Airetool FPT-9800-C-162 Instruction and safety manual

For additional product information visit our website at http://www.apextoolgroup.com
Operating & Service Manual
90109-IM
05/25/2011
FPT-9800 Series
Freeze Plug Removal Tool
Model Number Part Number (Order)
FPT-9800-C-162 5525147
FPT-9800-F-150 5524842
FPT-9800-GM 5524792
FPT-9800-M-175 5524844
FPT-9800-7-GC-44
FPT-9800-7-GM-134 5525135
FPT-9800-7-GM-162 5525177
FPT-9800-7-GM-150 5525192
FPT-9800-7-GM-35M 5525418
Airetool®

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Safety Recommendations
Some individuals are susceptible to disorders of the hands
and arms when exposed to tasks which involve highly
Tools with clutches can stall rather than shut-off if ad-
justed over the maximum power output of the tool, or if
there is a drop in air pressure. Operator must then resist
the stall torque until the throttle is released.
Higher torqueAiretrols, inline and right angleare supplied
with a torque reaction bar designed to work with the torque
of the tool it is for, be equipped with splined torque reac-
tion mounting plates which accept torque reaction bars.
These bars can be braced against the work or other suit-
able points to absorb and relieve the operator of the torque
reaction transmitted by the tool. Tool balance arms are
also available to absprb the torque reaction of the tool while
balancing the weight of the tool for improved ergonomic
applications.
When using right angle Airetrols with lever type throttles,
be sure the throttle is positioned relative to the angle head
so that the throttle will not become wedged against an
adjacent object in the “ON” position due to the torque reac-
tion. The angle head may be repositioned with the respect
to the lever to accommodate proper location foe the task. If
tool is to be reversed, locate the throttle lever in a neutral
position that will prevent entrapment. Refer to operating
instructions for additional information.
Hearing protectors are required in high noise areas, 85
dBA or greater. The operation of other tools and equipment
in the area, reflective surfaces, process noises and reso-
nant structures can substantially contribute to, and increase
the noise level in the area. For additional information on
hearing protection, refer to Federal OSHA Regulations, 29
Code of Federal Regulations Section 1910.95, Occupa-
tional Noise Exposure, and American National Standard
Institute, ANSI S12.6 Hearing Protectors.
HEARING PROTECTION
EYE AND FACE PROTECTION
For additional information on eye and face protection, refer
to Federal OSHA Regulations, 29 Code of Federal Regula-
tions, Section 1910.133., Eye and Face Protection, and
American National Standards Institute, ANSI A87.1, Oc-
cupational and Educational Eye and Face Protection. Z87.1
is available from the American National Standards Insti-
tute, Inc., 1430 Broadway, New York, NY 10018.
For your safety and the safety of others, read and under-
stand the safety recommendations and operating instruc-
tions before operating this tool.
ALWAYSWEARPROTECTIVEEQUIP-
MENT
Follow good machine shop practices. Rotating shafts and
moving components can entangle and enwrap, and can
result in serious injuries. Never wear long hair, loose fitting
clothes, gloves, ties or jewelry when working with or near
any power tool with an exposed rotating shaft or spindle.

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Use of this tool may produce hazardous fumes, particles,
and/or dust. To avoid adverse health effects utilize adequate
ventalation and/or a respirator. Read the material safety
data sheet of any materials involved in the tube expansion
process.
Safety Recommendations
This Airetool product is 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, mandrels, rolls and cages and may result in break-
age. Installation of a filter-regulator-lubricator in the air sup-
ply line ahead of the tool is required.
Before the tool is connected to the air supply, check the
throttle for proper operation (i.e., the throttle moves freely
and returns to the closed “OFF” position when released).
Clear the air hose of accumulated dust and moisture. Be
careful not to endanger adjacent personnel. Before remov-
ing 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.
repetitive motions and/or vibrations. Those individuals pre-
disposed to vasculatory or circulatory problems may be
particularly susceptibly. Cumulative trauma disorders such
as carpal tunnel syndrome and tendonitis can be caused
or aggravated by repetitions, forceful exertions of the hands
and arms. These disorders develop gradually over periods
of weeks, months, and years.
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 AND
CAN BE CONTROLLED THROUGH TOOL SELECTION
AND WORK LOCATION.
Any user suffering from prolonged symptoms of tingling,
numbness, blanching of the fingers, clumsiness or weak-
ened grip, nocturnal pain in the hand, or any other disorder
of the shoulders, arms, wrists, or fingers is advised to con-
sult with 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 not limited to, repositioning the
work piece or redesigning the workstation, reassigning
workers to other jobs, rotating jobs, altering 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.
The following recommendations will help reduce or mod-
erate the effects of repetitive work motions
•Use a minimum hand grip force consistent with
proper control and safe operation.
•Keep wrists as straight as possible.
•Keep body and hands warm and dry.
.
It is essential for safe operation that any operator of an
Airetrol use good balance, sure footing, and proper posture
in anticipation of a torque reaction. Insure that the opera-
tors hand will not be wedged or pinched between the work
and the tool when operating.
•Avoid anything that inhibits bloodcirculation
- Smoking tobacco
- Cold temperatures
- Certain drugs
• Avoid highly repetitive movements of the
hands and wrists, and continuous vibration ex
posure.
NOTE : ANY USE OF THIS TOOL OTHER THAN ITS
DESIGNED PURPOSE COULD CAUSE MAJOR
DAMAGE TO THE TOOL AS WELL AS POSE A RISK
TO THE OPERATOR.

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NOTE :
1. First, read and fully understand the Cleco nutrunner ser-
vice manual. The nutrunner used in this application has the
“M” right angle head, -5 gear train, stall -5 motor and modi-
fied 35TNAL backhead ( the 204172 reversing valve is re-
placed with Airetool valve spool part # 8567519.
2. The tool is controlled by a two position lever throttle. The
tool runs in the PULL direction when the lever is fully de-
pressed (PULL = FULL). The tool runs in the RESET di-
rection when the lever is depressed about half way (touch-
ing but not shifting the reverse valve). Approximate pulled/
reset points are marked with the red stripe. We recom-
mend that you become comfortable with the throttle action
before pulling a freeze plug.
3. There is generally no need to have the center of the
rollers go beyond the edges of the red strip. Avoid bottom-
ing out the guide rollers in the reset direction as this could
bend or break the guide rollers shoulder screws.
4. If the tool should bottom out in the reset direction, im-
mediately FULLY DEPRESS the throttle lever to correct.
TO PULL A FREEZE PLUG :
1. Insert the gripper into the plug.
2. With the end of the cam held against the bottom of the
plug, FULLY DEPRESS the lever throttle.
3. Guide the gripper into the plug (with the thrust collar
held square to the block face) as it expands to grip the
plug.
4. When the plug is gripped and starts to pull out, pull back
slightly on the tool so you can tell when the plug pulls free.
5. When the plug is free, move the throttle lever to the
RESET position until the plug is released. PLEASE NOTE
that the plug is fully released when the center of the roller
reaches the edge of the red stripe - DO NOT RUN THE
ROLLER TO THE END OF THE SLOT.
TO CHANGE THE GRIPPER SET :
OPERATING INSTRUCTIONS
Model FPT-9800-7-GM-35M (5525418)
FREEZE PLUG REMOVAL TOOL
1. Have the tool in the RESET position and unscrew the
thrust sleeve (4).
2. Remove the front O-ring (25) and pull the gripper seg-
ments (3) out of engagement with the pins (24).
3. Rotate one of the segments out from under the back O-
ring and slide the rest off over the cam (2).
4. Reverse the order to install a new gripper set. Make sure
that the cam segments are between the pins before install-
ing the thrust sleeve.
LUBRICATION :
The thrust bearing and screw should be kept well lubri-
cated with NLGI-2-EP or a teflon Grease such as Carlton-
Stuart Magnalube-G. The cam surface should be lightly
greased.
See the Cleco Manual for the nutrunner lubrication
recommendations.

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Model FPT-35-TNL-5m-1/8” (8405530) Right Angle Nut Runner for Tool Numbers 5524792 - 5524842 - 5524844 - 5525147
Model FPT-35-TNL-7m-1/8” (8405536) Right Angle Nut Runner for Tool Numbers 5525135 - 5525177 - 5525192 - 5525418

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P A R T S L I S T I N G F O R
GRIPPING MECHANISM
SERIES “FPT” FREEZE PLUG REMOVAL TOOL

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P A R T S L I S T I N G F O R
GRIPPING MECHANISM
SERIES “FPT” FREEZE PLUG REMOVAL TOOL

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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.
Dallas, TX Detroit, MI Houston, TX Lexington, SC
Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group
Sales & Service Center Sales & Service Center Sales & Service Center 670 Industrial Drive
1470 Post & Paddock 2630 Superior Court 6550 West Sam Houston Lexington, SC 29072
Grand Prairie, TX 75050 Auburn Hills, MI 48326 Parkway North, Suite 200 Tel: [phone]
Tel: [phone] Tel: [phone] Houston, TX 77041 Tel: [phone]
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Los Angeles, CA Seattle, WA York, PA Canada
Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group
Sales & Service Center Sales & Service Center Sales & Service Center Sales & Service Center
15503 Blackburn Avenue 2865 152nd Avenue N.E. 3990 East Market Street 5925 McLaughlin Road
Norwalk, CA 90650 Redmond, WA 98052 York, PA 17402 Mississauga, Ont. L5R 1B8
Tel: [phone] Tel: [phone] Tel: [phone] Canada
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Fax: [phone]
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Cooper Power Tools Cooper Power Tools Cooper Power Tools SAS Cooper (China) Co., Ltd.
GmbH & Co. OHG GmbH & Co. OHG a company of a company of
a company of a company of Apex Tool Group, LLC Apex Tool Group, LLC
Apex Tool Group, LLC Apex Tool Group, LLC 25 rue Maurice Chevalier 955 Sheng Li Road,
Industriestraße 1 C/O Spline Gauges 77330 Ozoir-La-Ferrière Heqing Pudong, Shanghai
73463 Westhausen Piccadilly, Tamworth France China 201201
Germany Staffordshire B78 2ER Tel: [phone] Tel: [phone]
Tel: [phone] United Kingdom Fax: [phone] Fax: [phone]
Fax: [phone] Tel: [phone]
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Mexico Brazil Hungary
Cooper Tools Cooper Tools Industrial Ltda. Cooper Tools Hungaria Kft.
de México S.A. de C.V. a company of a company of
a company of Apex Tool Group, LLC Apex Tool Group, LLC
Apex Tool Group, LLC Av. Liberdade, 4055 Berkenyefa sor 7
Vialidad El Pueblito #103 Zona Industrial - Iporanga Pf: 640
Parque Industrial Querétaro 18087-170 Sorocaba 9027 Györ
Querétaro, QRO 76220 SP Brazil Hungary
Mexico Tel: [phone] Tel: [phone]
Tel: [phone] Fax: [phone] Fax: [phone]
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90109-IM/Printed in USA 05/2011/Copyright © Apex Tool Group, LLC
Apex Tool Group, LLC
1000 Lufkin Road
Apex, NC 27539
Phone: [phone]
Fax: [phone]
www.apextoolgroup.com
Airetool®