Cooper Tools Cleco 5 SAD Series Installation and operating instructions

Operation & Service Manual
5/01
5 SAD Series Nutrunners
NORTH AMERICA EUROPE
CooperTools
P.O. Box 1410
Lexington, SC 29071
Cooper Power Tools GmbH & Co.
Postfach 30
D-73461 Westhausen

OPERATION - CLECOMATIC Models
No. 5 Series CLECOMATIC CCW screwdrivers are designed for the
clutch to shut-off in reverse. Accurate torque is achieved by setting the
CLECOMATIC clutch to the desired torque. The tool will automatically
shut off at this preset torque. The RSATP model is designed to start when
the trigger is pulled and stops when the clutch reaches the set torque or
the trigger is released. Releasing the trigger will reset the tool for the next
cycle.
CLUTCH ADJUSTMENT
Clutches are adjusted through the slot provided in the clutch housing. The
slot cover must be rotated to expose the adjustment slot. Rotate the clutch
housing until the hole in the adjustment lock plate is visible. Insert a No.
1 Phillips screwdriver and rotate in a clockwise direction to increase the
torque setting or a counterclockwise direction to decrease the setting.
After each adjustment, the slot cover should be rotated back to its locked
position.
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.
AIR SUPPLY
The tool is designed to operate at 90 psig (6.2 bar) air pressure. The air
pressure should be checked at the tool's air inlet while the tool is running.
The use of an automatic in-line filter-regulator-lubricator is highly recom-
mended. This will supply the tool with clean, lubricated air, keep it in
sustained operation, and increase tool life. For maximum performance,
use a 1/4" (6.5mm) I.D. air hose up to 8 feet in length. If additional length
is required, a 3/8" (9.5mm) I.D. or larger hose should be connected to the
1/4" (6.5mm) I.D. hose. The air hose should be cleared of accumulated
dirt and moisture, then one-quarter (1/4) (6.5cc) teaspoon of 10W
machine oil should be poured into the tool's air inlet before connecting the
hose to the tool.
LUBRICATION
The in-line lubricator should be checked regularly and filled with a good
grade of 10W machine oil. In the event a line lubricator is not used, tools
should be disconnected from the air supply several times daily and
several drops of oil poured into the tool's inlet bushing. Application of the
tool should govern how frequently it is greased. It is recommended that
the idler gears receive a 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.
DISASSEMBLY - GENERAL (All Models)
Clamp the air inlet bushing in a soft-jawed vise and unscrew (left hand
threads) the clutch housing and remove the clutch assembly. Use strap
wrenches to remove the gear case from the backhead. The throttle valve
rod and motor unit may now be removed from the front of the backhead.
See the following paragraphs for complete disassembly instructions on
the various subassemblies.
CLUTCH DISASSEMBLY - CLECOMATIC Clutch
Unscrew (left hand threads) the adjustment nut 869123, and remove the
adjustment lock ring 869140. The torque spring, spring sleeve, bearing
races 863455, thrust bearing 847104, ball retainer, 203573, and four (4)
steel balls 842161, may now be removed from the clutch spindle.
Washing the remaining spindle assembly in a solvent at this time will aid
in disassembly. Remove the ball retainer ring 203574, and ball retainer
plug 869149, from the clutch cam 204597. Rotate the clutch spindle to
allow the thirteen (13) steel balls 842980 to drop out of the ball loading
hole located in the clutch cam. Separate the clutch spindle and clutch
cam, being careful not to lose the reset pin 869112, reset spring 203585,
reset pin stop 869424, trip slide 203612, trip slide reset spring 203613,
and dowel pin 617226.
CAUTION!
GEAR TRAIN DISASSEMBLY — -174 Gear Train
When pressing the spider assembly out of the rear of the gear case
869162, be sure the idler gears 869163, are in line with the pockets
machined in the gear case. Press the idler gear pins 833862 out the rear
of the spider 869155 for inspection of the idler gear pins and idler gears
869163. Remove the bearing retainer ring 619017 and press the front
spider bearing 847595 out the front of the gear case.
MOTOR DISASSEMBLY
Slip the front bearing 842768 and front bearing plate 203641, off the front
of the rotor and remove the cylinder 203504, and four (4) rotor blades
203615. Set the rear bearing plate on the vise jaws with the rotor hanging
down. Use a 3/16" (4.8mm) punch to drive the rotor out of the rear rotor
bearing 842768.
BACKHEAD DISASSEMBLY
For inspection or replacement of the throttle valve or related parts, roll
down grip sleeve and drive throttle valve bushing retainer pin out and
remove bushing. Remove the valve cap 203559 and remove the shut-off
valve and seal for inspection. The reversing valve may be removed by
first unscrewing the reversing valve screw out of the reversing valve knob.
Then reversing valve may be removed from the front of the handle. On
reassembly make sure the reversing valve screw aligns with the threaded
hole in reversing valve.
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
bladesshouldbereplaced
if they measure less than
1/8"(3.2mm)on either end.
Inspect and replace any "O"-rings or seals that show signs of wear of
deterioration. All gears, gear pins, and open bearings should receive a
generous amount of NLGI 2-EP grease during reassembly. Reassembly
of all of the various subassemblies is in reverse order of disassembly:
however, the following paragraphs list some of the more important
reassembly procedures.
CLUTCH REASSEMBLY — Clecomatic Clutch
During reassembly of the clutch, all parts should receive a thin coating of
10W machine oil. In addition, the ball retainer 203573, should receive a
generous amount of NLGI 2-EP grease. When installing the dowel pin
617226, the tapered end goes into the clutch cam first. The trip slide
203612, goes into the clutch cam cupped-end first. All parts installed into
the clutch spindle 203625, and clutch cam 204597, should be checked for
smooth operation before complete assembly of the clutch.
MOTOR REASSEMBLY
Install the rear rotor bearing into the rear bearing plate 203506. Press the
bearing plate assembly (press on the bearing's inner race) onto the rear
rotor shaft until there is approximately .0015" (.038mm) clearance be-
tween the rear bearing plate and motor.
TRIP ROD SIZING
The trip rod No. 203586, should be sized to allow approximately 1/8"
(3.2mm) throttle valve opening.
IMPORTANT: During reassembly of the complete tool, the gear case
should be tightened to handle to 20 ft. lbs. (27Nm). Wrenches shown
below can be ordered to tighten the gear case and clutch housing.
SAFETY CHECK
After repair or replacement of parts, tools should be tested to verify that
they are functioning properly.
34 204 - ARMSTRONG U.S.A.
203803-2
GEAR CASE WRENCH
C 471 3/4 - 2
203804-0
CLUTCH HOUSING WRENCH
Replace blade if less
than 1/8"(3.2mm)
on either end.

5 CLECOMATIC CLUTCH
PARTS LIST — 5 CLECOMATIC CLUTCH
Part No. Qty.Part No.
203571
203573
203574
203575
203578
203579
203580
203584*
203585
203589
203612
203613
203993
204597
617226
842161
842980
847104
863455
869112
869123
869140
869149
869423*
869424
1
4
13
1
2
1
1
1
1
1
1
Clutch Spindle
Ball Retainer
Retainer Ring
Torque Spring - White
Torque Spring - Yellow
Torque Spring - Green
Torque Spring - Blue
Adj. Cover (incl. in 203581)
Clutch Reset Spring
Spring Spacer
Trip Slide
Slide Reset Spring
Clutch Housing
Clutch Cam
Dowel Pin
Ball (3/16" /4.76250mm)
Ball (3/32" /2.38125mm)
Needle Bearing
Thrust Race
Reset Pin
Adjustment Nut
Adjustment Lock Ring
Ball Retainer Plug
Clutch Spacer
Reset Pin Stop
Name of Part
Name of Part Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
The complete clutch can be purchased using these part numbers: 17, 25 - 201807
10 - 201484
203571
204597
203573
203574
203585
203612
203613
617226
842161
842980
847104
863455 863455
869112
869123
869140
869149
869424
203993
203584869423
203580 Blue
203579 Green
203575 White
203578 Yellow
203589

PART LIST — 2, 7 & 10 GEAR TRAINS & 104 1ST
REDUCTION GEAR TRAIN
PART NO. NAME OF PART QTY.
201550 2, 10 & 104 Reduction Spider— (2 req. 2) (incls. 869132, 203916) 1
201551 7 1st Reduction Spider (incls. 869132, 203916) 1
203644 2, 10 & 104 Motor Spacer 1
203917 2, 7, 10 & 104 Idler Gear Bushing (2 req. 9) 6
203919 Rotor Pinion (13T) 1
203920 2, 7, 10 & 104 Idler Gear (14T) (2 req. 9, 7 req. 3) 6
203924 & Gear Case (41T) 1
203925 7 1st Red. Idler Gear (16T) 3
203928 10 & 104 Gear Case (41T) 1
203976 7, 10 & 104 2nd & 2 3rd. Red. Spider (incls. 203916) 1
204136 7 Motor Spacer 1
619017 Bearing Retainer Ring 1
833859 2, 7, 10 & 104 Idler Gear Pin (2 req. 9) 6
847595 Spider Bearing 1
869132 2, 7, 10 & 104 Spider Pinion (13T) (2 req. 2) 1
The complete gear train can be purchased as a subassembly using the following
part numbers: 2 — 201589, 7 — 201586, 10 & 104 — 201587
619017
847595
203924
203976
833859 203920 203920
203917
833859
203917
201550
203920
833859
203917
201550
203919
203644
2 GEAR TRAIN
204136
619017
847595
203924
203976
833859 203920 203925
203917
833859
203917
201551
7 GEAR TRAIN
2, 7 & 10, GEAR TRAINS
& 104 1ST REDUCTION GEAR TRAIN
619017
847595
203928
203976
833859 203920 203920
203917
833859
203917
201550
10 GEAR TRAIN & 104 2ND REDUCTION GEAR TRAIN
203919
203644

PARTS LIST —5, 254 GEAR TRAIN
PART NO. NAME OF PART QTY.
203917 Idler Gear Bushing 3
203925 Idler Gear ( 16T) (incls. 203917) 3
203928 Gear Case (41T) 1
203978 Spider (incls. 203916) 1
204136 Motor Spacer 1
619017 Bearing Retainer Ring 1
203916 Idler Gear Pin 3
847595 Spider Bearing 1
The complete gear train can be purchased as a subassembly
using part no. 201588.
PARTS LIST —7, 174 GEAR TRAIN
PART NO. NAME OF PART QTY.
203646 Motor Spacer 1
619017 Bearing Retainer Ring 1
833862 Idler Gear Pin 3
847595 Front Spider Bearing 1
869155 Spider 1
869162 Gear Case (27T) 1
869163 Stepped ldler Gear (9T & 18T) 3
The complete gear train can be purchased as a subassernbly
using part number: 201474.
17 & 25 GEAR TRAINS
& 174, 254 1ST REDUCTION
GEAR TRAINS
619017
847595
869162 869155
833862
869163 203646
17 GEAR TRAIN & 174 1ST REDUCTION GEAR TRAIN
204136
619017
847595
203928
203978
833859
203917
25 GEAR TRAIN & 254 1ST REDUCTION GEAR TRAIN
203925

5 MOTORS
Name of Part
Cylinder
Rear Bearing Plate (All Others)
Rotor 7, 25, 254 (7T)
Rotor 2, 10, 104 (Hex)
Rotor 17, 174 (6T)
Trip Rod (Clecomatic)
Rotor Blade
Front Bearing Plate
Rear Bearing Plate (Button Rev.)
Bearing
Front Cylinder Pin
Reversible Rear Cylinder Pin
Non-Reversible Rear Cylinder Pin
Part No.
203504
203506
203545
203546
203547
203586
203615
203641
203721
842768
844897
847548
863036
Qty.
1
1
1
1
1
1
4
1
1
2
1
1
1
PARTS LIST —5 MOTORS
203504
842768842768 203615
Rev. 847548
Non-Rev. 863036
203586
844897
203546 -2, -10, -104
203545 -7, -25, -254
203547 -17, -174
203506
203641 203506 All Others
203721 Button Rev.

Name of Part
Part No.
203518
203519
203520
203521
203522
203523
203524
203525
203529
203530
Name of Part
Inlet Bushing (incl. 863598)
Exhaust Deflector
Muffler
Throttle Valve Spring
Throttle Valve
Throttle Valve Seat
Throttle Valve Bushing
Shut-off Valve Spring
Shut-off Valve
Throttle Valve Seal
Qty.
1
1
4
1
1
1
1
1
1
1
Part No.
203532
204407
204578
844308
847710
863598
865777*
869786
Motor Spacer
Motor Housing
Reversing Valve
"O"-ring (9/16" x 23/64")
"O"-ring (5/8" x 31/64")
Inlet Screen
Bail (Optional)
ThrottleValve Pin
1
1
1
1
1
1
1
1
Qty.
The complete handle can be purchased as a subassembly using part number: 201768
*Not included in subassembly.
PARTS LIST —5 CLECOMATIC HANDLE
5 CLECOMATIC HANDLE
865777
203519
203520
203518
203521
203522
844308
203523
203524
203525
203529
203530
204407
203532
204578
847710
863598

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