Cleco 111 Series Installation and operating instructions

1
Operation & Service Manual
823054 2/01
111 & 136 Series Nutrunners
Pistol
Handle:
OS
XXX
Nutrunner:
111 & 136
Series:
N OS XX
Gear Train Designation:
5
710 20 30 40
-
NORTH AMERICA EUROPE
P.O. Box 1410
Lexington, SC 29071 Postfach 30 D-73461 Westhausen

2
For your safety and the safety of others, read and understand the
safety recommendations and operating instructions before operat-
ing a nutrunner.
Always wear protective equipment:
For additional information on eye protection and face protection,
refer to Federal OSHA Regulations, 29 Code of Federal Regula-
tions, Section 1910.133., Eye and Face Protection, and American
NationalStandardsInstitute,ANSIZ87.1,OccupationalandEduca-
tional Eye and Face Protection. Z87.1 is available from the Ameri-
can National Standards Institute, Inc., 11 West 42nd Street, New
York, NY 10036.
Hearing protection is recommended in high noise areas 85 dBA or
greater. The operation of other tools and equipment in the area,
reflective surfaces, process noises and resonant structures can
substantially contribute to, and increase the noise level in the area.
Excessiveairpressure90PSIGorwornmotorcomponentscanalso
increase sound level emitted by tool. For additional information on
hearing protection, refer to Federal Regulations, Section 1910.95,
Occupational Noise Exposure, and American National Standards
Institute, ANSI S12.6, Hearing Protectors.
Cleco nutrunners 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. Excessive air pressure in-
creases the loads and stresses on the tool parts, sockets, and
fasteners and may result in breakage. Installation of a filter-regula-
tor-lubricator in the air supply line ahead of the tool is recom-
mended.
Before the tool is connected to the air supply, check the throttle for
proper operation (i.e., throttle moves freely and returns to closed
position). Clear the air hose of accumulated 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.
Itis essentialfor safeoperation thatany operatorof anutrunner use
good balance, sure footing, and proper posture in anticipation of a
torque reaction. Insure that the operator's hand will not be wedged
or pinched between the work and the tool when operating.
Reaction bar nutrunners are equipped with a torque reaction bar.
These bars can be braced against the work or other suitable points
toabsorband relievethe operator ofthe torquereactiontransmitted
Safety Recommendations
WARNING!
Impact resistant eye protection
must be worn while operating
or working near this tool.
CAUTION!
Personal hearing protection is
recommended when operating
or working near this tool.
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.
If the tool is to be reversed, locate torque reaction bar in a position
that will resist torque reaction and prevent entrapment. See Direc-
tions on next page.
Tools with clutches can stall rather than shut-off if adjusted over
maximum power output of tool, or if there is a drop in air pressure.
Reactionbarmustbeproperlypositionedtoresisttorque.Operator
must release throttle to stop tool if this occurs. Do not use without
properly positioned reaction bar.
Reversible tools can have torque reactions in either direction. The
reaction bar must be properly positioned to resist the torque
reaction.
Someindividualsmay besusceptible todisordersof thehands and
armswhen performing tasksconsisting ofhighly repetitive motions
and/or exposure to extended vibration. Cumulative trauma disor-
derssuchascarpaltunnelsyndromeandtendonitismaybecaused
or aggravated by repetitious, forceful exertions of the hands and
arms. Vibration may contribute to a condition called Raynaud's
Syndrome. These disorders develop gradually over periods of
weeks, months, and years. It is presently unknown to what extent
exposure to vibrations or repetitive motions may contribute to the
disorders. Hereditary factors, vasculatory or circulatory problems,
exposure to cold and dampness, diet, smoking and work practices
are thought to contribute to the conditions.
Any tool operator should be aware of the following warning signs
and symptoms so that a problem can be addressed before it
becomes a debilitating injury. Any user suffering prolonged symp-
toms 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 a
physician. If it is determined that the symptoms are job related or
aggravatedbymovementsandposturesdictatedbythejobdesign,
itmaybenecessaryfortheemployertotakestepstopreventfurther
occurrences. These steps might include, but are not limited to,
repositioning the workpiece or redesigning the workstation, reas-
signing workers to other jobs, rotating jobs, changing work pace,
and/or changing the type of tool used so as to minimize stress on
theoperator. Sometasks mayrequire morethan onetype oftool to
obtain the optimum operator/tool/task relationship.
CAUTION !
Repetitive work motions and/or vibration
may cause injury to hands and arms.
Use minimum hand grip force consistent
with proper control and safe operation.
Keep body and hands warm and dry.
Avoid anything that inhibits blood circulation.
Avoid continuous vibration exposure.
Keep wrists straight.
WARNING
!
Avoid repeated bending of wrists and hands.

3
Safety Recommendations
OVERLOADED REACTION BARS
MAYBENDOR BREAK! USE THIS
GUIDE FOR PROPER APPLICA-
TION OF THE CLECO REACTION
BAR.
The reaction bar is secured to the tool and braced
against the work in the opposite direction of spindle
rotation. This will transfer the torque reaction from the
tool to the work.
The following suggestions will help reduce or moderate the effects
of repetitive work motions and/or extended vibration exposure:
• Use a minimum hand grip force consistent with proper
control and safe operation
• Keep body and hands warm and dry (cold weather is
reported to be a major factor contributing to Raynaud's
Syndrome)
• Avoid anything that inhibits blood circulation
—Smoking Tobacco (another contributing factor)
—Cold Temperatures
—Certain Drugs
• 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 — select a tool
appropriate for the job and work location
• Avoid highly repetitive movements of hands and
wrists, and continuous vibration exposure (after each
period of operation, exercise to increase blood circu-
lation)
• Keep tool well maintained and replace worn parts
For more information on the safe use of portable air tools, see the
latest edition of ANSI B186.1, Safety Code for Portable Air Tools,
available from the American National Standards Institute, Inc. 11
West 42nd Street, New York, NY 10036.
This information is a compilation of general safety practices ob-
tained from various sources available at the date of production.
However, our company does not represent that every acceptable
safety practice is offered herein, or that abnormal or unusual
circumstances may not warrant or require additional procedures.
Yourworkmayrequireadditionalspecificsafetyprocedures.Follow
these procedures as required by your company.
Warning Labels
Thewarning labels found onthese tools are anessential part of this
product. Labels should not be removed. Labels should be checked
periodically for legibility. Replace warning labels when missing or
when the information can no longer be read. Replacement labels
can be ordered as any spare part.
203185-4
READ
OPERATING
INSTRUCTIONS
203185
OVER
CAUTION!
Personal hearing protection is recommended when operating or working near this tool.
WARNING!
Impact resistant eye protection must be worn while operating or working near this tool.
Read Operating Instructions carefully. Follow the Safety Recommendations for your safety and the safety of others. Hearing protection is recommended in high noise areas (above 85 dBA). Close proximity of other tools, reflective surfaces, process noises, and resonant structures can substantially contribute to the sound level experienced by the user.
WARNING
!
Repetitive work motions and/or vibration can cause injury to hands and arms. Use minimum hand grip force consistent with proper control and safe operation. Keep body and hands warm and dry. Avoid anything that inhibits blood circulation. Avoid continuous vibration exposure. Keep wrists straight.
Avoid repeated bending of wrists and hands.
Do not remove this tag until the operator of this tool has read these safety precautions.
203289
Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation
Avoid Avoid Avoid OK Avoid OK
Standard Length Spindle X = 2 1/2" Minimum
Y = 2 1/2" Maximum
Torque Capacity = 125 Ft. Lbs. Maximum
3" Longer Than
Standard Spindle X = 4" Minimum
Y = 5 1/2" Maximum
Torque Capacity = 80 Ft. Lbs. Maximum
These capacities apply to Cleco Reaction Bars code
numbers: 869769, 869770, 202007, 202008,
202009.
Substitute bars without proper
metallurgymaynotbeadequate.
Use Cleco reaction bars.
Due to the multitude and variety of tooling applications
involving reaction bar nutrunners,the "User's" Methods
Engineering, Standard Tooling Engineering, and/or Safety
Engineering Departments , etc. , must consider any
hazards associated with each specific application of this
product and provide adequate operator protection,
reaction points and strengths, and operator training in the
safe use of this product.
WARNING
!
WARNING
!

4
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
The No. 111 & 136 Series Reaction Bar Nutrunners are
designed to operate when the trigger is depressed and to
stop when the trigger is released.
AIR SUPPLY
Thetoolisdesignedtooperateat90psigairpressure.The
air pressure should be checked at the tool's air inlet while
the tool is running.
For maximum performance, use a 1/4" I.D. air hose up to
8' in length. If additional length is required, a 3/8" I.D. or
largerhoseshouldbeconnectedtothe1/4"I.D.hose.The
air hose should be cleared of accumulated dirt and mois-
ture.
LUBRICATION
An automatic in-line filter-lubricator is recommended as it
increasestoollifeandkeepsthetoolinsustainedoperation.
Thein-linelubricatorshouldberegularlycheckedandfilled
with a good grade of 10W machine oil. Proper adjustment
of the in-line lubricator is performed by placing a sheet of
paper next to the exhaust ports and holding the throttle
openforapproximately30seconds.Thelubricatorisprop-
erly set when a very light stain of oil collects on the paper.
Excessive amounts of oil should be avoided.
In the event that it becomes necessary to store the tool for
an extended period of time (overnight, weekend, etc.), it
should receive a generous amount of lubrication at that
timeandagainwhenreturnedtoservice.Thetoolshouldbe
stored in a clean and dry environment.
Application of the tool should govern how frequently it is
greased. It is recommended that the idler gears receive a
generous amount of NLGI 2-EP grease after every 40
hours of operation. The clutch housing (left hand threads)
and clutch must be removed and the grease applied
through the hex in the spider.
READ SAFETY RECOMMENDATIONS ON PAGES 2 AND 3 BEFORE CONNECTING TOOL.

5
2nd Reduction Spider 1st Reduction Spider
Fig. 2 —DOUBLE REDUCTION SPIDERS
MOTOR DISASSEMBLY
Secure the cylinder in a vise with the rear bearing plate
facing upward and using a 1/8" diameter punch, tap the
rotor out of the rear rotor bearing. This will allow removal
of the rear bearing plate, cylinder and rotor blades. Rest
thefrontbearingplateonthejawsofthevisewiththerotor
hanginglooselybetween thejawsand taptherotor outof
the front bearing. CAUTION: care should be exercised in
order to prevent damage to the rotor during disassembly
of the motor.
PISTOL GRIP HANDLE DISASSEMBLY
For inspection or replacement of the throttle valve, un-
screw the air inlet bushing. The air inlet screen, No.
412775,shouldalsobeinspectedatthistime.Replacethe
screenifcloggedortorn.Themufflermayberemovedfor
cleaning and inspection by removing the muffler screen
retainer, No. 847033.
REASSEMBLY — GENERAL
All parts should be washed in a solvent and inspected for
damageorwear.Particularattentionshouldbegiventoall
bearings, gears, gear pins, and rotor blades as failure of
thesepartscouldcausedamagetomoreexpensiveparts.
Rotor blades should be replaced every repair cycle or if
they measure less than 3/16" (4.7mm) on either end.
DISASSEMBLY — GENERAL
(ALL MODELS)
Unscrew (left hand threads) the reaction bar adapter and
remove the spindle. Unscrew and remove the gear case.
The motor unit may now be removed from the front of the
handle. See the following paragraphs for complete disas-
sembly instructions on the various sub-assemblies.
GEAR CASE DlSASSEMBLY
A. Single Reduction
Thespidershouldbepressedouttherearofthegearcase,
No. 867871. Remove the retainer ring, No. 844364, and
press the bearing, No. 847147, out the front of the gear
case.
If replacement of the idler gear pins is necessary, they
should be pressed out the rear of the spider See Fig. 1 for
replacement pin height.
Fig. 1 - SINGLE REDUCTION SPIDER
B. Double Reduction
Both spiders should be removed from the rear of the gear
case, No. 867907. Remove the retainer ring, No. 844364,
andpressthebearing,No.847147,outthefrontofthegear
case.
If replacement of the idler gear pins is necessary, they
should be pressed out the rear of the spider See Fig. 2 for
replacement pin height.
SERVICE INSTRUCTIONS
.240
.255
Front Rear
.360
.375
Front Rear
.240
.255
Front Rear
Must be replaced if less than
3/16" (4.7mm) on either end.

6
Inspectand replace any"O" ringsor seals thatshow signs
of wear or deterioration. All gears, gear pins, and open
bearingsshouldreceivea generous amountofNLGI2-EP
grease during reassembly. When assembling the gear
case to the backhead, the gear case should be torqued to
300/325 in. lbs. (33.9/36.7 Nm). Reassembly of all of the
varioussubassembliesisinthereverseorderofdisassem-
bly; however, the following paragraphs list some of the
more important reassembly procedures.
MOTOR REASSEMBLY
Install the rear rotor bearing into the rear bearing plate.
Press the bearing plate assembly (press on the bearing's
inner race) onto the rear rotor shaft until there is approxi-
mately .0015" clearance between the rear bearing plate
androtor.After final assembly,the cylinder shouldbeheld
SERVICE INSTRUCTIONS
firmly,butnottightlybetweenthetwobearingplatesandthe
rotor should turn freely and not rub either of the bearing
plates.
HANDLE
Wheninstallingthethrottlelinkpin,thenotchedendshould
be installed into the backhead in a vertical position to
engage the throttle valve stem.
SAFETY CHECK
Afterrepairorreplacementofparts,toolsequippedwithan
automatic shut-off device should be tested at low torque
and 90 p.s.i.g. to verify that the device is functioning
properly.
.0015" (.038mm)
Clearance

7
REACTION BAR AND ADAPTER
PART NO.
202007
202008
202009
202099
202324
202466
202467
QTY.
1
1
1
1
1
1
1
QTY.
PARTS LIST —REACTION BAR AND ADAPTER
NAME OF PART
Reaction Bar Head
15/16" Steel Reaction Bar
15/16" Aluminum Reaction Bar
Roll Pin
SpindleBushing
Reaction Bar Adapter (incl. 202324,
869767)
3/8" Sq. Dr. Spindle (incl. 844013,
844014,844016)
PART NO. NAME OF PART
844013
844014
844016
869761
869767
869769
869770
Retainer Plug
Spring
Socket Retainer
Lock Nut
Grease Seal
Aluminum Reaction Bar (complete)
Steel Reaction Bar (complete)
1
1
1
1
1
1
1
202467
869767 202324
202466
869761
202099
844016 844014
844013
REACTION BAR
Material Length of Reaction Reaction Complete
Reaction Bar Bar Only Bar Head Reaction Bar
Aluminum 15-3/16" 202009 202007 869769
Steel 15-3/16" 202008 202007 869770

8
PARTS LIST —20, 30, & 40 GEAR TRAINS
PART NO. NAME OF PART QTY.
844364 Bearing Retainer Ring 1
847147 Spider Bearing 1
865862 Pinion 40 Model Only (12T) 1
867866 20 Idler Gear (18T) (incl. 867921) 3
867871 Gear Case 1
867872 20 Spider (incl. 867922) 1
867921 20 & 30 Idler Gear Bearing 3
867922 Idler Gear Pin 3
869181 30 Idler Gear (16T) (incl. 867921) 3
869182 30 Spider (incl. 867922) 1
869554 40 Idler Gear (15T) 3
869584 Pinion Spacer 40 Model Only 1
869945 40 Spider (incl. 867922) 1
869949 Thrust Washer 40 Model Only 1
The complete gear cases can be purchased as a sub-assembly
using Part No. 20 - 861573, 30 - 861680, 40 - 861928.
20, 30, & 40 GEAR TRAINS
847147
844364
867922
20 867866
30 869181
40 869554
865862
40 MODEL ONLY
869584
40 MODEL ONLY
867871
869949
40 MODEL ONLY
20 867921
30 867921
40 NONE
20 867872
30 869182
40 869945
20, 30, & 40 GEAR TRAINS
847147
844364 867907
869255
867906
842728
832128 867904
203062
869254
867922
867921
869256
5 GEAR TRAIN
7 & 10 GEAR TRAINS
7 869259
10 867905
867902
10 ONLY
869584
869257 7 867922
10 884125 7 869258
10 867903
7 867921
10 867925
PART NO.
203062
832128
842728
844364
847147
867902
867903
867904
867905
867906
867907
PART NO.
867921
867922
867925
869254
869255
869256
869257
869258
869259
869584
884125
QTY.
3
3
3
1
1
1
3
3
1
1
1
QTY.
3
3
3
3
3
1
1
3
1
1
3
NAME OF PART
7 & 10 2nd Red. Gear Bushing
7 & 10 2nd Red. Gear Pin
5 2nd Red. Gear Pin
Retainer Ring
Spider Bearing
10 Rotor Pinion (15T)
10 1st Red.Gear (l5T) - incl. 867925
7 & 10 2nd Red. Gear (15T)
10 1st Red. Spider - incl. 884125
7 & 10 2nd Red. Spider - incl. 832128
Gear Case (45T)
NAME OF PART
5 & 7 1st Red. Gear Bearing
5 & 7 1st Red. Gear Pin
10 1st Red. Gear Bushing
5 1st Red. Gear (19T) - incl. 867921
5 2nd Red. Gear (15T)
5 1st Red. Spider - incl. 867922
5 2nd Red. Spider
7 1st Red. Gear (17T) - incl. 867921
7 1st Red. Spider - incl. 867922
10 Pinion Spacer
10 1st Red. Gear Pin
The complete gear cases can be purchased as a subassembly using Part No. 5- 861718, 7- 861719, 10 - 861578.
PARTS LIST —5, 7, & 10 GEAR TRAINS
5, 7, & 10 GEAR TRAINS

9
PART NO.
812165
843446
863654
863738
869445
869450
869451
869583
869585
869586
869588
869638
869788
869848
869849
QUANITY
1
1
1
3
2
1
1
1
1
1
1
1
4
1
1
111 & 136 MOTOR
PARTS LIST
MODEL NO. PART NO.
111 863738
136 869788
MODEL NO. 111 136
5
10 869588 869848
20
40
7
30 869586 869849
869445
869585
869583 812165
MODEL NO. PART NO.
111 869450
136 869451
MODEL NO. PART NO.
111DO 869638
136DO 863654
MODEL NO. PART NO.
111DO 869445
136DO 843446
NAME OF PART
CylinderPin
136 Rear Rotor Bearing
136 Rear Bearing Plate
111 Rotor Blade
Rotor Bearing (136 requires one (1) only)
111 Cylinder (incl. 812165)
136 Cylinder (incl. 812165)
Spacer
Front Bearing Plate
111 Rotor (9T)
111 Rotor (6T)
111 Rear Bearing Plate
136 Rotor Blade
136 Rotor (6T)
136 Rotor (9T)

10
PART NO.
202039
202093
412775
832638
833303
847033
847411
867054
QTY.
1
1
1
1
1
1
1
1
QTY.
PARTS LIST —HANDLE
NAME OF PART
111 Handle
136 Muffler
Air Inlet Screen
Trigger Pin
Muffler Screen
Retainer Ring
"O" Ring 11/16" x 13/16"
Trigger
PART NO. NAME OF PART
111 & 136 HANDLE
867916
869581
869582
869642
869647
869648
869719
869774
Air Inlet Bushing
111 Muffler
Throttle Valve Spring
Throttle Link Pin
Pilot Valve
Throttle Valve Spacer
136 Handle
Throttle Valve
1
1
1
1
1
1
1
1
The complete handle can be purchased as a subassembly using the following part numbers:
No. 111 Part No. 861964 —No. 136 Part No. 861856
832638
869642
867054
847033
833303
869774
869647 412775
869582 869648
847411 867916
HANDLE
MODEL NO. PART NO.
111 202039
136 869719
MUFFLER
MODEL NO. PART NO.
111 869581
136 202093