Wilson 3A-1000 User's Manual
Contents
1. PARTS LIST Cont x r VOOO OOO OOOO OO S N AAA Ma ne CaN Ga TAK SX jis 2 Naay A CA BEC ANS x EAN S N A Ki d n ws y Ka i E e i GF HGGHHHOOHHDAGOHOHOHH x DETAIL NO 3 DETAIL NO DETAIL NO 2 SECTION A A 11 PARTS LIST SM 97 Key Description 3A 3A 3A Key Description 3A 3A 3A 1000 750 450 1000 0750 0450 Torque Control Ass y 38641 38641 38641 26 Reaction Member 24907 1000 0750 0450 7 27 Retainer 28096 1 Retainer 2 24317 28 Latch Spring 24913 2 Spirolox Ring 34262 29 Latch Return Pawl 24911 3 Front Bearing 28069 7 30 Return Pawl Spring 24912 4 Control Housing Ass y 40024 40024 40024 7 5 Main Spring 24307 32 Roll Pin 2 25177 6 Main Spring Anchor 24318 33 Roll Pin 24908 7 Button Head Screw 2 24319 34 Latch 24910 8 Lock Washer 2 28106 35 Latch Release Spring 24331 9 Main Spring Pin 24313 36 Latch Release Pawl 24323 10 Internal Gear 38658 38657 38658 37__ Latch Release Pin 2 24330 11 Drive Spindle 38664 38664 38661 38 Dowel Pin 24298 12 Planet Gear 3 24504 24364 24321 39 _ Reverse Pa2. rust during tool storage be sur amount of oil has been introduced into valve and air Also be sure operat ing air moisture content is kept mum Compressor after coolers air line traps water separators and use of rust inhibiting lubricat ing oil all help Thor oughly clean or replace any rusted parts found during service checks MAINTENANCE amp SERVICING Bee Air Tools should be handled with reasonable care when servic ing It is important that the correct tools and fixtures are used when servicing this Air Tool Order replacement parts by part number model and serial number of tool To maintain Torg Air Matic efficiency periodic checks should be made of the follow ing Rotor Blades Generally these are the only parts requiring replacement after long service Always replace the rotor blades in a set of 4 only whenever they are broken or cylinder edge is gouged worn uneven or worn down 1 16 This would cause the blade edges to be 1 16 below top of its slot in rotor drum Cylinder and Rear End Plate Replacement is required only if part is broken or rubbing surfaces are gouged Ball Bearing normally these ball bearings should not require additional lubrication during tool life However whenever tub roller is disassembled for servicing the motor ball bearings should be lubricated with light oil SAE 10 while the drive ball bearings should receive a small amount of bearing grease All ball bearings should tu
3. SM 97 SPECIFICATIONS Model no 3A 450 3A 750 3A 1000 38640 0450 38640 0750 38640 1000 F RPM PEERED 450 750 1000 Min T Ft L in Torque Ft Lb 3 3 3 Max Torque Ft Lb 18 12 10 Air Pressure psi 90 Air Inlet 3 8 NPT nee 3 8 LD Air Flow Free 32 CFM Speed Spindle 1 2 Dia with 2 spots 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 16 Email tcwilson tcwilson com SM 97 Smarter Tools for Smarter Work Torg Air Matic Model 3A 450 450RPM Model 3A 750 750RPM Model 3A 1000 1000RPM OPERATING INSTRUCTIONS amp SERVICE MANUAL TO REDUCE THE RISK OF INJURY USER MUST READ AND UNDERSTAND OPERATOR S MANUAL 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 Email tcwilson tcwilson com SAFETY INSTRUCTIONS ae Ax 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 1 Do not allow corrosive gases or foreign material to enter the unit Moisture oil based contaminants or other liquids must be filtered out 2 Eye protection is always required when running motor 3 Hearing protection is recommended when in close prox imity to all operating air motors 4 Dust mask
4. alve trigger into reverse position depressed Valve locks in this position and only releases when throttle valve trigger lever is released Depress throttle valve trigger lever to reverse drive and back expander out of tube Note There must be a positive resistance to turning on the tool spindle of 5 6 inch pounds in the reverse direction before drive will reengage and set latching pawls for rotation in the forward direction 11 Measure tube s actual inside diameter If the amount of ex pansion is not sufficient adjust torque control to a slightly higher value and roll the next tube 12 When desired expansion has been attained maintain the set ting and roll the entire lot Reroll all trial tubes which were not completely expanded 13 Always record settings used and tube data such as tube 0 D and gauge with tube sheet thickness for future reference LUBRICATION Amount of oil used will vary with tool usage but daily filling of handle oil reservoir should normally be adequat Check that a fine mist of oil is always present in the air which passes out through exhaust deflector holes For continuous and heavy tool usage it is preferable to use an automatic air line lu bri cator For this purpose the Wilson Air Filter Lubricator Unit Cat 8596 for 3 8 lines is recommended This unit com bines an automatic lubricator with an efficient air filter a liberal motor at a mini Caution To inhibit
5. ays use a 3 8 I D or larger air line when maximum power is desired and be sure that air pressure at the tool is at least 90 psi gauge 5 The exhaust deflector can be rotated to deflect exhaust air in the most convenient direction 6 Select required snap on mandrel drive and attach it to tool spindle nose Be sure to align detents within it with drilled spots on spindle nose Instructions for releasing detents are stamped on mandrel drive sleeves 7 Adjust Thrust Collar on expander and attach mandrel to snap on mandrel drive by engag ing detent and circular groove on mandrel s square shank D PARTS LIST Cont SM 97 000 OOOHOOL SSS New TN Vy mae V oy Ki 3 9 f Y NE E S Q amp 6 6 13 PARTS LIST Cont SM 97 Key Description 3A 3A 3A Key Description 3A 3A 3A 1000 750 450 1000 0750 0450 Motor amp Spindle As 38649 38649 38649 77 Valve Ball 2629 2629 2629 awe E1009 ON 0D g Vaive Pin 51540 51540 51540 ee SAA SI SLEE eam eyer Pin 28215 28215 28215 55 Intermediate Spindle 51123 51122 51121 80 Throttle Valve Lever 53501 53501 53501 56 Planet Pin 2 24512 24512 24512 82 Trigger Pin 28215 28215 28215 57 Planet Gear 2 51102 24321 51105 84 Throttle Valve trigger 51563 51563 51563 58 Needle R
6. d is indicated for a 3 4 x 18 ga tube in a condenser Tube Expansion Calculations Tube Sheet Hole Dia 760 Tube O D 750 Clearance 010 Tube I D 652 I D Metal to Metal 662 4 Reduction 049x 04x2 004 Expanded I D 666 OPERATION RECOMMENDED OPERATING AIR PRESSURE 90 PSI 1 Make sure there is an adequate supply of clean air of 90 psi lubricated with light machine oil of SAE 10 viscosity This should be done before all long runs of tube expanding and after every four hours of continuous use unless an air line lubricator of ample capacity is used SEE LUBRICATION SECTION BELOW OPERATION Cont wares 2 Loosen the four hexagon socket set screws at rear of con trol housing 1 2 to 3 4 turn and rotate index mark on housing to desired torque Tighten all four screws See paragraph enti tled Calculating the Expansion Required To avoid the possibility of over rolling it is best to make the trial setting low and work up to the desired setting a re cord of which should be kept for future use 3 The clamp on handle Part No 24305 can be swiveled to the position most convenient for the operator Its use is optional but recommended for any job requiring more than three foot pounds torque 4 Always blow out air hose thoroughly before attaching it to throttle valve cap which takes the 3 8 pipe coupling of 3 8 hose assembly supplied No 50007 Alw
7. e setting set screws halfway out at rear of control housing Use 1 8 hexagon key supplied C Remove outside bearing shaft retainer ring Piece No 1 Group no 2 A Grasp unit by torque control housing with the 1 2 diameter output spindle uppermost and vertical Hold it with the motor handle 1 2 tol above the work surface B With a soft faced hammer tap the output spindle gently The entire internal mech anism will fall free as soon as the reduced diameter portion of output spindle has pass ed through front ball bearing NOTE Avoid hitting this bearing or housing Group no 3 A Remove inside bearing shaft retainer ring Pc 1 B Lift out front ball bearing Pc 25 C Lift off front brake shoe Pc 21 D Remove 3 brake rolls Pc 23 E Lift off brake roll retaining ring Pc 22 Group no 4 A The subassembly consisting of reaction member assembly with latch and various pawls mainspring with its pin and anchor and brake cam may then be lifted up off motor drive spindle assembly w When failure is due to a malfunction of torque control unit the failing parts usually can be found easily by observing operations of the various pawis and latch This can be done by holding subassembly in the hand and applying torque or turning force to internal gear Pc 10 within reaction mem ber Pc 26 See Trouble Shooting Chart DISASSEMBLY Cont SM 97 NOTE As machine is being d
8. h in re verse Broken latch or latch spring Replace see pg 8 Pc 28 34 pg 11 Broken reverse pawls springs or anchor pin Replace see pg 8 Pc 39 40 41 42 pg 11 Slot radii on internal gear oversized gouged Replace internal gear Pc 10 pg 11 Insufficient torque on drive spindle end See note on pg 5 Hold spindle end in vise and manually turn TAM ccw should relatch Excessive burrs or wear on internal gears pre venting free rotation Debur replace see pg 7 Pc 10 pg 11 Caution Disassembly or reassembly of torque control unit must be performed by qualified personnel It is advisable to return torque 15 control units to the factory or consult the factory for necessary repair SM 97 TROUBLE SHOOTING PROBLEM Motor will not run CAUSE amp REMEDY Inefficient air supply Check 90 psi and 32 CFM air supply Clogged air inlet screen Replace see pg 6 pc 75 pg 13 Broken or severely worn rotor blades Replace see pg 6 pc 69 pg 13 Rust due to improper storage of tool Disassemble and clean Refer to Dis assembly procedure Broken throttle valve pin or lever Replace see pg 6 pc 78 80 pg 13 Motor will not reach RPM Insufficient air volume Check 32 CFM supply Dirty air inlet screen Clean see pg 6 pc 75 pg 13 Worn rotor blades Replace see pg 6 pc 69 pg 13 Air supply hose chocked o
9. non skid safety shoes hard hat gloves and other personal safety equipment must be used 5 Stay alert watch what you are doing and use common sense when operating a power tool 6 Dress properly Do not wear loose clothing or jewelry 7 Keep your work area clean and well lit 8 Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust 9 Disconnect the tool from the air supply before installing making any adjustment changing accessories servicing or storing tool SM 97 TROUBLE SHOOTING Cont PROBLEM Torque control will not release at torque setting l CAUSE amp SOLUTION Broken latch release pawl Replace see pg 8 Pc 36 pg 11 Broken torque spring Replace see pg 8 Pc 5 pg 11 Broken latch Replace see pg 8 Pc 34 pg 11 Broken or excessive wear on tips of all pawls Replace see pg8 Pc29 36 40 amp 42 pg 11 Broken spring ends or anchor pins of latch pawls and reverse pawl Replace see pg 8 Springs amp pins pg 11 Reaction member seized to int gear assembly Consult factory Broken or short roll pin stop on reaction member Check for scoring on stop plate sec tion of handle connector Replace see pg 7 Pc 32 pg 11 Ball retainer has broken or lost any balls Check correct assembly of retainers Replace see pg 9 Pc 43 pg 11 Torque control will not relatc
10. ntermedi ate spindle assembly to air motor assembly Next screw interm diate internal gear with attached torque control assembly onto adapter ring Tighten air motor assembly to torque control as sembly See method of disassembly above Assure that gears mesh properly before tightening do not force Torque unit will screw onto motor assembly easily with proper gear mesh Maintenance and Repair tools 4 Oz Ball Pein Hammer 4 Oz Soft Faced Hammer Brass and Plastic Tip Set of Screwdrivers 1 8 w x 4 1g blade 1 4 w x 4 1g blade 9 Smooth Jaw Adjustable Wrench With 2 Minimum Opening 8 Pressure Lock Wrench vise grip Set of Allen Hex Wrenches 5 64 3 32 1 8 5 32 and 3 16 9 1 2 Channel Lock Pliers Long Needle Nose Pliers Set of Retaining Ring Pliers Waldes No 2 amp No 4 Set of Machinists long nose punches 1 16 3 32 1 8 5 32 3 16 and 1 4 6 1 2 Half Round Needle File for Deburring Small Hand Scraper for Deburring Sheets fine emery cloth for polishing
11. oller 2 Sets 24354 24354 24354 85 Sais Valve 51544 51544 35154 59 Roller retainer 2 Sets 24355 24355 24355 g6 iege Spiin 52635 52635 52635 60 Retainer Washer 51118 51118 51118 87 Drive Screw 2 6896 6896 6896 6l Rear Drive Ball Bearing 24525 24525 24525 88 Nameplate 38635 38635 38635 PEE ig EA PAR RR 89 Retaining Ring 53560 53560 53560 D g s1133 51132 saa 90 Gasket 51229 51229 51229 63 Adapter Ring 52497 52497 52497 Rear Plug 21224121394 21994 64 Bearing Separator 51191 51191 51191 327 Reap EBONY 21944 219447 2194A 65 Front Motor Bearing 51361 51361 51361 Rear End Plate 51532 51532 51532 66 Front Plate 50809 50809 50809 4 Roll Pin ILAJE LIA SIETA 67 Front Bearing Spacer 51135 51135 51135 5 Seal Ring a 2R IR ISIR 68 Cylinder 51225 51225 51225 9 Prhaust Muffler Assy 53840 53840 53840 69 Rotor Blade Setof4 51139 51139 51139 Dead Hangs 24393 Motor Housing Ass y 53579 53579 53579 a 32147 Key70thru86 90 93 amp 94 Hex Key 1 8 52144 70 Motor Housing 53580 53580 53580 Hex Key 3 16 51254 74 Throttle Valve Cap 42872 42872 42872 75 Air Screen 51179 51179 51179 76 Throttle Valve Spring 51541 51541 51541 12 SM 97 OPERATION Cont 8 Insert expander in tube as required O Completely depress throttle valve trigger lever to find forward speed When preset torque has been reached drive will dis engage and mandrel will stop rotating release throttle valve lever when this occurs 10 Fully squeeze reverse v
12. ounter clockwise direction when viewed from offset handle end D Unscrew and remove air motor and offset housing assembly complete E Remove intermediate spindle assembly from air motor assem bly or from within internal gear EF Unscrew adapter ring Pc 63 out of cast aluminum motor housing G Rotor with 4 rotor blades front plate spacer ball bearing and separator can now be lifted out Note Leave cylinder and assembled rear end plate within mo tor housing Refer to assembly drawing on page xx SM 97 REASSEMBLY To reassemble TORQUE CONTROL or AIR MOTOR follow disassembly steps in reverse Torque control special note On reassembly of ball retainers small ball retainer Pc 25 must be assembled with solid part of ball cage facing steel front bearing housing Pc 4 in aluminum control housing Large ball retainer Pc 43 must be assembled with solid part of ball cage facing steel handle connector Pc 48 e Air motor special note Be sure rotor blades are well oiled before replacing them in their rotor slots Also check that rotor turns very freely af ter air motor is reassembled and adapter ring is tightened down Observ xtreme care in mesh ing the rotor pinion and intermediate spindle pinion with their planet gears when reas sembling gear housing assembly to air motor e Complete torq air matic reassembly sequenc Assemble air motor into motor housing then assemble i
13. r too small See Operating Procedure recom mended hose Motor stalls at high torque Insufficient air pressure Check 90 psi supply Dirty air inlet screen Clean see pg 6 pc 75 pg 13 Rotor blades worn chipped or broken Replace see pg 6 pc 69 pg 13 Motor fails to stop Broken throttle valve spring Replace see pg 6 pc 76 pg 13 Valve ball does not seal Replace or rework valve seat Refer to pg 6 pce 77 pg 13 14 GUIDELINES FOR TUBE EXPANSION sas Improperly rolled joints create additional expense to correct whether they are under rolled and can be corrected merely by rerolling or over rolled and require removal and replacement The optimal joint is one that develops a leak tight joint with adequate strength for the ser vice intended with the minimum amount of cold working or reduction of the tube wall Experience indicates that joints of this type are ob tainable with non ferrous tubes in surface condensers by expanding to a wall reduction of 3 to 4 after metal to metal contact of the tube 0 D with the tube sheet hole Steel tubes in heat exchangers may require wall reductions of 5 to 10 soft copper and aluminum tubes in heat ex changers also require larger wall reductions in the area of 8 to 12 Boiler tubes requiring development of optimum joint strength require wall reductions of 12 to 14 A typical example of the application of this metho
14. riven in forward direction a coun terclockwise torque is applied to the internal gear when look ing at the open end This gear is prevented from turning in reaction member by the latch Pc 34 which can be released by tripping release pawl Pc 36 while applying a counterclock wise torque to internal gear which is then free to continue rotation in that direction When tool is reversed a clockwise torque is applied to internal gear which makes one turn only to reengage the main latch Pc 34 Group no 5 If investigation shows that malfunction is due to a broken latch pawl or spring they can be replaced in the following manner A Grasp brake cam Pc 24 and punch reaction member from it NOTE When replacing this brake cam for reassembly be sure it is seated squarely and firmly against the shoulder on the reac tion member Group no 6 A Mainspring Pc 5 with its anchor Piece No 6 and main spring pin Pc 9 can then be removed Group no 7 A Removal of retaining ring Pc 27 will permit removal of various pins on which the latch and pawls are pivoted consisting of reaction with latch and various pawls its pin and anchor and brake lifted up off motor drive Air motor disassembly procedure A Hold Torq Air Matic fixed with offset handle upwards B Prevent rotation with wrench locked on 2 hexagon located against torque calibrated index plat C Tap motor handle with a soft faced mallet in a c
15. rn smoothly and freely with no notice able looseness There should be a snub fit with no shake both in their housings and on their shafts However the front motor ball bearing is a mild press fit on its rotor shaft Note Dirty or gummed up ball bearings should be cleaned in kerosene and flushed with clean light oil SAE No 10 DO NOT USE AN AIR BLAST After flushing re lubricate as specified B sure both plastic seals are properly replaced on front drive ball bearing Intermediate Spindle Assembly and Drive Spindle Assembly Do not disassemble planet gears from their spindles unless the gears do not move freely about their planet pins Be careful not to lose any one of the nine needle rollers assembled within each planet gear Lubricate planet gear and needle rollers with a good bearing grease only Caution Note position of planet pin milled step in relation to steel retaining ring or turned step on drive spindle on assembly drawing before reassembling either spindle Air Screen Throttle valve air screen assembly should be cleaned by reverse flushing when necessary Before reassembly note on drawing that air screen cylinder is assembled within the throttle valve cap Also when reassembling be sure small end of conical throttle valve spring rests against the 3 8 diameter hardened steel ball Be sure air screen flange comes to rest cor rectly within its counter bore in steel seat insert SM 97
16. wl Pin 24328 13 Needle Roller 3 Sets 24354 40 Tongued ReversePawl 38665 38665 38665 14 Roller Retainer 3Sets 24355 41 1 Reverse Pawl Spring 24914 15 Planet Pin 3 24314 42 Grooved ReversePawl 24909 16 Snubber Shim 0 3 40561 43 Retainer 28067 0001 19 O Ring 28101 46 Screw 2 24320 20 Quad Ring 28103 47 Rear Bearing 51194 21 Brake Shoe 38643 48 Handle Connector 38651 22 Brake Rolls Retainer 24311 49 Internal Gear 38654 38653 38655 23 Brake Roll 3 24324 50 Balls 13 21941 24 Bearing Race Brake 38644 Cam 25 Front Ball Retainer 28088 10 DISASSEMBLY ae The following instructions should be studied carefully before attempting disassembly of Model 3A Torq Air Matic In most cases the major difficulty encountered has been caused by im proper disassembly and reassembly procedures Torque control disassembly procedure If air motor has been operating properly do not remove it from torque control section at this time but proceed as outlined The steps to be followed have been grouped Steps within a group may be performed in any sequence The groups however cannot and must not be per formed out of sequence All steps within a group must be completed before proceeding to the following group Refer to assembly drawing on Page 11 Group no 1 A Unscrew and remove both spring anchor button head screws Use 3 16 hexagon key supplied B B Unscrew all four torqu
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