Saltus GFA-COT Instruction sheet

GFA-COT
Printed Matter No. 9839 1815 01 Geared Front Attachment
Publication Date 2020-11-07
Valid from Serial No. - Product Instructions
Closed-end and Offset
Geared Front Attachments
WARNING
Read all safety warnings and instructions
Failure to follow the safety warnings and instructions may result in
electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference

2© Saltus Industrial Technique AB - 9839 1815 01
Table of Contents
Product Information................................................................................................3
General Information ..........................................................................................3
Safety Signal Words ..............................................................................3
Country of Origin ...................................................................................3
Overview...........................................................................................................3
System Description................................................................................3
System Components .............................................................................3
Installation ...............................................................................................................6
Installation Instructions .....................................................................................6
Assembly Instructions............................................................................6
Functional Test ......................................................................................6
Operation .................................................................................................................7
Ergonomic Guidelines.......................................................................................7
Operating Instructions.......................................................................................7
Operating the GFA System ...................................................................7
Changing a HAD Socket Bit ..................................................................8
Service ...................................................................................................................10
Service Overview............................................................................................10
Maintenance Instructions................................................................................10
Service Intervals and Activities............................................................10
Preventive Maintenance ......................................................................10
Lubrication Instructions...................................................................................10
Lubrication Instructions........................................................................10
Dismantling/Assembling Instructions ..............................................................11
Removing a Quick Index Adapter........................................................11
Removing a Fixed Index Adapter ........................................................12
Dismantling the GFA Module...............................................................13
Assembling the GFA Module...............................................................14
Attaching a Quick Index Adapter .........................................................16
Attaching a Fixed Index Adapter .........................................................17
Recycling ...............................................................................................................18
Environmental Regulations.............................................................................18

GFA-COT EN Product Information
© Saltus Industrial Technique AB - 9839 1815 01 3
Product Information
General Information
WARNING Risk of Property Damage or Severe Injury
Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow
all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.
►Read all Safety Information delivered together with the different parts of the system.
►Read all Product Instructions for installation, operation and maintenance of the different parts of
the system.
►Read all locally legislated safety regulations regarding the system and parts thereof.
►Save all Safety Information and instructions for future reference.
Safety Signal Words
The safety signal words Danger, Warning, Caution, and Notice have the following meanings:
DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or se-
rious injury.
WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if
not avoided, could result in minor or moderate injury.
NOTICE NOTICE is used to address practices not related to personal injury.
Country of Origin
For the Country of Origin, please refer to the information on the product label.
Overview
System Description
The Gear Front Attachment (GFA) system is used for tightening and loosening of screws and nuts. The
system can be used for screw connections in locations that are difficult to access.
The tightening operation is controlled by a separate drive unit to which the system is fitted. The drive unit
can be of either pneumatic or electric type.
The modular structure of the system allows for a wide range of configurations available for different screw
connections and tightening processes.
System Components
The modular GFA system is made up of the following main components:

Product Information EN GFA-COT
4© Saltus Industrial Technique AB - 9839 1815 01
Position Component Function
AAdapter With an adapter the GFA system can be fitted to different inter-
faces. The interface varies depending on the drive unit model.
The adapter can be of either fixed index or quick index type.
With a fixed index adapter the angle of the GFA system is speci-
fied from the factory. With a quick index adapter the operator can
easily change the angle depending on the application.

GFA-COT EN Product Information
© Saltus Industrial Technique AB - 9839 1815 01 5
Position Component Function
BGear Front Attachment
(GFA) module
The GFA module comprises a housing which contains a number
of gears, that is, the gear stage. The gear stage depends on the
length of the GFA module. The output gear, or output socket, can
be of type open-end or closed-end.
The open-end type can be used for pipe and hose connections.
The closed-end type is used for regular screw connections.
CStandard Socket With different sockets the GFA system can be used for various
screw profiles.
DHold and Drive
Socket
With a hold and drive socket the screw is kept fixed while the nut
is being tightened.
GFA System Components

Installation EN GFA-COT
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Installation
Installation Instructions
Assembly Instructions
The assembly procedure varies depending on the configuration. Make sure that the square drive of the
drive unit (1) matches the input gear profile (square hole) of the GFA module (2).
Functional Test
Perform a functional test before the first tightening operation, and after any performed maintenance activi-
ties.
To perform a functional test:
1. Turn the output gear wheel by hand. It should be turned easily.
2. If it is hard to turn, open the housing and check that all components are in the correct position.
3. Grease the system.

GFA-COT EN Operation
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Operation
Ergonomic Guidelines
Consider your workstation as you read through this list of general ergonomic guidelines to identify areas
for improvement in posture, component placement, or work environment.
■Take frequent breaks and change work positions frequently.
■Adapt the workstation area to your needs and the work task.
■Adjust for a convenient reach range by determining where parts and tools need to be located to
avoid static load.
■Use workstation equipment such as tables and chairs appropriate for the work task.
■Avoid work positions above shoulder level or with static holding during assembly operations.
■When working above shoulder level, reduce the load on the static muscles by lowering the weight
of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce
the load on the static muscles by holding the tool close to the body.
■Take frequent breaks.
■Avoid extreme arm or wrist postures, particularly during operations requiring a degree of force.
■Adjust for a convenient field of vision that requires minimal eye and head movements.
■Use appropriate lighting for the work task.
■Select the appropriate tool for the work task.
■In noisy environments, use ear protection equipment.
■Use high-quality inserted tools and consumables to minimize exposure to excessive levels of vibra-
tion.
■Minimize exposure to reaction forces.
■When cutting:
A cut-off wheel can get stuck if the cut-off wheel is bent or not guided properly. Use the correct
flange for the cut-off wheel and avoid bending the cut-off wheel during operation.
■When drilling:
The drill might stall when the drill bit breaks through. Use support handles if the stall torque is high.
The safety standard ISO11148 part 3 recommends using a device to absorb a reaction torque
above 10 Nm for pistol grip tools and 4 Nm for straight tools.
■When using direct-driven screwdrivers or nutrunners:
Reaction forces depend on the tool settings and joint characteristics. Strength and posture deter-
mine the amount of reaction force that an operator can tolerate. Adapt the torque setting to the op-
erator's strength and posture and use a torque arm or reaction bar if the torque is too high.
■In dusty environments, use a dust extraction system or wear a mouth protection mask.
Operating Instructions
Operating the GFA System
WARNING Risk of Injury
If the system moves around unexpectedly, or if reactive forces are absorbed incorrectly, it can lead to
severe injuries and property damage.
►Always check that the system is placed correctly on the head of the nut.

Operation EN GFA-COT
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WARNING Crushing Hazard
The Dual trigger forces the user to use both hands to operate the tool. If not used, the operator can
accidentally start the tool while adjusting the crowfoot, thus resulting in a serious hand injury.
►Make sure the tool cannot be started once the Dual trigger has been released.
►Always test the tool by first releasing the trigger of the Dual trigger, then push the trigger of the
tool. If the tool starts; stop working.
WARNING Risk of Injury
Make sure that the correct parameter file is being used. Wrong Parameter File might cause too high
torque with bodily injury as a result.
►Compare the maximum torque which is shown in the controller, with the maximum torque stated
in the stated technical data for the tool, they should be the same.
NOTICE Insufficient Lubrication
If the system is not sufficiently lubricated, it may be damaged.
►Lubricate the system as soon as there is no longer visible grease.
►Apply the grease gun to every grease nipple. Fill with lubricant until it emerges on the output socket.
Tightening procedure:
1. Place the GFA system (1) with the socket (2) onto the screw connection (3).
2. Check that the system is placed correctly on the head of the nut.
3. Start tightening by using the drive unit.
4. Remove the system from the screw connection. The system can now be positioned on the next con-
nection.
Changing a HAD Socket Bit
To Remove a Bit:
1. Loosen and remove the set screw from the socket.
2. Remove the bit.

GFA-COT EN Operation
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To Insert a Bit:
1. Insert the bit into the socket.
2. Insert the set screw into the socket and tighten.

Service EN GFA-COT
10 © Saltus Industrial Technique AB - 9839 1815 01
Service
Service Overview
As the gear wheels of the GFA module are exposed to hard wear it is important to regularly check their
condition. If any of the gear wheels are worn or damaged, all the gear wheels must be replaced. Needle
bearings are to be replaced if needed.
At regular intervals between the service, additional grease is to be supplied through the grease nipples.
Maintenance Instructions
Service Intervals and Activities
Interval Action
Daily ■Clean the GFA system
■Inspect the system for any damage
■Check all fastenings of the system
■Run functional tests and listen for any abnormal
noise
At least after every 50,000 tightenings ■Lubricate the system
At least after every 500,000 tightenings ■Service interval for overhaul and preventive main-
tenance
In case of wear-out parts or in case of faulty tightening
result
■Change the output socket gear
■Change the wear-out parts
Preventive Maintenance
Cleaning the System
To clean the system, wipe carefully with a clean, smooth cloth.
Lubrication Instructions
Lubrication Instructions
Component
Recommended
Lubricant Quantity
GFA module Molykote Longterm 2 Plus Until excess grease emerges on
the output socket

GFA-COT EN Service
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To lubricate the GFA module:
1. Use a grease gun to apply lubrication to every grease nipple of the GFA module.
The number of grease nipples varies with the design of the GFA module.
2. Operate the system a few times.
3. Remove any excess grease with a clean, smooth cloth.
Dismantling/Assembling Instructions
Removing a Quick Index Adapter
1. Fasten the GFA system, together with the drive unit, in a vice.
2. Loosen the drive unit from the adapter.
The adapter is left-hand threaded. Turn the drive unit clockwise for loosening.
The adapter is fixed to the drive unit with Loctite. Loosening the tool from the adapter requires
strong force. It is recommended to use a heat gun to facilitate the loosening.
3. Remove the drive unit from the adapter.
4. Loosen the ring inside the adapter. For service tool information, see the spare parts list of the specific
GFA model.
5. Remove the ring and the adapter from the GFA unit.

Service EN GFA-COT
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Removing a Fixed Index Adapter
1. Fasten the GFA system, together with the drive unit, in a vice.
2. Loosen the nut from the adapter. For service tool information, see the spare parts list of the specific
GFA model.
3. Remove the adapter, together with the drive unit, from the GFA unit.
4. Fasten the drive unit in a vice. Loosen the adapter clockwise to remove it from the drive unit.
The adapter is fixed to the drive unit with Loctite. Loosening the tool from the adapter requires
strong force. It is recommended to use a heat gun to facilitate the loosening.

GFA-COT EN Service
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Dismantling the GFA Module
The instruction below shows an example of a GFA module. The module comprises a housing which
contains a number of gears depending on model of the GFA system.
To dismantle the GFA module:
1. Loosen the shaft lid.
2. Remove the shaft lid.
3. Loosen and remove the screws. The number and type of screws depend on the GFA model.
4. Place the GFA module on a rubber mat. Hit the shafts to loosen the upper and lower part of the
housing.
5. Open the housing.
6. Remove the bearing housing and the snap ring, shim ring and needle carrier if needed.
7. Remove the output gear, middle gears and input gears. The amount of gears depend on the GFA
model.
Note the direction of the output gear (hexagonal shape up or down). It should be placed in the
same way when assembling the GFA module.
8. Remove the needle rollers.
Depending on the GFA model the needle rollers can be loose or assembled in bearing rings.

Service EN GFA-COT
14 © Saltus Industrial Technique AB - 9839 1815 01
Assembling the GFA Module
To assemble the GFA module:
1. Make sure the parallel pins are inserted. The amount and positions of the parallel pins depend on the
GFA model.
2. Depending on the type of needle carriers, assembled in bearing rings (A) or loose (B), do the fol-
lowing:
■A) Put the needle carrier bearing rings over the shafts.
■B) Put the middle gears over the shafts.
3. Depending on the type of needle carriers, assembled in bearing rings (A) or loose (B), do the fol-
lowing:
■A) Put the middle gears over the needle carriers.
■B) Insert the loose needles between the shafts and the middle gears. Make sure all the needles
go in - there should be no gaps.
4. Place the output gear in the housing. Position the gear with the same orientation (hexagonal shape
pointing up or down), as when dismantling.
5. Insert the input gear into the bearing housing and put back the snap ring, shim ring and needle car-
rier (if they were removed).
6. Depending on the adapter type the bearing house can be prepared in one of the following ways, be-
fore inserted into the GFA housing:
■A) GFA system with fixed index adapter:
Insert the bearing housing into the upper locking ring, nut, and lower locking ring.
■B) GFA system with quick index adapter:
Insert the bearing housing into the upper locking ring, guide ring, and lower locking ring.
Locking rings are not used in all GFA models, refer to the spare parts list of the GFA model in
question.
7. Insert the bearing housing, prepared as in the step above, into the GFA module housing.
The bearing housing can be inserted from the top or from below, depending on the GFA model.
8. Use a press tool to press the upper and lower parts of the housing together.
It is important to press evenly over the housing.
9. Make sure there is no gap between the upper and lower part of the housing.
10. If applicable, put the bearing support washer over the shaft lid. The bearing support is not available
of all GFA models.
11. Insert the shaft lid into the housing.
12. Tighten the shaft lid.
13. Tighten the screws. The number and type of screws depend on the GFA model.
14. Use a grease gun to apply lubrication to every grease nipple of the GFA module. Remove any ex-
cess grease with a clean, smooth cloth.

GFA-COT EN Service
© Saltus Industrial Technique AB - 9839 1815 01 15

Service EN GFA-COT
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Attaching a Quick Index Adapter
1. Attach the adapter and ring to the GFA unit.
Make sure the spring is inserted in the adapter before attaching the ring.
2. Tighten the ring inside the adapter. For service tool and tightening torque information, see the spare
parts list of the specific GFA model.
3. Clean the threads of the drive unit and the adapter.
4. Apply Loctite 2701, or similar, to the threads of the drive unit.
5. Attach the drive unit to the adapter and tighten.

GFA-COT EN Service
© Saltus Industrial Technique AB - 9839 1815 01 17
Attaching a Fixed Index Adapter
1. Clean the threads of the drive unit and the adapter.
2. Apply Loctite 2701, or similar, to the threads of the drive unit.
3. Fasten the drive unit in a vice and tighten the adapter.
4. Fasten the GFA in a vice and attach the adapter to the nut.
5. Tighten the nut. For service tool and tightening torque information, see the spare parts list of the spe-
cific GFA model.

Recycling EN GFA-COT
18 © Saltus Industrial Technique AB - 9839 1815 01
Recycling
Environmental Regulations
When a product has served its purpose it has to be recycled properly. Dismantle the product and recycle
the components in accordance with local legislation.
Batteries shall be taken care of by your national battery recovery organization.

Original instructions
Saltus Industrial Technique AB
SE-10523 STOCKHOLM
Sweden
Telephone: [phone]
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