Cleco 104 Series Installation and operating instructions

1
Operation & Service Manual
823197 2/01
104, 174 & 254 Series Screwdrivers
Top Air Inlet
104 174 254
Handle:
TP
Gear Train Designation:
Torque Control Mechanism:
A Clecomatic
5
Rev. Slide Screwdriver
Tool Type:
RS
XX A XTP -
U
XXX
(Trigger Start)Pistol
Output Drive:
Second
Generation:
B
Q
B Q-
Quick Change
NORTH AMERICA EUROPE
CooperTools
P.O. Box 1410
Lexington, SC 29071
Cooper PowerTools GmbH & Co.
Postfach 30
D-73461 Westhausen

2
OPERATING INSTRUCTIONS
READ SAFETY RECOMMENDATIONS BEFORE
CONNECTING TOOL.
OPERATION
CLECOMATIC Models
No. 5 Series CLECOMATIC screwdrivers are automatic
shut-off tools. Accurate torque is achieved by setting the
CLECOMATIC clutch to the desired torque. The tool will
automatically shut off at this preset torque.
The RSATP model is designed to start when the trigger is
pulled and stops when the clutch reaches the set torque or
thetriggerisreleased.Releasingthetriggerwillresetthetool
for the next cycle.
CLUTCH ADJUSTMENT
Theclutchisadjustedthroughtheslotprovidedintheclutch
housing.Theslotcoverwillhavetoberotatedtoexposethe
adjustment slot. Rotate the clutch until the hole in the
adjustment lock plate is visible. Insert a No. 1 Phillips
screwdriver and rotate in a clockwise direction to increase
the torque setting or a counterclockwise direction to de-
crease the setting.
If the clutch is adjusted over the maxi-
mumpoweroutputofthetool,theclutch
willnotfunctionandthetoolwilloperatelikeastall-typetool.
Also,ifthetoolisbeingoperatedatits 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 prepared to
counteractstalltorqueincaseclutchisimproperlyadjusted.
AIR SUPPLY
The tool is designed to operate at 90 psig (6.2 bar) air
pressure. The air pressure should be checked at the tool's
air inlet while the tool is running.
The use of an automatic in-line filter-regulator-lubricator is
highly recommended. This will supply the tool with clean,
lubricated air, keep it in sustained operation, and increase
tool life.
Formaximumperformance,usea1/4"(6.5mm)I.D.airhose
up to 8 feet in length. If additional length is required, a 3/8"
(9.5mm)I.D. orlargerhoseshouldbeconnectedtothe 1/
4" (6.5mm) I.D. hose.
The air hose should be cleared of accumulated dirt and
moisture, then one-quarter (1/4) teaspoon (6.5cc) of 10W
machine oil should be poured into the tool's air inlet before
connecting the hose to the tool.
LUBRICATION
Thein-line lubricatorshould bechecked regularlyand filled
with a good grade of 10W machine oil. In the event a line
lubricatorisnotused,toolsshouldbedisconnectedfromthe
airsupplyseveraltimesdailyandseveraldropsofoilpoured
into the tool's inlet bushing.
Application of the tool should govern how frequently it is
greased. It is recommended that the idler gears receive a
generousamountofNLGI2-EPgreaseafterevery40hours
of operation. The clutch housing (left hand threads) and
clutchmustberemovedandthegreaseappliedthroughthe
hex in the spider.
CAUTION!

3
SERVICE INSTRUCTIONS
DISASSEMBLY- GENERAL (All Models)
Clamp the handle in a soft-jawed vise and using a wrench
unscrew the quick change chuck (left hand threads). Un-
screw the clutch housing from gear case. Unscrew and
removethegearcaseassemblyfromthehandle.Themotor
unit may now be removed from the backhead.
CLUTCH DISASSEMBLY
Clecomatic Clutch:
Unscrew(lefthandthreads)theadjustmentnut869123,and
removetheadjustmentlockring869140.Thetorquespring,
bearingraces 863455, thrustbearing 847104, ballretainer,
203573, and four (4) steel balls 842161, may now be
removed from the clutch spindle.
Washingtheremainingspindleasemblyinasolvent willaid
disassembly.Removetheballretainerring203574,andball
retainer plug 869149, from the clutch cam 203572. Rotate
the clutch spindle, to allow the thirteen (13) steel balls
842980, to drop out of the ball loading hole located in the
clutch cam. Separate the clutch spindle and clutch cam,
being careful not to lose the reset pin 869112, reset spring
203585, reset pin stop 869424, trip slide 203612, trip slide
reset spring 203613, and dowel pin 617226.
Quick Change Chuck
Removing retainer ring 833688, will release all parts in the
quickchangechuck.Therestoftheclutchdisassemblesthe
same as finder clutch.
GEAR TRAIN DISASSEMBLY
-104 Gear Train
Spiders should be removed from the rear of the gear case.
Remove the bearing retainer ring 619017 and press the
spider bearing 847595, out the front of the gear case. If
replacementoftheidlergearpinsisnecessary,theyshould
be pressed out the rear of the spider. If replacement of the
first reduction spider pinion 869132 is necessary, if should
be pressed out the front of the spider. See Figure 1 for
replacement dimensions.
2nd Red. Spider 1st Red. Spider
Fig. 1: -104 Gear Spider Gear Train:
-174 Gear Train
When pressing the spider assembly out of the rear of the
gearcase869162,besuretheidlergears869163,areinline
with the pockets machined in the gear case.
Press the idler gear pins 833862, out the rear of the spider
869155, for inspection of the idler gear pins and idler gears
869163.
Remove the bearing retainer ring 619017, and press the
front spider bearing 847595, out the front of the gear case.
-254 Gear Train:
Press the spider assembly out the rear of the gear case.
Remove the bearing retainer ring 619017, and press the
front spider bearing 847595, out the front of the gear case.
If replacement of the idler gear pins, is necessary, they
shouldbepressedouttherearofthespider.SeeFigure2for
replacement pin height.
Fig. 2: -254 Gear Spider
MOTOR DISASSEMBLY — (All Models)
Slipthefrontbearing842768,andfrontbearingplate203641,
offthefrontoftherotorandremovethecylinder203504,and
four (4) rotor blades 203615. Set the rear bearing plate on
the vise jaws with the rotor hanging down. Use a 3/16"
(4.8mm)punchtodrivetherotoroutoftherearrotorbearing
842768.
HANDLE DISASSEMBLY — (All Models)
Forinspectionorreplacementofthethrottlevalveorrelated
parts, rol down the grip sleeve and drive trigger bushing
retainer pin out and removing bushing. Shut off valve and
seal can be removed by removing 203559 valve cap.
Thereversingvalvemayberemovedbyfirstunscrewingthe
reversingvalvescrewoutofthereversingvalveknob.Then
reversing valve may be removed from the handle. On
reassemblymakesurethereversingvalvescrewalignswith
the threaded hole in reversing valve.
.225
(5.72mm)
.220
(5.59mm)
Front Rear
Pinion should be
pressed in flush
to .005 (1.27mm)
below surface.
.222
(5.64mm)
.218
(5.54mm)
RearFront
.225
(5.72mm)
.220
(5.59mm)
Front Rear

4
SERVICE INSTRUCTIONS
REASSEMBLY— GENERAL
IMPORTANT: During reassembly of the complete tool, the
gear case should be tightened to the handle to 20 ft. lbs.
(27Nm). Wrenches can be ordered for performing this task.
All parts should be washed in a solvent and inspected for
damage or wear. Particular attention should be given to all
bearings,gears,gearpins,androtorbladesasfailureofthese
parts could cause damage to more expensive parts. Rotor
blades should be replaced if they measure less than 1/8"
(3.2mm)oneitherend.Rotorbladesshouldbesizedinlength
to .003"/.004" (.08mm/.10mm) shorter than the cylinder.
Inspect and replace any "O"-rings or seals that show signs of
wearof deterioration. Allgears, gear pins,andopen bearings
should receive a generous amount of NLGI 2-EP grease
during reassembly. Reassembly of all of the various subas-
semblies is in reverse order of disassembly: however, the
following paragraphs list some of the more important reas-
sembly procedures.
CLUTCH REASSEMBLY
Clecomatic Clutch:
Duringreassemblyoftheclutch,allpartsshouldreceiveathin
coating of 10W machine oil. In addition, the ball retainer
203573, should receive a generous amount of NLGI 2-EP
grease.Wheninstallingthedowlpin 617226, the taperedend
goesinto the clutch cam first.The tripslide 203612, goesinto
the clutch cam cupped-end first. All parts installed into the
clutchspindle and clutch cam 203572, should be checked for
smooth operation before complete assembly of the clutch.
MOTOR REASSEMBLY
Install the rear rotor bearing, into the rear bearing plate
203506. If using new parts, check for burrs or nicks. After
installingnewcylinderpins,checkforburrsaroundpins.Press
thebearingplateassembly(pressonthebearing'sinnerrace)
onto the rear rotor shaft until there is approximately .0015"
(.04mm) clearance between the rear bearing plate and rotor.
TRIP ROD SIZING
ThetriprodNo.203586,shouldbesizedtoallowapproxi-
mately 1/8" (3.2mm) throttle valve opening.
IMPORTANT: During reassembly of the complete tool,
gear case should be tightened to handle to 20 ft. lbs.
(27Nm).Wrenchesshownbelowcanbeorderedtotighten
the gear case and clutch housing.
SAFETY CHECK
Afterrepairorreplacementofparts,toolsshouldbetested
to verify that they are functioning properly.
Replace blade if less
than 1/8"(3.2mm)
on either end.
.0015" (.038mm)
Clearance
34 204 - ARMSTRONG U.S.A.
203803-2
GEAR CASE WRENCH
C 471 3/4 - 2
203804-0
CLUTCH HOUSING WRENCH

5
The complete clutch can be purchased using this number: 201219-3
Release Collar
Release Collar Spring
Spindle
Spindle Housing
Retainer Ring
Retainer Ring
Ball (1/8"/ 3.175mm)
Washer
Part No.
202833-0
202842-1
202847-0
203622-6
619524-2
833688-5
844265-9
864249-8
Name of Part Qty.
1
1
1
1
1
1
1
1
PARTS LIST —5 SCREWDRIVER
STALL SPINDLE
PARTS LIST —-104, -174 & -254 GEAR TRAIN
PART NO. NAME OF PART QTY.
203623-4 Idler Gear (14T) 3
203978-2 Spider 1
204282-8 Cage 1
619017-7 Bearing Retainer Ring 1
844111-5 Idler Gear Pin 3
847595-6 Spider Bearing 1
869135-4 Gear Case (41T) 1
The complete gear train can be purchased as a subassembly
using part no. 201659-0.
5 SCREWDRIVER
-104, -174 & -254
2ND REDUCTION
GEAR TRAIN
202833-0
619524-2
864249-8
202842-1
833688-5
844265-9
202847-0
203622-6
619017-7
847595-6
869135-4
204282-8
203623-4
-104, -174 & -254 2ND REDUCTION GEAR TRAIN
844111-5
5 SCREWDRIVER
STALL SPINDLE

6
5 CLECOMATIC CLUTCH
FOR -104, -174 & -254
PARTS LIST —5 CLECOMATIC CLUTCH FOR -104, -174 & -254
Part No. Qty.Part No.
203572-3
203573-1
203574-9
203575-6
203578-0
203579-8
203580-6
203584-8
203585-5
203589-7
203612-7
203613-5
203625-9
203626-7
617226-6
619017-7
842161-2
842980-5
844305-3
847095-7
847104-7
863455-2
869112-3
869123-0
869140-4
869149-5
869424-2
1
4
13
1
1
1
2
1
1
1
1
1
Clutch Cam
Ball Retainer
Retainer Ring
Torque Spring - White
Torque Spring - Yellow
Torque Spring - Green
Torque Spring - Blue
Adj. Cover (incl. in 203626)*
Clutch Reset Spring
Spring Spacer
Trip Slide
Slide Reset Spring
Clutch Spindle
Clutch Housing (incls. 203584)*
Dowel Pin
Retainer Ring*
Ball (3/16")
Ball (3/32")
"O"-ring (3/8" x 5/16")*
Ball Bearing*
Needle Bearing
Thrust Race
Reset Pin
Adjustment Nut
Adjustment Lock Ring
Ball Retainer Plug
Reset Pin Stop
Name of Part
Name of Part Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
The complete clutch can be purchased using these part numbers: 201461-1
* Not included in subassembly.
203625-9
203572-3
203573-1
203574-9
203585-5
203612-7
203613-5
617226-6
842161-2
842980-5
847104-7
863455-2 863455-2
869112-3
869123-0
869140-4
869149-5
869424-2
203626-7*
847095-7*
203580-6 Blue
203579-8 Green
203575-6 White
203578-0 Yellow
203584-8*619017-7*
203589-7

7
PARTS LIST —-254 GEAR TRAIN
PART NO. NAME OF PART QTY.
203916-2 Idler Gear Pin 3
203917-0 Idler Gear Bushing 3
203925-3 Idler Gear ( 16T) (incls. 203917) 3
203928-7 Gear Case (41T) 1
203978-2 Spider (incls. 203916) 1
204136-6 Motor Spacer 1
619017-7 Bearing Retainer Ring 1
847595-6 Spider Bearing 1
The complete gear train can be purchased as a subassembly
using part no. 201588-1.
204136-6
619017-7
847595-6
203928-7
203978-2
203916-2
203917-0
-254 1ST REDUCTION GEAR TRAIN
203925-3
-104, -174 & -254 1ST REDUCTION
GEAR TRAINS
619017-7
847595-6
869162-8 869155-2
833862-6
869163-6 203646-5
-174 1ST REDUCTION GEAR TRAIN
619017-7
847595-6
203928-7
203976-6
203916-2 203920-4 203920-4
203917-0
203916-2
203917-0
869132-1
201550-1
-104 1ST REDUCTION GEAR TRAIN
203919-6
203644-0
PART LIST —-104 GEAR TRAIN
PART NO. NAME OF PART QTY.
201550-1 -10 Reduction Spider (incls. 869132, 203916) 1
203644-0 -10 Motor Spacer 1
203916-2 -10 Idler Gear Pin 6
203917-0 -10 Idler Gear Bushing 6
203919-6 Rotor Pinion (13T) 1
203920-4 -10 Idler Gear (14T) 6
203928-7 -10 Gear Case (41T) 1
203976-6 -10 2nd. Red. Spider (incls. 203916) 1
619017-7 Bearing Retainer Ring 1
847595-6 Spider Bearing 1
869132-1 -10 Spider Pinion (13T) 1
The complete gear train can be purchased as a subassembly
using the following part number: -104 — 201587-3
PARTS LIST —-174 GEAR TRAIN
PART NO. NAME OF PART QTY.
203646-5 Motor Spacer 1
619017-7 Bearing Retainer Ring 1
833862-6 Idler Gear Pin 3
847595-6 Front Spider Bearing 1
869155-2 Spider 1
869162-8 Gear Case (27T) 1
869163-6 Stepped ldler Gear (9T & 18T) 3
The complete gear train can be purchased as a subassernbly
using part number: 201474-4.

8
5 —-104, -174 & -254 MOTOR
Name of Part
Cylinder
Rear Bearing Plate
Rotor -254 (7T)
Rotor -104 (Hex)
Rotor -174 (6T)
Trip Rod (Clecomatic)
Rotor Blade
Front Bearing Plate
Bearing
Front Cylinder Pin
Reversible Rear Cylinder Pin
Part No.
203504-6
203506-1
203545-9
203546-7
203547-5
203586-3
203615-0
203641-6
842768-4
844897-9
847548-5
Qty.
1
1
1
1
1
1
4
1
2
1
1
203504-6
842768-4842768-4 203615-0
847548-5
203586-3
844897-9
203545-9 -254
203547-5 -174
203546-7 -104
203506-1
203641-6
PARTS LIST —5—-104, -174 & -254
MOTOR

9
5 REVERSIBLE CLECOMATIC TRIGGER
PISTOL GRIP HANDLE (RSATP)
847031-2
847710-1
203568-1
203567-3 881276-0 203570-7
203502-0
203529-3 203559-0
203531-9
847710-1203532-7
203614-3
203569-9
812963-7
813315-9 203525-1
203563-2
619016-9
847272-2
203673-9
203739-8
412603-3
GRIP SLEEVE
203762-0
204275-2
204274-5
PART LIST
REVERSIBLE CLECOMATIC TRIGGER
PISTOL GRIP HANDLE
PART NO. NAME OF PART QTY.
203502-0 Handle 1
203525-1 Shut-off Valve Spring 1
203529-3 Shut-off Valve 1
203531-9 Reversing Valve 1
203532-7 Motor Spacer 1
203559-0 Valve Cap 1
203563-2 Muffler 1
203567-3 Throttle Valve* 1
203568-1 "O"-ring (11/64" x 3/8")* 1
203569-9 Trigger (incl. 813315)* 1
203570-7 Throttle Valve Bushing* 1
203614-3 Trigger Spring* 1
203673-9 Shut-off Valve Seat 1
203739-8 Screen 1
203762-0 Grip Sleeve 1
204274-5 Reversing Valve Knob 1
204275-2 Reversing Knob Spacer 1
412603-3 Bail 1
619016-9 Retainer Ring 1
812963-7 Reversing Valve Screw 1
813315-9 Set Screw* 1
847031-2 Roll Pin 1
847272-2 "O"-ring (5/8" x 3/4") 1
847710-1 "O"-ring (1/2" x 5/8")* 4
881276-0 Inlet Bushing 1
The complete Handle can be purchased as a subassembly using the following part
number: 201433-0
The complete Trigger subassembly can be ordered using part number: 201435-5
*Part included in Trigger subassembly.

10
5 UPPER INLET REVERSIBLE CLECOMATIC TRIGGER
PISTOL GRIP HANDLE (RSAUPT, RSAUTP)
PART LIST
5 UPPER INLET REVERSIBLE CLECOMATIC
TRIGGER PISTOL GRIP HANDLE
PART NO. NAME OF PART QTY.
203525-1 Shut-off Valve Spring 1
203529-3 Shut-off Valve 1
203531-9 Reversing Valve 1
203532-7 Motor Spacer 1
203559-0 Valve Cap 1
203563-2 Muffler 1
203567-3 Throttle Valve* 1
203568-1 "O"-ring (11/64" x 3/8")* 1
203569-9 Trigger (incl. 813315)* 1
203570-7 Throttle Valve Bushing* 1
203614-3 Trigger Spring* 1
203673-9 Shut-off Valve Seat 1
203739-8 Screen 1
203762-0 Grip Sleeve 1
203777-8 Handle 1
203778-6 Retainer Ring 1
203779-4 Air Inlet Ring 1
204274-5 Reversing Valve Knob 1
204275-2 Reversing Knob Spacer 1
619016-9 Retainer Ring 1
812963-7 Reversing Valve Screw 1
813315-9 Set Screw* 1
833954-1 "O"-ring (1-5/8" x 1-3/4") 2
847031-2 Roll Pin 1
847272-2 Valve Cap "O"-ring (5/8" x 3/4") 1
847710-1 "O"-ring (1/2" x 5/8")* 4
The complete handle can be purchased as a subassembly using the following part
number: 201519-6.
The complete Trigger subassembly can be ordered using part number: 201435-5
*Part included in Trigger subassembly.
847031-2
847710-1
203568-1
203567-3203570-7
203777-8
203529-3 203559-0
203614-3
203569-9
813315-9 203525-1
203563-2
619016-9
847272-2
203673-9
203739-8
865777-7
R
203531-9
847710-1203532-7
812963-7
204275-2
204274-5
203778-6
203779-4
833954-1
GRIP SLEEVE
203762-0