45 Series Inline Reaction Bar Nutrunners
Contents
1. 869059 Stall Tools 869058 Automatic Shut off Tools Automatic Shut off Tools Only PARTS LIST MOTORS PARTNO NAME OF PART 203168 Rotor 7T Non Rev Stall 203169 Cylinder Non Reversible incl 812164 203170 Cylinder Reversible incl 812164 203171 Rotor Hex Non Rev Automatic Shut off 619377 Front Rotor Bearing 812164 Cylinder Pin 843444 Rear Rotor Bearing Non Reversible 847096 Rear Rotor Bearing Reversible 847603 Alignment Pin Reversible 863172 Trip Rod Automatic Shut off 864234 Rotor Blade 865352 Rotor Lock Nut 869054 Front Bearing Plate 869058 Motor Spacer Automatic Shut off 869059 Motor Spacer Stall 869574 Rear Bearing Plate Non Reversible 869577 Rotor 7T Rev Stall 869578 Rotor Hex Rev Automatic Shut off 869656 Rear Bearing Plate Reversible sch sch sch mk mn mk ek JJ ee sch sch sch sch sch sch zch BUTTON HANDLE 86751621 _869657_ Non Reversible 45 HANDLE 867554 869658 Reversible Automatic i Reversible Only y Shut off Tools Only 869650 869655 617106 867667 E ces E A UI 4 03 i WU KN 202743 Reversible Tools Only 864737 869667 Reversible Only 412775 on omy la A Ni lt i 4 H 869663 861827 863009 PARTS LIST HANDLE SUBASSEMBLES LEVER HANDLE PARTNO NAME OF PART 847808 202743 Muffler 412775 Inlet Screen 617106 O Ring 1 3 8 x 1 9 16 844311 O2. Reaction bar nutrunners are equipped with a torque 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 Opera tor 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 arms when performing tasks con
3. P Operation amp Service Manual COOPER Tools 823110 2 01 45 Series Inline Reaction Bar Nutrunners Rotation Non Reversible R Reversible Nutrunner Clutch Designation A Clecomatic J Joint Rate Stall Type Handle B Button L Lever Gear Train Designation 2 4 3 6 NORTH AMERICA EUROPE CooperTools Cooper Power Tools GmbH 8 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 equipment 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 Edu cational Eye and Face Protection Z87 1 is available from the American 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 resonant structures can sub
4. Using a suitable wrench loosen and remove the gear case Using a soft faced mallet tap the front of the motor housing to remove the motor unit Automatic Shut Off Tools To disassemble the tool clamp the flats of the clutch housing in a soft jawed vise and loosen the gear case Clamp motor housing in the vise and using a suitable wrench loosen the clutch housing from the motor housing Tap the front of the motor housing with a soft faced mallet to remove the motor unit SUBASSEMBLY DISASSEMBLY Gear Train The complete gear train may be slipped out of the rear of the gear case By driving the idler gear pins out of the rear of the spiders the idler gears can be removed from the spider pockets Clecomatic Clutch Remove the adjustment cover by sliding it off the back of the clutch housing Be careful not to lose the steel ball No 844077 that will drop out atthis time Using the slots provided on the rear face of the adjusting nut No 867678 unscrew it from the clutch housing The torque spring bearing No 867683 spring plate No 867669 and torque spring No 867665 will come out through the rear of the clutch housing With a soft mallet tap on the gear end of the clutch to remove it from the clutch housing By removing the retainer ring No 847022 the drive shaft washer No 867666 trip sleeve spring No 202056 trip sleeve No 867670 and two 2 steel balls No 842161 can be removed from the drive shaft Remove
5. Ring 9 16 x 3 4 847275 O Ring 1 1 16 x 1 3 16 869061 Giel 847366 Throttle Valve Seal 869060 Automatic Shut off 847505 Throttle Lever 847808 Throttle Lever Pin 861827 Throttle Valve 863009 O Ring 3 4 x 7 8 863454 O Ring 9 16 x 11 16 863623 Throttle Valve Spring 864531 Throttle Valve Cap 864737 O Ring 1 7 8 x 2 Ree v W 867516 Throttle Button Suto 881016 Stall 867554 Reversing Valve Screw 869064 Automatic Shut off 867667 Shutoff Valve 867682 Valve Block 869060 Lever Handle Automatic Shut off 869061 Lever Handle Stall 869064 Throttle Valve Automatic Shut off JER incl 847366 869650 Reversing Valve ok ch ch sch an 0 kh ch ok nnn nin niin ii 869654 Inlet Bushing 202743 869655 Motor Spacer 864737 869736 869657 Non Reversible Button Throttle Handle 869658 Reversible Button Throttle Handle 869663 Throttle Valve Spring 869666 Valve Seat 869667 Reversing Ring 869736 Exhaust Deflector 881016 Throttle Valve Stall incl 847366 881276 Inlet Bushing a oo a mk om m m Cs CC COMPLETE HANDLE SUBASSEMBLIES 861639 45NL 861640 45NAL amp 45NJL 861817 45NAB amp 45NJB 861818 45RNAB 861820 45NB 861821 45RNB e COOPER Tools CooperTools 670 Industrial Drive Lexington SC 29072 Phone 803 359 1200 Fax 803 359 2013 www cooperindustries com
6. the clutch cam bearing No 619377 with a suitable puller Using a sharp instrument remove the spiral ring No 865436 This will allow the clutch cam No 867676 three 3 steel balls No 842161 trip plunger spring No 867671 and trip plunger No 867668 to be removed through the front of the drive shaft To remove the six 6 steel balls No 844265 slide the ball retainer No 867673 off over the rear of the drive shaft Motor Unit Clamp the cylinder lightly in the vise with the gear end of the rotor up Note The rotor pinion No 867524 used on the 4 and 6 models should be removed at this time Drive the rotor out of the front rotor bearing No 619377 Be careful not to damage the rotor The front bearing plate No 869054 cylinder and rotor blades No 869575 can now be removed from the rotor Clamp the body of the rotor in the vise with the rear bearing plate up After unscrewing the bearing lock nut No 865352 the rotor can be driven out of the rear rotor bearing Motor Housing Lever Unscrewing the throttle valve cap No 864531 will allow removal of the throttle valve for inspection of the throttle valve seal No 847366 Drive out the throttle lever pin No 847808 for removal of the throttle lever No 847505 The exhaust deflector No 869736 and muffler No 202743 can be slipped off the rear of the housing after the rear O ring No 864737 is removed On the automatic shut off tools the valve block
7. 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 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 Avoid Avoid OK Avoid p Z l 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 e Avoid highly repetitive movements of hands and wrists and continuous vibration exposure after each period of operation exercise to increase blood circu lation e 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 Standards Institute Inc 11 West 42nd
8. 9 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 incl Ret Pin 203107 3 6 2nd Red Gear 15T 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 inci Pin 861485 3 1st Red Spider 19T inci Pin Bann ED E ch ch ch nin 0 EA 0 EA 202056 619377 842161 844077 844265 847022 864711 864712 865436 867665 867666 867668 45 869263 7 864711 Bel 864712 867681 A 867665 PIIR d Wi J LN il Trip Sleeve Spring Clutch Cam Bearing Steel Ball 3 16 Dia Steel Ball 5 16 Dia Steel Ball 1 8 Dia Washer Retainer Ring Pin Pin Spring Spiral Ring Torque Spring Dri
9. No 867682 and shut off valve No 867667 can be removed from the front of the housing Motor Housing Button Unscrew the inlet bushing No 896654 to remove the throttle valve parts To remove throttle button No 867516 the throttle valve must be removed first Unscrew reversing valve screw to remove reversing ring No 869667 and reversing valve No 869650 Remove O ring No 864737 to remove exhaust deflector and muffler REASSEMBLY The tool is reassembled in the reverse order of disassembly Clean all parts thoroughly in kerosene 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 at every repair cycle or if they measure less than 7 32 5 6mm at either end All gear teeth bearings and pins should receive a close inspection and be replaced if necessary Must be replaced if 7 32 5 6mm or less j at either end 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 0015 clearance between the rotor and bearing plate The outer bearing race should be f
10. 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 203185 203289 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 Los Maximum These capacities apply to Cleco Reaction Bars code numbers 869769 0 869770 8 202007 1 202008 9 202009 7 Substitute bars without proper WARNING metallurgy may notbe adeguate Use Cleco reaction bars Due to the multitude and vari ety of tooling app
11. ediate lubrication of all motor parts when air is applied SAFETY CHECK After repair or replacement of parts tools equipped with an automatic shut off device should be tested to verify that they are functioning properly 45 amp 55 INLINE REACTION BAR NUTRUNNER GEAR TRAINS Part No Part No Model 844774 2 867526 2 844774 867526 3 844774 867523 4 844774 867523 6 Part No Model SE 203106 2 Part No 203107 3 NONE 203106 4 NONE 203107 6 Rocce 867524 867524 865576 RH 844774 090 e 844778 844773 203336 861525 203337 861485 203336 861484 203337 861486 869758 3 8 Sq Dr 869767 202324 869759 3 8 Sq Dr 3 Ext 869761 Incl in 202502 202502 Ingi In 202502 869756 1 2 Sq Dr 869757 1 2 Sq Dr 3 Ext 844016 3 8 REACTION BAR 844011 1 2 Material Complete Reaction Head Pin 844017 3 8 Reaction Bar Bar Only Only 844014 1 2 Aluminum 869769 202009 202007 884126 844013 3 8 Steel 869770 202008 202007 884126 844013 1 2 PARTS LIST 45 amp 55 GEAR TRAINS 202007 Reaction Bar Head 861486 6 1st Red Spider 19T inci Pin 202008 Reaction Bar Steel 1 861525 2 1st Red Spider 13T inci Pin 20200
12. h 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 one 1 teaspoon 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 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 receive a generous amount of NLGI 2 EP 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 motor housing lightly in a soft jawed vise with the tool in a vertical position
13. irmly seated and the rotor bumped forward when checking this clearance Pack both rotor bearings with a good grade of NLGI 2 EP grease after assembly of the motor unit t i _ o 5 4 4 Clearance t ch 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 H 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 NLGI 2 EP grease The clutch is assembled in the reverse order of disassembly The torque spring bearing No 867683 must be assembled so the solid side of the ball separator is facing toward the torque spring During reassembly of the stall tools the motor make up plate No 869059 should be installed with the opening toward the grease fitting inside the motor housing During reassembly on the automatic shut off tools the tip rod must be ground flush 0 to 1 32 with the hex end of the rotor Hold the motor firmly in the housing at the time the trip rod is being sized to length Pour a few drops of 10W machine oil into the air inlet after complete assembly to insure imm
14. lications invo Iving reaction bar nutrunners the User s Methods Engineering Standard Tooling Engineering and or Safety Engineering De partments etc must consider any hazards associated with each specific application of this product and provide adequate operator protection reaction points and strengths and op erator training in the safe use of this product SPINDLE DRIVE Q BR TORQUE AN pons FRONT OF TOOL FRONT 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 45 CLECOMATIC NUTRUNNERS The 45 Clecomatic nutrunner is designed to operate on 90 psig maximum air pressure but does not depend on controlled air pressure to maintain accurate torque Accurate torque is achieved by setting the Clecomatic 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 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 ty
15. pe 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 If the tool stalls the operator must release throttle to stop tool Reaction bar must be properly positioned against adequate stop Do not use without reaction bar CLECOMATIC CLUTCH ADJUSTMENT Depress the pin No 864711 and rotate the adjustment cover No 867677 180 so it lines up with the adjustment slot With the angle head end of the tool facing outward away from the operator use a 1 8 diameter pin to rotate the adjustment nut No 867678 clockwise to increase the torque and counter clockwise to decrease the torque Note The steel ball No 844077 is a positive lock for the adjustment nut and must be in place in a locking slot before the adjusting cover is rotated to the locked position after each clutch adjustment is completed 45 JOINT RATE NUTRUNNERS The 45 joint rate tool is designed to give repeatable torque and automatic shut off regardless of the joint conditions i e soft pull hard pull Target torque is achieved through the use of an in line pressure regulator Note To ensure automatic shut off the air pressure should not be adjusted below 40 psig at the tool with the tool operating AIR SUPPLY For maximum performance use a 3 8 I D air hose no longer than 8 in length If additional lengt
16. sisting 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 smok ing 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 de sign 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 reassigning workers to other jobs rotating jobs changing work pace and or changing the type of
17. stantially 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 onhearing protection referto Federal Regulations Section 1910 95 Occupational Noise Exposure and American National Standards Institute ANSI S12 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 regulator 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 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 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 Insure that the operator s hand will not be wedged or pinched between the work and the tool when operating
18. ve Shaft Washer Trip Plunger CLECOMATIC CLUTCH 844077 did 0 0 Wi 867669 867670 867671 867673 867674 867676 867677 867678 867681 867683 869263 867677 eg g s Se Torque Spring Plate Trip Sleeve Trip Plunger Spring Ball Retainer Drive Shaft Clutch Cam Adjustment Hole Cover Adjustment Nut Clutch Housing incl 864711 864712 869263 Torque Spring Bearing Pin Sleeve The complete clutch with housing can be purchased as a subassembly using Part No 861551 ae D wed 45 JOINT RATE CLUTCH 201398 869567 61 O 842274 o H DA du ul Le fe NI mt 869564 PARTS LIST JOINT RATE CLUTCH PART NO NAME OF PART PART NO NAME OF PART lary 201398 DRIVE SHAFT SUBASSEMBLY 865779 PIN 412055 RETAINER RING 869564 PLUNGER 619377 BALL BEARING 869567 HOUSING 842274 STEEL BALL 5 32 869568 PLUNGERSPRING 847807 SPRING The complete clutch with housing can be purchased as a subassembly using Part No 861019 45 NUTRUNNER MOTORS Non Reversible Tools Round Rotor 203168 Stall Tools 203171 Automatic Shut off Tools Reversible Tools Star Rotor 869577 Stall Tools 869578 Automatic Shut off Tools 843444 Non Rev 847096 Rev g 847603 Rev Models Only 812164 fy TA 203169 Non Rev 869574 Non Rev 619377 865352
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