Instruction Manual P1885E/EN 2008-04 80PTHD… Pulse shut-off nutsetter For additional product information visit our website at http://www.cooperpowertools.
Notes on this instruction manual The instruction manual has the following purposes: • It provides important instructions for safe and effective operation. • It describes the function and operation of the pulse shut-off nutsetter. • It serves as a reference work for technical data, service intervals and spare part orders. • It points out options. In the text: 80PTHD… stands for all of the designs of the pulse shut-off nutsetter described here. ➔ Identifies instructions to be followed.
Contents 1 Safety 5 1.1 1.2 1.3 1.4 1.5 1.6 Warnings and notes .............................................................................. Basic requirements for safe working practices ..................................... Operator training................................................................................... Personal protective equipment ............................................................. Designated use...........................................................................
9 Technical data 33 9.1 9.2 Dimensions in mm .............................................................................. 33 Performance Data............................................................................... 33 10 Service 34 11 Disposal 34 P1885E/EN 2008-04 P1885E_EN 80PTHD 0408IVZ.fm, 02.04.
Safety 1 Safety 1.1 Warnings and notes 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. WARNING! Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
1 Safety 1.2 Basic requirements for safe working practices You should read all instructions. Failure to observe the instructions listed below can result in serious injuries. CAUTION! 1.3 ➔ Before initial operation, check that the suspension bail is properly fastened to the balancer. ➔ Work with a maximum working pressure of 101.5 psi (700 kPa) (measured as the air inlet tube of the tool). ➔ If you hear unusual noises or vibrations, switch off the tool immediately.
Items supplied 1.4 Personal protective equipment • Wear the 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 wrapped 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 • 1.5 Wear hearing protection.
2 Items supplied 3 Product description 3.1 Operation and functional elements 8 1 7 2 (8) Alternative Position 6 3 9 5 4 Pos. 8 Designation 1 Reverse switch 2 Torque adjustment, siehe 4.4.1 Setting the torque, page 10 3 Speed adjustment, siehe 4.4.2 Changing the speed, page 11 4 Air inlet 5 Connection for Pneumatic Torque Verifier TVP100, signal connection kit, order no. 934918 (optional) 6 Start button 7 Reserve oil adjustment, see 6.
Before initial operation 4 Before initial operation 4.1 Ambient conditions 4.2 Ambient temperature 41 °F (5 °C) to a maximum of +104 °F (+40 °C) Permissible relative humidity 25 to 90 %, non-condensing Air supply Parameter Data Air hose Inner diameter 1/2" (ø 12,5 mm), maximum length 16.4 ft (5 m) Working pressure range 58 to 101.5 psi (400 to 700 kPa) Recommended: 90 psi (620 kPa) Compressed air Air quality according to ISO 8573-1, quality class 2.4.
Before initial operation 4.3.1 4.4 Testing ➔ Carry out a test in clockwise and counterclockwise rotation at maximum speed, see 4.4.2 Changing the speed, page 11. ➔ Check the speed at the output drive. Target: n > 6000 rpm. Setting up the tool The tool must be configured for the desired rundown. 4.4.1 Setting the torque CAUTION! Danger of injury from unintended startup. Shut off the compressed air before adjusting the torque.
Before initial operation Torque 1. Hold the output drive firmly. 2. Carefully push the size 2 hex wrench through the hole of the pistol grip housing until it reaches the torque adjustment screw . 3. Turn the torque adjustment screw and roughly set the required torque, see Abb. 4-1 , page 10. Total number of turns = 6. 4. Pull out the hex wrench. The hole closes automatically when the tool starts. 5. Carry out the rundown. 6. Check the shut-off mechanism worked properly, see 4.4.
5 Troubleshooting 4.4.3 Measuring the torque We recommend carrying out a static torque measurement by retightening the rundown. When carrying out a dynamic measurement using a transducer adapter, also carry out a static test, for example using a torque wrench (electronic). 4.4.4 Pulse frequency The pulse frequency is set optimally for most applications.
Maintenance 6 Maintenance CAUTION! Danger of injury due to unintentional activation – before service, disconnect the tool from the compressed air supply. 6.1 Service schedule Regular maintenance reduces operating faults, repair costs and downtime. Maintenance interval Rundowns W1 100,000 W2 W3 500,000 1,000,000 Measures ➔ 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.
6 Maintenance 6.1.1 Calculating a customer-specific maintenance plan A service interval W(1,2,3) depends on the following factors: Factor Value assumed in 6.1, "Maintenance plan" Description V V1 = 100,000 V2 = 500,000 V3 = 1,000,000 Number of rundowns after a maintenance measure is prescribed by Cooper Power Tools. 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.
Maintenance 6.2 Activating the reserve oil If pulse build-up stops, some of the oil in the pulse unit has been used up. The reserve oil must be activated. If the equalizing piston reaches the limit stop, oil must be refilled the next time (see 6.3 Refilling oil, page 16). ! 1. 2. Align both ends as shown in the illustration. <66> SW15 <70> <68> 4. Turn <68> clockwise till the detent. 5. Turn <68> approx. 2,5 turns anticlockwise… 3. <66> <70> <71> 6. …until <70> can be reinserted again.
6 Maintenance 6.3 Refilling oil 2 4 Approx. 7 oz. (200 ml) 7 1 3 5 6 9 15 14 10 8 4 Approx. 0.35 oz (10 ml) X + – 11 13 12 Item Designation 1 Oil filling device asm.1) 2 Oil filling device without filling piece 1) 3 Filling piece asm.1) 4 Oil order no. 925715, ESSO-UNIVIS HVI26, approx. 2.
Maintenance 1. Remove the threaded pin 15 and ball 14. 2. Remove the O-ring 12 and sleeve 13. 3. Align the output drive and claw as shown in the illustration, see 6.2 Activating the reserve oil, page 15. 4. Rotate the equalizing piston 11 clockwise as far as it will go until X = 0 (starting point). 5. Unscrew the equalizing piston 11 counterclockwise by 1,0 turns (reserve oil volume). 6. Connect the pulse unit 8 to the quick disconnect coupling 5 using the adapter. 7.
6 Maintenance 18 P1885E/EN 2008-04 86c_Wartung en bedingt.fm, 02.04.
Repair instructions 7 Repair instructions Refer also to 8 Spare parts, page 25 and 8.4 Equipment order list, page 32 7.1 Disassembling the motor unit <61> <54> <59> <59> Changing blades 7.2 Changing bearing / rotor Disassembling the throttle valve Size 3/8" 1. 86d_Reparatur en bedingt.fm, 02.04.2008 2. P1885E/EN 2008-04 3.
7 Repair instructions 7.3 Disassembling the pulse unit Size 1/2" CAUTION! Skin irritation in case of direct contact with oil. Wear protective gloves. CAUTION! Hydraulic blade is under spring pressure! Wear protective goggles. <65> NOTE Permitted only if filling is guaranteed with oil filling device, see 6.3 Refilling oil, page 16. The pulse unit must have cooled to room temperature. Abb. 7-1 7.
Repair instructions 7.4.1 Assembling the end plate <59> <54> <59> <54> <55> X Dimension X = 0.00" to 0.00236" (0.00 to 0.06 mm) 1. Press in <59>, see dimension X. Test force 1.12 – 3.37 lbf (5 – 15 N) Y Y Dimension Y = 0.0002" to 0.0006" (0.005 to 0.015 mm) 2. Check dimension Y. Dimension X 0.00 0.00079" (0.02 mm) 0.00158" (0.04 mm) 0.00236" (0.06 mm) <61> <60> <59> <54> <55> <56> 3.
7 Repair instructions 7.4.2 Assembling the shut-off piston ! <44> Do not use grease – to hold the balls in place! <49> (3×) 1. <45> <47> <48> 2. <59> Size 4 3. <44> <47> 4. <50> 5. 22 P1885E/EN 2008-04 86d_Reparatur en bedingt.fm, 02.04.
Repair instructions 7.4.3 Assembling the actuating ring ! <32> <44> <47> <55> <32> click! <34> <40> 33 (3×) <56> <60> 1. 3. 2. Dimension X < 0.053" (1,35 mm) <34> 935465 0.059±0.0059" (1,5±0.15 mm) 935464 > 0.065" (1,65 mm) 935463 <34> <44> Dimension X = <34> 0.059±0.0059" (1,5±0.15 mm) 4. 86d_Reparatur en bedingt.fm, 02.04.2008 5. <47> P1885E/EN 2008-04 6.
7 Repair instructions 7.5 Assembling the pulse unit NOTE To prevent damage, lubricate the gaskets and o-rings using grease (order no. 914392) before assembly. 7.5.1 Assembling the hydraulic blades <78> <73> <77> <73> 2. 1. <77> <75> <76> (2×) <74>(2×) 4. 3. 5. Size 1/2" <73> 133+7.4 ft lbf (180+10 Nm) ! <65> <71> 6. 24 7. P1885E/EN 2008-04 8. 86d_Reparatur en bedingt.fm, 02.04.
Spare parts 8 Spare parts Note Always use only original CLECO replacement parts. Failure to comply with this instruction can result in decreased performance and an increased need for maintenance. Installing replacement parts from other manufacturers will void all manufacturer's warranties. We would be glad to prepare a special quote for you for spare and wear parts.
8 Spare parts 8.1 Pistol grip OFF 0,7±0,1 Nm 0.5±0.1 lbf.ft 1 / ISO 4757 11 12 10 ! click 23 (22) 5 (24) 22 26 25 13 14 OFF 0,7 ±0,1 Nm 0.5 ±0.1 lbf.ft 15 1 935490 SW2 16 17 18 2 19 OFF 1 3 1,5+0,2 Nm 1.1+0.15 lbf.ft 931030 SW2,5 9 20 OFF 3+1 Nm 2.2+1 lbf.ft 21 : 933375 4 5 4 6 OFF 20+2 Nm 14.8+1.5 lbf.ft SW17 7 8 26 Connection for evaluation electronics TVP100 Adhesive, order no. 914860 Grease, order no.-Nr. 914392 P1885E/EN 2008-04 85e_Ersatzteile en.fm, 02.04.
Spare parts Index 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1) 935602 934917 935720 935434 922660 935437 905031 905599 S905998 935613 931792 935442 935482 539188 935441 504970 935440 912150 935439 905086 935446 911315 903764 935635 916772 917815 2) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3) K1 K1 K1 K1 K1 K1 K1 K1 K1 K1 K1 K1 K1 K1 Description pistol grip housing asm.
8 Spare parts 8.2 Motor unit 935635 Axial clearance, see 7.4.1 Assembling the end plate, page 21 Reference dimension X, see 7.4.3 Assembling the actuating ring, page 23 28 P1885E/EN 2008-04 85e_Ersatzteile en.fm, 02.04.
Spare parts Index 30 31 32 33 34 35 36 40 41 44 45 47 48 49 50 51 52 53 54 55 56 58 59 60 61 1) 935479 902862 935443 935405 935463 935464 935465 935404 935451 935491 902862 935431 926570 935614 917793 911315 935444 935450 917794 935498 926565 935624 935630 935627 935628 935621 915832 2) 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 7 1 1 1 3) Description K1 washer K1 retaining ring actuating ring K1 ball K1 ball sleeve 3,8 K1 ball sleeve 3,5 K1 ball sleeve 3,2 K1 washer K1 compression spring torque adj
8 Spare parts 8.3 Pulse unit 66 Tightening torque, see 7.5 Assembling the pulse unit, page 24 For disassembly, note the position of the balls in the control disc. Reassmble the balls in the same position. 70 67 68 69 (70) 77 71 76 72 78 65 94 93 92 75 73 79 7 80 ! 74 3 81 73 82 83 84 86 101 ! 85 87 88 OFF 89 fest tight 902904 ø53 OFF 1+0,3 Nm 0.75+0.25 lbf.ft 935490 SW2 90 30 P1885E/EN 2008-04 85e_Ersatzteile en.fm, 02.04.
Spare parts Index 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 1) * 921623 922645 935622 916809 935652 935960 916772 * 935631 935616 935632 935615 935618 935612 917793 935608 911315 919140 S909126 935646 902106 935633 921414 935647 935626 933818 914433 9D6481 26989 935651 * * * * * 935725 935644 2) 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3) K2 K2 K2 K2 K2 K2 K2 K2 K2 K2 K2 K2 K2 K2 K2 K2 K2 K2
8 Spare parts 8.4 Equipment order list 1)Order no. 32 P1885E/EN 2008-04 85e_Ersatzteile en.fm, 02.04.
Technical data 9 Technical data 9.1 Dimensions in mm SW2,5 19,7 190 27,6 194 18 ø29,5 ø16 f8 ø57 ø53 -0,1 ø3 4 46 15,1 192 25 Ø29 29,1 SW17 1/4-18NPT Abb. 9-1 9.2 Performance Data Order no. Recommended torque range ft.lbf (Nm) min. max. 80PTHD604 85f_TechnDaten en.fm, 02.04.2008 Air consumption rpm 10.9 mm 6000 M10 1/2" 37 (50) 80PTHD60Q Free speed 59 (80) 7/16" P1885E/EN 2008-04 lb (kg) 3.1 (1,40) 3.2 (1,45) ft3/min (m3/min) Free speed Pulses 26.5 (0,75) 19.
10 Service 10 Service NOTE If repair is required send the complete 80PTHD… to Cooper Power Tools. It may be repaired only by authorized technicians. If the tool is opened, the warranty is voided. 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. 34 ➔ Catch auxiliary materials (oils, greases) when drained and dispose of them properly.
Sales & Service Centers Note: All locations may not service all products. Please contact the nearest Sales & Service Center for the appropriate facility to handle your ser vice requirements. Dallas, TX Cooper Power Tools Sales & Service Center 1470 Post & Paddock Grand Prairie, TX 75050 Tel: (972) 641-9563 Fax: (972) 641-9674 Detroit, MI Cooper Power Tools Sales & Service Center 4121 North Atlantic Blvd. Auburn Hills, MI 48326 Tel: (248) 391-3700 Fax: (248) 391-6295 Cooper Power Tools P.O.
