearance Pack both rotor bearings with a good grade of No 2 Moly grease after assembly of the motor unit Note During reassembly of the complete tool it is important that the motor be free After the tool is completely assembled the 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 components During reassembly of the gear train all of the various gears and bearings should receive a generous amount of No 2 Moly grease Pour a few drops of 10W machine oil into the air inlet after complete assembly to insure immediate lubrication of all motor parts when air is applied 45 amp 55 INLINE REACTION BAR NUTRUNNER GEAR TRAINS Part
4. 9 Operation 8 Service Manual GOOPER Tools 823154 2 01 45 Series Pistol Reaction Bar Nutrunners Series Se Drive 3 3 8 Nutrunner 4 4 2 Handle Extension P Trigger Stall Type 3 3 Gear Train Designation 2 4 3 6 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 Safety 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 eye protection must be worn while operating or working near this tool For additional information on eye protection and face protection refer to Federal OSHA Regulations 29 Code of Federal Regula tions Section 1910 133 Eye 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 Ameri can National Standards Institute Inc 11 West 42nd Street New York NY 10036 A CAUTION Personal hearing protection is recommended when operating or working near this tool Hearing protection is recommended in high noise areas 85 dBA or greater The operation of other tools and eguipment in the area reflective surfaces process noises and resona
5. T incl 844774 869757 1 2 Sq Dr Spindle Ext ind Ret Pin 204809 2nd Red Gear 869758 3 8 Sq Dr Spindle incl Ret Pin 832125 2 3 4 6 1st Red Gear Pin 869759 3 8 Sq Dr Spindle Ext incl Ret Pin 844011 Socket Retainer Pin 869761 Lock Nut 844013 Retainer Plug 869767 Grease Seal 844014 Spring 869769 Aluminum Reaction Bar incl 202007 202008 844016 Socket Retainer Pin 884126 844017 Spring 869770 Steel Reaction Bar incl 202007 202008 844773 Ball Bearing 884126 844774 Gear Bearing 884126 Pin 844778 Retainer Ring 861484 4 1st Red Spider 13T incl Pin 861485 3 1st Red Spider 19T incl Pin EN 0 a GO omk io DDD 203168 203169 864234 619377 812164 619377 869760 Rotor 7T Cylinder Rotor Blade Front Rotor Bearing Cylinder Pin 869054 865352 843444 203169 PARTS LIST MOTOR UNIT PART NO NAME OF PART PART NO NAME OF PART 843444 865352 869054 869055 869760 _ Rear Rotor Bearing Rotor Lock Nut Front Bearing Plate Rear Bearing Plate Motor Spacer 869350 863072 869349 ame 869548 412775 iff 619016 833471 PARTS LIST HANDLE I PART NO NAME OF PART QTY PARTNO NAME OF PART 412775 Exhaust Screen 869548 Inlet Screen 619016 Retainer Ring 869712 O Ring 833471 Inlet Bushing 869755 Handle 863072 Throttle Valve Spring 869763 Trigger incl 869712 869349 Sleeve 869764 Muffler 869350 T
6. ained operation The in line lubricator should be regularly checked and filled with a good grade of 10W machine oil For proper adjustment of the in line lubricator place a sheet of paper next to the exhaust ports and hold the throttle open approximately 30 seconds to one minute All the oil needed is enough to produce a light stain on the paper If the oil mist is visible to the naked eye it is generally an excessive amount of oil 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 No 2 Moly grease through the grease fittings after 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 SERVICE INSTRUCTIONS DISASSEMBLY GENERAL Stall Tools To disassemble the tool clamp the handle 869755 in a vise and unscrew the gear case 869762 The motor unit may now be removed from the handle The gear train should be removed from the rear of the gear case 202325 The 2nd reduction idler gears are removed from the spider by driving the idler gear pins out the rear of the spider To disassemble the motor unit clamp the cylinder 864236 in the vi
7. d the tool when operating Reaction bar nutrunners are eguipped with a torgue reaction bar These bars can be braced against the work or other suitable points to absorb and relieve the operator of the torque reaction transmitted 2 by the tool Tool balance arms are also available to absorb the torque reaction of the tool while balancing the weight of the tool for improved ergonomic applications A CAUTION If the tool is to be reversed locate torque reaction bar in a position that will resist torque reaction and prevent entrapment See Direc tions on next page 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 Reaction bar must be properly positioned to resist torque Operator must release throttle to stop tool if this occurs Do not use without properly positioned reaction bar Reversible tools can have torque reactions in either direction The reaction bar must be properly positioned to resist the torque reaction 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 Avoid 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 ar
8. ds Institute Inc 11 West 42nd Street New York NY 10036 This information is a compilation of general safety practices ob tained 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 circumstances 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 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 read these safety precautions Do not remove this tag until the operator of this tool has 203185 OVERLOADED REACTION BARS WARNING MAY BEND OR BREAK USE THIS GUIDE FOR PROPER APPLICA TION OF THE CLECO REACTION BAR Standard Length Spindle X 2 1 2 Minimum Y 2 1 2 Maximum Torque Capacity 125 Ft Lbs Maximum 3 Longer Than Standard Spindle X 4 Minimum Y 5 1 2 Maximum Torque Capacity 80 Ft Lbs Maximum These capacities apply to Cleco Reaction Bars code numbers 869769 0 869770 202007 202008 202009 Due to the multitude and var
9. hrottle Valve The complete handle can be purchased as a sub assembly using Part No 861872 0 COOPER Tools CooperTools 670 Industrial Drive Lexington SC 29072 Phone 803 359 1200 Fax 803 359 2013 www clecotools com
10. iety of tooling applications involving reaction bar nutrunners the User s Methods Engineering Standard Tooling Engineering and or Safety Engineering Departments etc must consider any hazards associated with each specific application of this product and provide adequate operator protection reaction points and strengths and operator training in the safe use of this product Substitute bars without proper metallurgy may not be adequate Use Cleco reaction bars Torque Bar Opposes Rotation of Tool The reaction bar is secured to the tool and braced against the work in the opposite direction of spindle rotation This will transfer the torque reaction from the tool to the work OPERATING INSTRUCTIONS 45 STALL TYPE NUTRUNNERS The 45 stall type nutrunner is designed to develop maximum rated torque at 90 psig Torque output is controlled by a pressure regulator in the air supply line Adjust the regulator until the desired torque is reached AIR SUPPLY For maximum performance use a 3 8 I D air hose no longer than 8 in length If additional length is required a 1 2 or larger hose should be connected to the 3 8 hose The air hose should be cleared of accumulated dirt and moisture then a few drops 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 lubricator is recommended as it increases tool life and keeps the tool in sust
11. ms when performing tasks consisting of highly repetitive motions and or exposure to extended vibration Cumulative trauma disor ders 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 of the following warning signs and symptoms so that a problem can be addressed before it becomes a debilitating injury Any user suffering prolonged symp toms of tingling 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 steps to prevent further occurrences These steps might include but are not limited to repositioning the workpiece or redesigning the workstation reas signing workers to other jobs rotating jobs changing work pace
12. nt structures can substantially contribute to and increase the noise level in the area Excessive air pressure 90PSIG or worn motor components can also increase sound level emitted by tool For additional information on hearing protection refer to Federal Regulations Section 1910 95 Occupational Noise Exposure and American National Standards Institute ANSI 512 6 Hearing Protectors 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 recom mended 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 Clear the air hose of accumulated dust and moisture Be careful not to endanger adjacent personnel Before removing a tool from 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 Itis essential for safe operation that any operator of a nutrunner use good balance sure footing and proper posture in anticipation of a torgue reaction Insure that the operator s hand will not be wedged or pinched between the work an
13. se with the gear end of the rotor up Note Rotor pinion 867524 used on the 4 and 6 gear trains should be removed from the rotor Use a soft faced hammer to drive the rotor out of the front rotor bearing No 619377 Be careful not to damage the rotor The front bearing plate 869054 cylinder 203169 and rotor blades may now be removed from the rotor Clamp the body of the rotor in the vise and unscrew the rotor lock nut 865352 to remove the rear bearing plate 869055 and rear rotor bearing 843444 Unscrew the inlet bushing 833471 for inspection and cleaning of the inlet screen 869548 Wash the screen in a solvent and blow out in the reverse of normal air flow If the screen is damaged or torn it should be replaced The muffler 869764 may be removed for cleaning by removing the retainer ring 619016 and exhaust screen 412775 REASSEMBLY The tool is reassembled in the reverse order of disassembly Clean all parts thoroughly in solvent and inspect for damage or wear Check all bearings for wear which can be detected by excessive end play and or roughness which would indicate a brinelled condition The rotor blades should be replaced every repair cycle or if they measure less than 7 32 5 6mm at either end Must be replaced if 7132 5 6mm or less at either end All gear teeth bearings and pins should receive a close inspection and be replaced if necessary To assemble the motor install the rear rotor bearing
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