Cleco 48EAE51P3 User manual

For additional product information visit our website at http://www.apextoolgroup.com
48EAE…P…
Electric hand-held nutrunner
Instruction Manual
P2144BA/EN
2014-08

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Notes on this Instruction Manual
The original language of this Instruction Manual is German. This Instruction Manual is intended for any per-
sons working with this tool without carrying out adjustment work with the nutrunner control.
The Instruction Manual has the following purposes:
• It provides important instructions for safe and effective operation.
• It describes the function and operation of the electric hand-held nutrunner.
• It serves as a lexicon for technical data and service intervals.
• It points out options.
Nomenclature
Symbols in the text:
48 E A E … P …
Series Square version
48 4– 1/2"
3– 3/8"
6– 3/4"
Motor
E– Electric motor, brushless Output version
P– Pin
Tool version
A– Angle
Max. torque
Property 1 38 – 38 Nm
E– Air LB connector 51 – 51 Nm
61 – 61 Nm
85 – 85 Nm
120 – 120 Nm
175 – 175 Nm
230 – 230 Nm
italics Identifies menu items such as Diagnosis
> Identifies the selection of a menu item from the menu such as File > Print
<…> Identifies elements to be selected or chosen, such as buttons or external keyboard input,
e.g.<F5>
Courier Indicates the name of check boxes, options and input fields or also files, e.g.setup.exe
Identifies instructions to be followed.
• Identifies lists.
48EAE stands for all styles of the Electric hand-held nutrunner described here.
OK Okay
NOK Not okay

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Symbols in graphics:
Disclaimer:
Apex Tool Group reserves the right to modify, supplement or improve this document or the product without
prior notice. This document may not be reproduced in whole or in part in any way, shape or form, or copied
to another natural or machine-readable language or to a data carrier, whether electronic, mechanical, opti-
cal or otherwise, without the express permission of Apex Tool Group.
Identifies movement in one direction.
Identifies function and force.

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P2144BA-EN_2014-08_48EAE_P3_P4IVZ.fm, 09.09.2014 P2144BA/EN 2014-08 5
Contents
1 Safety 7
1.1 Illustrated Safety Instructions ...................................................................................... 7
1.2 Safety Instructions....................................................................................................... 8
1.3 Operator training ....................................................................................................... 10
1.4 Designated use ......................................................................................................... 10
1.5 Standards .................................................................................................................. 10
1.6 Noise and Vibration ................................................................................................... 10
2 Items supplied 11
2.1 Transport .................................................................................................................... 11
3 Ambient Conditions 11
4 Product Description 11
4.1 General Description.................................................................................................... 11
4.2 Operation and functional elements............................................................................ 12
5 Accessories 13
6 Initial Operation 13
6.1 Use of reaction bar .................................................................................................... 13
6.2 Carrying out rundown ................................................................................................ 13
7 Servicing 14
7.1 Service schedule ....................................................................................................... 14
7.2 Lubricants.................................................................................................................. 14
7.3 Prevent uncontrolled electrostatic discharge ............................................................ 15
8 Troubleshooting 15
9 Spare parts 17
9.1 Handle ....................................................................................................................... 18
9.2 Motor ......................................................................................................................... 20
9.3 2-stage gearing ......................................................................................................... 22
9.4 2-stage gearing ......................................................................................................... 24
9.5 3-stage gearing ......................................................................................................... 26
9.6 Angle attachment ...................................................................................................... 28
9.7 Reaction bar .............................................................................................................. 28
10 Technical data 29
10.1 Dimensions ............................................................................................................... 29
10.2 Performance Data ..................................................................................................... 31
10.3 Electrical Data ........................................................................................................... 31
11 Recalibration 31

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12 Disposal 32

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Safety 1
1Safety
These safety instructions must be accessible to all operators and other persons who have contact with
the tool.
Comply with the warning labels on the tool.
1.1 Illustrated Safety Instructions
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!
A symbol combined with the word WARNING warns of a potentially dangerous situation for the health
of personnel. If this warning is not observed, death or serious injury may occur.
CAUTION!
A symbol combined with the word CAUTION warns of a potentially harmful situation for the health of
personnel or damage to property or the environment. If this warning is not observed, injuries, property or
environmental damage may occur.
This sign warns of a possibly damaging situation.
If the note is not adhered to, the product or parts of it may be damaged.
This symbol indicates a general instruction.
General instructions include application tips and special useful information, but no warnings against
dangers.
ATTEN-
TION!

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Safety
1
1.2 Safety Instructions
Keep all safety notes and instructions for
future reference.
The term "electric tool" used in the safety
instructions refers to electrical tools powered
from mains electricity (with power cable).
General Safety Instructions for
Electric Tools - Workplace
Safety
a) Keep your work area clean and well illu-
minated. Untidyness and poorly illumi-
nated work areas can cause accidents.
b) Do not work with electric tools in an
explosive environment where there are
combustible fluids, gases or dust. Elec-
tric tools create sparks which could ignite
the dust or the vapors.
c) Keep children and other persons away
when using electric tools. If you are dis-
tracted, you could lose control over the
tool.
d) Route power cables safely. Avoid any
risk of tripping.
e) Avoid unintentional start-ups. Only store
the tool in the tool holder intended. Alter-
natively use a suspension bail.
f) Check that the suspension bail is prop-
erly secured to the balancer.
General Safety Instructions for
Electric Tools – Electrical
Safety
a) The plug on the electric tool must fit in
the connector socket. The plug must not
be modified in any way. Do not use an
adapter plug together with electric tools
with protective ground connection.
Unmodified plugs and matching connec-
tor sockets reduce the risk of an electric
shock.
b) Avoid physical contact with ground-pro-
tected surfaces such as pipes, heating,
ovens and fridges. The risk of an electric
shock will be greater if your body is con-
nected to ground.
c) Keep electric tools away from rain and
wetness. Water ingress into an electric
tool will increase the risk of an electric
shock.
d) Do not misuse cable to carry or suspend
the electric tool or to pull the plug from
the connector socket. Keep the cable
away from heat, oil, sharp edges or mov-
ing parts of the machine. Damaged or
tangled cables will increase the risk of an
electric shock.
The following instructions help prevent short
circuits:
Ensure that the PE connection is of low-
resistance.
Use a mains transformer for cable
lengths in excess of 20 m (max. 50 m).
General Safety Instructions for
Electric Tools – Personal
Safety
a) Be alert, pay attention to what you are
doing and act sensibly when working
with electric tools. Do not use electric
tools if you are tired or under the influ-
ence of drugs, alcohol or medication.
One moment of carelessness when
using an electric tool can lead to serious
injuries.
b) Use personal protection equipment and
always wear protective goggles.
Depending on the type electric tool and
on how it is being used, using personal
protection equipment such as a dust
mask, non-slip gloves, a hard hat or ear
protectors will reduce the risk of injuries.
c) Avoid unintentional start-ups. Make sure
the electric tool is switched off you con-
nect it to the power supply, pick it up or
carry it. Carry an electric tool with our fin-
ger on the switch or connecting the tool
to the power supply while it is switched
on could cause an accident.
d) Remove any adjustment tools or span-
ners before switching the electric tool on.
A tool or spanner in a turning part of the
tool could cause injuries.
e) Avoid any abnormal posture. Make sure
you are standing firmly and keep your
balance at all times. This will enable you
to keep better control over the electric
tool in unexpected situations.
WARNING!
Read all safety instructions marked with the symbol and all other instructions. Failure to comply
with safety instructions and other instructions could result in electric shocks, burns and/or serious injuries.

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Safety 1
f) Wear suitable clothing. Do not wear
loose clothing or jewelery. Keep hair,
clothing and gloves away from moving
parts. Loose clothing, jewelery or long
hair could get caught up in moving parts.
g) If dust extractor or collection systems
can be fitted, make sure that these are
connected and used correctly. Using a
dust extractor system can reduce the
hazards posed by dust.
General Safety Instructions for
Electric Tools - Use and
Handling of an Electric Tool
a) Do not overload the tool. Use the electric
tool appropriate to the job you are doing.
Your work will be better and safer with
the appropriate electric tool in the speci-
fied power range.
b) Do not use an electric tool if the switch is
defective. An electric tool that cannot be
switched on and off is dangerous and
must be repaired.
c) Pull the plug from the connector socket,
before making any adjustments to the
tool, changing the accessories or putting
the tool away. These precautionary mea-
sures will prevent the electric tool from
starting unexpectedly.
d) Keep electric tools out of the reach of
children when they are not being used.
Do not allow persons to use the tool
unless they are familiar with it and have
read these instructions. Electric tools are
dangerous if they are used by unexperi-
enced persons.
e) Take good care of electric tools. Check
that moving parts are working properly
and not sticking, that no parts are broken
or damaged such that the function of the
electric tool is impaired. Have any dam-
aged parts repaired before using the tool.
Many accidents are caused by poorly
maintained electric tools.
f) Use electric tools, accessories, insertion
tools, etc. in accordance with these
instructions. Take into account the work
conditions and the job to be done. The
use of electric tools for applications other
that those intended can lead to a danger-
ous situation.
General Safety Instructions for
Electric Tools – Service
a) Only have your electric tool repaired by a
qualified specialist and only using origi-
nal spare parts. This will ensure that the
safety of the electric tool is maintained.
Our advice: If repair is required send the
complete 48EAE to Sales & Service
Center.
Installing spare parts from other manu-
facturers will void all manufacturer's war-
ranties.
b) Do not open the angle attachment as this
will void the warranty. It is only permitted
conduct repair work and servicing on the
handle, motor and gearing.
c) Do not clean the tool with a high-pres-
sure cleaner and to not immerse it in
cleaning fluid.
Additional Safety Instructions
for Fastening Tools
a) Hold the tool by the insulated handle
areas when working on jobs where the
screw could contact concealed power
lines or the tool's own power cable. Con-
tact between the screw and a live power
line could energize metal parts of the tool
and cause an electric shock.
b) Hold the tool firmly. Be prepared for alter-
nating counter torques.
c) If the tool is used in a tight space or
torque is greater than
- 68 Nm on an angle nutrunner
a reaction bar is required in the form of
a mechanical support (see 6.1 Use of
reaction bar, page 13). On hard joints
or in unfastening operations, the
torque increases very rapidly and the
wrist is subjected to a rotational jolt.
This constitutes a risk of injury. Never
rest your hand on the reaction bar
when working.
d) Only use screw bits for machine-con-
trolled tools.
e) Make sure that the screw bits are
securely inserted.
f) Do not attach screw bit to the screw head
at an angle.

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Safety
1
1.3 Operator training
The fastening system and the electric tool may only be connected, adjusted or used by suitably quali-
fied1) and trained persons.
The electric tool must only be repaired by authorized technicians from the Apex Tool Group.
Ensure correct programming. Only qualified persons are permitted to adjust the controls for the specific
requirements of your threaded connections. Additional information can be found in the Programming
Manual.
1.4 Designated use
The tool is designed exclusively for fastening and releasing threaded fasteners.
Only use in conjunction with a control and tool cable supplies by Apex Tool Group.
Do not use as a hammer or for re-bending.
Do not open it or modify it structurally.
Do not use it in areas where there is a risk of explosion.
1.5 Standards
1.5.1 EMC
Industrial environment
EMC limit class A.
The tool complies with the following EMC standards:
EN 55011:2007, EN 61000-6-2:2005
1.6 Noise and Vibration
Sound pressure
Lp < 70 dB(A) in free speed (without load) as per DIN EN ISO 4871:1997-03
The vibration values < 2.5 m/s² are in accordance with DIN EN ISO 20643:2005-03
1. Due to their vocational training, knowledge, experience and understanding of the circumstances involved in this kind of work, suit-
ably qualified personnel are able to identify potential hazards and to initiate appropriate safety precautions. Qualified personnel are
obliged to comply with regulations.

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Items supplied 2
2 Items supplied
Check shipment for transit damage and ensure that all items have been supplied:
1 48EAE
1 This Instruction Manual
1 Installation declaration
1 Test Calibration Certificate
1MCS
2.1 Transport
Transport and store in the original packaging. The packing is recyclable.
3 Ambient Conditions
4 Product Description
4.1 General Description
• Sturdy, brushless motor with resolver. Shutoff is torque/angle-controlled.
• Integrated preamplifier, including service memory. Self-identification of tool when connected to
controller.
• LED display provides information about current rundown result.
• Clockwise/counterclockwise rotation
• Fastening parameters are set via the controller.
• Data is transmitted and power supplied between the controller and tool via the tool cable.
Storage Temperature Ambient Temperature Relative Humidity
-25 °C to +70 °C (-4 °F to + 158 °F) 0 to +40 °C (32 to +104°F) 0 to 90% non-condensing

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Product Description
4
4.2 Operation and functional elements
4.2.1 Illuminated ring LED display
(description serves only as example, function depends on software)
Operating status display and the result of the last rundown procedure:
4.2.2 Start button
Start rundown.
4.2.3 Reverse switch
The reverse switch changes the rotation direction of the 48EAE.
Turn reverse switch as far as it will go.
Clockwise rotation – for screwing in screws
Counterclockwise rotation – for loosening or screwing out screws
LED Operating status
Green continuous light OK
Red continuous light NOK
Yellow Enable
2
4
1
3
Item Designation
1 Illuminated ring LED display
2 Connection of power supply with AirLB connector
(see product catalog for tool cable)
3 Start button
4 Reverse switch

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Accessories 5
5 Accessories
6 Initial Operation
6.1 Use of reaction bar
6.2 Carrying out rundown
The 48EAE has been configured by Apex Tool Group. A setting for your specific screw joint must only be
made with the nutrunner control by a qualified person. The initial operation can vary depending on the type
and programming of the nutrunner control. See Softwarebeschreibung Nutrunner Control.
Connect the tool cable to 48EAE and the nutrunner control.
Make sure that the nutrunner control is switched on and correctly programmed.
Accept recognized values on the control in Tool Setup > Tool Settings > Accept. Adjust torque and
speed as necessary.
Make sure that the reverse switch is in the correct position.
Fit the bit and press the Start button to start the rundown.
If the tool switches off, release the Start button.
Tool holder
Order no. 941293
(1 set = 2× V-shape)
Start lever extension
Order no. S387710
Tool cable
Refer to product catalog
Protection, cable
1.4 m: Order no. 961265PT
2.5 m: Order no. 961268PT
Angle attachment protection
38 Nm: Order No. 937705PT
51 Nm: Order No. 937707PT
61 Nm: Order No. 937709PT
85 Nm: Order No. 937712PT
120 Nm: Order No. 937501PT
175 Nm: Order No. 937714PT
230 Nm: Order No. 937714PT
CAUTION!
Danger of hands being crushed.
Always use a reaction bar for applications in restricted space and
torques over 68 Nm.

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Servicing
7
7 Servicing
7.1 Service schedule
Only qualified and trained specialists are to perform servicing work on this tool.
Regular service reduces operating faults, repair costs and downtime. In addition to the following service
schedule, implement a safety-related maintenance program that takes the local regulations for repair and
maintenance for all operating phases of the tool into account.
7.2 Lubricants
In order to ensure faultless functioning and a long service life, it is absolutely necessary to use the right type
of grease according to the table.
Grease lubricants according to DIN 51502 /ISO 3498
CAUTION!
Danger of injury through unintentional activation
– prior to servicing 48EAE disconnect power supply.
Fastening Cycles1))
1) For number of fastening cycles, see Dynamic Service Counter of controller
Measures
100,000 Check the tool components for tight fit.
Check the tool and tool cable for damage.
Check the gearing and angle attachment for leaks.
250,000 Clean gearing parts with grease-dissolving agent and re-lubricate.
Check the gearing parts for wear, renew as necessary.
Recommendation: Subsequent dynamic calibration in order to
ensure machine capability, see 11 Recalibration, page 31.
1 million General overhaul. Send the 48EAE to Sales & Service Center.
Order no. Pack-
ing unit
[kg]
DIN
5150
2
Nye
Lubri-
cants,
Inc.
Dow
Corn-
ing
933027 1 KP1K – – – – Microlube
GL 261 ––
541444 0.06
(2 oz.) –– – – – – –
Rheolube
363AX-1
541445
0.45
(1
pound)
–– – – – – –
Rheolube
363AX-1

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Troubleshooting 8
7.3 Prevent uncontrolled electrostatic discharge
8 Troubleshooting
NOTE Electrostatically sensitive component. Note handling instructions.
The electronic assemblies of the tool can be destroyed or damaged by
electrostatic discharge (ESD). This can lead to immediate failure, or to
malfunctions at a later date. To prevent damage when repairing the tool,
make sure that there is a potential equalization between the person and
the tool.
Possibly set up equipment in an ESD-protected environment. Recom-
mendation for an ESD workplace: Electrically conductive work surfaces,
anti-static straps, appropriate furniture, clothing and footwear, as well as
grounding of all components.
Problem Possible cause Measure
Tool
Tool does not start Faulty start switch Replace start switch
No speed (rpm) programmed Program speed for all active stages
Control waiting for tool enablement Activate input Tool Enable
(Advanced > Inputs) or, if not
required
Deactivate Tool Enable
(Advanced > Tool Setup)
Faulty cable Repair or replace cable
Bent pins in the cable or tool Straighten contact pins or replace
faulty connector
Self identification data not recognized
after tool change
Accept Data again. (Tool Setup >
Tool Settings > Accept)
No acoustic signal after
connection of tool cable
Software incorrect Check controller software / measur-
ing board software
Cable defective Replace cable
Tool defective Change tool
Tool doesn't start with
counterclockwise rota-
tion activated
With counterclockwise rotation, param-
eter for speed is set to 0 rpm.
Program speed for counterclock-
wise rotation (Standard > Tool
Groups).
Tool starts in tightening
direction, but not in coun-
terclockwise rotation
No speed programmed for counter-
clockwise rotation
Programm speed for counterclock-
wise rotation
Faulty counterclockwise rotation switch Replace start/counterclockwise
rotation switch
Faulty cable Repair or replace cable
Bent pins in the cable or tool Straighten contact pins or replace
faulty connector
Tool switches off at
required torque, but with-
out angle indicator
Threshold torque is too high Correct fastening sequence or
reduce threshold torque value
Graphic: CANES-

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Troubleshooting
8
Tool switches off prema-
turely
Operator releases start switch before
the control stops the tool
Make sure that the operator keeps
the start switch pressed throughout
the entire sequence.
The fastening time exceeds the stan-
dard time by 10 seconds.
Increase the fastening time
Tool exceeds the angle setpoint Check the fastening sequence to
ensure that the torque shutoff value
and/or angle setpoint are correct.
Adjust as necessary.
Check whether the screwed joint
has changed significantly.
Tool does not change
speed
Speed is the same in all stages used Make sure that the speed and the
switching angle in the stages are
correct.
LEDs on the tool start to
flash when the reverse
switch is operated.
This is a normal function which is
defined in the default parameters.
Activate or deactivate the check
box Blink Lights when Tool
in Reverse (Advanced > Tool
Setup)
Warning in menu RUN
SCREEN: Offset
Transducer 1/2 NOK
The transducer does not return to a
zero torque vale
Transducer has been overloaded
and must be replaced
Faulty wiring in tool or in cable Check tool with different cable. The
offset and calibration values can be
checked in the Diagnosis menu.
Warning in menu RUN
SCREEN:
Tool Offline!
Tool has not been accepted in the tool
settings
Check the Tool List menu to make
sure that the tool has been
accepted. If it has not been
accepted, the status will show
Manual acceptance needed.
The correct line must be marked
before the setting can be accepted
in the Tool Settings menu.
A faulty cable will prevent the tool from
being recognized by the nutrunner con-
trol
Repair or replace cable
Different torque display in
the control and external
transducer
Torque calibration factor (Torque Cal.)
in Tool Settings must be adjusted.
Adjust Torque Cal. (Tool Setup >
Tool Settings > Accept) using the
following formula:
New calibration value =
(external value / tool value) × cali-
bration value used
Customer's angle attachment was
added to tool. Tool memory must be
updated.
Reprogram tool memory
Tool cable does not fit in
tool handle
Wrong cable. Tools in use with nutrun-
ner control mPRO400GC use an Air-
LB connector. Connector has different
size to previously used Matrix connec-
tor.
Use the right cable for the tool used
Problem Possible cause Measure

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Spare parts 9
9 Spare parts
Always use only original Cleco spare parts. Failure to comply with this instruction can result in
decreased performance and an increased need for maintenance. Installing spare parts from other man-
ufacturers will void all manufacturer's warranties

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Spare parts
9
9.1 Handle
Models
48EA(E)38(--)
48EA(E)51(--)
48EA(E)61(--)
48EA(E)85(--)
48EA(E)120(--)
48EA(E)175(--)
48EA(E)230(--)

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Spare parts 9
1)Order no.
2)Quantity
3)Recommended spare part for every 1 - 5 tools
4)Dimension

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Spare parts
9
9.2 Motor
Transducers cannot be exchanged –
see 11 Recalibration, page 31
11
12
Models
48EA(E)38(--)
48EA(E)51(--)
48EA(E)61(--)
Models
48EA(E)85(--)
48EA(E)120(--)
48EA(E)175(--)
48EA(E)230(--)