Apex Tool Group Cleco 80PTHH User manual

For additional product information visit our website at http://www.apexpowertools.eu
80PTHH
Pulse shut-off nutsetter
Instruction Manual
P2124BA/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 shut-off nutsetter(hereafter referred to simply as
80PTHH).
• 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
80PTHH stands for all of the designs of the pulse shut-off nutsetter described here.
identifies instructions to be followed.
• identifies lists.
<…> identifies an index, see .
In graphics:
identifies movement in a direction.
identifies function and force.
In graphic illustrations:
If not absolutely essential, 80PTHH (air from bottom) is illustrated.
80 P T H H × 35 ×
Max. capacity Output drive
80 – 80 Nm 4– External square 1/2"
Q– Quick change chuck 7/16"
Design Speed
P– Pistol grip 35 – 3,500 rpm
Shutoff 2. Air Inlet
T– Torque controlled shut-off A– Air from top
– None
Pulse mechanism Design
H– Hydraulics H

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Contents
1 Safety 5
1.1 Warnings and notes..................................................................................................... 5
1.2 Basic requirements for safe working practices............................................................ 6
1.3 Operator training ......................................................................................................... 6
1.4 Personal protective equipment.................................................................................... 7
1.5 Designated use ........................................................................................................... 7
1.6 Noise and vibrations.................................................................................................... 7
2 Items supplied 8
3 Product description 8
3.1 Operation and functional elements.............................................................................. 8
3.2 Options........................................................................................................................ 9
4 Before initial operation 9
4.1 Air supply..................................................................................................................... 9
4.2 Change air inlet: top / bottom (only on 80PTHHA).................................................... 10
4.3 Connect the tool........................................................................................................ 10
4.4 Setting up the tool ..................................................................................................... 11
5 Troubleshooting 13
6 Maintenance 15
6.1 Service schedule....................................................................................................... 15
6.2 Fill reserve oil............................................................................................................ 16
6.3 Complete oil filling..................................................................................................... 18
7 Disassembly instructions 21
7.1 Remove motor unit.................................................................................................... 21
7.2 Remove throttle valve................................................................................................ 23
7.3 Remove pulse unit..................................................................................................... 24
8 Assembly instructions 24
8.1 Install motor unit........................................................................................................ 24
8.2 Install pulse unit......................................................................................................... 28
9 Spare parts 29
9.1 Pistol grip 80PTHH…................................................................................................ 30
9.2 Pistol grip 80PTHHA….............................................................................................. 32
9.3 Motor unit .................................................................................................................. 34
9.4 Pulse unit................................................................................................................... 36
9.5 Equipment order list .................................................................................................. 38
10 Technical data 39
10.1 Dimensions 80PTHH… in mm .................................................................................. 39

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10.2 Dimensions 80PTHHA… in mm................................................................................ 40
10.3 Performance Data..................................................................................................... 40
10.4 Ambient conditions.................................................................................................... 41
11 Service 41
12 Disposal 41

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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.
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.

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Safety
1
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.
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.
CAUTION! Work with a maximum working pressure of 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.
80PTHHA: 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 9 Spare parts, page 29.
Use only accessory parts authorized by Apex Tool Group (see product catalog).
Adjust the torque using the provided hex wrench only. Never use an angular wrench.
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
1.4 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 80PTHH 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 / clockwise rotation for n 3,500 rpm < 77 dB(A)
Vibration values in accordance with DIN EN ISO 28927-2
Idle / clockwise rotation ahv for n 3,500 rpm < 1.0 m/s²
Pulses ahv 80PTHH < 4.5 m/s²
Pulses ahv 80PTHHA < 5.0 m/s²
Pulses ahv 80PTHHA + 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 80PTHH
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 Torque adjustment, see Abb. 4-1 , page 11
3 Pulse count settings, see 4.4.2 Change pulse count, page 12
4 Air inlet
2
5
4
4
1
53
6
8
7
9
(8)
Alternative
position
2
80PTHH…
80PTHHA…

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Before initial operation 4
3.2 Options
4Before 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
5 Connection for evaluation electronics TVP100,
6 Start button
7 Reserve oil, see 6.2 Fill reserve oil, page 16
8 Suspension bail
9 Hex wrench (WAF 2), order no. 935490
Order no. 934918
Signal connection kit
for evaluation elec-
tronics TVP100
Protective sleeve
Order No. 937450PT – 80PTHH…
Order No. 937445PT – 80PTHHA…
Vibration absorber
Order No. 935966 – 80PTHHA…
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.
Item.Designation

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Before initial operation
4
Oils according to DIN 51524 / ISO 3498
4.2 Change air inlet: top / bottom (only on 80PTHHA)
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 9.2 Pistol grip 80PTHHA…,
page 32, 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 in anticlockwise rotation.
Regulator To attain constant work results, the working pressure must be
kept constant for every individual tool.
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 shut-off nutsetter = 4
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
Fully open exhaust air throttle anti-
clockwise.
Check speed at output drive:
Clockwise rotation 3,500 ±500 rpm
Anticlockwise rotation 6,000
±500 rpm.
CAUTION! Danger of injury from unintended startup.
Shut off the compressed air before adjusting the torque.
CAUTION! Danger of injury from rotating hex wrench.
Adjust the torque using the provided hex wrench only. Never use an angular wrench.
Settings example:
Tightening: 69 Nm
Screw M10: 10.9
Approximately 3.5 turns of the
torque adjustment screw
Nm
Torque
Settings example: 69 Nm
Turns of torque adjustment screw

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Before initial operation
4
Abb. 4-2
4.4.2 Change pulse count
Abb. 4-3
1. Hold the output drive firmly.
2. Carefully push the hex wrench (WAF 2)
through the hole of the pistol grip housing until
it reaches the torque adjustment screw .
3. Turn the torque adjustment screw and roughly
set the required torque, see Abb. 4-1 ,
page 116.
Total number of turns = 6.
4. Remove hex wrench.
The hole will automatically close after starting.
5. Carry out the rundown.
6. Check the shutoff mechanism worked
properly, see 4.4.3 Measuring the torque,
page 13.
7. In case of deviations, correct the torque setting
and
8. Repeat the rundown.
Requirement Measure
High shut-off accuracy –
especially with hard screwed joints.
Increase number of pulses per tighten-
ing.
Recommended number of pulses 6.
Reduce the speed. 1. Unscrew the threaded pin using the
hex wrench (WAF 2).
2. Turn exhaust air throttle clock-
wise.
Shortening the rundown time, particu-
larly for soft joints. Increase the speed. 1. Unscrew the threaded pin using the hex wrench (WAF 2).
2. Turn exhaust air throttle anti-
clockwise.
NOTE A pulse count change may be carried out while the compressed air is activated.
After changing the pulse count, check the screwed torque and correct the setting as necessary,
see Abb. 4-2 , page 12.
Torque
Speed

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Troubleshooting 5
4.4.3 Measuring the torque
We recommend carrying out a static torque measurement by retightening the screwed joint.
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).
5 Troubleshooting
Error Possible causes Measures and remedies
Tool
does not switch off Torque set too high Reduce the torque setting, see Abb. 4-1 , page 11
Pulse count set too low Increase pulse count, see 4.4.2
Change pulse count, page 12
Working pressure < 400 kPa 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. Use a shorter or more rigid exten-
sion.
Replace the socket
Insufficient oil in the pulse unit (no
pulse build-up) See 6.2 Fill reserve oil, page 16
If X = 0 (see picture 2), the reserve
oil is exhausted and must be
refilled to guarantee a controlled
process., page 16
Screen in the air inlet tube /
muffler is dirty Clean or replace parts
Insufficient shut-off
accuracy Pulse count too low: <6 Increase pulse count,
pulse count > 6
Adapter parts Replace adapter parts
Use extension and socket with
guide diameter
Pressure fluctuations in the air network Use a pressure regulator
Fastening time too
long: > 4 seconds Joint too soft; crush nuts, self-tapping screws Use a pulse nutsetter with higher
capacity. Use next tool size.
Use a mechanical screwdriver

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Troubleshooting
5
Empty side

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Maintenance 6
6 Maintenance
6.1 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 6.1.1 Calculating a customer-specific maintenance plan, page 16.
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 6.3 Complete oil filling, page 18.
Motor service kit, see 3) Part of motor service kit K1, order
no. 936253PT, page 31.
Hydraulic service kit, see 3) Part of hydraulic service kit K2,
order no. 936212, page 37.
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
6
6.1.1 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.
6.2 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

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Maintenance 6
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 present.
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
6
6.3 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 vac-
uum 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 6
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>.
• Small air bubbles that become visible due to the high pressure during filling do not mean that the pulse
unit is leaking. The filling process is not impaired.
• If a flow of large rapid bubbles appear and continue to be produced and the pressure drops, there is a
leak inside of the pulse unit.
<B1>
<B2>
Approx. 5 ml
X approx. 2.5 mm

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Maintenance
6
Empty side