Cleco 11PHH Instruction Manual

11PHH Pulse nutsetter without shutoff Instruction Manual P1991BA/EN 2014-06

Notes on this Instruction Manual The original language of this instruction manual is German. This instruction manual • provides important instructions for safe and effective operation. • It describes the function and operation of the pulse nutsetter (hereafter referred to simply as 11PHH). • It serves as a reference work for technical data, service intervals and spare part orders. • It points out options. Secondary information P2204BA Instruction Manual Oil filling unit In the text 11PHH stands for all styles of the pulse nutsetter described here.  identifies instructions to be followed. • identifies lists. <…> identifies an index, see 8 Spare parts, page 27. In graphics: identifies movement in a direction. identifies function and force. In graphic illustrations: If not absolutely essential, 11PHH (air from bottom) is illustrated.

P1991BA/EN 2014-06 3 Model Key Disclaimer: Apex Tool Group reserves the right to modify, supplement or improve the document or the product without prior announcement. 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. 11 P H H × 65 × Max. capacity Output drive 11 –11 Nm Q – Quick change chuck 1/4" 2 – External square 1/4" 3 – External square 3/8" Design Speed P – Pistol grip 65 – 6500 rpm Pulse mechanism 2. Air Inlet H – Hydraulics A – Air from top – None Design H – 3 Chamber motor

1.2 Basic requirements for safe working practices............................................................ 7 1.3 Operator training ......................................................................................................... 8 1.4 Personal protective equipment.................................................................................... 8 1.5 Designated use ........................................................................................................... 8 1.6 Noise and vibrations.................................................................................................... 8 2 Items supplied 9 3 Product description 9 3.1 Operation and functional elements.............................................................................. 9 3.2 Options...................................................................................................................... 10 4 Before initial operation 10 4.1 Air supply................................................................................................................... 10 4.2 Change air inlet: top / bottom (only on 11PHHA)....................................................... 11 4.3 Connect the tool ........................................................................................................ 11 4.4 Setting up the tool ..................................................................................................... 11 4.5 Troubleshooting......................................................................................................... 13 5 Maintenance 15 5.1 Service schedule....................................................................................................... 15 5.2 Fill reserve oil ............................................................................................................ 16 5.3 Complete oil filling ..................................................................................................... 18 6 Disassembly instructions 21 6.1 Remove motor unit.................................................................................................... 21 6.2 Remove throttle valve................................................................................................ 22 6.3 Remove pulse unit..................................................................................................... 22 7 Assembly instructions 23 7.1 Install motor unit........................................................................................................ 23 7.2 Install pulse unit......................................................................................................... 25 8 Spare parts 27 8.1 Pistol grip 11PHH…................................................................................................... 28 8.2 Pistol grip 11PHHA… ................................................................................................ 30 8.3 Motor unit .................................................................................................................. 32 8.4 Pulse unit................................................................................................................... 34 8.5 Equipment order list .................................................................................................. 36 9 Technical data 37 9.1 Dimensions 11PHH… in mm..................................................................................... 37 9.2 Dimensions 11PHHA… in mm................................................................................... 38

10 Service 39 11 Disposal 39

Warning notes are identified by a signal word and a pictogram: • The signal word describes the severity and the probability of the impending danger. • The pictogram describes the type of danger. 1.2 Basic requirements for safe working practices All instructions must be read carefully. Failure to observe the instructions listed below can result in serious injuries. WARNING! Potentially hazardous situation for health and safety. If this warning is not observed, death or serious injury may occur. CAUTION! Potentially hazardous situation to health and safety, or risk of material and environmental damage. If this warning is not observed, injuries or damage to materials or the environmental could occur. NOTE General notes include application tips and particularly useful information but no hazard warnings. CAUTION!  Work with a maximum working pressure of 101.5 psi (700 kPa) (measured at the air inlet tube of the tool).  Before initial operation, check that the suspension bail is properly fastened to the balancer.  11PHHA: Before using the air inlet from above, make sure that the pipe plug is correctly fitted in the lower air inlet.  If you hear unusual noises or vibrations, switch off the tool immediately. Cut off the air supply immediately.  Before carrying out repairs, adjusting the torque or replacing screw bits, disconnect the tool from the compressed air line. The compressed air line must be depressurized before disconnecting it.  Never use the air hose to hold, raise or lower the tool. Air hoses, the suspension bail and fittings must be regularly checked for damage and wear. Renew as necessary. Always carry out assembly according to Chapter 8 Spare parts, page 27.  Use only accessory parts authorized by Apex Tool Group (see product catalog).  Only use screw bits for machine-controlled fastening tools.  Make sure that the screw bits are securely inserted.  Inspect screw bits for visible damage and cracks. Renew damaged bits immediately. The operation, maintenance and repair conditions set forth in the instruction manual must be observed.  Follow generally valid and local safety and accident prevention rules.

Manual accessible to users and make sure that the users have read and understood it. The tool may only be connected, used, serviced and repaired by qualified persons. Repairs to the tool may only be performed by authorized personnel. 1.4 Personal protective equipment • Wear protective goggles to protect against sprays of metal splinters and fluids. • Wear gloves to protect against skin irritation in case of direct contact with oil. Danger of injury by being wound up in and caught by machinery • Wear a hairnet. • Wear close-fitting clothing. • Do not wear jewelry. Sound level in the area of the user > 80 dB(A), danger of hearing damage • Wear hearing protection. 1.5 Designated use The 11PHH is designed exclusively for fastening and releasing threaded fasteners. • Do not use it as a hammer. • Do not open it or modify it structurally. • Do not use it in areas where there is a risk of explosion. 1.6 Noise and vibrations With vibration levels ahv > 2.5 m², the exposure time is to be reduced. See example Sound pressure level Lp in accordance with DIN EN ISO 15744 Idle for n  6500 rpm < 75 dB(A) Vibration values in accordance with DIN EN ISO 28927-2 11PHH: Idle ahv for n  6500 rpm < 1.7 m/s² Pulses ahv < 2.0 m/s² 11PHHA: Idle ahv for n  6500 rpm < 1.7 m/s² Pulses ahv < 2.0 m/s² Vibration level ahv m/s² Allowed daily exposure time (hrs.) Example Not allowed Allowed

2 Items supplied Check shipment for transit damage and ensure that all items have been supplied: 1 11PHH 1 This instruction manual 1 Declaration of Conformity 1 Hex wrench (WAF 2) 3 Product description 3.1 Operation and functional elements Abb. 3-1 Item. Designation 1 Reverse switch 2 Exhaust air throttle: torque adjustment, see Abb. 4-1 , page 12 3 Air inlet 4 Start button 5 Reserve oil, see 5.2 Fill reserve oil, page 16 6 Suspension bail 3 3 1 2 4 6 5 (6) Alternative position 11PHH… 11PHHA…

4 3.2 Options 4 Before initial operation 4.1 Air supply  Make sure that the pressure before the pressure regulator is at least 0.5 bar higher than the required inlet air pressure at the tool.  Keep the inside of the air hose free of residue; clean it if necessary. Air quality In accordance with ISO 8573-1, quality class 2.4.3, compressed air must be dry and clean. Air preparation units Our recommendation: air preparation units (filters, regulators, lubricators) should be installed Protective sleeve Order No. 937447PT – 11PHH… Order No. 937442PT – 11PHHA… Parameter Data Air hose Inner diameter 3/8" (ø 9.5 mm), maximum length 5 m Air inlet 1/4" NPT, inner diameter 7.5 mm Parameter Data Working pressure range 400 … 700 kPa Max. dew point + 10° C Device Explanation Filter Retention of particles > 15 micrometers. Removes more than 90% of condensation. Regulator To attain constant work results, the working pressure must be kept constant for every individual tool. Lubricator Compressed air requires a small amount of oil and is orientated to the air consumption of the tool.  Calculate the time (T) between two drops of oil and make the following settings at the lubricator: F = Factor for pulse nutsetter = 2 L = Air consumption of tool at idle m³/min (see performance data for pulse shut-off nutsetter) T 60 F L  ------------- =

Oils according to DIN 51524 / ISO 3498 4.2 Change air inlet: top / bottom (only on 11PHHA) When delivered, the air inlet is at the BOTTOM and sealed with a screw plug. To change the air supply from top to bottom:  Remove the air strainer from the air inlet at the TOP (do not discard), see 8.2 Pistol grip 11PHHA…, page 30, Detail X.  Remove screw plug from BOTTOM. When doing this, counterhold with wrench (WAF 17).  Seal the air inlet at TOP with screw plug in accordance with specifications. 4.3 Connect the tool  Connect the tool to the compressed air line. Maximum screwing-in torque = 40 Nm. Reaction torque at flat end. Counterhold with wrench (WAF 17). Activate compressed air: 620 kPa. 4.3.1 Testing 4.4 Setting up the tool The tool must be configured for the desired rundown. Order no. Packaging unit Liter Name ARAL BP elf ESSO INA Mobil Klüber SHELL 933090 2 HL32 Aralub EE 100 Energol HL 32 Polyelis 32 Olna 32 Nuto H 32 Hydraol 32A D.T.E.Oil Light Vactra Oil Light Crukolan 32 Molina 32 Molina 22 CAUTION! The air hose can come off by itself and whip around uncontrollably.  Shut off the compressed air before making the connection.  Fully open exhaust air throttle anti- clockwise.  Check speed at output drive: >6500 rpm

4 4.4.1 Setting the torque Abb. 4-1 To achieve better repeat precision for fastenings, throttle the speed back at the tool until the required torque is achieved at the end of rotation of the fastening. On hard to medium-hard screwed joints, this is achieved in 1 to 2 seconds. Longer fastening then does not result in higher torque. 4.4.2 Changing Torque Abb. 4-2 4.4.3 Checking torque We recommend carrying out a static torque check by retightening the screwed joint.  If the torque difference is too large, it may be necessary to change the torque setting. See 4.4.2 Chang- ing Torque.  If the setting has been changed, check the torque again. When carrying out a dynamic measurement using a transducer adapter, also carry out a static test on the screwed joint, for example with a torque wrench (electronic). Settings example: Tightening: 8 Nm Screw M5: 8.8  Set speed to approximately 4400 rpm  Unscrew the threaded pin using the hex wrench (WAF 2). To reduce torque, turn the exhaust air throttle clockwise. To increase torque, turn the exhaust air throttle counter-clockwise. NOTE The torque setting may be corrected when the compressed air is activated. Nm Torque Example: 8 Nm Speed RPM Torque

4.5 Troubleshooting Error Possible causes Measures and remedies Tool too strong Torque set too high  Reduce the torque setting, see 4.4.2 Changing Torque, page 12 Tool too weak Working pressure too low  Check the cross section of the hose and coupling: Inner diameter 3/8" (ø 9.5 mm), maxi- mum length 5 m  Increase the working pressure. Reverse button is not at the detent Turn the reverse button to the detent Excessive transmission damping due to extension and worn socket.  Increase the speed, see 4.4.1 Set- ting the torque, page 12.  Use a shorter or more rigid exten- sion.  Replace the socket Insufficient oil in the pulse unit (no pulse build-up)  See 5.2 Fill reserve oil, page 16 Screen in the air inlet tube / muffler is dirty  Clean or replace parts Accuracy insufficient Adapter parts  Replace adapter parts  Use extension and socket with guide diameter Pressure fluctuations in the air network  Use a pressure regulator Premature release of the start button  Keep start button pressed until nut- setter has stopped rotating Fastening time too long: > 4 seconds Joint too soft; crush nuts, self-tapping screws  Increase the speed  Use a pulse nutsetter with a higher capacity.

This maintenance schedule uses values that are valid for most applications. For a specific maintenance interval, see 5.1.1 Calculating a customer-specific maintenance plan, page 16. Implement a safety-related maintenance program that takes the local regulations for repair and mainte- nance for all operating phases of the tool into account. CAUTION! Danger of injury due to unintentional activation – before service, disconnect the tool from the compressed air supply. Maintenance interval Rundowns Measures W1 100.000  Check the suspension bail for functional safety.  Check the air hose for wear.  Check the square on the output drive for wear.  Check the air inlet for tight fit.  Check the housing of the pulse unit for tight fit.  Check the maximum idling speed.  Check the reserve oil. W2 500.000  Oil change, see 5.3 Complete oil filling, page 18.  Motor service kit, see 3) Part of motor service kit K1 order no. 936158, page 29.  Hydraulic service kit, see 3) Part of hydraulic service kit K2, order no. 936210, page 35.  Replace muffler, filter. W3 1.000.000 Check individual parts and replace if necessary  Suspension bail Throttle valve  Exhaust air throttle  Motor  Pulse unit

A service interval W(1,2,3) depends on the following factors: T2, S and VS are variable factors and can differ depending on the specific application. Example for service interval W2: After 500,000 rundowns (V), a specific rundown time of 1.8 seconds (T1) with an actual fastening time of 3 seconds (soft joint) and 3 completed shifts per day and 750 rundowns per shift: You have to carry out the maintenance measures marked W2 after an operating time of 200 days. 5.2 Fill reserve oil If X = 0 (see picture 2), the reserve oil is exhausted and must be refilled to guarantee a controlled process. Factor Value assumed in 6.1, "Maintenance plan" Description V V1 = 100,000 V2 = 500,000 V3 = 1,000,000 Number of rundowns after which a maintenance measure is pre- scribed by Apex Tool Group. T1 1.8 seconds Specific rundown time, measured in life and endurance tests. T2 2 seconds Actual rundown time, depending on the hardness of the joint. S 1; 2; 3 Number of shifts per day. VS 750 Number of rundowns per shift. 1  Remove pulse unit. 2  Remove set bolt and ball. W 1 2 3    V T1  T2 S  VS  ------------------------------ = W2 500000 1 8   2 3  750  --------------------------------- = 200Tage = <103> <102> X = 0

4  To avoid air pockets, fill the filling hole full of oil. 5  Position the injector so that it has a sealing effect and add reserve oil until distance X for spacer is achieved.  Maintain distance X and secure with .  Refit set bolt and ball.  Remove . Approx. 5 ml X approx. 2.5 mm

If no more pulses are generated, or if the pulse unit has been removed and refitted, the pulse unit must be completely refilled with oil: Oil order No. 925715, ESSO-UNIVIS HVI26, approx. 2 liters, temperature 20 ±5 °C 1  Remove set bolt and ball 2 Align both ends of the pulse unit as shown in the picture (internal equalization hole is opened) 3  Use adapter to connect pulse unit to the quick disconnect coupling.  Close shutoff valve . 4  Set the working pressure to approx. 500 kPa.  Slowly open the shut-off valve all the way until the gauge shows a negative pressure of <10 mbar (-1 bar).  Wait approx. 2 minutes until the number of vacuum bubbles has reduced significantly.  Slowly close the shut-off valve. The gauge shows atmospheric pressure again. Missing oil will be pressed back into the pulse unit.  If necessary, repeat the last 3 rundown steps until bubbles are reduced practically to zero. <103> <102>

adapter. To avoid air pockets, fill the filling hole full of oil. 6  Position the injector so that it has a sealing effect and add reserve oil until distance X for spacer is achieved.  Maintain distance X and secure with .  Refit set bolt and ball.  Remove . NOTE Small air bubbles that become visible due to the high pressure during filling do not mean that the pulse unit is leaking. This will not negatively affect the filling result. Approx. 5 ml X approx. 2.5 mm

6 Disassembly instructions <…> Please refer to 8 Spare parts, page 27 and 8.5 Equipment order list, page 36 6.1 Remove motor unit 1 2 Changing blades Changing bearings / rotor <61> <59> <59> <54>

6.3 Remove pulse unit Abb. 6-1 1 2 Spring force! 3 CAUTION! Skin irritation in case of direct contact with oil. Wear protective gloves. CAUTION! Hydraulic blade is under spring pressure! Wear protective goggles. NOTE Permitted only if filling is guaranteed with oil filling device, see 5.3 Complete oil filling, page 18. Pulse unit must have cooled down to room temperature. WAF 3/ WAF 1/2" <84>

7 Assembly instructions <…> Please refer to 8 Spare parts, page 27 and 8.5 Equipment order list, page 36 7.1 Install motor unit CAUTION! • Only perform installation in accordance with exploded drawing, see 8.3 Motor unit, page 32. Incorrect installation can lead to uncontrolled reactions, e.g. unexpected start-up or parts being hurled out. • Tighten all screwed joints of the tool carefully, according to the specifications. NOTE To prevent damage, lubricate the gaskets and O-rings using grease (order no. 914392) before assembly.

1. Press <59> in with , see X. 2. Examine Y with thickness gage. If dimension > Y, step 1 with support , , repeat. Press <61> in with . <59> X <54> <55> X Base 0.02 0.03 0.04 0.05 Thickness gage = 0.03 mm max. 2 mm Y <61> <56> <60>

7.2 Install pulse unit 7.2.1 Assembling the hydraulic blades NOTE To prevent damage, lubricate the gaskets and O-rings using grease (order no. 914392) before assembly. 1 2 3 4 5 6 7 8 <93> <98> <93> <97> <95> <94> (2×) <97> <96> (2×) <93> <91> Tightening torque 50+10 Nm WAF 1/2" <84>

8 Spare parts NOTE Only Cleco original spare parts should ever be used. Using other parts could lead to inferior performance and increased maintenance requirements. If non-original spare parts are installed, the tool manufacturer is entitled to declare all warranty obligations for null and void. We would be glad to prepare a special quote for you for spare and wear parts. Please give the following data: • Tool model • Number of tools • Number of rundowns per day or per shift • Turn-off torque • Fastening time per rundown

Adhesive, order no. 914860 Grease, order no. 914392

1)Order no. 2)Quantity 3)Part of motor service kit K1 order no. 936158 4)Dimensions

Adhesive, order no. 914860 Grease, order no. 914392

1)Order no. 2)Quantity 3)Part of motor service kit K1 order no. 936158 4)Dimensions

1)Order no. 2)Quantity 3)Part of motor service kit K1 order no. 936158 4)Dimensions

For disassembly, note the position of the balls in the control disc. Reassemble balls in the same position.

1)Order no. 2)Quantity 3) Part of hydraulic service kit K2, order no. 936210 4)Dimensions TAB 8.4 Order no. <84> <93> <112> <113> <114> <115> <116> <117> <118> <119> <120> 11PHH652 11PHHA652 1/4" 936039 935660 915345 904693 915346 – – – – – – 11PHH653 11PHHA653 3/8" 936038 935658 914517 9D6481 26989PT 11PHH65Q 11PHH65Q 1/4" 936040 935685 931789 931789 931789 931789 917794 935477 935406 931793 931789

1)Order no.

9 Technical data 9.1 Dimensions 11PHH… in mm Abb. 9-1 Order no. A 11PHH653 173 11PHH652 168 11PHH65Q 173

Abb. 9-2 9.3 Performance Data Order no. Recommended torque range Idling speed Air consumption Nm 8.8 m3/min min. max. rpm mm kg Idling Pulses 11PHH652 11PHHA652 1/4" 6 11 6500 M6 0.78 0.84 < 0.30 < 0.25 11PHH653 11PHHA653 3/8" 0.79 0.84 11PHH65Q 11PHHA65Q 1/4" 0.80 0.89 Order no. A 11PHHA653 174 11PHHA652 169 11PHHA65Q 174

authorized personnel. Opening the tool will invalidate the warranty. 11 Disposal CAUTION! Injuries and environmental damage from improper disposal. The components and auxiliary materials of a machine incorporate risks to health and the environment.  Catch auxiliary materials (oils, greases) when drained and dispose of them properly.  Separate the machine parts by material and dispose of them properly.  Separate the components of the packing and dispose of them by segregating them clearly.  Wear suitable protective clothing at the time of disposal.  Follow the general prevailing disposal guidelines.  Follow the locally applicable regulations.

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