Paoli Dp05-34b User manual

Operating instructions

Read the manual carefully before use!

Keep for future use!

Information about this manual

This manual enables the safe and efficient handling of the battery

nutrunners (referred to in the following as “nutrunner”).

The manual is a component of the nutrunner and must be kept in

its immediate vicinity so that the user can access it at any time.

The user must have read and understood this manual prior to

com-mencing any tasks. A basic prerequisite for ensuring that

work is performed safely is compliance with all safety instructions

and guidelines in this manual. In addition, the local accident

prevention regulations and general safety provisions for the

nutrunner’s area of application apply.

Illustrations in this manual serve to provide a basic understanding

and may differ from the actual design.

This manual is valid for the following battery nutrunners and soft-

ware:

Versions

Information about this manual

BATTERY NUTRUNNERS

DP05-34B

DP10-34B

DP20-10B

DP30-10B

DP36-10B

DP48-15B

DP80-15B

Table of contents

1 Unpacking............................................................................ 7

2 Getting to know the nutrunner........................................... 9

2.1 Illustration of the nutrunner........................................... 9

2.2 Brief description.......................................................... 10

2.3 Rating plate................................................................. 11

2.4 Performance variables................................................ 11

2.5 Nutrunner controls...................................................... 12

2.6 Overview of functions................................................. 16

2.7 Accessories................................................................ 17

3 Before you begin............................................................... 18

3.1 Symbols in this manual............................................... 18

3.2 Symbols on the nutrunner........................................... 20

3.3 Intended use............................................................... 22

3.4 Misuse........................................................................ 23

3.5 General safety instructions for electric tools............... 23

3.5.1 Workplace safety..................................................... 24

3.5.2 Electrical safety........................................................ 24

3.5.3 Personal safety........................................................ 25

3.5.4 Using and handling the electric tool......................... 25

3.5.5 Service..................................................................... 26

3.6 Residual risks............................................................. 26

3.6.1 Electrical dangers.................................................... 27

3.6.2 Mechanical dangers................................................. 29

3.6.3 Noise and ergonomics............................................. 32

3.7 Operator's obligations................................................. 35

3.8 Who is permitted to use the nutrunner?...................... 36

3.9 Personal protective equipment................................... 38

3.10 Environmental protection.......................................... 39

4 Determining the bolting process..................................... 40

5 Preparing the nutrunner................................................... 41

6 Supplying with energy...................................................... 43

6.1 Battery care................................................................ 43

6.2 Charging the battery................................................... 45

6.3 Connecting the nutrunner to the battery..................... 46

7 Setting the torque levels.................................................. 47

8 Bracing the reaction arm.................................................. 48

9Tightening.......................................................................... 50

10 Loosening.......................................................................... 53

Table of contents

11 Performing maintenance.................................................. 55

11.2 Having the nutrunner maintained by the user........... 57

11.3 Having service tasks performed by the manufac-

turer.......................................................................... 58

12 Troubleshooting................................................................ 60

12.1 Identifying faults........................................................ 60

12.2 Performing troubleshooting....................................... 61

13 Disposing of the nutrunner.............................................. 62

14 Technical data................................................................... 63

Table of contents

11.1 Having the nutrunner maintained by the user........... 55

1 Unpacking

The nutrunner is delivered in a plastic transport case together with

the other items in the scope of delivery.

The transport case is packed in a cardboard box upon delivery.

The transport case is fitted with a foam inlay. The recesses in the

inlay enable precision storage of the scope of delivery.

Check the delivery for transport damage and

ensure it is complete immediately upon receipt. If it

is incomplete or if there are defects, note the

extent of the damage on the transport documents

and lodge a complaint immediately.

The scope of delivery includes:

nTransport case

nTrolley

nNutrunner

nReaction arm

nCirclip pliers

nCirclip

nO-ring

nDocument folder

– Operating instructions

– Torque chart

– EU declaration of conformity

– Technical data sheet

nBatteries

nBattery charger

Options:

nImpact wrench socket

nTest certificate for torque chart

nReaction arm versions

nAny accessory ordered

nDiagnostic Setting Software DSS

nProgramming adapter, USB cable

Delivery

Fig. 1: Transport case

Checking the delivery

Scope of delivery

Unpacking

ENVIRONMENT!

Danger to the environment due to incorrect dis-

posal!

Packaging materials are valuable raw materials

and, in many cases, can be further utilised or

appropriately reconditioned and recycled. Incorrect

disposal of packaging materials can be hazardous

to the environment.

– Reuse pallets.

– Dispose of packaging materials in an environ-

mentally sound manner.

– Observe the locally applicable disposal regula-

tions. If necessary, engage the services of a

specialist company with regard to disposal.

Always store and transport the nutrunner in the transport case.

Set the direction of rotation to the middle position (transport posi-

tion).

Do not take the nutrunner out of the transport case until shortly

before use.

Batteries contain hazardous substances are classified globally as

dangerous goods. These products are therefore only approved for

commercial transport under certain conditions.

With regard to road transport in Europe, the regulations of the ADR

must be complied with; the regulations of IATA DGR must be com-

plied with for air transport. These contain specifications for pack-

aging and accompanying documentation, for example.

Handling packaging material

Transport and storage

Transporting batteries

Unpacking

The individual packages are packed according to the expected

transport conditions. Only environmentally friendly materials are

used for the packaging.

The packaging should provide protection against transport

damage, corrosion and other damage. For this reason, do not

destroy the packaging and do not remove it until shortly before use.

Dispose of packaging material in accordance with the applicable

statutory provisions and local regulations.

Before transporting hazardous substances, always

familiarise yourself with current regulations per-

taining to the transport of dangerous goods.

Fig. 2: Illustration of the nutrunners

1 Reaction arm

2 Square drive (tool holder)

3 Reaction arm circlip

4 Safety swivel joint

5 Gear setting

6 Setting levels

Drive motor

Ventilation slot

Direction of rotation setting

10 Handle

11 Battery

12 Trigger

2 Getting to know the nutrunner

2.1 Illustration of the nutrunner

Getting to know the nutrunner

1 Battery release button

2 Electrical contacts and guide rail

3 Battery charge status indicator button

4 4 LEDs for battery charge status indicator

1 LED display

2 Battery connection

3 Power cable (not shown)

Fig. 4: Illustration of battery charger

2.2 Brief description

The nutrunner is a hand-held tool for tightening and loosening

bolted connections in a dry environment.

The nutrunner is powered electrically with the aid of a battery.

An individually adjustable reaction arm is used to brace the tool

against the torque.

The desired torque can be selected by switching the gearbox

stages and by actuating the setting potentiometer.

With the nutrunner version, information and events can be

documented in the nutrunner and subsequently transferred to a

terminal device.

Battery

Fig. 3: Illustration of battery

Battery charger

Getting to know the nutrunner

The following data is inscribed on the rating plate:

nName of the manufacturer including their full address

nMachine designation

nType designation

nArticle/serial number

nMaximum torque

nYear of construction

nWeight

nCE mark

2.4 Performance variables

Overview of available performance variables for the nutrunner ver-

sions:

2.3 Rating plate

Nutrunner

BATTERY NUTRUNNERS

DP05-34B

DP10-34B

DP20-10B

DP30-10B

DP36-10B

DP48-15B

DP80-15B

Getting to know the nutrunner

2.5 Nutrunner controls

Fig. 5: Controls

1 Gear setting

2 Setting levels

3 Direction of rotation setting

4 Handle

5 Battery charge status indicator

6 Battery charge status indicator button

7 4 LEDs for battery charge status indicator

8 Battery release button

9 Trigger

Getting to know the nutrunner

The nutrunner features the following controls:

1 Gear setting

2 Marking for setting level

3 Setting levels

The torque is selected using a combination of gear and setting

level.

Note the enclosed torque chart.

Gear: Gear 1 to 4

The gearbox gears are adjusted manually.

The highest torque is obtained in gear 1.

Setting level: Level 1 to 15

The potentiometer is adjusted electronically.

The highest torque is obtained in level 15.

Breakaway torque level:

The breakaway torque level is located at the start and end of the

setting level scale .

The breakaway torque level must not be used to

tighten the bolted connections.

The direction of rotation can be changed with the aid of the direc-

tion of rotation setting (Fig. 7/1).

Standard direction of rotation: Right-hand thread

Direction of rota-

tion setting

Direction of rotation

Right-hand side is

pressed. Clockwise (CW)

Tightening in clockwise direction

Middle position No rotation possible.

Transport position

Gear setting and setting levels

Fig. 6: Gear setting and setting levels

Direction of rotation setting

Fig. 7: Direction of rotation setting (1)

Getting to know the nutrunner

Direction of rota-

tion setting

Direction of rotation

Left-hand side is

pressed. Counterclockwise (CCW)

Loosening in counterclockwise direc-

tion

The nutrunner can be gripped securely and carried by the handle

(Fig. 5/4). Ergonomic use of the trigger is possible.

1 Battery charge status indicator

2 Button and 4 LEDs for charge status indicator

3 Battery release button

A proactive battery charge status indicator is fitted below the

handle of the nutrunner. The white LED (Fig. 8/1) warns the user of

insufficient battery capacity, thereby preventing a sudden loss of

torque and faulty bolted connections.

Fig. 9: Charge status

Level LED Meaning

0 LED is not illuminated Battery charged.

1 LED flashing slowly There is still approx. 30% of the usable battery

capacity available.

It is still possible to tighten the bolted connections with

the set torque.

2 LED flashing rapidly Battery capacity is no longer sufficient to achieve the

set torque.

The nutrunner switches off automatically.

It is no longer possible to continue working.

The results of further bolted connections are NOK.

Handle

Battery charge status indicator

Fig. 8: Battery charge status indicator

Getting to know the nutrunner

The battery charge status can only be displayed

correctly when the drive motor is switched off.

The battery charge status is displayed (as a percentage) by

pressing the button.

LED Meaning

1 to 4 LEDs light up green The charge status is displayed as a percentage:

25% – 50% – 75% – 100%

LED lights up red continuously The battery is empty.

Charge the battery.

LED flashes red The battery is not operational.

Bring the battery to within the operating temperature range and then

charge it.

The battery is released from the nutrunner using the release button

(Fig. 8/3) and can be removed.

The set bolting process is initiated with the trigger (Fig. 5/9) and is

executed for as long as the trigger is pressed.

Do not pulse!

(Press and release the trigger in quick succession)

Always execute the bolting process in full. To this

end, press and hold the trigger for the entire dura-

tion of the bolting process.

The trigger operates digitally. The drive is off when the trigger is

pressed to a point (0). 100% of the torque is available beyond this

(1). The trigger does not need to be operated sensitively. This facil-

itates use in the event of prolonged utilisation and if gloves are

worn.

Button and LEDs for charge status

indicator

Fig. 10: LED display and charge

status indicator button

Battery release button

Trigger

Getting to know the nutrunner

LED display Meaning

Continuous yellow light The battery charger is operational. Mains voltage is available.

Flashing green light Quick charging is active.

Continuous green light Quick charging has concluded.

Flashing red light Charging is not possible. Potential causes:

nThe contacts are dirty.

Measure: Clean the contacts by inserting and removing the bat-

tery multiple times.

nThe battery is faulty.

Measure: Replace the battery.

Flashing green light

and flashing red light The battery temperature is located outside the charging tempera-

ture range of +5 to +45°C.

If the battery reaches the permissible charging temperature range,

quick charging is initiated.

2.6 Overview of functions

The nutrunner versions offer the following functions:

nTightening and loosening

nTorque can be set via 4 gears and 15 setting levels

nTrigger with On/Off switch function

nDiagnostic Setting Software DSS (option)

– Read out data from the nutrunner.

(Bolted connection documentation)

– Block individual torque levels.

– Update the firmware.

– Save the status report as a PDF file.

nAutomatic safety swivel joint

nAutomatic release function

LED display for battery charger

Getting to know the nutrunner

The safety swivel joint between the drive motor and gearbox

makes it possible to rotate the handle into any position you wish.

As soon as the torque on the handle exceeds 2 Nm, the safety

swivel joint is automatically locked such that no reaction force is

applied to the user's hand.

If the nutrunner is switched off, the safety swivel joint is unlocked

again and can be rotated freely.

Load on the gearbox is relieved after the bolting process. The

reac-tion arm retracts slightly. This makes it easier to remove the

nutrunner from the bolt and facilitates further work.

Automatic safety swivel joint

Automatic release function

2.7 Accessories

The following accessories can be ordered in addition to the

nutrunner and can be enclosed with the delivery:

nImpact wrench socket with circlip (spring clip)

nReaction arm with circlip

Special reaction arm

Nose extension

n“Torque Control TC1” mobile measuring unit

nImpact wrench sockets in various designs

nCertificate

Technical, more detailed supplement to the torque chart

nOffset heads for long studs

Contact PAOLI service.

Special accessories

3 Before you begin

This section provides an overview of all safety aspects that are

essential to the best possible protection of the personnel and the

safe and trouble-free operation of the machine. Additional safety

instructions for specific work tasks are contained in the sections

regarding the individual life stages of the machine.

Safety instructions are indicated by symbols in this manual. The

safety instructions are initiated by signal words that indicate the

degree of the danger.

DANGER!