Cooper Tools 35 Series Installation and operating instructions

1
Operation & Service Manual
823099 11/01
35 Series High Torque Nutrunners
ClecomaticA
LLever
Handle:
35
Clutch Designation:
Nutrunner:
Rotation:
Reversible
35
Non Reversible
R
Series:
XNXLXX-
Ext. HousingE
Gear Train Designation:
15D
30D
15˚
30˚
Output Drive:
Angle Terminations:
Q
M
104
204
304
404
Quick Change
XX X-
28
3/8-24 Spindle External Thread3T
5/16-24 Spindle Internal Thread
1/4-28 Spindle Internal Thread
24
Built-in SocketS
(Specify Size)
.25 MagneticM
3/8"3
NORTH AMERICA EUROPE
CooperTools
P.O. Box 1410
Lexington, SC 29071
Cooper Power Tools GmbH & Co.
Postfach 30
D-73461 Westhausen

2
Safety Recommendations
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
National Standards Institute, ANSI Z87.1, Occupational and Edu-
cational Eye and Face Protection. Z87.1 is available from the
American National Standards Institute, Inc., 11 West 42nd Street,
New York, N.Y. 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.
Excessive air pressure above 90 PSIG or worn motor components
can also increase sound level emitted by tool. Proper hearing
conservation measures, including annual audiograms and training
in the use and fit of hearing protection devices may be necessary.
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 Pro-
tectors.
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-
regulator-lubricator in the air supply line ahead of the tool is
recommended.
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). Being careful not to endanger adjacent personnel, clear
the air hose of accumulated dust and moisture. Before connecting
a tool to the air hose, 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.
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.
When using right angle nutrunners, be sure the throttle is posi-
tioned relative to the angle head so that the throttle will not become
wedged against an adjacent object in the "ON" position due to
torque reaction. The angle head may be repositioned with respect
to the lever to accommodate proper location for task. If tool is to be
reversed, locate throttle lever in a neutral position that will prevent
entrapment. Refer to operating instructions for additional informa-
tion.
It is essential for safe operation that any operator of a nutrunner use
good balance, sure footing, and proper posture in anticipation of a
torque reaction.
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.
Operator must then resist stall torque until throttle is released.
Tool balance arms are available to absorb the torque reaction of the
tool while balancing the weight of the tool for improved ergonomic
applications.
Some individuals may be susceptible to disorders of the hands and
arms when performing tasks consisting of highly repetitive motions
and/or exposure to extended vibration. Cumulative trauma disor-
ders such as carpal tunnel syndrome and tendonitis may be caused
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-
Spindle Rotation Torque Reaction
CAUTION!

3
Extension Neutral Flexion Radial Deviation Neutral Ulnar Deviation
Avoid Avoid Avoid OK Avoid OK
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
aggravated by movements and postures dictated by the job design,
it may be necessary for the employer to take steps to prevent further
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
the operator. Some tasks may require more than one type of tool to
obtain the optimum operator/tool/task relationship.
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
Work gloves with vibration reducing liners and wrist supports are
available from some manufacturers of industrial work gloves. Tool
wraps and grips are also available from a number of different
manufacturers. These gloves, wraps, and wrist supports are de-
signed to reduce and moderate the effects of extended vibration
exposure and repetitive wrist trauma. Since they vary widely in
design, material, thickness, vibration reduction, and wrist support
qualities, it is recommended that the glove, tool wrap, or wrist
support manufacturer be consulted for items designed for your
specific application. WARNING! Proper fit of gloves is important.
Improperly fitted gloves may restrict blood flow to the fingers
and can substantially reduce grip strength.
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, N.Y. 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.
Your work may require additional specific safety procedures.
Follow these procedures as required by your company.
Warning Labels
The warning labels found on these tools are an essential part of this
product. Labels should not be removed. Labels should be checked
periodically for ligibility. Replace warning labels when missing or
when the information can no longer be read. Replacement labels
can be ordered as any spare part.
Safety Recommendations

4
Safety Recommendations
ADDITIONAL SAFETY RECOMMENDATIONS FOR USE OF
RIGHT ANGLE DRILLS
Follow good machine shop practices. Rotating shafts and moving
components can entangle and entrap, and can result in serious
injuries. Never wear long hair, loose-fitting clothes, gloves, ties, or
jewelry when working with or near a drill of any type.
Drilling or other use of this tool may produce hazardous fumes and/
or dust. To avoid adverse health effects, utilize adequate ventila-
tion and/or a respirator. Read the material safety data sheet of any
cutting fluids or materials involved in the drilling process.
• Drill bits are sharp. Handle them carefully to avoid injury.
• The cutting tool maximum speed rating must equal or exceed
the rated speed of the tool.
• Use the appropriate size chuck key to securely tighten a drill
bit in the chuck.
• Use precautions when drilling because of the possibility of the
cutting tool bending or breaking.
• High reaction torque may be experienced by the operator with
any drill at breakthrough.
• Drill bits or accessories not centered properly in the chuck can
cause excessive wobble or vibration.
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
obtained 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.
Your work may require additional specific safety procedures.
Follow these procedures as required by your company.
Warning Labels
The warning labels found on these tools are an essential 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. Replace-
ment labels can be ordered as any spare part.
!
Do not wear loose fitting clothes,
long hair, gloves, ties or jewelry.
WARNING
203289
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.
203185
203185-4
READ
OPERATING
INSTRUCTIONS
WARNING
!
Wear respirator where
necessary.
CAUTION!

5
OPERATING INSTRUCTIONS
CLECOMATIC MODELS
Tools equipped with the CLECOMATIC clutch are designed to tighten
the fastener to a predetermined torque and shut off automatically.
Releasing the throttle lever will allow the tool to reset for the next cycle.
CLUTCH ADJUSTMENT
Shut off air supply to the tool and rotate the adjustment cover, No.
202829, 180°to uncover the adjustment slot in the clutch housing.
Rotate the spindle until the hole in the adjustment nut is visible in the
slot. Use a 1/8" diameter pin to hold the nut. Use a suitable tool to turn
the spindle in a counterclockwise direction to increase torque or
clockwise to decrease torque. Return the adjustment cover to its closed
position after every adjustment.
If the clutch is adjusted over the maximum power output of the tool, the
clutch will not function and the tool will operate like a stall-type tool. Also,
if the tool is being operated at its 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 he releases throttle.
Operational check: Grip tool securely and be prepared to counteract
stall torque in case clutch is improperly adjusted. THIS IS A HIGH
TORQUE TOOL.
FLOW VALVE
The flow valve No. 203036, can be adjusted with a screwdriver
clockwise to lower the RPM and counterclockwise to raise the RPM of
the tool.
THROTTLE POSITION
The throttle lever may be repositioned to accomodate proper location
for task and to avoid hand entrapment. Repositioning of the angle head
is done by adding or removing head positioning shims. Retighten head
with proper wrench.
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.
For maximum performance, use a 5/16" I.D. air hose up to 8' in length.
If additional length is required, a 3/8" I.D. or larger hose should be
connected to the 5/16" I.D. hose.
SERVICE INSTRUCTIONS
LUBRICATION
An automatic in-line filter- regulator- lubricator is recommended as it
increases tool life and keeps the tool in sustained operation. The in-line
lubricator should be regularly checked and filled with a good grade of
10W machine oil. Proper adjustment of the in-line lubricator is per-
formed by placing a sheet of paper next to the exhaust ports and holding
the throttle open approximately 30 seconds. The lubricator is properly
set when a light stain of oil collects on the paper. Excessive amounts of
oil should be avoided.
Application of the tool should govern how frequently it is greased. It is
recommended that the idler gears and right angle gears receive a
generous amount of No. 2 Moly grease through the grease fittings after
40 hours of operation.
STORAGE
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 time and again when returned to service.
The tool should be stored in a clean and dry environment.
DISASSEMBLY —GENERAL (ALL MODELS)
Unscrew (left hand threads) and remove the angle head. Unscrew and
remove the second reduction gear train. Unscrew (left hand threads)
and remove the clutch housing and clutch. Unscrew and remove the
gear case assembly. On models equipped with a joint rate device,
unscrew and remove the joint rate device housing and device. The trip
rod should be removed at this time to prevent its being lost or misplaced.
The motor unit may now be removed from the backhead. See the
following paragraphs for complete disassembly instructions on the
various sub-assemblies.
"M" RIGHT ANGLE HEAD DISASSEMBLY
Using a suitable spanner wrench, unscrew (left hand threads) the
bearing cap No. 864396. Remove the spindle, ball bearing No. 842517,
and driven gear by clamping the spindle in a vise and driving the right
angle housing No. 869048, away from the spindle using a soft-faced
mallet. The ball bearing can now be removed by pressing the larger end
of the spindle through the bearing I.D. Press the smaller end of the
spindle through the gear to remove the driven gear. The pinion bearing
retainer No. 863564, may be removed by utilizing a 5/8" hex engage the
hex in the bearing retainer and unscrew the retainer using the deep
socket.
15°& 30°ANGLE HEAD DISASSEMBLY
Clamp the hex drive of the pinion gear in a vise and drive the angle head
off (use a soft-faced mallet). Remove the two (2) hex nuts No. 833785,
and unscrew the two (2) bearing post screws No. 847027. Unscrewing
the four (4) base plate screws will allow the base plate No. 869207, and
related components to be removed from the angle head. Note: When
removing the base plate, care should be exercised to avoid the loss of
the fifty-six (56) steel balls No. 842980, located in the two (2) ball races
No. 864264. The angle head can now be broken down into its basic
components for inspection and replacement of parts.
CLUTCH DISASSEMBLY
Unscrew the adjustment nut No. 202755. This will allow the adjustment
plate No. 202754, thrust bearing No. 847596, thrust race No. 202753,
torque spring, release spring No. 202752, release sleeve No. 203271,
two (2) steel balls No. 842161, ball retainer No. 203272, and five (5)
steel balls No. 844077, to be removed from the clutch spindle assembly.
Wash the spindle assembly in a solvent and rotate the cam No. 203270,
to remove as much grease as possible. Remove the retainer ring No.
202749, ball plug No. 202748, and twelve (12) steel balls No. 842161,
from the cam. This will allow the trip plunger No. 202745, reset spring
No. 202763, and pin No. 843231, to ;be removed from the rear of the
clutch spindle No. 203162.
GEAR CASE DISASSEMBLY
Single Reduction —204, 304, 404 Gear Trains
The spider should be pressed out the rear of the gear case 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
CAUTION!
.240
.255
Front Rear

6
Double Reduction —104 Gear Train
Both spiders should be removed from the rear of gear case No. 867907.
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. 2 for replacement pin height.
104 2nd Reduction 104 1st Reduction
Spider Spider
Fig. 2 —Double Reduction Spiders
2ND REDUCTION GEAR TRAIN
Press the spider No. 203161, out of the rear of the gear case No.
867907. Remove retainer ring No. 844364, from front of gear case.
Remove bearing No. 847147. If replacement of idler gears are neces-
sary, the idler gear pins No. 203160 can be driven out the rear of the
spider with a punch. Idler gear bearings No. 203062, can be pressed out
of the idler gears No. 867904.
MOTOR DISASSEMBLY
Use a soft-faced hammer to drive the rotor out of the front rotor bearing
No. 619377. This will allow the cylinder and five (5) rotor blades to be
removed from the rotor. Set the rear bearing plate on the vise jaws with
the rotor hanging down. Use a 7/32" punch to drive the rotor out of the
rear rotor bearing.
BACKHEAD DISASSEMBLY
Unscrew and remove the inlet bushing No. 867882, for inspection and
cleaning of the air inlet screen No. 833300. Replace the screen if
clogged or torn. The throttle valve and related components may be
removed by unscrewing the throttle valve cap No. 832207. Unscrew the
button head cap screw No. 202696, for removal of the reversing valve
No. 203025, and related components. Remove flow valve No. 203036,
by removing retainer ring No. 864271, then unscrewing flow valve with
screwdriver.
REASSEMBLY —GENERAL
All parts should be washed in a solvent and inspected for damage or
wear. Particular attention should be given to all bearings, gears, gear
pins, and rotor blades as failure of these parts could cause damage to
more expensive parts. Rotor blades should be replaced at every repair
cycle or if they measure less than 3/16" (4.7mm) on either end.
Inspect and replace any "O"-rings or seals that show signs of wear or
deterioration. All gears, gear pins, and open bearings should receive a
generous amount of No. 2 Moly grease during reassembly.
During reassembly of the clutch, all parts should receive a thin coating
of a mixture of 10W machine oil and No. 2 Moly grease.
Reassembly of all of the various sub-assemblies is in the reverse order
of disassembly; however, the following paragraphs list some of the
more important reassembly procedures.
"M" RIGHT ANGLE HEAD REASSEMBLY
Assemble the spindle and related components in the head and securely
tighten (left hand threads) the bearing cap No. 864396. Use bearing
spacer No. 869050, to press the pinion needle bearing No. 863360,
(press on the bearing's stamped end) in the head. Install ball bearing
No. 847846, and bearing retainer No. 863564, in the head and tighten
retainer securely using the 5/8" hex nut and 5/8" deep socket.
15°& 30°ANGLE HEAD REASSEMBLY
Install a pinion needle bearing No. 847746, on the pinion and press
(press on the bearing's stamped end) the bearing and pinion assembly
into the angle housing until the bearing bottoms out against the shoulder
in housing. Insert the needle bearing spacer No. 869206, into the
housing and press (press on the bearing's stamped end) the rear needle
bearing into the housing until it bottoms out.
See paragraph Final Assembly —Complete Tool for information on
spacing the bevel gears.
MOTOR REASSEMBLY
Assemble the rear rotor bearing and rear bearing plate (press on the
bearing's inner race) onto the rear rotor shaft until there is approximately
.0015" clearance between the plate and rotor.
Assemble the five (5) rotor blades, cylinder, front bearing plate, and
front rotor bearing (press on the bearing's inner race) to the rotor
assembly. After final assembly, the cylinder should be held firmly, but
not tightly between the two (2) bearing plates and the rotor should turn
freely and not rub either bearing plate.
REVERSIBLE BACKHEAD REASSEMBLY
During reassembly, all "O"-rings should be lubricated with a good "O"-
ring lubricant. Button head cap screw No. 202696, tighten securely.
FINAL ASSEMBLY —COMPLETE TOOL —15°& 30°HEADS
During reassembly of the complete tool, the bevel gears must be
spaced for proper engagement. Spacers No. 847747, should be added
between the end of the pinion gear and pinion spacer No. 864751, until
gear interference is felt. One (1) spacer should then be removed for
proper spacing.
TRIP ROD SIZING
Assemble the tool completely less clutch assembly and trip rod.
Position the right angle head in relation to the throttle lever as shown.
Use spacers No. 863698, to position head. Break assembly apart at the
clutch housing and first reduction gear case (left hand threads) and
install the clutch assembly and trip rod. Screw clutch housing down until
maximum RPM is reached. Measure the gap between the clutch
housing and gear case. Cut this amount off the trip rod.
SAFETY CHECK
After repair or replacement of parts, tools equipped with an automatic
shut-off device should be tested to verify that the device is functioning
properly.
5
.360
.375
Front Rear
.240
.255
Front Rear
.0015" (.038mm)
Clearance
Must be replaced if less than
3/16" (4.7mm) on either end.

7
"M" RIGHT ANGLE HEAD
*Number of spacers required is variable.
**Denotes parts not included in subassemblies listed below.
The complete "M" Right Angle Head can be purchased as a subassembly.
3/8" Square Drive Spindle —861637
PARTS LIST —"M" RIGHT ANGLE HEAD
PART NO. PART NO.
NAME OF PART NAME OF PART
QTY. QTY.
201102
201103
201104
201214
202566
202567
202568
202569
202725
842517
842980
843589
847219
847710
847846
863360
863564
863698
864076
864396
865723
867641
867642
867643
869034
869048
869049
869050
882629
10mm Conversion Kit
13mm Conversion Kit
15mm Conversion Kit
11mm Conversion Kit
10mm Flush Socket Spindle
13mm Flush Socket Spindle
15mm Flush Socket Spindle
Bearing Cap
11mm Flush Socket Spindle
Spindle Ball Bearing
3/32' Steel Ball
Grease Fitting
Lock Pin Spring
"O"-Ring 1/2" x 5/8"
Pinion Ball Bearing
Pinion Needle Bearing
Pinion Bearing Retainer
Head Positioning Shim (.008')
Driven Gear
Spindle Bearing Cap
Head Positioning Shim (.004')
Lock Pin Retainer Plug
Socket Lock Pin
3/8" Sq. Dr. Spindle (incl. 847219, 867641,
867642)
Angle Head Adapter
Right Angle Head (incl. 843589)
Pinion
Bearing Spacer
Spindle Needle Bearing
1
1
1
1
1
1
1
1
1
1
30
1
1
1
1
1
1
*
1
1
*
1
1
1
1
1
1
1
1
863564
869050
863360
847846
869048 869049
882629
864076 842517 847710
864396
867641
869034
ANGLE HEAD ADAPTER
Stall Tools Only
843589
867642
847219
867643
842980 202569
863698 .008"
865723 .004"
FLUSH SOCKET SPINDLE
SIZE SPINDLE CONVERSION
PART NO. KIT* PART NO.
10mm 202566-6 201102
11mm 202725-8 201214
13mm 202567-4 201103
14mm ------------ ------------
15mm 202568-2 201104
*Conversion kit contains all parts
needed to convert a "M" right angle
head to flush socket operation.
3/8-24 Drill Spindle
869051

8
861690 15°Gear Set (10T & 15T) 1
863462 Base Plate Screw 2
864201 Bearing Post 2
864202 Idler Gear Bearing 2
864264 Ball Race 2
864745 15°Angle Head 1
864751 Pinion Spacer 1
869206 Needle Bearing Spacer 1
869207 Base Plate 1
869211 15°Gear Shaft 1
869214 Angle Head Lock Ring 1
869215 Angle Head Lock Nut 1
869222 Base Plate Screw 2
PART NO. NAME OF PART QTY.
202127 Driving Gear (24T) 1
202128 Idler Gear (24T) (incl. 864202) 2
812164 Bearing Post Pin 2
833075 Base Plate Pin 1
833785 Hex Nut 2
842980 Steel Ball (3/32") 56
843589 Grease Fitting 1
843827 Base Plate Needle Bearing 1
847027 Bearing Post Screw 2
847095 Gear Shaft Ball Bearing 1
847282 Set Screw 1
847746 Pinion Needle Bearing 2
847747 Gear Spacer (.005") *
PART NO. NAME OF PART QTY.
PARTS LIST —15°ANGLE HEAD
*Number of spacers required is variable.
The complete "D" model angle head can be purchased as a subassembly (specify socket gear size when ordering) using the following
part number: 15°—201000
15°ANGLE HEAD
864751
847747
847095
812164
864201 864202
864264
L
842980
SOCKET GEAR
Hex Size Part No.
5/16 202129
3/8 202130
7/16 202131
1/2 202132
9/16 202133
10MM 202134
11MM 202135
13MM 202136
14MM 202137
15MM 202138
Extended
3/8 x 1/2L 203824
7/16 x 1/2L 203825
8MM x 1/2L 203775
12MM x 1/2L H203660
13MM x 1/2L 202304
13MM x 3/4L 204177
1/2 x 3/4L 204326
ALL GEARS HAVE 24T
202128
833075
202127-7
843827
869222
847027
863462
869207
843589
833785
847746
869206
861690
869214
869215 847282
864745
1-11/16"
869211
Socket Gear
(See Chart)
1/2"
1-19/32"
1/8"
861690

9
861691 30°Gear Set (10T & 15T) 1
863462 Base Plate Screw 2
864198 30°Angle Head 1
864201 Bearing Post 2
864202 Idler Gear Bearing 2
864264 Ball Race 2
864751 Pinion Spacer 1
869206 Needle Bearing Spacer 1
869207 Base Plate 1
869208 30°Gear Shaft 1
869214 Angle Head Lock Ring 1
869215 Angle Head Lock Nut 1
869222 Base Plate Screw 2
PART NO. NAME OF PART QTY.
202127 Driving Gear (24T) 1
202128 Idler Gear (24T) (incl. 864202) 2
812164 Bearing Post Pin 2
833075 Base Plate Pin 1
833785 Hex Nut 2
842980 Steel Ball (3/32") 56
843589 Grease Fitting 1
843827 Base Plate Needle Bearing 1
847027 Bearing Post Screw 2
847095 Gear Shaft Ball Bearing 1
847282 Set Screw 1
847746 Pinion Needle Bearing 2
847747 Gear Spacer (.005") *
PART NO. NAME OF PART QTY.
PARTS LIST —30°ANGLE HEAD
*Number of spacers required is variable.
The complete "D" model angle head can be purchased as a subassembly (specify socket gear size when ordering) using the following
part number: 30°—201001
30°ANGLE HEAD
864751
847747
847095
812164
864202
864264
L
842980
SOCKET GEAR
Hex Size Part No.
5/16 202129
3/8 202130
7/16 202131
1/2 202132
9/16 202133
10MM 202134
11MM 202135
13MM 202136
14MM 202137
15MM 202138
Extended
3/8 x 1/2L 203824
7/16 x 1/2L 203825
8MM x 1/2L 203775
12MM x 1/2L H203660
13MM x 1/2L 202304
13MM x 3/4L 204177
1/2 x 3/4L 204326
ALL GEARS HAVE 24T
202128
833075
202127843827
869222
847027
863462
869207
833785
847746
869206
861691
869214
869215 847282
864198
1-9/16"
869208
Socket Gear
(See Chart)
7/8"
1-1/2"
1/32"
861691
864201
843589

10
The complete gear case can be purchased as a subassembly using Code No. 201335
203062
203160
203161
844364
847147
867904
867907
Idler Gear Bearing
Dowel Pin
2nd Reduction Spider
Retainer Ring
Ball Bearing
Idler Gear
Gear Case
6
3
1
1
1
6
1
PART NO. NAME OF PART QTY.
PARTS LIST —2ND REDUCTION GEAR TRAIN ASSEMBLY
2ND REDUCTION GEAR TRAIN ASSEMBLY
844364-0 867907-8
867904-5
203160-0
203161-5
203062-5
867904-5
203062-5
847147-6

11
202749-8
842161-2
202748-0
844308-7
203270-4
844077-8
202745-6
843231-2
202763-9
842161-2
203162-3
203272-0
203271-2
202752-2
202753-0
847596-4
202754-8
202755-5
203163-1
843791-5
202829-8
Green - 204,
304, 404 202822-3
Yellow - 104 869306-1
844975-3
842517-5
PARTS LIST—DOUBLE CLECOMATIC CLUTCH
202745
202748
202749
202752
202753
202754
202755
202763
202822
202829
203162
203163*
203270
203271
203272
842161
842517*
843231
843791
844077
844308*
844975*
847596
869306
Trip Plunger
Ball Plug
Retainer Ring
Release Spring
Thrust Race
Adjustment Plate
Adjustment Nut
Reset Spring
Torque Spring (Green) (2- 7 ft. Ibs.)
Adjustment Cover
Clutch Spindle
Clutch Housing
Clutch Cam
Release Sleeve
Ball Retainer
3/16" Steel Ball
Ball Bearing
Reset Pin
Retainer Ring
5/16" Ball
"O"-Ring
Retainer Ring
Thrust Bearing
Torque Spring (Yellow) (5- 20 ft. Ibs.)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
14
1
1
1
5
1
1
1
1
PART NO. NAME OF PART QTY.
*Denotes parts not included in subassembly. The complete clutch can be purchased as a subassembly using Part No.
201390 —04
201391 —- 204, - 304, - 404
DOUBLE
CLECOMATIC
CLUTCH

12
1st REDUCTION 104 GEAR TRAIN
PARTS LIST —204, 304, 404 GEAR TRAINS
PART NO. NAME OF PART QTY.
844364 Bearing Retainer Ring 1
847147 Spider Bearing 1
865862 Pinion 404 Model Only (12T) 1
867866 204 Idler Gear (18T) (incl. 867921) 3
867871 Gear Case 1
867872 204 Spider (incl. 867922) 1
867921 204 & 304 Idler Gear Bearing 3
867922 Idler Gear Pin 3
869181 304 Idler Gear (16T) (incl. 867921) 3
869182 304 Spider (incl. 867922) 1
869554 404 Idler Gear (15T) 3
869584 Pinion Spacer 404 Model Only 1
869945 404 Spider (incl. 867922) 1
869949 Thrust Washer 404 Model Only 1
The complete gear cases can be purchased as a subassembly
using Part No. 204 - 861573, 304 - 861680, 404 - 861928.
PARTS LIST —104 GEAR TRAIN
PART NO. NAME OF PART QTY.
203062 2nd Red. Gear Bushing 3
832128 2nd Red. Gear Pin 3
844364 Retainer Ring 1
847147 Ball Bearing 1
867902 Rotor Pinion (15T) 1
867903 1st Red. Gear (15T) (incl. 867925) 3
867904 2nd Red. Gear (15T) 3
867905 1st Red. Spider (incl. 884125) 1
867906 2nd Red. Spider (incl. 832128) 1
867907 Gear Case 1
867925 1st Red. Gear Bushing 3
869584* Pinion Spacer 1
884125 1st Red. Gear Pin 3
*Denotes parts not included in sub-assembly.
The complete gear case can be purchased as a subassembly
using Part No. 861578.
847147-6
844364-0 867906-0
832128-3 867904-5
203062-5
867903-7
884125-6
867925-0
867905-2
867902-9
869584-3
867907-8
847147-6
844364-0
867922-7
204 867866-6
304 869181-8
404 869554-6
865862-7
404 MODEL ONLY
869584-3
404 MODEL ONLY
867871-6
869949-8
404 MODEL ONLY
204 867921-9
304 867921-9
404 NONE
204 867872-4
304 869182-6
404 869945-6
1ST REDUCTION
204, 304, 404 GEAR TRAINS

13
847609
Non-Rev. 202719
Rev. 202703
Non-Rev. 203124
Rev. H203125
869788
812165
619377
Non-Rev. 202718
Rev. 202704
203126 104, 204, 404
203127 304
869583
202769 104
202766 204, 304, 404
MOTOR ASSEMBLY
PART NO.
202703
202704
202718
202719
202766
202769
203124
H203125
203126
203127
619377
812165
847609
869583
869788
NAME OF PART
Rev. Rear Bearing Plate
Rev. Front Bearing Plate
Non-Rev. Front Bearing Plate
Non-Rev. Rear Bearing Plate
Trip Rod (.062" Dia. x 5" Lg.)
Trip Rod (.062" Dia. x 5 3/4" Lg.)
Non-Rev. Cylinder (incl. 812165)
Rev. Cylinder (ind. 812165)
Rotor (6T, Clecomatic)
Rotor (9T, Cecomatic)
Ball Bearing
Cylinder Pin (Non-reversible requires one only)
Ball Bearing
Gear Case Spacer
Rotor Blade
QTY.
1
1
1
1
1
1
1
1
1
1
1
2
1
1
5
PARTS LIST —MOTOR ASSEMBLY

14
REVERSIBLE HANDLE
FOR
HIGH TORQUE 35RNAL
202701-9
203025-2
203420-5
203286-0
847599-8
867874-0
202410-7
867877-3
833300-7
863454-5
865728-0
867882-3
869510-8
833954-1
203187-0
203016-1
203015-3
202696-1
REVERSIBLE
412603-3
203386-8
844306-1
203036-9
864271-0
201176-5 844307-9
847426-4
844060-4 832207-5
PART NO. NAME OF PART QTY.
PARTS LIST —HIGH TORQUE 35RNAL HANDLE
PART NO. NAME OF PART QTY.
202410 Throttle Lever Pin 1
202696 Button Head Cap Screw 1
202701 Motor Spacer 1
202774 Throttle Valve (incl. 847426) 1
203015 Screw Seal 1
203016 Reversing Valve Sleeve 1
203025 Reversing Valve 1
203036 Flow Valve 1
203187 Reversible Backhead 1
203286 Shut-off Valve Spring 1
203420 Shut-off Valve 1
412603 Bail 1
832207 Throttle Valve Cap (incl. 844307) 1
833300 Air Inlet Screen 1
833954 "O" -Ring 1 3/8" x 1 1/2" 2
844060 Throttle Valve Spring 1
844306 "O"-Ring 5/16" x 7/16" 1
844307 "O"-Ring 3/8" x 1/2" 1
847426 Throttle Valve Seal (incl. in 202774) 1
847599 "O" -Ring 15/16" x 1 1/16" 1
863454 "O" -Ring 9/16" x 11/16" 1
864271 Retainer Ring 1
865728 Inlet Spring 1
867874 Exhaust Deflector 1
867877 Throttle Lever 1
867882 Inlet Bushing (incl. 833300) 1
869510 Muffler 1
The complete backhead can be purchased as a subassembly using the part number 201358.

15
NON-REVERSIBLE HANDLE
FOR
HIGH TORQUE 35NAL
PART NO. NAME OF PART QTY.
PARTS LIST —HIGH TORQUE 35NAL HANDLE
PART NO. NAME OF PART QTY.
202410 Throttle Lever Pin 1
202701* Motor Spacer 1
202720* Inlet Plate (incl. 812165) 1
203036 Flow Valve 1
203186 Non-Reversible Backhead 1
203286* Shut-off Valve Spring 1
203420* Shut-off Valve 1
412603 Bail 1
812165* Inlet Plate Pin (incl. in 202720) 1
832207 Throttle Valve Cap (incl. 844307) 1
833300 Air Inlet Screen 1
844060 Throttle Valve Spring 1
844306 "O"-Ring 5/16" x 7/16" 1
844307 "O"-Ring 3/8" x 1/2" 1
847426 Throttle Valve Seal (incl. in 869036) 1
847445* "O"-Ring 15/16" x 1- 1/16" 1
863454 "O" -Ring 9/16" x 11/16" 1
864271 Retainer Ring 1
865728 Inlet Spring 1
867874 Exhaust Deflector 1
867877 Throttle Lever 1
867882 Inlet Bushing (incl. 833300) 1
869036 Throttle Valve (incl. 847426) 1
869510 Muffler 1
The complete backhead can be purchased as a subassembly using the part number 201357.
* Parts not included in 201357 backhead subassembly.
812165-9
847445-4
202701-9
202720-9
203420-5
203286-0
867874-0
202410-7
867877-3
833300-7
863454-5
865728-0
869510-8
203186-2
NON-REVERSIBLE
412603-3
867882-3
203386-8
844306-1
203036-9
864271-0
201176-5 844307-9
847426-4
844060-4 832207-5

16
CooperTools
670 Industrial Drive
Lexington, SC 29072
Phone: [phone]
Fax: [phone]
www.cooperindustries.com