Cleco 80PTHD Series User manual

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80PTHD…
Pulse shut-off nutsetter
Instruction Manual
P1885E/EN
2008-07

2 P1885E/EN 2008-07 85a_ Deckbl en.fm, 27.10.2010
Notes on this instruction manual
The instruction manual has the following purposes:
• It provides important instructions for safe and effective operation.
• It describes the function and operation of the pulse shut-off nutsetter.
• It serves as a reference work for technical data, service intervals
and spare part orders.
• It points out options.
Nomenclature
Disclaimer:
Cooper Power Tools GmbH & Co. OHG 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, optical or otherwise, without the express per-
mission of Cooper Power Tools GmbH & Co. OHG.
In the text:
80PTHD… stands for all of the designs of the
pulse shut-off nutsetter described here.
➔Identifies instructions to be followed.
• Identifies enumerations.
<…> Identifies an index number, see 8 Spare parts, page 25
In graphics:
Identifies movement in a direction.
Identifies function and force.
In pictured illustrations:
Where not necessary, 80PTHD… (air from buttom) is shown.
80 P T H D × 60 ×
Max. capacity Output drive
80 – 59.0 ft/lb (80 Nm) 4– External square 1/2"
Q– Quick change 7/16"
Design Speed
P– Pistol grip 60 – 6000 rpm
Shut-off 2. Air inlet
T– Torque controlled shut-off A– Air from top
– None
Pulse mechanism Design
H– Hydraulics D– 3-chamber motor / inertia shut-off

P1885E-EN_80PTHD_2008-07IVZ.fm, 27.10.2010 P1885E/EN 2008-07 3
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 vibration ............................................................................... 7
2 Items supplied 7
3 Product description 8
3.1 Operation and functional elements ....................................................... 8
4 Before initial operation 9
4.1 Ambient conditions ............................................................................... 9
4.2 Air supply ............................................................................................ 9
4.3 Changing air inlet: top / buttom (80PTHDA only).................................. 9
4.4 Connect the tool.................................................................................... 9
4.5 Setting up the tool............................................................................... 10
5 Troubleshooting 12
6 Maintenance 13
6.1 Service schedule ................................................................................ 13
6.2 Activating the reserve oil..................................................................... 15
6.3 Refilling oil .......................................................................................... 16
7 Repair instructions 19
7.1 Disassembling the motor unit ............................................................. 19
7.2 Disassembling the throttle valve ......................................................... 19
7.3 Disassembling the pulse unit .............................................................. 20
7.4 Assembling the motor unit .................................................................. 20
7.5 Assembling the pulse unit................................................................... 24
8 Spare parts 25
8.1 Pistol grip 80PTHD….......................................................................... 26
8.2 Pistol grip 80PTHDA… ....................................................................... 28
8.3 Motor unit 935635............................................................................... 30

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8.4 Pulse unit ............................................................................................ 32
8.5 Equipment order list............................................................................ 34
9 Technical data 35
9.1 Dimensions 80PTHD… in mm............................................................ 35
9.2 Dimensions 80PTHDA… in mm ......................................................... 36
9.3 Performance Data............................................................................... 36
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.
WARNING!
Indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION!
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury or property and environmental damage. If this warning is not observed, injuries, property
or environmental damage may 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
You should read all instructions.
Failure to observe the instructions listed below can result in serious injuries.
1.3 Operator training
Operators must be trained in correct handling of the tool. The user must make the operating manual avail-
able to the machine operator and ensure that the operator has read and understood it. The tool may be con-
nected, used, serviced and repaired by qualified persons only. The tool may be repaired by authorized
technicians only.
CAUTION!
➔Before initial operation, check that the suspension bail is properly fastened to the bal-
ancer.
➔Work with a maximum working pressure of 101.5 psi (700 kPa) (measured as the air inlet
tube of the tool).
➔80PTHDA: When air inlet from top is used make sure, that plug is properly mounted
accordingly.
➔If you hear unusual noises or vibrations, switch off the tool immediately.
Shut 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. Replace if necessary.
➔Always carry out assembly according to Chapter 8 Spare parts, page 25.
➔Use only accessory parts authorized by Cooper Power Tools GmbH & Co. OHG
(see product catalog).
➔Adjust the torque using the provided hex wrench only. Never use an angular wrench.
➔Only use screw inserts for machine-controlled fastening tools.
➔Make sure that the screw bits are securely inserted.
➔Inspect screw bits for visible damage and cracks.
Replace damaged screw bits immediately.
➔The operation, maintenance and repair conditions set forth in the operating instructions
must be observed.
➔Follow generally valid and local safety and accident prevention rules.

86b_1_5 en bedingt.fm, 27.10.2010 P1885E/EN 2008-07 7
Items supplied 2
1.4 Personal protective equipment
• Wear the 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 wrapped 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 80PTHD… 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 vibration
2 Items supplied
Check shipment for transit damage and ensure that all items have been supplied:
1 80PTHD…
1 This instruction manual
1 Declaration of Conformity
1 Size 2 hex wrench
Sound pressure level Lp gemäß DIN EN ISO 15744
Free speed
for n 6000 rpm
< 80 dB(A)
Vibration values according to DIN EN ISO 20643
Free speed: ahv for n 6000 rpm < 6.56 ft/s² (2.0 m/s²)
Load: ahv 80PTHD… < 14.76 ft/s² (4.5 m/s²)
Load: ahv 80PTHDA…
Load: ahv 80PTHDA…+ absorber (option on request)
< 16.40 ft/s² (5.0 m/s²)
< 8.20 ft/s² (2.5 m/s²)

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Items supplied
2
3 Product description
3.1 Operation and functional elements
Pos. Designation
1 Reverse switch
2 Torque adjustment, siehe 4.5.1 Setting the torque, page 10
3 Speed adjustment, siehe 4.5.2 Changing the speed, page 11
4 Air inlet
5 Connection for Pneumatic Torque Verifier TVP100,
signal connection kit, order no. 934918 (optional)
6 Start button
7 Reserve oil adjustment, see 6.2 Activating the reserve oil, page 15
8 Suspension bail
9 Size 2 hex wrench, order no. 935490
4
1
5
3
6
8
7
9
2
(8)
Alternative
Position
2
4
5
80PTHDA…
80PTHDA…

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Before initial operation 4
4 Before initial operation
4.1 Ambient conditions
4.2 Air supply
➔The inside of the air hose must be free of residue; clean it if necessary.
➔Spray a few drops of light oil into the air inlet tube.
Oils according to DIN 51524 / ISO 3498
4.3 Changing air inlet: top / buttom (80PTHDA only)
At delivery the air inlet at the buttom is sealed with a screwed plug. If a change is required, change follow-
ing:
➔Remove air strainer from the top (and store it). See demand 8.2 Pistol grip 80PTHDA…, page 28, see
detail X..
➔Remove screwed plug from the buttom, thereby arresting A/F 17.
➔Screw screwed plug into air inlet at the top.
4.4 Connect the tool.
➔Connect the connection couplings to the tool and compressed air line properly.
Ambient temperature 41 °F (5 °C) to a maximum of +104 °F (+40 °C)
Permissible relative humidity 25 to 90 %, non-condensing
Parameter Data
Air hose Inner diameter 1/2" (ø 12,5 mm),
maximum length 16.4 ft (5 m)
Working pressure range 58 to 101.5 psi (400 to 700 kPa)
Recommended: 90 psi (620 kPa)
Compressed air Air quality according to ISO 8573-1, quality class 2.4.3
The compressed air must be clean and dry.
NOTE
To attain consistent results, maintain a constant working pressure using a 1/2" service unit con-
sisting of filter, pressure regulator and lubricator.
Order no. Packaging
unit
liter
Designation 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
A 32
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.

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Before initial operation
4
➔Activate the compressed air.
4.4.1 Testing
4.5 Setting up the tool
The tool must be configured for the desired rundown.
4.5.1 Setting the torque
Abb. 4-1
➔Carry out a test in clockwise and coun-
terclockwise rotation at maximum
speed, see 4.5.2 Changing the speed,
page 11.
➔Check the speed at the output drive.
Target: n > 6000 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.
Example settings:
47.9 ft lbf (65 Nm) rundown
➔Approx. 3 turns of the torque
adjustment screw
Speed: 5000 rpm
50
60
5500
4000
4500
5000
6000
3500
Max.
Min.
3000
0
90
0
1
2
3
2800
80
70
4
5
6
+
–
Nm
Torque
Torque adjustment screw
47.9 ft lbf (65 Nm)
Exhaust air throttle
Speed rpm
Curve for medium
working range

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Before initial operation 4
Abb. 4-2
4.5.2 Changing the speed
Abb. 4-3
1. Hold the output drive firmly.
2. Carefully push the size 2 hex wrench
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 10.
Total number of turns = 6.
4. Pull out the hex wrench.
The hole closes automatically when the
tool starts.
5. Carry out the rundown.
6. Check the shut-off mechanism worked
properly, see 4.5.3 Measuring the torque,
page 12.
7. In case of deviations, correct the torque
setting
8. Repeat the rundown.
Requirement Measure
Better shut-off accuracy –
particularly for hard joints.
Increase the number of pulses per rundown.
Recommended number of pulses 6.
➔Reduce the speed
Reducing the noise pressure level ➔Reduce the speed
Reducing vibration ➔Reduce the speed
Shortening the rundown time, particularly for
soft joints.
➔Increase the speed
1. Unscrew the threaded pin using the size 2
hex wrench.
2. To reduce the speed, turn the exhaust air
throttle clockwise.
3. To increase the speed, turn the exhaust
air throttle counterclockwise.
NOTE
A speed change may be carried out while the compressed air is activated.
After changing the speed, correct the torque if necessary;
see 4.5.1 Setting the torque, page 10.
Torque
Speed

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Troubleshooting
5
4.5.3 Measuring the torque
We recommend carrying out a static torque measurement by retightening the rundown.
When carrying out a dynamic measurement using a transducer adapter, also carry out a static test, for
example using a torque wrench (electronic).
5 Troubleshooting
Error Possible causes Measures and remedies
Tool
does not shut off
Torque set too high ➔Reduce the torque setting, see
4.5.1 Setting the torque, page 10.
Speed set too low ➔Increase the speed, see 4.5.2
Changing the speed, page 11.
Working pressure < 58 psi (400 kPa) ➔Check the cross section of the
hose and coupling: Inner
diameter 1/2" (ø 12,5 mm), maxi-
mum length 16.4 ft (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 4.5.2
Changing the speed, page 11.
➔Use a shorter or more rigid exten-
sion.
➔Replace the socket.
Insufficient oil in the pulse unit (no
pulse build-up)
➔See 6.2 Activating the reserve oil,
page 15.
➔See 6.2 Activating the reserve oil,
page 15.
Screen in the air inlet tube /
muffler is dirty
➔Clean or replace parts.
Insufficient shut-off
accuracy
Number of pulses too low: < 6 ➔Reduce speed,
number of pulses > 6.
Adapter parts ➔Replace adapter parts.
➔Use extension and socket with
guide diameter.
Pressure fluctuations in the air net-
work
➔Use a pressure controller.
Fastening time too
long: > 4 seconds
Joint too soft; self-locking nuts, drive
screws
➔Increase the speed.
➔Use a pulse nutsetter with a
higher capacity.
➔Use a mechanical screwdriver.

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Maintenance 6
6 Maintenance
6.1 Service schedule
Regular maintenance reduces operating faults, repair costs and downtime.
This maintenance schedule uses values that are valid for most applications. For a specific service interval,
see 6.1.1 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.
Mainte-
nance
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 max. free speed.
W2 500,000 ➔Oil change, see 6.3 Refilling oil, page 16.
➔Motor service kit, see 3) Part of motor service kit K1,
order no. 935655, page 27.
➔Hydraulic service kit, see 3) Part of hydraulic service
kit K2, order no. 935656, 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
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 133 days.
Factor Value assumed in
6.1, "Maintenance
plan"
Description
VV1 = 100,000
V2 = 500,000
V3 = 1,000,000
Number of rundowns after a maintenance measure is pre-
scribed by Cooper Power Tools GmbH & Co. OHG.
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.
W123VT
1

T2SVS
------------------------------=W2 500000 1 8
33750
---------------------------------= 133 days=

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Maintenance 6
6.2 Activating the reserve oil
If pulse build-up stops, some of the oil in the pulse unit has been used up. The reserve oil must be activated.
If the equalizing piston reaches the limit stop, oil must be refilled the next time (see 6.3 Refilling oil,
page 16).
1. 2. Align both ends as shown in the illustra-
tion.
3. 4. Turn <68> clockwise till the detent.
5. Turn <68> approx. 2,5 turns anticlock-
wise…
6. …until <70> can be reinserted again.
The reserve oil can be adjusted approx.
1 – 2 times until <71> is at the detent and
<70> can still be reinserted.
If necessary, turn back to the next groove.
!
<66>
<70>
<68>
SW15
<66>
<70>
<71>

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Maintenance
6
6.3 Refilling oil
4
5
9
10
8
11
12
13
6
7
15
14
–
+
X
1
2
3
4
Item Designation
1 Oil filling device asm.1)
1) See 8.5 Equipment order list, page 34
2 Oil filling device without filling piece 1)
3 Filling piece asm.1)
4 Oil order no. 925715, ESSO-UNIVIS HVI26, approx. 2.1 qt (2 liters),
temperature 68 ±9 °F (20 ±5 °C)
5 Quick disconnect coupling
6 Working pressure 65 – 80 psi (450 – 550 kPa)
7 Shut-off valve
8 Pulse unit
9 Hydraulic rotor
10 Bearing ring
11 Equalizing piston
12 O-ring
13 Sleeve
14 Ball
15 Threaded pin
Approx.
7 oz.
Approx.
0.35 oz
(10 ml)

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Maintenance 6
1. Remove the threaded pin 15 and ball 14.
2. Remove the O-ring 12 and sleeve 13.
3. Align the output drive and claw as shown in the illustration, see 6.2 Activating the reserve oil, page 15.
4. Rotate the equalizing piston 11 clockwise as far as it will go until X= 0 (starting point).
5. Unscrew the equalizing piston 11 counterclockwise by 1,0 turns (reserve oil volume).
6. Connect the pulse unit 8 to the quick disconnect coupling 5using the adapter.
7. Close the shut-off valve 7.
8. Set the working pressure to approx. 73 psi (500 kPa).
9. Slowly open the shut-off valve 7 all the way until the
gauge shows a negative pressure of –13 psi (–90 kPa).
10. Wait approx. 2 minutes until the number of vacuum bubbles has reduced significantly.
11. Close the shut-off valve 7 slowly. The gauge shows atmospheric pressure again. Missing oil is pushed
into the pulse unit 8 .
12. Repeat steps 8 through 11 if necessary until the number of bubbles approaches zero.
13. Uncouple pulse unit 8, unscrew the adapter and add a couple of drops of oil using the injector.
14. Mount the ball 14 and screw the threaded pin 15 into place (0.75+0.25 ft lbf, or 1 +0.3 Nm).
15. Turn the equalizing piston 11 another 2,5 turns counterclockwise, or slightly more if necessary, until
the sleeve 13 can be inserted (oil compensation volume).
16. Install the sleeve 13 and O-ring 12.
NOTE
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.

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Maintenance
6

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Repair instructions 7
7 Repair instructions
Refer also to 8 Spare parts, page 25 and 8.5 Equipment order list, page 34
7.1 Disassembling the motor unit
7.2 Disassembling the throttle valve
Changing blades Changing bearing / rotor
1. 2. 3.
<C1>
<C2>
<59>
<61>
<C3> <C3>
<C1> <59>
<54>
Size 3/8"

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Repair instructions
7
7.3 Disassembling the pulse unit
Abb. 7-1
7.4 Assembling the motor unit
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 6.3 Refilling oil, page 16. The pulse unit
must have cooled to room temperature.
CAUTION!
• Always carry out assembly according to the exploded drawing, see 8 Spare parts, page 25.
Incorrect assembly causes uncontrollable reactions, such as unexpected startup or ejection of parts.
• Tighten all screwed joints of the tool carefully, according to the specifications.
NOTE
To prevent damage, lubricate the gaskets and O-rings using grease (order no. 914392) before
assembly.
<65>
<D>
Size 1/2"