OPERATING INSTRUCTIONS AND SERVICE MANUAL 5ML-.6B- 837 FIXTURIZED NUTRUNNER COMPLETE TOOL MODEL NO. CODE NO. 5ML-.6B-837 230837 READ SAFETY RECOMMENDATIONS BEFORE OPERATING TOOL Printed in U.S.A. 2--97
Safety Recommendations For your safety and the safety of others, read and understand the safety recommendations and operating instructions before operating any tool. Always wear protective equipment:! For additional information on eye protection and face protection, refer to Federal OSHA Regulations, 29 Code of Federal Regulations, Section 90.33., Eye and Face Protection, and American National Standards Institute, ANSI Z87., Occupational and Educational Eye and Face Protection. Z87. is available from the American National Standards Institute, Inc., West 42nd Street New York, NY. 0036.! WARNING Impact resistant eye protection must be worn while operating or working near this tool. 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 equipment in the area, reflective surfaces, process noises and resonant structures can substantially contribute to, and increase the noise level in the area. Excessive air pressure above 90 PSIG or worn motor components can also increase sound level emitted by tool. For additional information on hearing protection, refer to Federal Regulations, Section 90.95, Occupational Noise Exposure, and American National Standards Institute, ANSI S2.6, Hearing Protectors. Cleco tools 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 increases 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). Being careful not to endanger adjacent personnel, clear the air hose of accumulated dust and moisture. 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.! WARNING Repetitive work motions and/or vibration can 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 consisting of highly repetitive motions and/or exposure to extended vibration. Cumulative trauma disorders such as carpal tunnel syndrome and tendonitis can 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, smoking 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 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 symptoms 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 design, 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 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. 2
Safety Recommendations The following suggestions will help reduce or moderate the effects of repetitive work motions and/or extended vibration exposure: Use a minimum hand grip force consistent with proper control and safe operation Keep body and hands warm and dry (cold weather is reported to be a major factor contrib uting to Raynaud's Syndrome) Avoid anything that inhibits blood circulation Smoking Tobacco (another contributing factor) Cold Temperatures Certain Drugs Avoid OK Avoid Avoid OK Avoid Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation 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. Stressful postures should be avoided select a tool appropriate for the job and work location Avoid highly repetitive movements of hands and wrists, and continuous vibration exposure (after each period of operation, exercise to increase blood circulation) Keep tool well maintained and replace worn parts Work gloves with vibration reducing liners and wrist supports are available from some manufacturers of industrial work gloves. Tool wraps and grips are also available from a number of different manufacturers. These gloves, wraps, and wrist supports are designed to reduce and moderate the effects of extended vibration exposure and repetitive wrist trauma. Since they vary widely in design, material, thickness, vibration reduction, and wrist support qualities, it is recommended that the glove, tool wrap, or wrist support manufacturer be consulted for items designed for your specific application. WARNING! Proper fit of gloves is important. Improperly fitted gloves may restrict blood flow to the fingers and can substantially reduce grip strength. A booklet, Assembly Tool Ergonomics, is available free of charge by writing the following address: Industrial Tool Division P. O. Box 40430 Houston, Texas 77240 USA 73/462-452 Please request Form No. 60669. For more information on the safe use of portable air tools, see the latest edition of ANSI B86., Safety Code for Portable Air Tools, available from the American National Standards Institute, Inc. West 42nd Street New York, NY. 0036. 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 ligibility. Replace warning labels when missing or when the information can no longer be read. Replacement labels can be ordered as any spare part. 3
OPERATING INSTRUCTIONS FOR YOUR SAFETY AND THE SAFETY OF OTHERS READ AND UNDERSTAND THE SAFETY RECOMMENDATIONS BEFORE OPERATING TOOL. OPERATION The tools are designed to operate on 90 PSIG (6.2 bar) air pressure. The 5ML series requires a 3/8" hose. The 5ML series is started by depressing the lever and stopped by releasing the lever. 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 0W 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. 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. All other gears and open bearings should receive a generous amount of Shell #655 Maleus compound during assembly. After completing assembly of the gear case, and prior to assembling it with the motor and motor housing, additional Shell lubricant must be added until the gear case cavity is approximately 2/3 full. Do not overfill. 4
SERVICE INSTRUCTIONS FOR YOUR SAFETY AND THE SAFETY OF OTHERS READ AND UNDERSTAND THE SAFETY RECOMMENDATIONS BEFORE SERVICING TOOL. DISASSEMBLY The tool should be clamped in the vise with the gear train in a vertical position. Using a suitable wrench, unscrew the gear case and slip the motor out of the motor housing. NOTE: On the double reduction tools, the first reduction spider will remain with the motor and should be removed at this time. This completes the disassembly of the tool into three (3) major subassemblies (Gear Case, Motor, and Motor Housing). See the following paragraphs for complete disassembly instruction. GEAR CASE: Holding the second gear case No. 6336, in the vise, unscrew bearing retainer No. 203672. Drive third reduction gear spider No. 204623, out of bearing No. 84365. Unscrew second gear case No. 6336, from gear case. The second reduction spider assembly may be pressed out the rear of the gear case, No. 20369, after the retainer ring, No. 864240, is removed from the inside of the gear case. After the spider bearings have been removed, using a suitable bearing puller, the idler gears may be removed for inspection by driving the idler gear pins out the rear of the spiders. MOTOR: Using a soft-faced mallet, drive the rotor out of the front rotor bearing, No. 6999. This will allow the removal of the front bearing plate, No. 865344, cylinder, No. 864236, and rotor blades, No. 869575. After removing the rotor lock nut, No. 865352, from the rear rotor shaft, the rotor may be driven out of the rear rotor bearing, No. 843444. MOTOR HOUSING: The throttle valve, No. 869350, used in the pistol grip handle may be removed for inspection by unscrewing the inlet bushing, No. 83347. The lever backhead throttle valve seal, No. 847366, may be removed by unscrewing the throttle valve cap, No. 86453. Unscrew the inlet bushing, No. 88276, for inspection and cleaning of the air screen on the lever backhead. REASSEMBLY The tool is reassembled in the reverse of disassembly. All parts should be thoroughly cleaned and inspected for wear before reassembly. Replace all bearings which feel rough or have excessive end play. The seals on bearing No. 6999 and No. 84365 should be checked closely and the bearing should be replaced if visible damage is evident to the seals. All other gears and open bearings should receive a generous amount of Shell #655 Maleus compound during assembly. After completing assembly of the gear case, and prior to assembling it with the motor and motor housing, additional Shell lubricant must be added until the gear case cavity is approximately 2/3 full. Do not overfill. 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 rotor lock nut to start. Tighten the lock nut until there is approximately.005" (.038mm) clearance between the rotor and bearing plate. The outer bearing race should be firmly seated and the rotor bumped forward when checking this clearance. SOFT JAWED VISE.005" Clearance It is recommended that new rotor blades be installed at each repair cycle. If not replaced, the used ones must measure a minimum of 7/32" (5.5mm) at both ends. Must be replaced if 7/32" (5.5mm) or less at either end. The front motor bearing is sealed, so it cannot be packed with greased. The rear rotor bearing should be packed with a good grade of NLGI 2-EP grease after assembly of the motor unit. During assembly of the gear case to the motor and motor housing, be sure that the teeth of the rotor mesh with the teeth of the idler gears. Rotate the gear train by hand to be sure the teeth are properly meshed before air is applied. 5
PART NO. NAME OF PARTS QTY. 2003-2 202339-8 203672-20369- 204623-3 20463-6 * 204632-4 6336-5 63363-4 6999-3 8264-2 843444-84365-6 844364-0 844773-2 844774-0 * 844799-7 * 84747-6 847366-2 84770-847808-3 86992-6 863623-5 864236-5 864240-7 864323- * 864329-8 864340-5 86453-9 864737-2 864964-2 865344-6 865352-9 869055-4 869575-869777-3 869778-8806-0 88276-0 EXHAUST DEFLECTOR SAFETY LABEL BEARING RETAINER GEAR CASE 3RD RED. SPIDER 2ND. RED. SPIDER (4T) ST. RED. SPIDER (4T) GEAR CASE PIN, DOWEL PIN, ROLL RETAINER RING IDLER GEAR BEARING PIN THROTTLE VALVE SEAL "O"RING PIN, GROOVE LOCK-OFF LEVER SPRING, THROTTLE VALVE CYLINDER BEARING RETAINER 2ND. & 3RD. RED. IDLER GEAR (6T) GEAR, RING ST. RED. IDLER GEAR (8T) CAP "O"-RING GREASE FITTING FRONT BEARING PLATE NUT, LOCK REAR BEARING PLATE ROTOR BLADE ROTOR BACKHEAD VALVE, THROTTLE BUSHING s 2 6 6 4 2 4 * PARTS INCLUDED IN 2ND. RED. SPIDER SUBASSEMBLY 20767 PARTS INCLUDED IN ST. RED. SPIDER SUBASSEMBLY 20766 6
864323 844774 204623 864323 20463 844774 204632 865344 6999 86992 7