Parts Manual PL2-029EN Formerly: PC-468-5080 SW00PRY220 (4685080) Reversible Pistol Grip Swivel Reaction Bar Nutrunner Caterpillar # 8T-590 For additional product information visit our website at http://www.apextoolgroup.com
PL2-029EN Cleco General Description Free Weight Order Bolt Size Square Torque Length Model Speed (w/o Torque Bar) Number Drive (in.) in. mm ft. lbs. Nm RPM in. mm lbs. kg SW00PRY220 4685080 3/4 M20 /2 220 298 70 0.8 274 8.0 3.6 Language Version: This Parts Manual is the Original Instructions intended for all persons who will use or repair these tools. Noise and Vibration: Refer to documents CE-000DC and CE-000TD. General Description: Air powered reversible pistol grip portable nutrunner equipped with a swivel reaction bar. Intended Use: This air assembly tool is intended for tightening of threaded joints or running down fasteners. Use only for the designated purpose. Do not use as a hammer, lever or other improper usage that can cause tool damage and operator injury. 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
Cleco General Instructions PL2-029EN Maintenance and Service: Installation: Make certain the airline is clean and free of scale and dirt before connecting to the air motor. Check all fittings to make sure there are no air leaks. An airline filter/lubricator should be installed as close to the tool as possible. If an excessive amount of water is present in the airline, a water trap should be installed to trap as much as possible before it reaches the tool. Lubrication: If the airline carries an excessive amount of water and a water trap can not be installed, use a good grade of motor oil (an oil that will emulsify with water) to prevent damage to vital nutrunner parts. Use a good grade of oil, SAE0 or 0W, with a viscosity of 00-50. Do not use oil in the gear case. Use a good quality Extreme Pressure (E.P.) lubricant. Before installing o-rings, coat the o-rings and the adjacent surfaces with Parker-O-Lube. During Reassembly: Needle rollers must be lubricated with E.P. grease after installation into the idler gears. Fill the gear pockets in gear cages and coat the idler gear teeth with E.P. grease. Brush coat all thrust washers with E.P. grease. Torque Adjustment: Torque adjustment can be accomplished by the use of a dedicated pressure regulator supplying air to the tool. A 0 PSI change in air pressure will change the output torque by approximately 3% and the speed will change by 5%. If a line pressure regulator is not available, output torque can be adjusted by installing the Cleco SelecTork option. Refer to Service Note 2. Disassembly Instructions: Refer to exploded parts illustrations A through D for disassembly. Motor: Using a /4 diameter, or smaller, soft rod, tap on the back of the rotor to remove the upper end plate and bearing. The rotor and lower end plate are a press fit. and reversing sleeve bushing onto the reversing sleeve. Insert the throttle valve into the trigger and secure with the trigger pin. Install the trigger spring over the throttle valve and into the trigger. Install the trigger assembly into the reversing sleeve and secure with the valve seat washer and o-ring. Note: The reversing sleeve bushing must rotate freely (360 ) after assembly. This will assure proper spring force return of the trigger when assembled into the pistol grip housing. Install the o-ring into the reversing valve bore of the pistol grip housing. Assemble the reversing valve assembly into the pistol grip housing. Align the shoulder screw hole in the reversing sleeve bushing with the corresponding hole in the pistol grip housing. Install the shoulder screw, with lock washer, to secure the reversing valve assembly. Assemble the air regulator components into the pistol grip housing. Assembly the air inlet bushing components or SelecTork option into the pistol grip housing. Motor Assembly: Install the bearing and wave washer into the lower end plate. Press the end plate assembly onto the rotor (press across both bearing races) and secure with the retaining ring. Assembly the o-ring onto the lower end plate and install the rotor blades. Install the cylinder by aligning the roll pin with the hole in the lower end plate. Place the bearing spacer on the back of the rotor. The bearing spacer is furnished in three sizes. Select the size that will provide a 0.0005 to 0.005 clearance between the rotor and the upper end plate, when assembled. Example: If a 0.002 feeler gauge can be inserted on one side when the upper end plate is pushed away from the rotor, this indicates a clearance of 0.00 when the motor is assembled, see Figure. The end plate should turn with a little resistance indicating the clearance has been correctly measured. Figure Assembly Instructions: Refer to exploded parts illustrations A through D for assembly. Pistol Grip Housing Assembly: Reversible Throttle: Install the reversing sleeve spring Page 3
PL2-029EN Cleco General Instructions Install the upper end plate by aligning the roll pin in the upper end plate with the hole in the cylinder. Install the bearing and secure with the button head screw (left hand thread). Make sure the rotor shaft turns freely after assembly. Install the motor assembly into the pistol grip housing. Caution: If the pins are not properly located, the gear case will not seat correctly, resulting in a loss of power. Swivel Assembly: Note: Do not coat the packing with any lubricant. The packing must be assembled dry. Hold the swivel motor housing in your hand with your thumb inside the unthreaded end. Install the packing into the threaded end of the swivel motor housing (packing lip and o-ring installed towards the threads). Use your thumb to help work the packing into the groove. Trying to work the last inch of packing into place may cause the it to roll in the groove. Using a small screwdriver and your thumb, the packing can be squared up so it will fit into the groove properly. Install the swivel gear housing into the swivel motor housing. Align the ball grooves and insert the 27 steel balls through the pipe plug hole, then install the pipe plug. At first, the swivel may appear to be tight. After a short break in period the swivel should provide sufficient resistance to hold the reaction bar in position and still permit the operator to rotate the bar when required. Install the swivel motor housing into the pistol grip housing. Use a spanner wrench on the flats to tighten the swivel motor housing (R.H. thread) to 65-75 foot pounds torque. Install the inner exhaust deflector and o-ring. Gearing Assembly: Install the gear housing muffler and deflector ring on the gear housing (first and second stages). Assemble the muffler, o-ring and exhaust deflector onto the gear housing. Thread the gear housing assembly onto the swivel gear housing and tighten to 65-75 foot pounds torque. Gearing assembly note: The idler gear needle rollers must be lubricated with E.P. grease after installation into the idler gears. Fill the gear pockets in the gear cages and coat the idler gear teeth with E.P. grease. Brush coat the thrust washers with E.P. grease. Install one thrust washer into the gear housing. Make sure it seats in the deflector ring. Assemble the idler gears, needle rollers, washers and idler pins into the first stage gear cage. Work this gearing assembly into the gear housing (splined end out) and onto the splined end of the rotor. Install two thrust washers. Assemble the idler gears, needle rollers, washers and idler pins into the second stage gear cage. Work this gearing assembly into the gear housing (splined end out) and onto the splined end of the first stage gearing assembly. Apply Loctite #242 to the threads of both gear housings. Thread the third stage gear housing (L.H. thread) onto the first and second stage gear housing. Tighten to 45-50 foot pounds torque. Install two thrust washers. Assemble the idler gears, needle rollers, washers and idler pins into the third stage gear cage. Work this gearing assembly into the gear housing (splined end out) and onto the splined end of the second stage gearing assembly. Output and Torque Reaction Bar Assembly: Press the sealed needle bearing into the bearing cap. The seal should be facing the front of the bearing cap and flush with the outer bearing cap face. Install the spacer, output spindle and ball bearing into the bearing cap. Thread the bearing cap assembly (L.H. thread) into the gear housing. Tighten to 45-50 foot pounds torque. Install the lock ring; align the lock ring tangs with the slots in the gear housing by tightening the bearing cap beyond 45 foot pounds torque. Install the torque reaction bar and secure it in place with the lock nut (L.H. thread). Bending: Use a template to determine the correct torque reaction bar configuration. The torque reaction bar must be heated to a dull cherry red prior to bending. Normally, it is best to bend the reaction bar using a bar-bending fixture or a piece of pipe rather than hammering into shape. The reaction bar should be allowed to air cool and not quenched in either water or oil. Page 4
Cleco General Instructions PL2-029EN Installation: After bending the torque reaction bar to the desired configuration, assemble as shown in Figure 2. Figure 2 Color code the reaction side of the bar if the reaction point does not completely contain the torque reaction bar. To reduce the chance of personnel injury, make the torque reaction bar as short as possible without exceeding the recommended bending proportions. Do not use drive extensions without taking into account the bar proportions. Gearing Assembly Lock Nut Torque Reaction Bar Since the reaction of the torque bar opposes the spindle rotation, it should be used with the bar against the work opposite the tool s rotation, see Figure 3. Figure 3 Warning Label: 4606842 Run the tool at a low air pressure to assure the torque reaction bar configuration is correct. Add a piece of rubber air hose over the end of the torque reaction bar to protect painted or finished surfaces. Lock into the reaction point whenever possible: holes, adjacent fasteners, inside channel, fork bar around pipes or tubular members. Page 5
PL2-029EN Cleco 4804603 Pistol Grip Housing Assembly A 2 0 4 5 6 4 5 7 6 3 9 2 3 8 2 7 8 9 5/6 Flats 2 See Service Notes Page 6
Cleco 4804603 Pistol Grip Housing Assembly PL2-029EN Illustration "A" Ref Number # X 480450 Pistol Grip Housing 2 942002 2 Lockwasher 3 46066 2 Shoulder Screw 4 80089PT Air Regulator 5 93000 3 O-Ring (Air Regulator) 6 80090 Air Regulator Plug 7 5808006 Air Inlet Bushing (includes Ref. 8-9) 8 250082 3 Air Inlet Screen 9 92600006 3 Retaining Ring 0 8443 3 O-Ring 9300007 3 O-Ring (Trottle Valve) 2 46046 Valve Seat Washer 3 4207823 Reversing Sleeve Bushing 4 4656 3 Reversing Sleeve Spring 5 246057 Reversing Sleeve 6 46035 Throttle Valve 7 843067 3 Trigger Spring 8 8433A Trigger 9 92530037 3 Trigger Pin (#) Quantity (X) Recommended Spare Parts (quantity shown based on -5 tools in operation) EN Description Page 7
PL2-029EN Cleco Motor and Swivel Assembly B A 3 2 8 6 5 3 9 4 0 L.H. Thread 4 2 4 7 3 8 6 5 7 20 2 2-/6 x 3/8 Flats 9 2-/6 x 3/8 Flats 3 See Service Notes Page 8
Cleco Motor and Swivel Assembly PL2-029EN Illustration "B" Ref Number # X EN Description -- 4887002 Motor Assembly (includes Ref. -4) 4802907 Button Head Screw 2 920007 2 Ball Bearing 3 4804702 Upper End Plate (includes Ref. 4) 4 92530033 2 4 Roll Pin 480922 Bearing Spacer - Black (.580/.585) 5 480992 Bearing Spacer - Copper (.570/.575) 480993 Bearing Spacer - Plain (.560/.565) 6 4802704 Cylinder (includes Ref. 4 and Ref. 7) 7 9253005 2 Roll Pin 8 480927 5 5 Rotor Blade 9 48775 Rotor 0 480729 Lower End Plate 9300022 3 O-Ring (Lower End Plate) 2 94080005 2 Wave Washer 3 9200006 2 Ball Bearing 4 926002 2 Retaining Ring 5 487803 Inner Exhaust Deflector 6 9300022 3 O-Ring (Inner Exhaust Deflector) -- 487800 Swivel Assembly (includes Ref. 7-2) 7 * Note Swivel Motor Housing 8 260432 Pipe Plug 9 9305005 3 Packing 20 9400008 27 27 Steel Ball (3/6") 2 * Note Swivel Gear Housing (#) Quantity (X) Recommended Spare Parts (quantity shown based on -5 tools in operation) * Note: Can not be purchased separately. Must purchase Swivel Assembly 487800 Page 9
PL2-029EN Cleco 48036022 Gearing Assembly C 3 2 4 5 20 8 9 8 9 2 5 9 2 0 9 9 3 8 7 6 2 Flats L.H. Thread Loctite 242 4 6 L.H. Thread Loctite 242 7 3 2-/8 Flats L.H. Thread See Service Notes Page 0
Cleco 48036022 Gearing Assembly PL2-029EN Illustration "C" Ref Number # X 8072B 3 Gear Housing Muffler 2 480387 Deflector Ring 3 8072C 3 Muffler 4 480826 Exhaust Deflector 5 9304004 3 O-Ring (Exhaust Deflector) 6 4803707 Gear Housing (st and 2nd Stages) 7 92060023 Thrust Washer 8 4803725 Gear Cage (st Stage) 9 48098 2 24 Idler Gear Washer 0 480480 3 6 Idler Gear (20T) 9288005 50 50 Idler Gear Needle Roller 2 48090 6 2 Idler Gear Pin 3 9206008 4 Thrust Washer 4 4803772 Gear Cage (2nd Stage) 5 4803829 3 6 Idler Gear (5T) 6 4803703 Gear Housing (3rd Stage) 7 480370 Gear Cage (3rd Stage) 8 480395 6 2 Idler Gear Washer 9 4803804 3 6 Idler Gear (7T) 20 480396 3 6 Idler Gear Pin (#) Quantity (X) Recommended Spare Parts (quantity shown based on -5 tools in operation) (T) Teeth EN Description Page
PL2-029EN Cleco Output and Reaction Bar Assembly D 2 4 4 3 6 5 5 7 8 L.H. Thread L.H. Thread L.H. Thread 4 5 See Service Notes Page 2
Cleco Output and Reaction Bar Assembly PL2-029EN Illustration "D" Ref Number # X EN Description 920003 2 Ball Bearing 2 4803763 Output Spindle (/2" Square Drive) 3 4803932 Spacer 4 4803709 Bearing Cap 5 92000056 2 Needle Bearing 6 4803826 Lock Ring 7 4803859 Torque Reaction Bar - 7-/4" (Stamped 8T592) 4803860 Torque Reaction Bar - 3" (Stamped 8T59) 8 480383 Lock Nut (#) Quantity (X) Recommended Spare Parts (quantity shown based on -5 tools in operation) Page 3
PL2-029EN Cleco Service Notes Tightening Torque 3 Assembly Tool SK-0 Illustration Reference Tightening torque Ft-Lbs Nm (in-lbs) B 7 65-75 88-0 6 65-75 88-0 C 6 45-50 6-68 D 4 220 298 Do not clamp rotor in a vise. Use assembly tool SK-0 Rotor SK-0 2 4807073 SelecTork Option (replaces 5808006 Inlet Bushing) 2 3 4 5 6 7 7 8 The SelecTork option allows the user to adjust the output torque of the tool from it s rated torque at 90 PSI to 75% of the rated torque. Set air pressure at 90 PSI (a small air bleed is permitted) Check tool for maximum torque output and the adjusting screw flush with the manifold Back off adjusting screw, counterclockwise, to obtain the desired torque Ref Number # X EN Description 48082 Complete Manifold 2 4808209 SelecTork Valve 3 94070245 3 Spring 4 93040038 3 O-Ring 5 4808225 Adjusting Screw 6 92530039 Roll Pin 7 93040033 2 6 O-Ring 8 92740003 Retaining Ring (#) Quantity (X) Recommended Spare Parts (quantity shown based on -5 tools in operation) Page 4
Cleco Service Notes PL2-029EN 4 Assembly Tool SK-06 Lock Ring Torque Bar Bearing Cap SK-06 is a disassembly (assembly) tool for removing the bearing cap from the third stage gear housing without damaging either piece. Secure the SK-06 tool in a vise. Slide the third stage gear housing, with bearing cap and torque bar, over the SK-06 tool. Rotate the torque reaction bar clockwise to remove the bearing cap. Gear Housing (3rd Stage) SK-06 Assembly Tool Vise 5 Torque Reaction Bar Configuration Bending: Use a template to determine the correct torque reaction bar configuration. The torque reaction bar must be heated to a dull cherry red prior to bending. Normally, it is best to bend the reaction bar using a bar-bending fixture or a piece of pipe rather than hammering into shape. The reaction bar should be allowed to air cool and not quenched in either water or oil. Installation: Since the reaction of the torque bar opposes the spindle rotation, it should be used with the bar against the work opposite the tool s rotation. Lock into the reaction point whenever possible: holes, adjacent fasteners, inside channel, fork bar around pipes or tubular members. Page 5
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