41NDR Series Air Shut-Off Ratchet Wrench

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1 Instruction Manual PL17EN-41NDR 41NDR Series Air Shut-Off Ratchet Wrench For additional product information visit our website at

2 PL17EN-41NDR Cleco General Information For this Instruction Manual This Instruction Manual is the Original Instruction Manual intended for all persons who will operate and maintain these tools. This Instruction Manual provides important notes for the safe and efficient use of these tools. describes the function and operation of the 41NDR series tools. serves as a reference guide for technical data, service intervals and spare parts ordering. provides information on optional equipment. Identification text: 41NDR represents all models of the air shut-off ratchet wrench as described in this manual Ú indicates a required action indicates a list <..> indicates a reference number from the exploded parts drawings Arial indicates an important feature or instruction written in Arial Bold Identification graphic: indicates a directional movement ò indicates a function or force Copyright protection: Apex 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

3 Cleco Nomenclature PL17EN-41NDR 41 N DR XXX XXX Tool Series 41 Tool Rotation N = Non-Reversible Tool Type DR = Ratchet Wrench: Air Shut-Off Motor Speed 130 = 1300 RPM 172 = 1720 RPM 236 = 2360 RPM Ratchet Attachment Code Refer to PL17-RA for attachment information Page 3

4 PL17EN-41NDR Cleco Contents 1 Safety Warning and notes Basic requirements for safe working practices Operator training Personal protective equipment Designated use Codes and standards Noise and vibration Scope of supply, transport and storage Items supplied Transport Storage Product description General description Operation and functional elements Accessories 11 5 Before initial operation Ambient conditions Air supply Connecting the air supply to the tool Tool set up Setting the torque First operation Puting into use Troubleshooting 15 8 Maintenance Service schedule Calculating a customer specific maintenance plan Lubricants Repair instructions Motor assembly Air Shut-Off Valve...19 Page 4

5 Cleco Contents PL17EN-41NDR 10 Spare parts NDR Handle Assembly Motor Assembly Single Stage Gearing Assembly Double Stage Gearing Assembly Cam Adapter Assembly Ratchet Wrench Attachments Technical data NDR Specifications Service Replacement parts Tool repairs Warranty repairs Disposal 33 Page 5

6 PL17EN-41NDR Cleco Safety 1 Safety 1.1 Warnings and notes Warning notes are identified by a signal word and a pictogram. The signal word indicates the severity and probability of the impending danger. The pictogram indicates the type of danger WARNING identifies a potentially hazardous situation which, if not avoided, may result in serious injury CAUTION identifies a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property and environmental damage NOTE identifies general information which may include application tips or useful information but no hazardous situations Important information that must be read and understood by all personnel installing, operating or maintaining this equipment Page 6

7 Cleco Safety PL17EN-41NDR 1.2 Basic requirements for safe working practices All personnel involved with the installation, operation or maintenance of these tools must read and understand all safety instructions contained in this manual. Failure to comply with these instructions could result in serious injury or property damage. These safety instructions are not intended to be all inclusive. Study and comply with all applicable National, State and Local regulations Work Area: Ú Ensure there is enough space in the work area. Ú Keep the work area clean. Ú Keep the work area well ventilated. Personnel Safety: Ú Inspect the air supply hoses and fittings. Do not use damaged, frayed or deteriorated hoses. Ú Make sure the air supply hose is securely attached to the tool. Ú Ensure a secure standing position and maintain balance. Ú Make sure the throttle is positioned relative to the head so the throttle will not become wedged against an adjacent object in the ON position due to torque reaction. Ú Keep the tool clean and dry to provide the best possible grip. Ú Firmly grasp the handle of the 41NDR and apply the socket to the application before starting. Ú Be prepared for high short-term reaction torques. Safety working with and around fastening tools: Ú Use only power tool sockets available from Apex Tool Group. Ú Inspect socket for visible damage and cracks. Replace damaged items immediately. Ú Disconnect the air supply before installing or replacing the socket. Ú Engage the socket fully on the application Operator training All personnel must be properly trained before operating the 41NDR tools. The 41NDR tools are to be repaired by fully trained personnel only. 1.4 Personal protective equipment When working Wear eye protection to protect against flying metal splinters. Wear hearing protection Danger of injury by being caught by moving equipment. Wear a hairnet Do not wear close fitting clothing Do not wear jewelry Page 7

8 PL17EN-41NDR Cleco Safety 1.5 Designated use The 41NDR is designed exclusively for fastening and releasing threaded fasteners. The 41NDR series are air shut-off ratchet wrenches. Do not modify the 41NDR, any guard or accessory. Use only with accessory parts which are approved by the manufacturer. Do not use as a hammer, pry-bar or any other improper usage. 1.6 Codes and standards It is mandatory that all national, state and local codes and standards be followed. 1.7 Noise and vibration Noise level 00 db(a) free speed (without load) according to ISO 12100: 2011 Vibration values < 0.0 m/s 2 according to ISO 12100: 2011 Page 8

9 Cleco Scope of Supply, Transport and Storage PL17EN-41NDR 2 Scope of supply, transport and storage 2.1 Items supplied Check shipment for transit damage and ensure that all items have been supplied: 1 41NDR 1 PL17EN-41NDR and PL17EN-RA instruction manual 1 Declaration of Conformity 1 Lubrication sheet 1 Warranty statement 2.2 Transport Transport and store the 41NDR in the original packaging. The packaging is recyclable. 2.3 Storage For short term storage (less than 2 hours) and protection against damage: Ú Place the 41NDR in a location on the workbench to avoid accidental depression of the lever. or Ú Suspend the 41NDR from a suitable balancer or tool positioner. For storage longer than 2 hours: Ú Disconnect the air supply from the 41NDR Object Time Period Storage Temperature 41NDR without air supply No guideline -13 F to 104 F (-25 C to 40 C) Page 9

10 PL17EN-41NDR Cleco Product Description 3 Product description 3.1 General description Pneumatic powered ratchet wrench Lever actuated Non-reversible: tool is reversed by rotating it 180 Air shut-off Various side plate widths accomodate a wide selection of socket hex sizes 3.2 Operation and functional elements This section describes the operational and functional elements of the 41NDR Ref. Description 1 Air Inlet 2 Throttle Lever 3 Motor and Gearing 4 Ratchet Attachment 5 Hex Socket Page 10

11 Cleco Accessories PL17EN-41NDR 4 Accessories Numerous Rachet Head Styles: NOTE: Not all attachments shown can be used with this motor, refer to sales catalog Miniature Straight Thin & Extra Thin Standard Straight 20 Angled Right 20 Angled Left 3 Extended 40 Angled Right Bent Right 40 Angled Left Bent Left Page 11

12 PL17EN-41NDR Cleco Before Initial Operation 5 Before initial operation 5.1 Ambient conditions Ambient temperature: Acceptable relative humidity: 41 F (5 C) to a maximum of 104 F (40 C) 25% to 90%, non-condensing 5.2 Air supply Parameter Air Hose Working pressure range Compressed air Description Hose diameter: 3/8" (9,5 mm) Maximum length: 16.4' (5 m) 58 to psi (400 to 700 kpa) Recommended: 90 psi (620 kpa) Air quality according to ISO , quality class The compressed air must be clean and dry. To attain consistent results, maintain a constant working pressure using a suitable air line unit consisting of a filter, regulator and lubricator. Ú The inside diameter of the air hose must be free of residue, clean if necessary. Ú Spray a few drops of light air tool oil into the air inlet adapter. Ú Adjust the lubricator to a minimum setting to reduce the amount of excess oil in the exhaust air. Oil identification Part No. Packaged Designation Vendor Quart (0.94 liter) Airlube 10W/NR-420LB DR Fuchs Lubricants Co US Gallon (3.78 liter) Airlube 10W/NR-420LB DR Fuchs Lubricants Co. 5.3 Connecting the air supply to the tool The air hose can disconnect from the tool by itself and whip around uncontrollably. Ú Turn off the compressed air before connecting to the tool. Ú Securely connect the air hose to the tool. Ú Turn on the compressed air Page 12

13 Cleco Before Initial Operation PL17EN-41NDR 5.4 Tool set up The tool must be configured for the application Setting the torque Torque is infinitely adjustable by regulating the air line pressure from a minimum of 55 psig to a maximum of 90 psig. Shut-off torque will be reduced approximately 12% for each 10 pound drop in air line pressure, below 90 psig. Operating the tool on less than 55 psig air pressure could produce erratic performance. Page 13

14 PL17EN-41NDR Cleco First Operation 6 First operation 6.1 Putting into use Ú Make sure the air supply is securely attached and the compressor is turned on. Ú Place the socket on the application and depress the lever to start the rundown. Ú When the tool shuts off after reaching torque, release the lever. Ú Remove the tool from the application. Page 14

15 Cleco Troubleshooting PL17EN-41NDR 7 Troubleshooting Malfunction Possible causes Remedy Tool does not start Improper air supply Make sure there is adequate air pressure at the tool air inlet Plugged air strainer Clean air strainer Apply several drops of air tool oil to the air Motor dry from lack of lubrication inlet. Using the cam, manually rotate the motor. Reconnect the air supply and run the motor to free it up. Broken gears Tool disassembly required (parts replacement) Tool runs slow Make sure there is adequate air pressure at Improper air supply and lacks torque the tool air inlet Plugged air strainer Clean air strainer Motor dry from lack of lubrication Apply several drops of air tool oil to the air inlet. Using the cam, manually rotate the motor. Reconnect the air supply and run the motor to free it up. Grease socket, pawl and cam areas with Attachment dry from lack of lubrication Teflon grease. Motor runs but socket does not turn Motor runs and socket oscillates but does not rotate Push rod not picking up socket teeth due to broken, bent or owrn cover plate. Broken push rod return spring Broken or worn push rod roller Broken or worn push rod tip Broken cam or motor gears Broken pawl springs Broken or worn pawl tooth Broken or worn socket teeth Broken push rod tip Worn push rod roller or cam preventing full stroke Worn side plate hole at socket Jammed pawl from dirt or lack of lubrication Remove cover plate and re-adjust or replace. Replace return spring Replace push rod roller Replace push rod Disassemble tool and replace broken parts Disassemble attachment and replace parts Disassemble attachment and replace parts Disassemble attachment and replace parts Disassemble attachment and replace parts Disassemble attachment and replace parts Disassemble attachment and replace parts Clean pawl area and apply lubricant Page 15

16 PL17EN-41NDR Cleco Maintenance 8 Maintenance Danger of injury from accidental start up. Turn off the compressed air before performing any maintenance Service schedule Only qualified and trained personnel are permitted to perform maintenance on these tools. Regular maintenance reduces operating faults, repair costs and downtime. In addition to the following service schedule, implement a safetu related maintenance program that takes the local regulations for repair and maintenance for all operating phases of the tool into account. Maintenance Interval Daily Rundowns Daily W1 100,000 W2 500,000 W3 1,000,000 Designation Visual inspection of air supply hose and connections Inspect airline filter, regulator and lubricator for proper operation Check the tool excessive vibration or unusual noises Visual inspection of all external components of the tool Inspect the air hose for damage or wear inspect the socket and pawl area for damage or wear Inspect the air inlet adapter for a secure fit Check the maximum free speed Check individual parts and replace if necessary Replace O-rings and seals Clean mufflers Check individual parts and replace if necessary Throttle valve Motor Gearing Ratchet attachment This maintenance schedule uses values that are valid for most applications. For a specific maintenance interval, refer to Calculating a customer-specific maintenance plan. Page 16

17 Cleco Maintenance PL17EN-41NDR Calculating a customer specific maintenance plan A service interval W(1, 2, 3) depends on the following factors: Factor Value assumed in "Service Schedule" Description V V1 = 100,000 Number of rundowns after a maintenance measure is prescribed by Apex V2-500,000 Tool Group. V3 = 1,000,000 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. 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. V x T x 1.8 W (1, 2, 3) = W2 = = 133 (days) T2 x S x VS 3 x 3 x 750 You will need to perform the maintenance indicated as W2 after an operating time of 133 days.) 8.2 Lubricants For proper function and long service life, use of the correct grease is essential. Grease lubricants recommended for this tool. Part No. Packaged Designation Vendor oz. (0.51 kg) Black Pearl EP-NLGI-0 Chevron oz. (0.06 kg) Magnalube-G Carleton-Stuart Corp oz. (0.45 kg) Magnalube-G Carleton-Stuart Corp oz. (0.06 kg) Rheolube 363AX-1 Nye Lubricants, Inc oz. (0.45 kg) Rheolube 363AX-1 Nye Lubricants, Inc. Page 17

18 PL17EN-41NDR Cleco Repair Instructions 9 Repair instructions 9.1 Motor assembly Clean all parts, except blades, in a solvent and blow dry. Inspect all parts for excessive wear or damage and replace as necessary. Minor scoring in the cylinder and on the faces of the end plates can be removed by honing or resurfacing. Rotor blades should be replaced as part of a regular maintenance service program. Rotor blades should be.002 (.05mm) to.005 (.13mm) shorter than the cylinder. Lower End Plate Rotor Blade Upper End Plate Rotor Cylinder Coat all motor components with a light film of air tool oil before reassembly. Align the cylinder so the locating pins are inserted through the slots in the end plates. Rotate the rotor spindle to make sure the rotor turns freely before tightening the stack-up nut. After tightening the stack-up nut, rotate the rotor spindle to make certain it turns freely. Page 18

19 Cleco Repair Instructions PL17EN-41NDR 9.2 Air Shut-Off Valve Removing the adjustment cap allows disassembly of the shut-off valve components. IMPORTANT: During disassembly, make note of how the shut-off valve is oriented in the bushing. The shut-off valve must be reassembled into the bushing in this same position. SERVICE NOTE: The bushing is not serviceable in the field. Bushing replacement must be performed at the factory. Metering Screw Adjustment Cap Shut-Off Valve Spring Air Shut-Off Valve The metering screw is not used to adjust the tool output torque. It is designed to control the amount of air bled from the shut-off valve cavity to ajust for proper shut-off function. From a fully seated position, back the metering screw out approximately 2 turns. If the tool stalls at this setting, back the metering screw off in 90 (1/4 turn) increments until the tool shuts off properly. Shut-off torque is adjusted by the use of a separate air line pressure regulator, refer to section Setting the torque. Page 19

20 PL17EN-41NDR Cleco Spare Parts NDR Handle Assembly 1 2 OFF Page 20

21 Cleco Spare Parts PL17EN-41NDR NDR Series Handle Assembly Ref Number # X Inlet Fitting PT 1 3 O-Ring Sleeve (included Ref. 4) O-Ring 5 A Screen Spring Throttle Valve PT 2 6 O-Ring Valve Seat Retaining Ring Handle (includes Ref. 16) Valve Stem Throttle Lever 14 RP103P 2 2 Throttle Lever Pin Lower Cushion Air Shut-Off Valve D 1 3 Shut-Off Valve Spring Adjustment Cap (includes Ref ) Upper Cushion Metering Screw (#) Quantity (X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation) EN Description Page 21

22 PL17EN-41NDR Cleco Spare Parts 10.2 Motor Assembly OFF 6 13 Page 22

23 Cleco Spare Parts PL17EN-41NDR 10.2 Motor Assembly Ref Number # X Signal Block (includes Ref. 2-4) Signal Block Gasket 3 RP102B 1 Roll Pin Signal Block Gasket Retaining Ring Needle Bearing Upper End Plate Cylinder (includes Ref. 9) 9 RP Cylinder Pin 10 Table Rotor Rotor Blade Lower End Plate Stack Up Nut (#) Quantity (X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation) EN Description Page 23

24 PL17EN-41NDR Cleco Spare Parts 10.3 Single Stage Gearing Assembly Models 41NDR172(---) 41NDR236(---) L 7 3 L 4 OFF L L Lubricate with Grease (18 oz. can) Page 24

25 Cleco Spare Parts PL17EN-41NDR 10.3 Single Stage Gearing Assembly Ref Number # X Retaining Ring Needle Bearing Washer Gear Cage 5 Table Planetary Gear Planetary Gear Pin Retaining Ring Washer Gear Case Needle Bearing PT 1 3 O-Ring Muffler Deflector (#) Quantity (X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation) (T) Teeth Table 10.3 Ref. Description # 41NDR172 # 41NDR236 5 Planetary Gear (27T) (25T) EN Description Page 25

26 PL17EN-41NDR Cleco Spare Parts 10.4 Double Stage Gearing Assembly Models 41NDR130(---) L L L L 5 8 L L 12 OFF L Lubricate with Grease (18 oz. can) Page 26

27 Cleco Spare Parts PL17EN-41NDR 10.4 Double Stage Gearing Assembly Ref Number # X Retaining Ring Needle Bearing Washer Slip On Gear (7T) Upper Gear Cage Upper Planetary Gear (18T) Upper Planetary Gear Pin Retaining Ring Short Spindle Gear 10 O Short Spindle Gear Key Washer Lower Gear Cage Lower Planetary Gear (18T) Lower Planetary Gear Pin Gear Case Needle Bearing PT 1 3 O-Ring Muffler Deflector (#) Quantity (X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation) (T) Teeth EN Description Page 27

28 PL17EN-41NDR Cleco Spare Parts Cam Adapter Assembly Used with Attachment Code Prefix: H, L, M, P, R, X, Y OFF ft.lbs. (54-68 Nm) 5 3 Page 28

29 Cleco Spare Parts PL17EN-41NDR 10.5 Cam Adapter Assembly Ref Number # X Cam Adapter Assembly Needle Bearing Adapter Thrust Race Needle Bearing Cam Shim (#) Quantity (X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation) EN Description Page 29

30 PL17EN-41NDR Cleco Spare Parts 10.6 Ratchet Wrench Attachments - Refer to PL17EN-RA Parts Manual Code Attachment Number EN Description EN Description A12 AA9D Miniature - Straight Side Plates S15 AA Straight Housing - 20 Bent Side Plate A13 AA9D Miniature - Straight Side Plates S16 AA Straight Housing - 20 Bent Side Plate B09 AA9D64359 Miniature - Straight Thin Side Plates T Angle Housing B12 AA9D Miniature - Straight Thin Side Plates T Angle Housing B13 AA9D Miniature - Straight Thin Side Plates V Angle Housing - Thin Type C13 AA " Extended - Straight Side Plates V Angle Housing - Thin Type D13 AA " Extended - 20 Bent Side Plate V Angle Housing - Thin Type E12 AA Angle Housing W Angle Housing - Extra Thin Type E13 AA Angle Housing W Angle Housing - Extra Thin Type F12 AA Angle Housing X " Extended - 20 Angle Housing F13 AA Angle Housing X " Extended - 20 Angle Housing G Angle Housing - Thin Type Y " Extended - 20 Angle Housing H15 AA9D Standard - Straight Side Plates Z13 AA " Extended - 20 Bent Side Plate H16 AA9D Standard - Straight Side Plates HD20 AA Straight H18 AA9D Standard - Straight Side Plates HD24 AA Straight H20 AA9D Standard - Straight Side Plates HD32 AA Straight H25 AA9D Standard - Straight Side Plates HD40 AA Straight H29 AA9D Standard - Straight Side Plates HD48 AA Straight H37 AA9D Standard - Straight Side Plates HD56 AA Straight J Straight Housing - Extra Thin Type J Straight Housing - Extra Thin Type K Straight Housing - Thin Type K Straight Housing - Thin Type K Straight Housing - Thin Type K Straight Housing - Thin Type L16 AA " Extended - Straight Side Plates L20 AA " Extended - Straight Side Plates M27 AA Straight Housing - Open End N16 AA Straight Housing - 20 Bent Side Plate N20 AA Straight Housing - 20 Bent Side Plate P Angle Housing P Angle Housing P Angle Housing P Angle Housing P Angle Housing P Angle Housing Q Angle Housing Q Angle Housing Q Angle Housing R Angle Housing R Angle Housing R Angle Housing R Angle Housing R Angle Housing Note: Refer to the suffix code in the model number to determine the proper attachment part number. Code Attachment Number Page 30

31 Cleco Technical Data PL17EN-41NDR 11 Technical data NDR Specifications Free Maximum Maximum Overall Model Number Speed Torque Socket Size Length Weight RPM Ft. Lbs. Nm in. mm in. mm lbs. kg 41NDR236H / NDR172H / NDR130H / NDR236H / NDR172H / NDR130H / NDR236H / NDR130H * / NDR172H / NDR130H * / NDR172H * / NDR130H * / * WARNING: These terminations are not recommended for applications over 50 Ft. Lbs. (68 Nm) torque. Page 31

32 PL17EN-41NDR Cleco Service 12 Service 12.1 Replacement parts Use only original Cleco replacement parts. Failure to comply can result in reduced power and increased service requirements. The tool warranty may be voided if replacement parts are not manufactured or approved by Apex Tool Group Tool repairs Only qualified and trained personnel are to repair this equipment Warranty repairs All warranty repairs are to be performed by an authorized Apex Tool Group service center. Contact your local representative for assistance with warranty repair claims. Page 32

33 Cleco Disposal PL17EN-41NDR 13 Disposal Injuries and environmental damage from improper disposal. Components and auxillary materials of the tool pose risks to health and the environment. Ú Capture auxillary materials (oils, greases) when drained and dispose of them properly. Ú Separate the packaging components and dispose of them properly. Ú Comply with all applicable local regulations. Observe local disposal guidelines for all components of this tool and its packaging Page 33

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36 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 service requirements. Detroit, MI Houston, TX Lexington, SC Los Angeles, CA Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group Sales & Service Center Sales & Service Center 670 Industrial Drive Sales & Service Center 2630 Superior Court 6550 West Sam Houston Lexington, SC Stanton Avenue Auburn Hills, MI Parkway North, Suite 200 Tel: Unit B Tel: Houston, TX Tel: Buena Park, CA Fax: Tel: Fax: Tel: Fax: Fax: Seattle, WA York, PA Canada Germany Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group Sales & Service Center Sales & Service Center Sales & Service Center GmbH & Co. OHG nd Avenue N.E East Market Street 5925 McLaughlin Road Industriestraße 1 Redmond, WA York, PA Mississauga, Ont. L5R 1B Westhausen Tel: Tel: Canada Germany Fax: Fax: Tel: Tel: +49 (0) Fax: Fax: +49 (0) England France China Mexico Apex Tool Group Apex Tool Group S.N.C. Cooper (China) Co., Ltd. Cooper Tools GmbH & Co. OHG 25 rue Maurice Chevalier a company of de México S.A. de C.V. C/O Spline Gauges B.P. 28 Apex Tool Group, LLC a company of Piccadilly, Tamworth Ozoir-La-Ferrière 955 Sheng Li Road, Apex Tool Group, LLC Staffordshire B78 2ER Cedex, France Heqing Pudong, Shanghai Vialidad El Pueblito #103 United Kingdom Tel: China Parque Industrial Querétaro Tel: Fax: Tel: Querétaro, QRO Fax: Fax: Mexico Tel: +52 (442) Fax: +52 (442) Brazil Hungary Cooper Tools Industrial Ltda. Apex Tool Group a company of Hungaria Kft Apex Tool Group, LLC Platànfa u.2 Av. Liberdade, Györ Zona Industrial - Iporanga Hungary Sorocaba Tel: SP Brazil Fax: Tel: Fax: Apex Tool Group, LLC 1000 Lufkin Road Apex, NC Phone: Fax: PL17EN-41NDR/Printed in USA 01/2013/Copyright Apex Tool Group, LLC

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