Aimco AcraDyne HT ABG Series Operation manual

1
Operation and Service Manual
Operation
and
Service
Manual
ABG Series
Battery
Powered
Nutrunners

2
ABG Battery-Powered Nutrunners
Congratulations on your purchase of an ABG Battery-Powered
Nutrunner. You have acquired a superior quality product that
sets international standards and meets the highest safety
requirements. To ensure continued compliance with these
requirements, the device needs to be maintained and serviced
regularly. We therefore suggest that you read these operating
and service instructions carefully and observe the following:
The ABG Nutrunner and the supplied Battery Charger may only
be serviced and repaired by authorized AIMCO service
personnel.
If health hazards or material damages to the device occur
because of improper maintenance or operation, the warranty
will be rendered null and void.
This operating and service manual contains basic information to
be observed during operation and maintenance. The operating
personnel is required to read these instructions before
operation or maintenance. The manual must be available and
accessible at the location of the AcraDyne tools/devices. This
operating and maintenance manual refers exclusively to the
AcraDyne ABG Battery-Powered Nutrunners, AcraDyne Li-Ion
battery packs, and the AcraDyne charger station.
Please observe not only the general safety notices and warnings
listed below, but also observe all generally applicable
regulations, directives, and warnings.
Identification of Notices
Safety notice for the prevention of hazard to life
and limb of persons.
Safety notice for the prevention of damage to
AcraDyne tools, devices, their functions, and
the environment.
Notice regarding proper and safe operation.
Advice to make work easier.
Content Page
Incoming
Inspection and Packaging
3
General
Description
3
Model
Description
3
1.
Technical Data
4
2.
Safety instructions
4
2.1
Intended Use
4
2.2
Operators Responsibilities
4
2.3
Hazard
Notices
5
3.
Operati
ng the Charger Station
5
3.1
Self-Test
5
3.2
Starting
5
4.
Operating the AcraDyne ABG Nutrunner
6
4.1
Starting
6
4.1.1
Remove, Charge, Insert, or Change
Li-Ion Battery
Pack
6
4.1.1
Battery Pack, Capacity, and Signal Display
6
4.2
Preparing for Work with the Power Tool
7
5.
Electric
Operation
7
5.1
Switching On / Off
7
5.2
Direction of Rotation, Transport Lock
8
5.3
Gear Change
8
5.4
Setting the
Shut-Off Torque
8
6.
Mechanical
Operation
9
6.1
Safety Instruction for Tightening and Loosening
9
6.1.1
Tightening and
Loosening
9
7.
Function and
Operation Test
10
7.1
Visual and
Mechanical Inspection
10
8.
Servicing /
Storage / Maintenance
10
8.1
Replacing Accessories
10
8.2
Storage in Lockable Containers
10
8.3
Decommissioning
10
8.4
Service and
Maintenance
10
9.
Technical
Notes
11
9.1
Safety Shut-Off
11
9.2
Causes and
Problem Solving
11
10.
Noise
Level and Vibration
11
11.
Environmental
Protection
11

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Operation and Service Manual
Incoming Inspection and Packaging
The product is shipped with the following:
One (1) AcraDyne ABG Battery-Powered Nutrunner, two (2)
high-performance Li-ion rechargeable battery packs, and one
(1) AcraDyne charger station.
All parts must be visually inspected for possible
transport damages. If any such damage is identified,
please notify the shipping agent immediately. All
returns must be in the original packaging to prevent
damages to the tools/devices. Always retain
packaging for future use.
General Description
AcraDyne ABG Battery-Powered Nutrunners are continuously
rotating power tools. Nuts/bolts are tightened or loosened with
a high torque and when a set value or required final torque
value is reached, the machine is switched off. The device is
driven with a maintenance-free, low-wear brushless
synchronous motor. The tool has a wide torque range and is
capable of high assembly speed.
Model Description
AcraDyne ABG Battery-Powered Nutrunners are dual-gear
nutrunners with rechargeable batteries and torques* of 90 Nm
to 4,000 Nm. A constant torque precision and exact shut-off
torque are also ensured at low battery charging levels. You can
simply and quickly switch from the fast gear for run down to the
power gear for reaching the shut-off torque. Each gear has
eleven torque values to choose from.
* all torque values depend on model
High Performance Li-Ion Rechargeable Battery Pack
A full charge of the battery pack ensures approx. 180 boltings in
a row (model ABG1400). With the second battery pack included,
the number of boltings can be doubled without interruption.
Smart electronics prevent depth discharge of the cells. The
charging level can be checked any time directly on the battery
pack.
AcraDyne Charger Station
Intelligent battery charging technology ensures rapid charging.
Overload protection and the cooling function provide for a long
battery life.

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ABG Battery-Powered Nutrunners
1. Technical Data
AcraDyne Li-Ion rechargeable battery pack:
Voltage 18 V, 5.2 Ah
Charging time approx. 100 min.
AcraDyne charger station:
220-240 V / 50-60 Hz / 65 W
Output 12-42 V / 3.0 A max (optional 110 V / 50 Hz)
2. Safety Instructions
2.1 Intended Use
The AcraDyne ABG Nutrunner has been designed for
continuous tightening and loosening of heavy duty nuts and
bolts. The power supply must be only through AcraDyne Li-Ion
rechargeable battery packs. Other types of rechargeable
batteries may cause fires or physical injury. The AcraDyne
charger station has been dimensioned exclusively for charging
AcraDyne Li-Ion rechargeable battery packs.
Any other use is considered improper. Any damages resulting
from improper use are the responsibility of the user.
2.2 Operator Responsibilities
The user is obliged to read the operating and maintenance
instructions before using or servicing the device. The device
must only be used by persons aware of the purpose, the
consequences of their action, and the precise usage of the
device. Users must not be under the influence of intoxicating
substances, e.g. drugs, alcohol, medication.
For further information on the safety measures and
applications, please contact your AcraDyne partner.
Incorrect or improper use, or operation by
unqualified personnel can result in severe
physical injury and material damage.
The user is responsible for any third parties
accessing the work zone.
The AcraDyne charger station must not be used
in areas with an explosion hazard rating. Always
observe the locally applicable and relevant
safety instructions.
Independent modifications or changes on the
product are not permissible.
Accessories

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Operation and Service Manual
2.3 Hazard notices
In case of mechanical or electrical damages to the Li-Ion
battery pack or the charger station, the use of the
specific device must be interrupted immediately. The
damaged unit must be inspected for mechanical or
electrical damages and safety. Defects must be repaired
by qualified personnel and before renewed use.
Before repairing mechanical or electrical components
or devices always disconnect the rechargeable power
pack and the mains power supply from the power
supply to the power tool.
Protect rechargeable battery packs (1)
against dampness and wetness and do
not subject to open fire.
Do not use deformed or defective battery packs. Do
not attempt to open battery packs. Do not touch or
short battery pack contacts. Keep away from small
metal objects that could cause an electrical short
between contacts. A short circuit can cause fire and
physical injury through burns.
A slightly acidic and flammable liquid may seep out
of defective Li-Ion rechargeable batteries. If the
battery liquid comes into contact with human skin
immediately rinse with plenty of water. If battery
liquid comes into contact with an eye, immediately
rinse and wash with plenty of water and consult a
physician.
Do not attempt to charge non-rechargeable batteries.
Doing so could cause an explosion.
Do not recharge fully charged batteries!
Do not use the charger station outdoors.
Protect the charger station against
dampness and wet.
Keep children away from the charger station and the
work area.
In case of smoke or fire from the charger station
immediately pull out the electric mains supply plug.
Do not insert objects in the ventilation slots of the charger
station. This could result in electric shock or short circuit.
3. Operating the Charger Station
The charger station must only be used if the mains
electrical supply matches the voltage and frequency
specifications on the charger label. The charger station
is an electrical device creating a direct current, which
can trip simple residual current circuit breakers (RCCB).
Use type F or better, with a trigger current of no more
than 30 mA.
Before using the charger station, ensure that the
ventilation slots are not covered or blocked. Minimum
distance to other objects should at least 5 cm (2 in).
3.1 Self-Test
Plug the main plug into a
suitable outlet. The warning
indicator (4) and the
operation indicator (3) will
light up in sequence for
approx. 1 second; the built-in
fan will run for approx. 5
seconds.
3.2 Starting
Charging: Push rechargeable battery pack (1) completely onto
the seat (2). The operating indicator will start to flash.
To check the charging level of the battery pack, first remove the
pack from the charger, then push the button on the battery pack.
Trickle charging: If the battery pack is fully charged, the
charger statin will switch automatically to trickle charging. The
battery pack can be left in the charger and ready for use any
time. The operating indicator (3) will remain lit.
Fault: The warning indicator (4) is lit permanently; the battery
pack is not charged. This is due to the temperature being too
high or too low. Once the battery pack temperature is between
0° C and 50° C (32° F and 122° F) charging starts automatically.
If the warning indicator (4) flashes, check to see that the battery
pack is seated correctly, or check if the battery pack is defective.
Immediately remove the battery pack from the charger.
4
2
Operation indicator Warning indicator
3

6
ABG Battery-Powered Nutrunners
4. Operating the AcraDyne ABG Nutrunner
The ABG Nutrunner must not be damp or wet, and
may not be used in a damp or humid environment.
Always provide rain protection. Before first use,
always fully charge the battery pack. Before any later
use, always check the charge status of the battery
pack and recharge, also in case of power decrease.
4.1 Starting
4.1.1 Remove, Charge, Insert, or Change Li-Ion Battery Pack
Remove battery pack
Push safety catch (5), and pull battery pack to the front (6).
Charge battery pack
Push the battery pack completely onto the seat of the charger.
Insert battery pack
Push the battery pack all the way into the battery seat of the
power tool (7), until the safety catch locks audibly.
4.1.2 Battery Pack, Capacity, and Signal Display*
* Charge status indicators are approximate and may be slightly
different, depending on the battery pack type.
Push button (8) on the battery pack and check the
charge status. If the battery pack is almost empty,
it must be recharged. Replace the battery pack on
the power tool.
If one of the LEDs flashes, the battery pack is
almost empty. The electronic circuitry protects
the battery pack against damage due to
complete discharge. Replace battery back on the
power tool. Recharge battery pack.

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Operation and Service Manual
alkitronic®
4.2 Preparing for Work with the Power Tool
Before preparing the power tool for work remove the
Li-Ion battery pack from the tool.
Depending on the specific job, various adapters for tightening
and loosening of bolted connections are needed.
•Place the ABG Nutrunner on a flat surface.
•If the reaction torque absorber is fitted with a safety
screw, completely remove this screw (the position of this
screw varies between the tool types).
•Push the reaction bar (9) onto the gear cogs (10).
•Tighten the safety screw completely to secure the
reaction bar.
For reaction bars without safety lock, a safety washer is available
as an accessory. This washer prevents a loosening of the
reaction bar and can be pushed over the gear cogs and screwed
tight.
•Push the socket/connector (11)/(12) onto the square
drive (bore holes of the adapter and of the square must
be aligned).
•Insert safety pin (13), secure with rubber ring (14) or
completely tighten connector safety screw (15).
5. Electric operation
5.1 Switching on / off
Switch on: Push and hold button (D). The electronic control
system will ensure a soft start.
Switch off: Release button (D).
Note: The noise that is emitted during startup is due to the
construction of the tool and has no influence on the function or
longevity of the machine.
Never block the rocker switch. This would make
proper operation impossible.

8
ABG Battery-Powered Nutrunners
5.2 Direction of Rotation, Transport Lock
5.3 Gear Change (Rapid Mode / Power Mode)
Actuate the slide
switch only when the
motor is stopped.
Gear 1
In order to optimize
the bolting cycle, it is
recommended to
start in gear 2 (fast)
and then, depending
on the required
torque, switch to
gear 1 (power gear) until the stopping point. See also
section 5.4 Setting the Shut-Off Torque.
5.4 Setting the Shut-Off Torque
Setting the torque is done by means of the torque table on the
tool or according to the standard torque chart included.
Machine-specific torque values can be compiled and
documented on request by the AIMCO calibration
lab.
Torque table Torque chart (sample)
Your AcraDyne HT Nutrunner has been adjusted according to this torque
chart. Repeatable accuracy of shut-off is
± 3%.
In the torque table, each position number is assigned a respective
torque. The shut-off torque is set by means of the setting wheel
(SR) using the position number (1–11) (Fig. 1).
•The selection of the shut-off torque is done by means of
the setting wheel, with 11 settings per gear (values 1-11
according to torque table).
•Position 12 will provide the full torque available for
loosening bolts and nuts.
When the set torque value has been reached, the tool will switch
off precisely and an audible signal (beep) will sound. Actuate the
slide switch only when the motor is stopped.
Direction right (clockwise,
tightening). Push the slide
switch completely to the
left.
Direction left (counter-clockwise,
loosening). Push the slide switch
completely to the right.
Transport lock (start lock). Push
the slide switch to the middle.
Precision shut-off torque
Align the arrow on the tool
case with the required
position number on the
wheel.

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Operation and Service Manual
6. Mechanical Operation
6.1 Safety Instructions for Tightening and Loosening
Always observe local regulations and directives when
starting the tool. Always inspect power tool to make
sure that it can safely function. Never work with
damaged tools or objects.
Beware freely rotating accessories. Loose garments,
long hair, cables, etc. must be kept outside the
danger zone / rotation range.
The ABG Nutrunner must never be operated without
supervision. Immediate stopping must be possible at
all times. Observe safety distances.
6.1.1 Tightening and Loosening
Always place the socket/connector completely and
safely on the bolt/nut. The support of the reaction bar
to absorb the reaction torque must always be safe
and stable. Please consult your AIMCO partner for
customized reaction bar solutions.
An incomplete or incorrect connection orsupport will
lead to the following whenbolting:
– Possible overload fractures of the socket/connector,
gear and even drive square
– Incorrect torque application
– Contusions or severe injuries caused by spun-off
parts or splinters.
Improper usage may also render all warranties null and void.
Never reach between reaction bar and support point.
Doing so presents a high risk of injury.
Work steps
•Place the ABG nutrunner with socket/connector onto the
bolt/nut.
•The reaction bar must absorb the reaction torque on the
level of the socket/connector (S); a stable abutment (G)
must be provided.
•Always hold the nutrunner perpendicular over the bolt
axis.
•Start bolting action.
•The tool will stop as soon as the set shut-off torque or
entered value has been reached.
Before moving to the next bolt / nut:
•If the torque multiplier cannot be pulled off the bolted
joint (torsional forces caused), change the direction of
rotation and switch the tool on and immediately off again
to release the tool.

10
ABG Battery-Powered Nutrunners
7. Function and Operation Test
7.1 Visual and Mechanical Inspection
Battery packs, charger station, operating and display
elements, case and accessories, such as reaction bars,
mustberegularlyinspected for damages and must be
replaced professionally if necessary.
Do not obstruct ventilation opening. Soiled or
blocked ventilation openings can cause malfunction
and damage to the motor.
In case of reduced power, strong gear noise, or
obvious severe damage, immediate repair is
necessary. Please send all devices to be repaired in
their original packaging to your nearest AIMCO
partner.
8. Servicing / Storage / Maintenance
8.1 Replacing Accessories
See section 4.2 Preparing for Work with the Power Tool.
Follow steps in the opposite direction.
8.2 Storage in Lockable Containers
Store ABG Nutrunners and the charger station in a dry
and cooled-off state in the original case, or in any
other closable container. Heat and moisture lead to
oxidation of the gear and other components inside
the case. This can cause the tool to malfunction and
can cause damage to the electronic circuitry and
motor. When storing, ensure that the charger station
power cable is not squeezed anywhere or damaged
in any way.
Notes for the Li-Ion rechargeable battery pack:
Always remove the battery pack from the power tool
when not in use. Do not touch or short the contacts.
Although the electronic circuitry will protect the
battery packs against complete discharge, a long life
is best ensured by maintaining a sufficient charge in
the battery pack.
LED display on the battery pack
In order to maintain the battery pack in a fully charged
state, a trickle charge of about 70 to 75% is required
(see illustration above).
8.3. Decommissioning
If the AcraDyne tools and devices are not used over
an extended period of time, they should be cleaned
and stored in a dry and closable space that is
inaccessible to children. The optimum storage
temperature is between 10° and 30° C (50° and 86° F).
Rotating components must be protected against
oxidation (see Section 8.2).
8.4 Service and Maintenance
The ABG Nutrunner is an extremely powerful and
robust product. To ensure long life and reliability over
many years, the machine must be serviced at regular
intervals (performance check, motor check, safety
inspection, and calibration service).
Service intervals
The power tool must be inspected at least once per
year. In the case of high usage or excessive operating
hours, servicing and calibration will be necessary
more frequently. In the case of unusual gear noises, a
gear lubrication is urgently recommended to prevent
subsequent damage.
AcraDyne ABG Nutrunners must always be packed in
the original packaging when sending items in to your
AIMCO partner or AIMCO.