Apex Tool Group Cleco 55PHH User manual

For additional product information visit our website at http://www.apexpowertools.eu
55PHH
Pulse nutsetter without shutoff
Instruction Manual
P1994BA/EN
2014-06

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Notes on this Instruction Manual
The original language of this instruction manual is German.
This instruction manual
• provides important instructions for safe and effective operation.
• It describes the function and operation of the pulse nutsetter
(hereafter referred to simply as 55PHH).
• It serves as a reference work for technical data, service intervals
and spare part orders.
• It points out options.
Model Key
Disclaimer:
Apex Tool Group reserves the right to modify, supplement or improve the document or the product without
prior announcement. 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.
Secondary information
P2204BA Instruction Manual Oil filling unit
In the text
55PHH stands for all styles of the pulse nutsetter described here.
identifies instructions to be followed.
• identifies lists.
<…> identifies an index, see 8 Spare parts, page 25.
In graphics
identifies movement in a direction.
identifies function and force.
In graphic illustrations:
If not absolutely essential, 55PHH (air from bottom) is illustrated.
55 P H H × 60 3
Max. capacity Output drive
55 –55 Nm 3– External square 3/8"
Design Speed
P– Pistol grip 60 – 6000 rpm
Pulse mechanism 2. Air Inlet
H– Hydraulics A– Air from top
– None
Design
H– 3 Chamber motor

P1994BA-EN_2014-06_55PHHIVZ.fm, 11.06.2014 P1994BA/EN 2013-09 3
Contents
1 Safety 5
1.1 Warnings and notes..................................................................................................... 5
1.2 Basic requirements for safe working practices............................................................ 5
1.3 Operator training ......................................................................................................... 6
1.4 Personal protective equipment.................................................................................... 6
1.5 Designated use ........................................................................................................... 6
1.6 Noise and vibrations.................................................................................................... 6
2 Items supplied 7
3 Product description 7
3.1 Operation and functional elements.............................................................................. 7
3.2 Options........................................................................................................................ 8
4 Before initial operation 8
4.1 Air supply..................................................................................................................... 8
4.2 Change air inlet: top / bottom (only on 55PHHA)........................................................ 9
4.3 Connect the tool.......................................................................................................... 9
4.4 Setting up the tool ..................................................................................................... 10
4.5 Troubleshooting......................................................................................................... 11
5 Maintenance 13
5.1 Service schedule....................................................................................................... 13
5.2 Fill reserve oil............................................................................................................ 14
5.3 Complete oil filling..................................................................................................... 16
6 Disassembly instructions 19
6.1 Remove motor unit.................................................................................................... 19
6.2 Remove throttle valve................................................................................................ 20
6.3 Remove pulse unit..................................................................................................... 20
7 Assembly instructions 20
7.1 Install motor unit........................................................................................................ 21
7.2 Install pulse unit......................................................................................................... 23
8 Spare parts 25
8.1 Pistol grip 55PHH… .................................................................................................. 26
8.2 Pistol grip 55PHHA…................................................................................................ 28
8.3 Motor unit .................................................................................................................. 30
8.4 Pulse unit................................................................................................................... 32
8.5 Equipment order list .................................................................................................. 34
9 Technical data 35
9.1 Dimensions 55PHH… in mm..................................................................................... 35
9.2 Dimensions 55PHHA… in mm.................................................................................. 36

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9.3 Performance Data..................................................................................................... 37
9.4 Ambient conditions.................................................................................................... 37
10 Service 37
11 Disposal 37

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Safety 1
1 Safety
1.1 Warnings and notes
Warning notes are identified by a signal word and a pictogram:
• The signal word describes the severity and the probability of the impending danger.
• The pictogram describes the type of danger.
1.2 Basic requirements for safe working practices
All instructions must be read carefully. Failure to observe the instructions listed below can result in serious
injuries.
WARNING! Potentially hazardous situation for health and safety.
If this warning is not observed, death or serious injury may occur.
CAUTION! Potentially hazardous situation to health and safety, or risk of material and environmental damage. If this
warning is not observed, injuries or damage to materials or the environmental could occur.
NOTE General notes
include application tips and particularly useful information but no hazard warnings.
CAUTION! Work with a maximum working pressure of 101.5 psi (700 kPa) (measured at the air inlet tube of the
tool).
Before initial operation, check that the suspension bail is properly fastened to the balancer.
55PHHA: Before using the air inlet from above, make sure that the pipe plug is correctly fitted in the
lower air inlet.
If you hear unusual noises or vibrations, switch off the tool immediately.
Cut off the air supply immediately.
Before carrying out repairs, adjusting the torque or replacing screw bits, disconnect the tool from the
compressed air line.
The compressed air line must be depressurized before disconnecting it.
Never use the air hose to hold, raise or lower the tool.
Air hoses, the suspension bail and fittings must be regularly checked for damage and wear. Renew as
necessary.
Always carry out assembly according to Chapter 8 Spare parts, page 25.
Use only accessory parts authorized by Apex Tool Group (see product catalog).
Only use screw bits for machine-controlled fastening tools.
Make sure that the screw bits are securely inserted.
Inspect screw bits for visible damage and cracks.
Renew damaged bits immediately.
The operation, maintenance and repair conditions set forth in the instruction manual must be observed.
Follow generally valid and local safety and accident prevention rules.

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Safety
1
1.3 Operator training
Users must be given instruction in the correct usage of the tool. The operator must make the Operating
Manual accessible to users and make sure that the users have read and understood it. The tool may only
be connected, used, serviced and repaired by qualified persons. Repairs to the tool may only be performed
by authorized personnel.
1.4 Personal protective equipment
• Wear protective goggles to protect against sprays of metal splinters and fluids.
• Wear gloves to protect against skin irritation in case of direct contact with oil.
Danger of injury by being wound up in and caught by machinery
• Wear a hairnet.
• Wear close-fitting clothing.
• Do not wear jewelry.
Sound level in the area of the user > 80 dB(A), danger of hearing damage
• Wear hearing protection.
1.5 Designated use
The 55PHH is designed exclusively for fastening and releasing threaded fasteners.
• Do not use it as a hammer.
• Do not open it or modify it structurally.
• Do not use it in areas where there is a risk of explosion.
1.6 Noise and vibrations
With vibration levels ahv > 2.5 m², the exposure time is to be reduced. See example
Sound pressure level Lp in accordance with DIN EN ISO 15744
Idle for n 6000 rpm < 80 dB(A)
Vibration values in accordance with DIN EN ISO 28927-2
55PHH:
Idle ahv for n 6000 rpm < 1.8 m/s²
Pulses ahv < 4.0 m/s²
55PHHA:
Idle ahv for n 6000 rpm < 1.8 m/s²
Pulses ahv < 4.5 m/s²
Pulses ahv 55PHHA + absorber (on request) < 2.5 m/s²
Vibration level ahv m/s²
Allowed daily exposure time (hrs.)
Example
Not allowed
Allowed

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Items supplied 2
2 Items supplied
Check shipment for transit damage and ensure that all items have been supplied:
1 55PHH
1 This instruction manual
1 Declaration of Conformity
1 Hex wrench (WAF 2)
3 Product description
3.1 Operation and functional elements
Item.Designation
1 Reverse switch
2 Exhaust air throttle: torque adjustment, see Abb. 4-1 , page 10
3 Air inlet
4 Start button
5 Reserve oil, see 5.2 Fill reserve oil, page 14
6 Suspension bail
3
3
1
2
4
65
(6)
Alternative
position
55PHH…
55PHHA…

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Before initial operation
4
3.2 Options
4 Before initial operation
4.1 Air supply
Make sure that the pressure before the pressure regulator is at least 0.5 bar higher than the required
inlet air pressure at the tool.
Keep the inside of the air hose free of residue; clean it if necessary.
Air quality
In accordance with ISO 8573-1, quality class 2.4.3, compressed air must be dry and clean.
Air preparation units
Our recommendation: air preparation units (filters, regulators, lubricators) should be installed
Protective sleeve
Order No. 937449PT – 55PHH…
Order No. 937444PT – 55PHHA…
Vibration absorber
Order No. 935965 – 55PHHA…
Quick change chuck adapter
Order No. 935472
Parameter Data
Air hose Inner diameter 3/8" (ø 9.5 mm), maximum length 5 m
Air inlet 1/4" NPT, inner diameter 7.5 mm
Parameter Data
Working pressure range 400 … 700 kPa
Max. dew point + 10° C
Device Explanation
Filter Retention of particles > 15 micrometers.
Removes more than 90% of condensation.
Regulator To attain constant work results, the working pressure must be
kept constant for every individual tool.

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Before initial operation 4
Oils according to DIN 51524 / ISO 3498
4.2 Change air inlet: top / bottom (only on 55PHHA)
When delivered, the air inlet is at the BOTTOM and sealed with a screw plug. To change the air supply from
top to bottom:
Remove the air strainer from the air inlet at the TOP (do not discard), see 8.2 Pistol grip 55PHHA…,
page 28, Detail X.
Remove screw plug from BOTTOM. When doing this, counterhold with wrench (WAF 17).
Seal the air inlet at TOP with screw plug in accordance with specifications.
4.3 Connect the tool
Connect the tool to the compressed air line.
Maximum screwing-in torque = 40 Nm. Reaction torque at flat end. Counterhold with wrench (WAF 17).
Activate compressed air: 620 kPa.
Lubricator Compressed air requires a small amount of oil and is orientated to
the air consumption of the tool.
Calculate the time (T) between two drops of oil and make the
following settings at the lubricator:
F= Factor for pulse nutsetter = 2
L= Air consumption of tool at idle m³/min
(see performance data for pulse shut-off nutsetter)
Order
no. Packaging unit
Liter
Name ARAL BP elf ESSO INA Mobil Klüber SHELL
933090 2 HL32 Aralub
EE 100 Energol HL 32 Polyelis 32 Olna 32 Nuto H 32 Hydraol 32A D.T.E.Oil Light Vactra Oil Light Crukolan 32 Molina 32
Molina 22
CAUTION! The air hose can come off by itself and whip around uncontrollably.
Shut off the compressed air before making the connection.
Device Explanation
T60
FL
-------------=

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Before initial operation
4
4.3.1 Testing
4.4 Setting up the tool
The tool must be configured for the desired rundown.
4.4.1 Setting the torque
Abb. 4-1
To achieve better repeat precision for fastenings, throttle the speed back at the tool until the required
torque is achieved at the end of rotation of the fastening. On hard to medium-hard screwed joints, this is
achieved in 1 to 2 seconds. Longer fastening then does not result in higher torque.
Fully open exhaust air throttle anti-
clockwise.
Check speed at output drive:
>6000 rpm
Settings example:
Tightening: 45 Nm
Screw M10: 8.8
Set speed to approximately
5000 rpm
N
m
Torque
Example: 45 Nm
Speed
RPM

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Before initial operation 4
4.4.2 Changing Torque
Abb. 4-2
4.4.3 Checking torque
We recommend carrying out a static torque check by retightening the screwed joint.
If the torque difference is too large, it may be necessary to change the torque setting. See 4.4.2 Chang-
ing Torque.
If the setting has been changed, check the torque again.
When carrying out a dynamic measurement using a transducer adapter, also carry out a static test on the
screwed joint, for example with a torque wrench (electronic).
4.5 Troubleshooting
Unscrew the threaded pin using the hex
wrench (WAF 2).
To reduce torque,
turn the exhaust air throttle
clockwise.
To increase torque,
turn the exhaust air throttle
counter-clockwise.
NOTE The torque setting may be corrected when the compressed air is activated.
Error Possible causes Measures and remedies
Tool too strong Torque set too high Reduce the torque setting, see
4.4.2 Changing Torque, page 11
Tool too weak Working pressure too low Check the cross section of the
hose and coupling: Inner
diameter 3/8" (ø 9.5 mm), maxi-
mum length 5 m
Increase the working pressure.
Reverse button is
not at the detent Turn the reverse button
to the detent
Excessive transmission damping due
to extension and worn socket. Increase the speed, see 4.4.1 Set-
ting the torque, page 10.
Use a shorter or more rigid exten-
sion.
Replace the socket
Insufficient oil in the pulse unit (no
pulse build-up) See 5.2 Fill reserve oil, page 14
Screen in the air inlet tube /
muffler is dirty Clean or replace parts
Torque

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Before initial operation
4
Accuracy insufficient Adapter parts Replace adapter parts
Use extension and socket with
guide diameter
Pressure fluctuations in the air network Use a pressure regulator
Premature release of the start button Keep start button pressed until nut-
setter has stopped rotating
Fastening time too
long: > 4 seconds Joint too soft; crush nuts, self-tapping screws Increase the speed
Use a pulse nutsetter with a higher
capacity.
Error Possible causes Measures and remedies

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Maintenance 5
5 Maintenance
5.1 Service schedule
Regular service reduces operating faults, repair costs and downtime.
This maintenance schedule uses values that are valid for most applications. For a specific maintenance
interval, see 5.1.1 Calculating a customer-specific maintenance plan, page 14.
Implement a safety-related maintenance program that takes the local regulations for repair and mainte-
nance for all operating phases of the tool into account.
CAUTION! Danger of injury due to unintentional activation
– before service, disconnect the tool from the compressed air supply.
Maintenance
interval Rundowns Measures
W1 100.000 Check the suspension bail for functional safety.
Check the air hose for wear.
Check the square on the output drive for wear.
Check the air inlet for tight fit.
Check the housing of the pulse unit for tight fit.
Check the maximum idling speed.
Check the reserve oil.
W2 500.000 Oil change, see 5.3 Complete oil filling, page 16.
Motor service kit, see 3) Part of motor service kit K1 order
no. 936169, page 27.
Hydraulic service kit, see 3) Part of hydraulic service kit K2,
order no. 936211, page 33.
Replace muffler, filter.
W3 1.000.000 Check individual parts and replace if necessary
Suspension bail
Throttle valve
Exhaust air throttle
Motor
Pulse unit

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Maintenance
5
5.1.1 Calculating a customer-specific maintenance plan
A service interval W(1,2,3) depends on the following factors:
T2, Sand VS are variable factors and can differ depending on the specific application.
Example for service interval W2:
After 500,000 rundowns (V),
a specific rundown time of 1.8 seconds (T1)
with an actual fastening time of 3 seconds (soft joint) and
3 completed shifts per day and 750 rundowns per shift:
You have to carry out the maintenance measures marked W2 after an operating time of 200 days.
5.2 Fill reserve oil
If X = 0 (see picture 2), the reserve oil is exhausted and must be refilled to guarantee a controlled process.
Factor Value assumed in
6.1, "Maintenance plan" Description
VV1 = 100,000
V2 = 500,000
V3 = 1,000,000
Number of rundowns after which a maintenance measure is pre-
scribed by Apex Tool Group.
T1 1.8 seconds Specific rundown time, measured in life and endurance tests.
T2 2 seconds Actual rundown time, depending on the hardness of the joint.
S1; 2; 3 Number of shifts per day.
VS 750 Number of rundowns per shift.
1
Remove pulse unit. 2 Remove set bolt and ball.
W123VT
1

T2SVS
------------------------------=W2 500000 1 8
23750
---------------------------------= 200Tage=
<103>
<102>
X= 0

1994c_Wartung_en-bedingt.fm, 11.06.2014 P1994BA/EN 2014-06 15
Maintenance 5
3
Align both ends as shown in the picture (internal equalization hole is opened).
4
To avoid air pockets, fill the filling hole full of oil. 5 Position the injector so that it has a sealing
effect and add reserve oil until distance Xfor
spacer <B2> is achieved.
Maintain distance Xand secure with <B2>.
Refit set bolt and ball.
Remove <B2>.
<B1>
<B2>
Approx. 5 ml
X approx. 2.5 mm

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Maintenance
5
5.3 Complete oil filling
If no more pulses are generated, or if the pulse unit has been removed and refitted, the pulse unit must be
completely refilled with oil:
Oil order No. 925715, ESSO-UNIVIS HVI26, approx. 2 liters, temperature 20 ±5 °C
1
Remove set bolt and ball 2 Align both ends of the pulse unit as shown in the
picture (internal equalization hole is opened)
3
Use adapter to connect pulse unit to the
quick disconnect coupling.
Close shutoff valve .
4
Set the working pressure to approx. 500 kPa.
Slowly open the shut-off valve all the way until
the gauge shows a negative pressure of
<10 mbar (-1 bar).
Wait approx. 2 minutes until the number of
vacuum bubbles has reduced significantly.
Slowly close the shut-off valve. The gauge
shows atmospheric pressure again. Missing oil
will be pressed back into the pulse unit.
If necessary, repeat the last 3 rundown steps
until bubbles are reduced practically to zero.
<103>
<102>

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Maintenance 5
5
Uncouple the pulse unit and unscrew the
adapter.
To avoid air pockets, fill the filling hole full of oil.
6
Position the injector so that it has a sealing
effect and add reserve oil until distance Xfor
spacer <B2> is achieved.
Maintain distance Xand secure with <B2>.
Refit set bolt and ball.
Remove <B2>.
NOTE Small air bubbles that become visible due to the high pressure during filling do not mean that the pulse unit
is leaking. This will not negatively affect the filling result.
<B1>
<B2>
Approx. 5 ml
X approx. 2.5 mm

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Maintenance
5
Empty side

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Disassembly instructions 6
6 Disassembly instructions
<…> Please refer to 8 Spare parts, page 25 and 8.5 Equipment order list, page 34
6.1 Remove motor unit
12
Changing blades Changing bearings / rotor
<C3>
<C2>
<C1>
<61>
<59>
<C3>
<C1> <59>
<54>

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Assembly instructions
7
6.2 Remove throttle valve
6.3 Remove pulse unit
Abb. 6-1
7 Assembly instructions
<…> Please refer to 8 Spare parts, page 25 and 8.5 Equipment order list, page 34
1 2 Spring force! 3
CAUTION! Skin irritation in case of direct contact with oil.
Wear protective gloves.
CAUTION! Hydraulic blade is under spring pressure!
Wear protective goggles.
NOTE Permitted only if filling is guaranteed with oil filling
device, see 5.3 Complete oil filling, page 16. Pulse unit
must have cooled down to room temperature.
WAF 3/
WAF 1/2"
<D3>
<D2>
<D1>
<84>