Apex Tool Group Airetool 2055-R Series Instruction and safety manual

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Operating & Service Manual
90020-IM
05/25/2011
2055-R Series
Airetrol Rolling Motor
Model Number Part Number (Order)
2055-R-90
2055-R-190
Airetool®

2
For your safety and the safety of others, read and under-
stand the safety recommendations and operating instruc-
tions before operating an Airetrol.
Safety Recommendations
For additional information on eye and face protection, re-
fertoFederalOSHARegulations,29CodeofFederalRegu-
lations, Section 1910.133., Eye and Face Protection, and
the American National Standards Institute, ANSI A87.1,
Occupational and Educational Eye and Face Protection.
Z87.1 is available from the American National Standards
Institute, Inc., 1430 Broadway, New York, NY 10018.
Hearing protectors are required in high noise areas, 85
dBA or greater. The operation of other tools and equip-
ment in the area, reflective surfaces, process noises and
resonant structures can substantially contribute to, and in-
crease the noise level in an area. For additional informa-
tion on hearing protection, refer to Federal OSHA Regula-
tions, 29 Code of Federal Regulations, Section 1910.95,
OccupationalNoiseExposure,andAmericanNationalStan-
dards Institute, ANSI S12.6 Hearing Protectors.
Airetool Airetrols 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. Exces-
sive air pressure increases the load and stresses on the
tool parts, which may result in cage, mandrel or roll break-
age.Installation of a filter-regulator-lubricatorin the air sup-
ply 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 the closed position). Clear the air hose of accu-
mulated dust and moisture. Be careful not to endanger
adjacent personnel. 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.
It is essential for the safe operation that the operator of an
Airetrol use good balance, sure footing, and proper pos-
ture in anticipation of the torque reaction. Insure that the
operator’s hand will not be wedged or pinched between
the work and the tool when operating.
Toolswith clutches canstall rather than shut-off ifadjusted
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 torque right angle Airetrols are supplied with a
splined torque reaction mounting plate and reaction bar
complete. ALWAYS USE WITH REACTION BAR DEVICE
SUPPLIED WITH THE AIRETROL! These bars can be
braced against the work or other suitable points to absorb
and relieve the operator of the torque reaction transmitted
by the tool. Tool balance arms are also available to absorb
the torque reaction of the tool while balancing the weight
of the tool for improved ergonomic applications.
Some individuals are susceptible to disorders of the hands
and arms when exposed to tasks which involve highly re-
petitive motions and/or vibration. Those individuals predis-
posed to vasculatory or circulatory problems may be par-
ticularly susceptible. Cumulative trauma disorders such as
carpal tunnel syndrome and tendonitis can be caused or
aggravated by repetitious, forceful exertions of the hands
and arms. These disorders develop gradually over periods
of weeks, months and years.
When using right angle Airetrols, 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 torque reaction. The angle head may be
repositionedwithrespect to the levertoaccomodateproper
location for the task. If tool is to be reversed, locate throttle
leverinaneutralpositionthatwill prevent entrapment. Refer
to operating instructions for additional information.

3
Safety Recommendations
* Tasks should be performed in such 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 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
with a physician. If it is determined that the symptoms are
job related or aggravated by movements and postures in-
dicated by the job design it may be necessary for the em-
ployer to take steps to prevent further occurrences. These
steps might included, but are not limited to, repositioning
the work piece or redesigning the workstation, reassigning
workers to the 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 rela-
tionship.
The following recommendations will help reduce or mod-
eratetheeffects of repetitive workmotionsand/orextended
vibration exposure:
* 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.
* Avoid anything that inhibits blood circulation.
- Smoking Tobacco
- Cold Temperatures
- Certain Drugs
* Avoid highly repetitive movements of hands and wrists,
and continuous vibration exposure.
ADDITIONALSAFETY RECOMMENDATIONS FOR
USE OF RIGHT ANGLE AIRETROLS
Follow good machine shop practices. Rotating shafts and
components can entangle and enwrap, and can result in
serious injures. Never wear long hair, loose-fitting clothes,
gloves, ties, or jewelry when working with or near a drill
or any machine with exposed rotating shaft.
Drilling or other use of this tool may produce hazardous
fumes, particles, and/or dust. To avoid adverse health ef-
fects utilize adequate ventilation and/or a respirator. Read
the material safety data sheet of any cutting fluids or mate-
rials involved in the drilling process.
* Attach the mandrel and the chuck securely to the Airetrol
to prevent the expander from jumping off work.
* High reaction torque may be experienced by the operator
when reversing tool to remove the expander.
* Expanders or accessories not centered properly in the
chuck can cause excessive wobble or vibration.

4
OPERATING INSTRUCTIONS
The 2055 Clutch Type Airetrol is designed to operate on
90 psig maximum air pressure but does not depend on
controlled air pressure to maintain accurate torque. Accu-
rate torque is achieved by setting the clutch to the desired
torque on the application. The tool will shut off automati-
cally at this torque. Releasing the throttle will allow tool to
shut off. Reversing the throttle will allow the expander to
release for the next operation. GRIP TOOL SECURELY
AS FULL TORQUE IS APPLIED IN THE REVERSE
CYCLE.
If the clutch is adjusted over the maximum power of the
tool, the clutch will not function and the tool will operate
like a stall-type tool. Also, if the tool is being operated at its
upper torque limits, a drop in air pressure could cause the
clutch not to function due to a loss of motor power and the
tool will function like a stall-type tool. If tool stalls operator
must resist stall torque until throttle is released.
OPERATIONAL CHECK : Grip tool securely and be pre-
pared to counteract stall torque in case clutch is improp-
erly adjusted. THIS IS A HIGH TORQUE TOOL.
CLUTCH ADJUSTMENT
Depress the pin No. 864711, and rotate the adjustment
cover, No. 867677, 180 degrees so it lines up with the ad-
justment slot. With the angle head end of the tool facing
outward, away from the operator, use a 1/8” diameter pin
to rotate the adjustment nut, No. 867678, clockwise to in-
crease the torque or counterclockwise to decrease the
torque. Note: The steel ball, No. 844077, is a positive lock
for the adjustment nut and must be in place in a locking
slot before the adjusting cover is rotated to the locked po-
sition after each clutch adjustment is completed.
THROTTLE POSITION (Lever Tools)
The throttle lever may be repositioned to accommodate
proper location for task and to avoid entrapment. Reposi-
tioning of the angle head is done by loosening housing
lock nut No. 867521, and lifting the angle head until the
spline on the angle head clears the gear case and can be
rotated to the desired position. Lower the angle head back
into place and tighten housing lock nut.
AIR SUPPLY
For maximum performance, use a 1/2” I. D. air hose no
longer than 8’ in length. If additional length is required, a 5/
8”I. D. or largerhoseshould be connectedtothe 1/2” hose.
The air hose should be cleared of accumulated dirt and
moisture, then one (1) teaspoonful of 10W machine oil
should be poured into the tool’s air inlet before connecting
the hose to the tool.
LUBRICATION
An automatic in-line filter-lubricator is recommended as it
increases tool life and keeps the tool in sustained opera-
tion. The in-line lubricator should be regularly checked and
filled with a good grade of 10W machine oil. Proper adjust-
mentofthe in-line lubricator is performedbyplacinga sheet
of paper next to the exhaust ports and holding the throttle
open for approximately 30 seconds. The lubricator is prop-
erly set when a light stain of oil collects on the paper. Ex-
cessive amounts of oil should be avoided.
Composite rotor blades permit tool operation with out lu-
brication when oil mist is undesirable. Application of the
tool should govern how frequently it is greased. It is rec-
ommended that the idler gears and the right angle gears
receive a generous amount of No. 2 Moly grease through
the grease fittings after 40 hours of operation.
STORAGE
In the event that it becomes necessary to store the tool for
an extended period of time, 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.
SERVICE INSTRUCTIONS
DISASSEMBLY IN GENERAL
Automatic Shut off Tools
To disassemble the tool, clamp the flats of the clutch hous-
ing in a soft-jawed vise and loosen the motor housing.
Clamp the angle head in the vise and loosen the angle
housing lock nut, No. 867521 (left hand threads). Using a
suitable wrench, loosen the clutch housing from the gear
case. Be careful not to lose any of the gear train compo-
nents.Removethetoolfromtheviseandunscrewthemotor
housing from the clutch housing. Unscrew the angle hous-
ing lock nut (left hand threads) from the gear case for re-
moval of the right angle head. Tap the front of the motor
housing with a soft faced mallet to remove the motor unit.
SUBASSEMBLY DISASSEMBLY-“T” Right Angle Head
Loosen the bearing cap lock screw No. 867997, and un-
screw (left handed threads) the bearing cap No. 867509.
Remove the square drive spindle No. 867510, ball bearing
No. 867547, and driven gear by clamping the square drive
in the vise. Drive the right angle housing away from the
square drive using a soft-faced mallet. Press the square
drive end of the spindle through the bearing I. D. to re-
move the ball bearing. The driven gear may be removed
bypressing the smaller endofthe spindle throughthegear.
Remove the grease plug No. 867546, and using a suitable
driver, drive the pinion gear out of the right angle housing.

5
GEAR TRAIN
The complete gear train may be slipped out of the rear of
the gear case. By driving the idler gear pins out of the rear
of the spiders, the idler gears can be removed from the
spider pockets.
CLUTCH
Remove the adjustment cover by sliding it off the back of
the clutch housing. Be careful not to lose the steel ball No.
844077, that will drop out at this time. Using the slots pro-
vided on the rear ace of the adjusting nut No. 867678, un-
screw it from the clutch housing. The torque spring bear-
ingNo. 867683, spring plateNo.867669, and torquespring
No. 869626, will come out through the rear of the clutch
housing. With a soft-faced mallet, tap on the gear end of
the clutch to remove it from the clutch housing. By remov-
ing the retainer ring No. 847022, the drive shaft washer
No. 867666, trip sleeve spring No. 867672, trip sleeve No.
867670, and two (2) steel balls No. 842161, can be re-
moved from the drive shaft. Remove the clutch cam bear-
ing No. 619377, with a suitable puller. Using a sharp in-
strument, remove the spiral ring No 865436. This will allow
theclutch cam No 867676,three(3)steel balls No. 842161,
tripplungerspring No. 867671, andtripplungerNo. 867688
to be removed through the front of the drive shaft. To re-
move the six (6) steel balls No. 844265, slide the ball re-
tainer No. 867673, off over the rear of the drive shaft.
MOTOR UNIT
Clamp the cylinder lightly in the vise with the gear end of
the rotor up. Note: Rotor pinion No. 867524, used on the
No. 6 model should be removed at this time. Drive the ro-
tor out of the front rotor bearing No. 619377. Be careful not
to damage the rotor. The front bearing plate No. 867671,
cylinderNo. 203103 androtor blades No.869569, can now
be removed from the rotor. Clamp the rotor in the vise with
therear bearing plate up.After unscrewing the bearinglock
nut No. 865352, the rotor can be driven out of the rear
rotor bearing.
REASSEMBLY
The tool is reassembled in the reverse order of disassem-
bly. Clean all parts thoroughly in kerosene and inspect for
damage or wear. Check all bearing for wear which can be
detected by excessive end play and/or roughness which
wouldindicateabrinelledcondition.Therotor blades should
be replaced if they measure less than 1/4” at either end.
All gear teeth, bearings and pins should receive a close
inspection and be replaced if necessary.
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 lightly in
the vise with the threaded end up and slip the rear bearing
plate assembly onto the rotor far enough for the bearing
lock nut to start. Tighten the lock nut until there is approxi-
mately .0015” clearance between the rotor and the bear-
ing plate. The outer bearing race should be firmly seated
and the rotor bumped forward when checking this clear-
ance. Pack both rotor bearings with a good grade of No. 2
Moly grease after assembly of the motor unit.
Note: During reassembly of the complete tool, it is impor-
tant that the motor be free. After the tool is completely as-
sembled, the right angle square drive spindle should turn
freely using a small hand wrench. If the spindle does not
turn freely, the motor should be checked for proper spac-
ing. Do not run the tool until the spindle turns freely. Fail-
ure to do this could result in damage to motor components.
During reassembly of the gear train and the angle head, all
of the various gears and bearings should receive a gener-
ous amount of No. 2 Moly grease. The pinion needle bear-
ingshouldbe slipped onto the piniongearandthen pressed
into the right angle housing until the rear of the bearing is
flush or slightly below the step in the housing. Note: Dur-
ing reassembly of the “T” right angle head, the bearing cap
No. 867509 should be torqued to 100-110 ft. lbs. Also, the
bearing cap lock screw No. 867997 should be torqued to
10 in. lbs. minimum.
The clutch is assembled in the reverse order of disassem-
bly. The torque spring bearing No. 867683 must be as-
sembled so the solid side of the ball separator is facing
toward the torque spring.
During reassembly of the automatic shut off tools, the trip
rod must be ground flush (+0 -1/32”) with the hex end of
the rotor. Hold the motor firmly in the housing at the time
the trip rod is being ground to length.
Pour a few drops of 10W machine oil into the air inlet after
complete assembly to ensure immediate lubrication of all
motor parts when air is applied.
SAFETY CHECK
After repair or replacement of parts, tools equipped with
an automatic shut off devise should be tested to verify that
they are functioning properly.

6
ITEM # PART NO. DESCRIPTION QUAN.
1882661 Spindle Needle Bearing 1
2867507 "T" Right Angle Head 1
3382633 Spindle Protector 1
4867521 * Housing Lock Nut 1
5867522 * Housing Clamp Ring 1
6867546 Grease Plug 1
7867512 Driven Gear 1
8867787 1/2"-20 Threaded Drill Spindle 1
9867511 "T" Pinion Gear 1
10 867548 Pinion Needle Bearing 1
11 842517 Ball Bearing 1
12 867520 * Housing Make-Up Plate 1
13 867510 !/2" Square Drive Spindle 1
14 867547 Spindle Ball Bearing 1
15 867509 Bearing Cap (includes 3867997) 1
16 867997 Bearing Cap Set Screw 1
* - Denotes parts not included in sub-assemblies listed below
The "T" right angle gears can be purchased as a set using Part No. 861478.
The "T: ri
g
ht an
g
le head can be purchased as a set usin
g
Part No. 861496.
P A R T S L I S T For Ri
g
ht An
g
le Head

7
REACTION BAR
BRACKET ASSEMBLY
ITEM # PART NO. DESCRIPTION QUAN.
17 202319 Reaction Bracket 1
18 202320 Reaction Bar Clamp 1
19 842554 5/16"-18 x 1 3/4' Socket Head Cap Screw 2
20 8566413 Handle Grip 1
21 8566412 Pipe Handle 1
The complete reaction bar bracket can be purchased as a sub-assembly using
Part No. 201012.
The reaction bracket Part No. 202319 must fully engage the right angle head.
Position the bracket forward on the small diameter of the head and move it rear-
ward to engage the spline. Securely tighten the reaction bar and bolts to prevent
loosening!
N O T S H O W N
CAUTION:
PARTS LIST For reaction bar bracket assembl
y

8
GEAR TRAINS #3 & #6
# 3 # 6
ITEM # PART # DESCRIPTION QUAN QUAN
22 864544 Gear Case 50T 1 1
23 203107 2nd Reduction Gear 15T (includes 3203062) 3 3
24 203062 2nd Reduction Gear Bearing 6 6
25 864671 2nd Reduction Gear Pin 3 3
26 203105 2nd Reduction Gear Spider 1 1
27 861485 1st Reduction Gear Spider 19T (includes pin) 0 1
27 861486 1st Reduction Gear Spider 19T (includes pin) 1 0
28 832125 1st Reduction Gear Pin 3 3
29 844774 1st Reduction Gear Bearing
30 867526 1st Reduction Gear 21T (includes 3844774) 3 0
30 867523 1st Reduction Gear 17T (includes 3844774) 0 3
31 867521 Lock Nut
PARTS LIST For # 3 and # 6 GEAR TRAINS
Gear Train 2nd Reduction Gear Gear
Model # Spider Case Train
# 3 201308 201311 201351
# 6 201308 201313 201353
Gear Train Sub-Assemblies
ITEM # PART # DESCRIPTION QUAN.
32 619377 Front Rotor Bearing 1
33 867536 Front Bearing Plate 1
34 869570 Rotor 1
35 869569 Rotor Blade 5
36 203103 Cylinder (includes 3812165 & 3847603) 1
37 847603 Drive Screw 1
38 812165 Cylinder Pin 1
39 869660 Rear Bearing Plate 1
40 847096 Rear Rotor Bearing 1
41 865352 Rotor Lock Nut 1
PARTS LIST For Motor Unit

9
CLECOMATIC CLUTCH
ITEM # PART # DESCRIPTION QUAN. ITEM # PART # DESCRIPTION QUAN.
42 867674 Drive Shaft Washer 1 55 867681 Clutch Housing 1
43 865436 Spiral Ring 1 (includes 3864711,
44 867673 Ball Retainer 1 3864712 & 3869263)
45 869670 Trip Sleeve Spring 1 56 864712 Pin Spring 1
46 202056 Trip Sleeve Spring 1 57 864711 Pin 1
47 867666 Drive Shaft Washer 1 58 869263 Pin Sleeve 1
48 847022 Washer Retainer Ring 1 59 844077 Steel Ball 5/16" Dia. 1
49 869626 Torque Spring 1 60 867677 Adjustment Hole Cover 1
50 867669 Torque Spring Plate 1 61 619377 Clutch Cam Bearing 1
51 867683 Torque Spring Bearing 1 62 867676 Clutch Cam Bearing 1
52 867678 Adjustment Nut 1 63 842161 Steel Ball 3/16" Dia. 3
53 842161 Steel Ball 3/16" Dia. 2 64 867671 Trip Plunger Spring 1
54 844265 Steel Ball 1/8" Dia. 6 65 867668 Trip Plunger 1
PARTS LIST For Clecomatic Clutch

10
ITEM # PART # DESCRIPTION QUAN. ITEM # PART # DESCRIPTION QUAN.
66 869933 Inlet Bushing 1 80 844077 5/16" Steel Ball 1
67 869965 Throttle Sleeve 1 81 869964 Valve Rod 1
68 622062 "O" Ring 7/8" x 1 1/16" 1 82 869659 Reversing Valve 1
69 869931 Throttle Valve Seat 1 83 619164 "O" Ring 2" x 2 1/8" 1
70 202055 Throttle Valve 1 84 869655 Motor Spacer 1
71 864973 Throttle Valve Spring 1 85 867667 Shut-Off Valve 1
72 843656 Screen 1 86 202633 Handle (includes 3843589)
73 869963 Throttle Retainer 1 87 201148 Reversing Ring 1
74 869944 "O" Ring 15/16" x 1 1/8" 1 88 869966 Throttle Return Spring 1
75 863468 * Trip Rod 1 89 202011 Seal Ring 1
76 202638 Reversing Valve Screw 1 90 202632 Muffler 1
77 202639 Screw Spacer 1 91 202673 Exhaust Deflector 1
78 843589 Grease Fitting 1 92 617754 033B0 "O" Ring 2" X 2 1/8" 2
79 832128 Stop Pin 1
ROLL THROTTLE HANDLE ASSEMBLY
ITEM # PART # DESCRIPTION 3/8" 1/2"
93 8506500 TruArc Ring 5108-81 1 0
93 8503600 TruArc Ring 5108-100 0 1
94 8501225 Chuck Sleeve 1 0
94 8566702 Chuck Sleeve 0 1
95 8501250 Spring 1 0
95 8501900 Spring 0 1
96 2990914 3/8" Chuck Body 1 0
96 3236600 1/2" Chuck Body 0 1
97 3235400 Steel Ball 1 0
97 3227500 Steel Ball 0 1
PARTS LIST For Quick Chan
g
e Chucks
QUANTITY