Airetool® - Apex Power Tools
Contents
1. 52 442 103 0443 Apex Tool Group LLC 1000 Lufkin Road Apex NC 27539 Phone 919 387 0099 Fax 919 387 2614 www apextoolgroup com Detroit MI Apex Tool Group Sales amp Service Center 2630 Superior Court Auburn Hills MI 48326 Tel 248 391 3700 Fax 248 391 7824 Seattle WA Apex Tool Group Sales amp Service Center 2865 152nd Avenue N E Redmond WA 98052 Tel 425 497 0476 Fax 425 497 0496 England Apex Tool Group GmbH amp Co OHG C O Spline Gauges Piccadilly Tamworth Staffordshire B78 2ER United Kingdom Tel 44 1827 8741 28 Fax 44 1827 8741 28 Brazil Cooper Tools Industrial Ltda a company of Apex Tool Group LLC Av Liberdade 4055 Zona Industrial Iporanga 18087 170 Sorocaba SP Brazil Tel 55 15 2383929 Fax 55 15 2383260 90074 IM Printed in USA 09 2011 Copyright Apex Tool Group LLC Houston TX Apex Tool Group Sales amp Service Center 6550 West Sam Houston Parkway North Suite 200 Houston TX 77041 Tel 713 849 2364 Fax 713 849 2047 York PA Apex Tool Group Sales amp Service Center 3990 East Market Street York PA 17402 Tel 717 755 2933 Fax 717 757 5063 France Apex Tool Group SAS 25 rue Maurice Chevalier 77330 Ozoir La Ferri re France Tel 33 1 6443 2200 Fax 33 1 6443 1717 Hungary Cooper Tools Hungaria Kft a company of Apex Tool Group LLC Berkenyefa sor 7 Pf 640 9027 Gy r Hungary Tel 36 96 66 1383 Fax 36 962. Page 13 90074 IM Airetool 09 06 2011 Throttle amp Valve Assembly Page 14 Airetool 90074 IM Throttle amp Valve Assembly 03 06 2011 Illustration D X Description i 8566060 1 tThrotteGnp 100089 Cd Split Pin 1 8 x 3 4 5 8010058 8 8 Socket Head Cap Sorew 0032xm O O O 6 32313000 1 2 Pn I083 S S SA 7 3225400 1 Retainer 1000 88 8 snom 1 2 Beag 008 lt S SS A 9 856605 1 jVaveActatr i 30 11 8405290 1 Vave Assembiy 1000278348 O 12 8565300 1 VaveBody f55010 OO o Socket Head Cap Screw 1 4 20 x 2 1 2 15 3225800 1 jVaveBushing 1000359 16 3231200 1 Bushing 100082 gt gt gt 18 8565520 1 jVave i5023 Par 8565490 1 VaveBox f55020 E 24 8565530 1 VaveHead 155024 O O 25 3224000 1 Bwshng 100022 S S SSSS S 26 8565310 1 Case 5502 S 27 8565330 1 HandeBase f5504 O Lock Washer 1 4 Socket Head Cap Screw 1 4 20 x 3 4 30 3211400 1 JExhaust Extension 750 17 92 sr 321700 1 Cowling J5017C E ESES S S S Muffler Assembly A 1000 61 MF includes Ref 33 36 33 3228750 1 Grip 1000 61 AB not shown Baffle Ass
3. Remove the retaining ring from the output end of the spindle The spindle can now be removed for inspection and replacement if necessary A new spindle is necessary only if the faces of the three splined grooves are brinelled severely by the balls that operate in the spline Install the cleaned or new spindle Place the pressure pad with the pressure pins down into the cam case Install the needle thrust bearing along with the spring guide Place the regulating spring over the spring guide making sure the spring is down over the pilot diameter Install the operating cam over the spindle allowing it to rest on the stop collar In each of the three splined grooves install one 1 guide spring and five 5 3 16 diameter balls Note These are precision balls and only Airetool replacement parts should be used After installing the balls install the inner and outer ball retainers on the cam Place some grease on the three incline faces of the operating cam and install two 2 1 4 diameter balls on each incline The grease will hold the balls in position allowing proper installation of the drive cam After the drive cam has been installed replace the snap ring to secure the assembly Page 6 Airetool 90074 IM 09 06 2011 Service Instructions Motor Section Refer to Illustrations A amp B Remove the ring gear clean and re grease the gears Remove the four 4 cap screws securing the end cap to the motor c
4. tool from service or changing sockets disconnect from the air supply Page 4 Airetool 90074 IM 09 06 2011 Operating Instructions Airetrol model 1550 900 was designed to roll up to 2 O D steel tubes This capacity will vary some depending upon tube wall thickness and tube sheet thickness The Airetrol should be attached to an air line with a minimum inside diameter of 1 2 and a maximum length of 25 If the maximum length is exceeded the inside diameter of the hose should be increased to 3 4 minimum An inline lubricator should be installed in the air line and set with the oil rate adjusted at approximately 6 to 8 drops per minute This product is designed to operate on a minimum of 90 psig 6 2 bar and a maximum of 125 psig 8 6 bar air pressure If the tool is properly sized and applied higher air pressure is not necessary Excessive air pressure increases the load and stress on tool parts mandrels rolls and cages and may result in premature wear or breakage The tool will operate on less air pressure but the RPM and the maximum developed torque of the motor will be proportionally reduced by the loss of pressure The tool is equipped with a safety roll throttle which will neutralize or shut off the air supply when the handle is released With the roll throttle held on the right side of the Airetrol turn the throttle in the forward or clockwise direction The tool will run in the forward direction Rota
5. 4 8565360 1 Reor s07 ____ 16 8565460 1 EndPlte i5501 O Quantity X Recommended Spare Parts t Parts included in 8405588PT Airetool 1550 900 Service Kit Page 9 Airetool 90074 IM 09 06 2011 Gearing Assembly Page 10 Airetool 90074 IM Gearing Assembly 09 06 2011 Illustration B X Description 2 8565580 1 RigGear iBBD29 o 3 8565660 f 4 8 Pin 550 87 4 8565370 1 GearCage 15508 5 8565560 3 6 PanetGear fbb027 E 6 8567541 1 6 12 bearing 400 6 y E 8 8565570 1 finiemalGear 155028 O C 9 8565620 1 Spaces O Quantity X Recommended Spare Parts t Parts included in 8405588PT Airetool 1550 900 Service Kit Page 11 90074 IM Airetool 09 06 2011 Cam amp Spindle Assembly Page 12 Airetool 90074 IM Cam amp Spindle Assembly CH Illustration C X Description 1 322700 6 18 Steel Ball 1 4 1000 51 3 8565640 1 Cam 5035 O 4 3227600 1 pJRetainer 100052 0 5 3227400 1 BalRetiner i00050 6 3227300 1 jObereingCam 100049 8 32269000 1 lekRig i0045 9 323220 f 1 2 Sn
6. 66 1135 Lexington SC Apex Tool Group 670 Industrial Drive Lexington SC 29072 Tel 800 845 5629 Tel 803 951 7544 Fax 803 358 7681 Canada Apex Tool Group Sales amp Service Center 5925 McLaughlin Road Mississauga Ont L5R 1B8 Canada Tel 905 501 4785 Fax 905 501 4786 China Cooper China Co Ltd a company of Apex Tool Group LLC 955 Sheng Li Road Heging Pudong Shanghai China 201201 Tel 86 21 28994176 Fax 86 21 51118446 Airetool
7. Operating amp Service Manual 900744M Airetool 1550 900 Airetrol Rolling Motor For additional product information visit our website at http www apextoolgroup com 90074 IM 09 06 2011 Airetool Description Tool Specifications Model 1550 900 8404290 Free Speed Maximum Torque Minimum Torque Weight Overall Length Side to Center Distance Recommended Hose Diameter max 6 Air Consumption Square Drive Male Quick Change Chuck standard Quick Change Chuck optional Tube Capacities 756 rpm 30 7 Ft lbs 41 6 Nm 4 7 Ft lbs 6 4 Nm 27 lbs 12 25 Kg 18 457mm 1 15 16 50mm long 3 4 13mm 70 CFM 3 8 1 2 3 4 1 1 1 2 38 1mm Note Varies depending on tube material gauge and tube sheet thickness Language Version This Parts Manual is the Original Instructions intended for all persons who will use or repair these tools Product Identification Refer to the Model Nomenclature page in this document Noise and Vibration Refer to documents CE 1015DC and CE 1015TD General Description Air powered right angle portable nutrunners equipped with an adjustable clutch Intended Use These air assembly tools are intended for tightening of threaded joints or running down fasteners Use only for their designated purpose Do not use as a hammer lever or other improper usage that can cause tool damage and operator injury Copyright protection Apex
8. Tool Group LLC reserves the right to modify supplement or improve this document or the product without prior notice This document may not be reproduced in any way shape or form in full or parts thereof or copied to another natural or machine readable language or to a data carrier whether electronic mechanical optical or otherwise without the express permission of Apex Tool Group LLC Page 2 Airetool Safety Recommendations Important For your safety and the safety of others read understand and comply with all safety recommendations and product operating instructions ALWAYS WEAR PROTECTIVE EQUIPMENT Eye and Face Protection WARNING Impact resistant eye protection must be worn while operating or working near this tool For additional information on eye and face protection refer to Federal OSHA Regulations 29 Code of Federal Regulations Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI A87 1 Occupational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 130 Broadway New York NY 10018 Hearing Protection CAUTION Personal hearing protection is recommended when operating or working near this tool Hearing protection is required 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 ca
9. apRing 10009 10 3222000 1 SPnde 10004 Steel Ball 3 16 12 s227100 t 3 9 Spring 100047 14 3223100 1 SPngGuide 100012 OO 17 3223000 1 PrsswePad io t OO 18 3222000 3 6 PrssuePin i001 _19 X 80100014 8 16 LockWasher 1 4 20 8010023 6 6 Socket Head Cap Screw 1 4 20 x 3 4 Socket Head Cap Screw 1 4 20 x 1 22 322170 1 jCamCase 10002 26 3226300 1 AdwsigNut 10043 O Nylon Tip Set Screw 8 32 x 3 16 28 322800 1 Motor Support 1000 56 1 30 3228700 1 Memo 34 8565970 1 jT ipCover 155053 S 35 3223600 1 Folowr i0001 OoOO O 38 840070 1 Quick Change Chuck Assembly 1000 375 not shown includes Ref 39 44 39 3236100 1 Chuck Body 1000 375 1 not shown 40 8566705 1 Chuck Sleeve 1000 375 2 not shown Chrome Ball 7 32 not shown Split Pin 1 8 x 7 8 8400800 1 Quick Change Chuck Assembly 100000 84009000 1 3 4 ChuckAssembly 1000 750 8404820 1 1 Chuck Assembly 1000 1000 Quantity X Recommended Spare Parts t Parts included in 8405588PT Airetool 1550 900 Service Kit
10. ase Grasp the cylinder liner and remove the motor assembly from the motor case Lightly tap the geared portion of the spindle with a lead or brass hammer to remove the front bearing plate from the rotor assembly Remove the cylinder to inspect the rotor blades Under normal usage new rotor blades should be installed every six months If excessively worn replace the front bearing support plate and rear rotor bearing Adjust the cap screw so there is approximately 001 to 0015 clearance between the rotor and the end plate Clean and re grease the planetary gear system with a semi solid lubricant Reinstall the motor housing aligning the outside groove of the ring gear with the groove in the motor housing and install the pin Install the assembled motor into the motor housing placing the dowel pin into the proper hole in the center of the motor housing Replace the end cap and four 4 cap screws Having replaced the end cap which properly aligns the cylinder and end plate use an Allen wrench to evenly tighten the three set screws to the point of clamping pressure which allows the motor to operate freely Roll Throttle Valve Refer to Illustration D To inspect the self closing throttle remove the pin and grip This will expose the self closing spring If the spring is broken replace it making sure one ear of the spring is hooked on the stop pin Then with pliers grasp the other ear of the spring and place on the oppo
11. embly 1000 61 G not shown 35 32950 1 Deecor ns S 37 410504 1 Hose Assembly 1 2 2 Ply x 10 not shown 8010144 i Pewen mo O 801045 1 HexWrnch Sb4F ooo S S 801049 1 Pewen s S S E 8010150 1 HexWenh 3n amp i E 801048 1 HexWrenh 94 SSS S SE 8010308 a HexWrenh 3i2 O 801147 1 Pewen mw lt lt TTT Quantity X Recommended Spare Parts t Parts included in 8405588PT Airetool 1550 900 Service Kit Page 15 Sales amp Service Centers Note All locations may not service all products Please contact the nearest Sales amp Service Center for the appropriate facility to handle your service requirements Dallas TX Apex Tool Group Sales amp Service Center 1470 Post amp Paddock Grand Prairie TX 75050 Tel 972 641 9563 Fax 972 641 9674 Los Angeles CA Apex Tool Group Sales amp Service Center 15503 Blackburn Avenue Norwalk CA 90650 Tel 562 623 4457 Fax 562 802 1718 Germany Apex Tool Group GmbH amp Co OHG IndustriestraRe 1 73463 Westhausen Germany Tel 49 0 73 63 81 0 Fax 49 0 73 63 81 222 Mexico Cooper Tools de M xico S A de C V a company of Apex Tool Group LLC Vialidad El Pueblito 103 Parque Industrial Quer taro Quer taro QRO 76220 Mexico Tel 52 442 211 3800 Fax
12. er torque Airetrols inline and right angle are supplied with a torque reaction bar designed to work with the torque of the tool it is specified for These bars can be braced against the work or other suitable points to absorb and relieve the operator of the torque reaction transmitted 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 90074 IM 09 06 2011 Airetool Safety Recommendations Ergonomics Some individuals are susceptible to disorders of the hands and arms when exposed to tasks which involve highly repetitive motions and or vibrations Those individuals pre disposed to vascular or circulatory problems may be particularly susceptible Cumulative trauma disorders such as carpal tunnel syndrome and tendonitis can be caused or aggravated by repetitious forceful exertions of the hands and arms These disorders develop gradually over periods of weeks months and years Tasks should be performed in such a manner that the wrists are maintained in a neutral position which is not flexed hyper extended or turned side to side d FA K 4 N A Stressful postures should be avoided and can be controlled through tool selection and work environment Any user suffering from prolonged symptoms of tingling numbness blanching of the fingers clumsiness or weakened grip nocturnal pain in the ha
13. n Page 5 90074 IM 09 06 2011 Airetool Service Instructions After extensive use it may be necessary to adjust or service the tool to maintain the highest degree of efficiency WARNING Disconnect the air supply line from the tool before disassembling Adjusting the Trip If the tool fails to shut off properly check the trip adjustment Figure 1 Valve Head Trip Cover Screws 2 Lock Nut Remove the two screws to remove the trip cover see Figure 1 The trip engages the valve head There should be approximately 5 64 clearance between the outside diameter of the valve head and the notch of the trip when in the proper operating position If adjustment is necessary use a 5 64 078 diameter drill as a gauge If the trip is adjusted to deeply loosen the lock nut and turn the screw until the 5 64 diameter drill just touches both the valve head and the trip Tighten the lock nut Caution Do not overtighten the lock nut This could break the small end of the trip arm Torque Section Refer to Illustrations B amp C Remove the six cap screws securing the cam case to the motor case and remove the torque section With the cam case in a vertical position secure the output end of the spindle in a smooth jawed vise Remove the large retaining ring to remove the cam and ball retainers Now remove the regulating spring spring guide pressure pad and needle bearing assembly
14. n substantially contribute to and increase the noise level in the area For additional information on hearing protection refer to Federal OSHA Regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and American National Standards Institute ANSI S12 6 Hearing Protectors CAUTION AN CAUTION AN CAUTION AN Page 3 90074 IM 09 06 2011 Follow good machine shop practices Rotating shafts and moving components can entangle and enwrap and can result in serious injuries Never wear long hair loose fitting clothes gloves ties or jewelry when working with or near any power tool with an exposed rotating shaft or spindle When using right angle Airetrols with lever type throttles 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 the torque reaction The angle head may be repositioned with respect to the lever to accommodate proper location for the application If the tool is to be reversed locate the throttle lever in a neutral position that will prevent entrapment Refer to the operating instructions for additional information Tools with clutches can stall rather than shut off if they are adjusted over the maximum power output of the tool or if there is a drop in air pressure The operator must then resist the stall torque until the throttle is released High
15. nd or any other disorder of the shoulders arms wrists or fingers is advised to consult with 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 work piece or redesigning the workstation reassigning workers to other jobs rotating jobs altering 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 recommendations will help reduce or moderate the effects of repetitive work motions e Use a minimum of hand grip force consistent with proper control and safe operation Keep wrists as straight as possible s Keep body and hands warm and dry Avoid anything that inhibits blood circulation smoking tobacco cold temperatures certain drugs etc Avoid highly repetitive movements of the hands and wrists and continuous vibration exposure CAUTION AN Any use of this tool other than it s intended purpose could cause damage to the tool or pose a risk to the operator Before the tool is connected to the air supply check the throttle for proper operation throttle moves freely and returns to the OFF position when released Before removing a
16. site side of the pin This places the spring under torsion so it will return the throttle valve to the off position when released Install the grip and pin Directional Valve Refer to Illustration D To service the directional valve remove the four 4 cap screws securing the handle assembly to the valve body The valve can now be removed and inspected for wear or damage Oil all parts and reassemble Make sure the handle gasket is in place before installing the handle After the motor has been serviced the torque section can now be installed on the motor Adjust the trip and replace the trip cover Page 7 90074 IM Airetool 09106 2011 Motor amp Rear Handle Assembly Page 8 Airetool 90074 IM Motor amp Rear Handle Assembly 09 06 2011 Illustration A X Description Pa 3231000 1 RerHande i0nB Oo Socket Head Cap Screw 1 4 20 x 3 4 3 8010039 3 6 Socket Head Set Screw 1 4 20x 1 2 SSS Socket Head Cap Screw 1 4 20 x 1 1 2 6 8565350 1 EndCap issO S 8 8010001 1 1 Button Head Screw 1 4 28 x 1 2 E e ICE 10 3196200 1 2 Beaig o258 1 856470 t JjSpacer 5501 2 85654580 1 jEndPate tbOi E 5 13 8565440 1 1 Cylinder 1550 15 includes one 8565690 SpringPin 1
17. te the grip in the counterclockwise direction and the tool will reverse to back the expander out of the tube NOTE ANYTIME THE MOTOR WILL NOT RUN IN THE FORWARD DIRECTION ROTATE THE THROTTLE HANDLE TO THE FULL COUNTERCLOCKWISE POSITION THIS WILL RESET THE TRIP AND ALLOW THE MOTOR TO RUN IN THE FORWARD DIRECTION Select the proper drive chuck that will accept the Airetool expander being used The torque adjusting dial on the front of the machine is divided 0 to 30 These particular divisions are for reference only and to indicate the up and down adjustment depending upon the requirement needed to satisfactorily roll the tube Elsewhere in this manual is the recommended method for determining the proper amount of expansion for tubes We recommend starting at a low torque setting of the machine rolling a joint and checking the inside diameter to the calculated inside diameter If the rolled I D is not large enough the torque should be increased and the tube should be rolled again When the tube is rolled satisfactorily we recommend rolling the second tube for which the finished I D has been calculated to check the setting When the required LD is reached and maintained the entire tube bundle can be rolled at this setting NOTE THE FIRST TEST TUBES THAT WERE NOT ROLLED ENOUGH IN THE FIRST TEST ROLLS SHOULD BE ROLLED AGAIN TO THE SAME TORQUE SETTING As with any power tool precautions should be observed during operatio
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