Airetool® - Apex Tool Group

Instruction Manual
PL19-6010EN
11/21/2012
Airetool
®
DAS II 850 Series
DAS II Dominator Rolling Motors
For additional product information visit our website at http://www.apextoolgroup.com
PL19-6010EN
11/21/2012
Airetool®
General Information
For this Instruction Manual
This Instruction Manual is the Original Instruction Manual intended for all persons who will operate and maintain
these tools.
This Instruction Manual
•
provides important notes for the safe and efficient use of these tools.
•
describes the function and operation of the DAS II 850 series rolling motors.
•
serves as a reference guide for technical data, service intervals and spare parts ordering.
•
provides information on optional equipment.
Identification text:
DAS II 850
represents all models of the DAS II Dominator rolling motors as described in this manual
Ú
indicates a required action
•
indicates a list
<..>
indicates a reference number from the exploded parts drawings
Arial
indicates an important feature or instruction written in Arial Bold
Identification graphic:
¢
ò
indicates a directional movement
indicates a function or force
Copyright protection:
Apex Tool Group, LLC reserves the right to modify, supplement or improve this document or the product without
prior notice. This document may not be reproduced in any way, shape or form, in full or parts thereof, or copied
to another natural or machine readable language or to a data carrier, whether electronic, mechanical, optical or
otherwise without the express permission of Apex Tool Group, LLC.
Page 2
PL19-6010EN
Airetool®
11/21/2012
Nomenclature
Model Number
DAS II 850 1250
DAS II 850 1250 CL
DAS II 850 600
DAS II 850 600 CL
Order
Number
8405562
8405567
8405569
8405578
Description
DAS II Dominator Rolling Motor - Push-to-start
DAS II Dominator Rolling Motor - Push-to-start with cycle counter and lubricator
DAS II Dominator Rolling Motor - Push-to-start
DAS II Dominator Rolling Motor - Push-to-start with cycle counter and lubricator
Page 3
PL19-6010EN
11/21/2012
Airetool®
Contents
1
Safety
6
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Warning and notes.................................................................................................. 6
Basic requirements for safe working practices....................................................... 7
Operator training..................................................................................................... 7
Personal protective equipment............................................................................... 7
Designated use....................................................................................................... 8
Codes and standards............................................................................................. 8
Noise and vibration................................................................................................. 8
2
Scope of supply, transport and storage
2.1
2.2
2.3
Items supplied........................................................................................................ 9
Transport................................................................................................................ 9
Storage................................................................................................................... 9
3
Product description
3.1
3.2
General description.............................................................................................. 10
Operation and functional elements....................................................................... 10
4
Accessories
11
5
Before initial operation
12
5.1
5.2
5.3
5.3.1
5.4
5.4.1
5.4.2
Ambient conditions............................................................................................... 12
Air supply.............................................................................................................. 12
Connecting the air supply to the tool.................................................................... 12
Quick-Disconnect Couplers.................................................................................. 12
Tool set up............................................................................................................ 13
Setting the torque................................................................................................. 13
Loading an Expander........................................................................................... 14
6
First operation
6.1
6.2
6.3
6.4
Puting into use...................................................................................................... 15
DAS II 850 tube rolling.......................................................................................... 15
DAS II 850 operating notes.................................................................................. 15
DAS II 850 trip adjustment.................................................................................... 15
7
Troubleshooting
16
8
Maintenance
17
8.1
8.2
Service schedule.................................................................................................. 17
Lubrication............................................................................................................ 17
9
Repair instructions
9.1
9.2
DAS II 850 trip adjustment.................................................................................... 18
Control circuit diagram with cycle counter and expander lubricator..................... 19
9
10
15
18
Page 4
Airetool®
PL19-6010EN
11/21/2012
Contents
10
Spare parts
10.1
10.2
10.3
10.4
10.5.1
10.5.2
10.6
10.7
DAS II 850 600 Series Motor................................................................................ 20
DAS II 850 600 Series Output.............................................................................. 22
DAS II 850 1250 Series Motor.............................................................................. 24
DAS II 850 1250 Series Output............................................................................ 26
DAS II 850 Series Motor Positioner...................................................................... 28
DAS II 850 Series Motor Positioner...................................................................... 30
DAS II 850 Series Cycle Counter - Lubricator...................................................... 32
(Reference) DAS II Dominator - Lubricator.......................................................... 34
11
Technical data
11.1
DAS II 850 Series Rolling Motor Specifications.................................................... 36
12
Service
12.1
12.2
12.3
Replacement parts............................................................................................... 37
Tool repairs........................................................................................................... 37
Warranty repairs................................................................................................... 37
13
Disposal
36
37
38
Page 5
PL19-6010EN
11/21/2012
Airetool®
Safety
1
Safety
1.1
Warnings and notes
Warning notes are identified by a signal word and a pictogram.
•
The signal word indicates the severity and probability of the impending danger.
•
The pictogram indicates the type of danger.
--------------------------------------------------------------------------------------------------------------------------------------WARNING identifies a potentially hazardous situation which, if not avoided, may result in serious
injury.
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------CAUTION identifies a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or property and environmental damage.
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------NOTE identifies general information which may include application tips or useful information but no
hazardous situations.
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Important information that must be read and understood by all personnel installing, operating or
maintaining this equipment.
---------------------------------------------------------------------------------------------------------------------------------------
Page 6
Airetool®
Safety
1.2
PL19-6010EN
11/21/2012
Basic requirements for safe working practices
All personnel involved with the installation, operation or maintenance of these tools must read and
understand all safety instructions contained in this manual. Failure to comply with these instructions
could result in serious injury or property damage.
These safety instructions are not intended to be all inclusive. Study and comply with all applicable
National, State and Local regulations.
--------------------------------------------------------------------------------------------------------------------------------------Work Area:
Ú
Ensure there is enough space in the work area.
Ú
Keep the work area clean.
Ú
Keep the work area well ventilated.
Personnel Safety:
Ú
Inspect the air supply hoses and fittings. Do not use damaged, frayed or deteriorated hoses.
Ú
Make sure the air supply hose is securely attached to the tool.
Ensure a secure standing position and maintain balance.
Ú
Ú
Make sure the unit is positioned to provide unobstructed operator movement during the tube
rolling process and the Dominator arm has full movement.
Ú
To avoid unintended contact with the arm or rolling motor, always park and latch the arm in the
arm rest whenever the unit is unattended.
Keep the tool clean and dry to provide the best possible grip.
Ú
Ú
Maintain a firm grasp of the DAS II 850 during the tube rolling process.
Safety working with and around fastening tools:
Use only condenser expanders available from Apex Tool Group.
Ú
Ú
Inspect condenser expander for visible damage and cracks. Replace damaged items immediately.
Ú
Disconnect the air supply before installing or replacing the condenser expander.
Make sure the condenser expander is fully assembled into the chuck and locked in postion.
Ú
Ú To avoid unintended motor startup, make sure the toggle switch is in the OFF position
---------------------------------------------------------------------------------------------------------------------------------------
1.3
Operator training
All personnel must be properly trained before operating the DAS II 850 rolling motors. The DAS II 850
rolling motors are to be repaired by fully trained personnel only.
1.4
Personal protective equipment
When working
•
Wear eye protection to protect against flying metal splinters.
•
Wear hearing protection
Danger of injury by being caught by moving equipment.
•
Wear a hairnet
•
Wear close fitting clothing
•
Do not wear jewelry
Page 7
PL19-6010EN
11/21/2012
1.5
Airetool®
Safety
Designated use
The DAS II 850 rolling motors is designed exclusively for tube rolling processes and is used in conjunction
with the DAS II Dominator tube rolling system.
The DAS II 850 series rolling motors have a push-to-start motor activation system.
1.6
•
Do not modify the DAS II 850, any guard or accessory.
•
Use only with accessory parts which are approved by the manufacturer.
•
Do not use as the DAS II 850 as a pry-bar or any other improper usage.
Codes and standards
It is mandatory that all national, state and local codes and standards be followed.
1.7
Noise and vibration
Noise level ≤ 95 dB(A) free speed (without load) according to ISO 12100: 2011
Vibration values < 2.5 m/s2 according to ISO 12100: 2011
Page 8
Airetool®
PL19-6010EN
Scope of Supply, Transport and Storage
2
Scope of supply, transport and storage
2.1
Items supplied
11/21/2012
Check shipment for transit damage and ensure that all items have been supplied:
1 DAS II 850
1 PL19-6010EN instruction manual
1 Declaration of Conformity
1 Lubrication sheet
1 Warranty statement
2.2
Transport
Transport and store the DAS II 850 in the original packaging. The packaging is recyclable.
2.3
Storage
For storage during when not in operation and protection against damage:
Ú
Park and latch the DAS II Dominator arm in arm rest and flip the toggle valve on the DAS II 850
to the center (off) position to prevent accidental start-up.
For extended storage:
Ú
Disconnect the air supply from the DAS II Dominator unit
Object
Time Period
Airetrol without air supply No guideline
Storage Temperature
-13°F to 104°F (-25°C to 40°C)
Page 9
PL19-6010EN
Airetool®
11/21/2012
3
Product Description
Product description
The DAS II 850 series rolling motors do not use a “clutch mechanism”. They have a torque sensing
cam that works with balls on an inclined plane. As the torque set point is reached, the cams separate
causing the trip to release a valve that shuts off the motor.
3.1
3.2
General description
•
Torque control rolling motor with on-board pneumatic control logic
•
Dial-a-torque adjustment collar for easy set up
•
Push-to-start configuration runs only when activated, reducing noise and conserving shop air
•
Cycle Counter tool option (C suffix)
•
Expander Lubricator tool option (L suffix)
Operation and functional elements
This section describes the operational and functional elements of the DAS II 850.
6
6
5
4
8
7
3
1
2
Ref.
1
2
3
4
5
6
7
8
Description
Air Inlet
Exhaust Hose
DAS II 850 series rolling motor
Torque Adjusting Nut
Tube Expander
Rear and Front Handle Assemblies
Toggle Switch (Forward, Off, Reverse)
DAS II Dominator Articulating Arm
Page 10
Airetool®
Accessories
4
PL19-6010EN
11/21/2012
Accessories
Integral Cycle Counter
Model Suffix “C”
Lubricator Valve
Model Suffix “L”
Expanders
Application Specific (refer to product catalog)
Page 11
PL19-6010EN
Airetool®
11/21/2012
Before Initial Operation
5
Before initial operation
5.1
Ambient conditions
5.2
Ambient temperature:
41°F (5°C) to a maximum of 104°F (40°C)
Acceptable relative humidity:
25% to 90%, non-condensing
Air supply
Parameter
Air Hose
Working pressure range
Compressed air
Description
Minimum inside diameter: 3/4" (19.1 mm)
58 to 125 psi (400 to 860 kPa)
Recommended: 90 psi (620 kPa)
Air quality according to ISO 8573-1, quality class 2.4.3
The compressed air must be clean and dry.
Ú
The inside diameter of the air hose must be free of residue, clean if necessary.
Ú
Excess air pressure stresses the tool components and expanders.
Ú Lower air pressure reduces the tools torque capacity and free speed.
Ú Air line pressure MUST be measured with the tool running at free speed.
Ú
Adjust the lubricator to a minimum setting to reduce the amount of excess oil in the exhaust air.
Oil identification
5.3
•
High quality SAE 10W oil
•
Adjust the lubrication rate at 5 drops per minute
•
Insufficient lubrication will decrease DAS II 850 performance and life
•
Over lubrication can clog the control logic valves which may result in erratic operation
Connecting the air supply to the tool
--------------------------------------------------------------------------------------------------------------------------------------The air hose can disconnect from the tool by itself and whip around uncontrollably.
Ú
Turn off the compressed air before connecting to the tool.
Ú
All hose connections to the DAS II 850 must be made before connecting the main air supply
hoses to the DAS II Dominator unit
Ú
Turn on the compressed air.
---------------------------------------------------------------------------------------------------------------------------------------
5.3.1
Quick-Disconnect Couplers
Quick-disconnect couplers used on the DAS II 850 have integral shut-off valves. Slide the knurled
sleeve up to turn the air flow on and down to turn the air flow off.
Page 12
Airetool®
Before Initial Operation
5.4
PL19-6010EN
11/21/2012
Tool set up
The tool must be configured for the application.
5.4.1
Setting the torque
--------------------------------------------------------------------------------------------------------------------------------------Danger of injury from accidental start up.
Turn off the compressed air before adjusting the clutch.
--------------------------------------------------------------------------------------------------------------------------------------The torque adjusting nut at the front of the DAS II 850 is divided into thirty (30) increments. These
increments (three revolutions, ten increments per revolution) are used for reference only and
represent an up or down adjustment and not any particular torque value.
Page 13
PL19-6010EN
Airetool®
11/21/2012
5.4.2
Before Initial Operation
Loading an Expander
1. Using a 1/8” hex wrench, reach through the access hole (Figure 5.4.2.A) in the side of the Airtrol
and loosen the set screw in the stop collar. Leave the hex wrench engaged with the set screw.
Figure 5.4.2.A
Access Hole
Spring
Tension
Collar
2. While holding the stop collar in place with the hex wrench, move the expander bracket far enough
away from the chuck to allow installation of the expander. Retighten the set screw.
3. Select the correct adapter for the expander being used. Install the adapter into the expander
bracket with the flange toward the outside and the through hole aligned with the wing screw. The
tapped holes in the adapters are not used on this version of the DAS. The adapater size is the
thrust bearing size +1.
4. Connect the mandrel square to the Airetrol chuck and slide the thrust collar into the adapter until
Adapter
1-3/16
1-1/2
1-5/8
1-3/4
1-7/8
2
2-1/8
Order Number
8567120
8567121
8567122
8567123
8567124
8567125
8567126
Expander Size
797-810
811-834, 841-842
835-840, 843-848, 853-854
849-852, 855-858, 865-866
859-864, 867-878, 887-888
879-886, 889-890
887-888, 891-900
it stops against the lip in the back. Hand tighten the wing screw against the collar to hold it in
position.
5. Reference steps 1 and 2; adjust the collar position so there is approximately 1/16” gap between
the mandrel washer and the end of the cage with the expander holder positioned fully forward.
Retighten the set screw in the collar. Note: If the washer is tight against the cage, the retainer nut
can unthread causing excessive wear on the expander thrust nuts.
6. Adjust the spring tension collar to provide enough force to return the collar but do not allow the
spring to go solid when the mandrel is fully bottomed out in the cage.
Page 14
Airetool®
PL19-6010EN
First Operation
6
First operation
6.1
Putting into use
11/21/2012
NOTE: Torque MUST be set prior to rolling tubes.
Ú
Make sure the expander guard is securely in position
Ú
Turn on the air supply
Ú
Lubricator models: open the auxiliary valve for the expander lubricator
Ú
With the expander bracket fully extended, move the toggle switch to the “ON” position.
6.2
DAS II 850 tube rolling
•
Insert the expander into the tube and push forward on the DAS II 850 to engage the mandrel,
activating the control logic to start the motor.
•
Once the mandrel engages the rolls, it will be drawn into the cage and does not need to be
pushed by the operator.
•
When the preset torque is reached, the DAS II 850 reverses and begins to back out of the tube.
•
When the mandrel is fully retracted, the stop collar trips the limit switch, stopping the motor and
resetting the control logic for the next cycle.
•
The cycle counter (if equipped) will increase one count during the reverse portion of each
complete cycle.
6.3
DAS II 850 operating notes
•
To stop the tube rolling process in mid-cycle, move the toggle switch to the “OFF” position.
•
If the DAS II 850 is re-started with the mandrel not fully retracted, it will restart in reverse. The
cycle counter (if equipped) WILL increment.
•
If the toggle switch is held in “REVERSE”, the DAS II 850 will run in reverse until the limit switch
is tripped. The cycle counter (if equipped) WILL NOT increment.
•
If the operator wants to go directly from forward to reverse, it is recommended to use the down
(REVERSE) position.
6.4
DAS II 850 trip adjustment
The trip should be set at a maximum engagement of. 0.062” with the abutting valve plunger. The
850 trip gage (provided with the tool) can be used to make adjustments as shown below. Be sure to
tighten the locknut after making adjustments.
Page 15
PL19-6010EN
Airetool®
11/21/2012
7
Troubleshooting
Troubleshooting
Malfunction
Motor does not
start
Motor runs slow
Motor rolls okay,
but then shuts off
or will not reverse
Possible causes
No or low air pressure
Ú
QC couper integral shut-off valve
Ú
Toggle switch in off position
Ú
Push-to-start stop collar not set
correctly
Ú
Air logic valving problem
Ú
Broken gears binding motor
Ú
FWD/REV valve is not fully open
Ú
Exhaust muffler assembly saturated
with oil (on DAS2 Dominator)
Ú
Logis circuit saturated with oil
Ú
For model "T": QE valve failure
Ú
Valve actuator centering spring broken Ú
Logis circuit saturated with oil
Ú
Motor runs only in
Valve actuator centering spring broken Ú
reverse
Valve plunger o-rings
Ú
Motor does not
Torque adjustment nut set to high
shut off with switch
in ON position
Push-to-start stop collar not set
correctly
Trip adjustment set incorrectly
Page 16
Ú
Ú
Ú
Remedy
Check pressure gauge on DAS2 tower. Static
pressure should not exceed 125 psi.
Make sure the QC shut-off valve is engaged
at the motor inlet.
Make sure the toggle switch on the motor is
in the ON position.
Refer to section 5.4.2 for stop collar set up
procedure.
Verify that the valve actuator is shifting freely
(some disassembly required).
Tool disassembly required (parts
replacement)
Verify that the valve actuator is shifting freely
(some disassembly required).
Inspect, clean or replace the muffler element.
(refer to DAS2 Dominator service literature)
Check the oil drip rate. Purge oil from the
logic circuit (drain volume chamber).
Verify operation of the QE valve in the timer
box.
Verify valve actuator shifting freely (some
disassembly required).
Check the oil drip rate. Purge oil from the
logic circuit (drain volume chamber).
Verify valve actuator shifting freely (some
disassembly required).
Inspect o-rings (disassembly of motor
required)
Reduce the torque setting on torque
adjustment nut. Refer to section 5.4.1
Refer to section 5.4.2 for stop collar set up
procedure.
Refer to section 9.1 for adjustment procedure
PL19-6010EN
Airetool®
11/21/2012
Maintenance
8
Maintenance
--------------------------------------------------------------------------------------------------------------------------------------Danger of injury from accidental start up.
Turn off the compressed air before performing any maintenance.
---------------------------------------------------------------------------------------------------------------------------------------
8.1
Service schedule
Only qualified and trained personnel are permitted to perform maintenance on these tools.
Regular maintenance reduces operating faults, repair costs and downtime. In addition to the following
service schedule, implement a safety related maintenance program that takes the local regulations for
repair and maintenance for all operating phases of the tool into account.
Maintenance
Hours of Use
Interval
Daily
As required
8.2
Daily
Designation
Ú Visual inspection of air supply hose and connections
Ú Inspect motor housing, expander bracket assembly and handles for loose
fasteners and retighten as necessary
Ú Verify guards are intact and mounted as designed
Ú Check the motor for excessive vibration or unusual noises
10-12
Ú Grease gearing (refer to Section 8.2)
continuous use
Preventative
Maintenance 1
~ 3000
Preventative
Maintenance 2
~ 6000
Preventative
Maintenance 3
~ 9000
Ú
Ú
Ú
Ú
Ú
Ú
Ú
Ú
Ú
Disassemble tool, inspect motor, gearing and clutch components for wear
Use PM service kit to replace all low cost items.
Replace worn or damaged parts as needed
Disassemble tool, inspect motor, gearing and clutch components for wear
Use PM service kit to replace all low cost items.
Replace worn or damaged parts as needed
Disassemble tool, inspect motor, gearing and clutch components for wear
Use PM service kit to replace all low cost items.
Replace worn or damaged parts as needed
Lubrication
For proper function and long service life, use of the correct grease is essential.
Grease lubrication recommended for this tool.
•
Grease Type: Chemtool type Chemplus-EP-2-BG
•
Quantity: Two (2) shots of grease from a hand operated grease gun
•
Frequency: Every 10-12 hours of continuous use. Adjust as required for lighter use.
NOTE: Do not over-grease the rolling motor. To much grease will force lubricant into the motor
assembly causing a decrease in performance and increased maintenance costs.
Page 17
PL19-6010EN
11/21/2012
Airetool®
Repair Instructions
9
Repair instructions
9.1
DAS II 850 trip adjustment
The trip should be set at a maximum engagement of. 0.062” with the abutting valve plunger. The
850 trip gage (provided with the tool) can be used to make adjustments as shown below. Be sure to
tighten the locknut after making adjustments
Page 18
PL19-6010EN
Airetool®
11/21/2012
Repair Instructions
9.2
Control circuit diagram with cycle counter and expander lubricator options
MOTOR REV/FWD
REV FWD
1A1
1V5
(Optional)
Cycle
Counter
A
B
1V3
1V4
1V2
“FWD ON”
Signal
Port
1.0
IN3
VOL
A
1V7
B
(Optional)
1S1
I
O
1V1
I
From
Lubricator
O
Filtered
Air
Page 19
To Expander
Lube Port
PL19-6010EN
Airetool®
11/21/2012
10.1
Space Parts
DAS II 850 600 Series Motor
Models
DAS II 850 600 (8405569)
DAS II 850 600CL (8405578)
2
4
5
6
1
3
7
9
10
13
11
8
16
23
24
25
14
32
33
26
31
35
27
32
28
15
33
22
36
12
17
29
18 19
21
42
39
41
30
31
20
37
38
40
Page 20
Airetool®
Spare Parts
10.1
DAS II 850 600 Series Motor
Ref
Number
#
-1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
8405397
3214477
8567185
3094500
3167600
3214471
8567183
3106200
3138510
8010499
8567184
3154600
3214480
3226200
8567597
8009300
3165900
3214465
3154400
3415282
3214456
8010215
3114600
3230600
3230100
3230200
3230400
3215300
3126500
3231800
3217100
3164100
3127700
3165200
3217000
3164200
3219500
3216500
3202000
3219900
3216300
3215900
8010193
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
4
1
1
1
1
1
2
10
5
1
3
1
1
1
1
1
1
2
EN
Description
Valve Assembly (850-28-AA) (includes Ref. 1-12)
Cap (850-26)
Shaft Seal (850-70)
3 O-Ring (RTV-65)
3 O-Ring (500-31)
3 Spring (850-22)
Valve (850-21-A)
3 O-Ring (200-16)
3 O-Ring (2-011)
6 O-Ring (2-020)
Directional Valve (850-28-A)
3 Lock Ring (402-S-24)
Bushing (850-27)
Plug (1000-42)
Motor Case (DAS2 850-1)
2 Zerk Fitting (1/4-28)
2 Retaining Ring (500-24)
Lock Nut (850-19)
2 Retaining Ring (402-23)
Trip Gauge (850-15)
Cover (850-1-C)
4 Button Head Cap Screw (6-32 x 3/8)
2 Bearing (300-G-29)
Rear End Plate (1000-74)
Cylinder (1000-71-S)
12 Rotor Blade (1000-72-S)
Rotor (1000-73-700-S)
Front End Plate (900-7-45)
2 Bearing (400-13)
2 Bearing (1000-88)
Gear Spider (900-25-45-1)
4 Planetary Gear (500-12-30)
20 Planetary Gear Bearing (400-16)
10 Planetary Gear Pin (500-18)
Gear Spider (900-25-45)
6 Planetary Gear (500-12-40)
3 Key (900-53)
Gear Housing (900-20-45)
2 Bearing (700-9)
Bearing Support (900-58-45)
2 Pin (900-19)
2 Retaining Ring (900-15)
4 Lock Washer (#6)
X
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
Page 21
PL19-6010EN
11/21/2012
PL19-6010EN
Airetool®
11/21/2012
10.2
Spare Parts
DAS II 850 600 Series Output
Models
DAS II 850 600 (8405569)
DAS II 850 600CL (8405578)
4
5
9
11
1
12
2
3
13
6
7
8
14
10
16
15
17
21
19
22
29
20
30
31
32
23
35
34
24
25
33
26
27
28
Page 22
18
PL19-6010EN
Airetool®
11/21/2012
Spare Parts
10.2
DAS II 850 600 Series Output
Ref
Number
#
X
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
8566706
3216800
3219600
842161
3219400
3227600
3219100
3218700
8000700
3215900
3219000
3218900
3214800
3214498
3215700
3229300
3215800
3215500
3215400
3214600
8008500
8010057
3226000
3216100
3214462
3223500
8010079
8010058
3164400
3215100
3215000
Table 10.2
Table 10.2
3218400
8010134
8566244
8010318
8010144
8010145
8010147
8010149
1
1
1
6
1
1
1
1
1
1
15
3
1
1
1
1
1
1
3
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
3
2
38
EN
Description
O-Ring (2-033)
Retaining Ring (900-24)
Cam (900-54)
18 Steel Ball (3/16)
Ball Retainer (900-52)
Retainer (1000-52)
Operating Cam (900-49)
Lock Ring (900-45)
2 Socket Head Set Screw (8-32 x 1/8)
2 Retaining Ring (900-15)
30 Steel Ball (900-48)
9 Guide Spring (900-47)
Spindle (900-4)
2 Spring (850-44)
Spring Guide (900-13)
2 Bearing (1000-64)
2 Needle Bearing (900-14)
Pressure Pad (900-11)
Pressure Pin (900-10)
Cam Case (900-2-A)
8 Lock Washer (#10)
8 Button Head Cap Screw (10-32 x 5/8)
2 Pin (1000-37)
Follower (900-17)
Trip (850-18)
3 Spring (1000-16)
2 Hex Nut (6-32)
2 Socket Head Set Screw (6-32 x 1/2)
2 Bearing (500-13)
2 Retaining Ring (900-6)
2 Retaining Ring (900-5)
Quick Change Chuck Assembly
2 Split Pin
Adjusting Nut (900-43)
2 Nylon Tip Set Screw (8-32 x 3/16)
Name Plate (not shown)
Drive Screw (not shown)
1/16" Hex Wrench (not shown)
5/64" Hex Wrench (not shown)
1/8" Hex Wrench (not shown)
5/32" Hex Wrench (not shown)
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
Table 10.2
Quick Change Chuck Assembly *
850-375
850-500
#
#
(3/8" Capacity)
(1/2" Capacity)
32 Quick Change Chuck Assembly
1
8400100
1
8400200
** Chuck Body
1
3214502
1
3214501
** Ball
1
3235400
1
3227500
** Chuck Sleeve
1
8501225
1
8566702
** Spring
1
8501250
1
8501900
** Lock Ring
1
8503500
1
8503600
**33 Split Pin
1
8010158
1
8010127
* Note: Both Quick Change Chuck sizes are provided. 3/8" chuck installed as standard.
** Note: Component parts included in the Quick Change Chuck assembly (32).
Ref.
Description
Page 23
PL19-6010EN
Airetool®
11/21/2012
10.3
Spare Parts
DAS II 850 1250 Series Motor
Models
DAS II 850 1250 (8405562)
DAS II 850 1250CL (8405567)
2
4
5
6
1
3
7
9
10
13
11
8
16
23
24
25
26
14
27
31
30
31
32
15
22
33
12
17
18
36
22
19
28
21
38
20
29
34
35
37
Page 24
Airetool®
Spare Parts
10.3
DAS II 850 1250 Series Motor
Ref
Number
#
-1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
8405397
3214477
8567185
3094500
3167600
3214471
8567183
3106200
3138510
8010499
8567184
3154600
3214480
3226200
8567597
8009300
3165900
3214465
3154400
3415282
3214456
8010215
3114600
3230600
3230100
3230200
3230500
3215200
3214700
3216900
3215600
3127700
3216200
3219500
3216400
619499
3219800
3216300
8010193
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
4
1
1
1
1
2
4
2
1
1
1
1
1
2
EN
Description
Valve Assembly (850-28-AA) (includes Ref. 1-12)
Cap (850-26)
Shaft Seal (850-70)
3 O-Ring (RTV-65)
3 O-Ring (500-31)
3 Spring (850-22)
Valve (850-21-A)
3 O-Ring (200-16)
3 O-Ring (2-011)
6 O-Ring (2-020)
Directional Valve (850-28-A)
3 Lock Ring (402-S-24)
Bushing (850-27)
Plug (1000-42)
Motor Case (DAS2 850-1)
2 Zerk Fitting (1/4-28)
2 Retaining Ring (500-24)
Lock Nut (850-19)
2 Retaining Ring (402-23)
Trip Gauge (850-15)
Cover (850-1-C)
4 Button Head Cap Screw (6-32 x 3/8)
4 Bearing (300-G-29)
Rear End Plate (1000-74)
Cylinder (1000-71-S)
12 Rotor Blade (1000-72-S)
Rotor (1000-73-S)
Front End Plate (900-7)
2 Bearing (900-3)
Gear Spider (900-25)
4 Planetary Gear (900-12)
8 Planetary Gear Bearing (400-16)
4 Planetary Gear Pin (900-18)
3 Key (900-53)
Gear Housing (900-20)
2 Ball Bearing
Bearing Support (900-58)
2 Pin (900-19)
4 Lock Washer (#6)
X
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
Page 25
PL19-6010EN
11/21/2012
PL19-6010EN
Airetool®
11/21/2012
10.4
Spare Parts
DAS II 850 1250 Series Output
Models
DAS II 850 1250 (8405562)
DAS II 850 1250CL (8405567)
4
5
9
11
1
12
2
3
13
6
7
8
14
10
16
15
17
21
19
22
29
20
30
31
32
23
35
34
24
25
33
26
27
28
Page 26
18
PL19-6010EN
Airetool®
11/21/2012
Spare Parts
10.4
DAS II 850 1250 Series Output
Ref
Number
#
X
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
**
**
**
**
**
33
34
35
36
37
8566706
3216800
3219600
842161
3219400
3227600
3219100
3218700
8000700
3215900
3219000
3218900
3214800
3218500
3215700
3229300
3215800
3215500
3215400
3214600
8008500
8010057
3226000
3216100
3214462
3223500
8010079
8010058
3164400
3215100
3215000
8400100
3214502
3235400
8501225
8501250
8503500
8010158
3218400
8010134
8566244
8010318
8010144
8010145
8010147
8010149
1
1
1
6
1
1
1
1
1
1
15
3
1
1
1
1
1
1
3
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
3
2
38
EN
Description
O-Ring (2-033)
Retaining Ring (900-24)
Cam (900-54)
18 Steel Ball (3/16)
Ball Retainer (900-52)
Retainer (1000-52)
Operating Cam (900-49)
Lock Ring (900-45)
2 Socket Head Set Screw (8-32 x 1/8)
2 Retaining Ring (900-15)
30 Steel Ball (900-48)
9 Guide Spring (900-47)
Spindle (900-4)
2 Spring (900-44)
Spring Guide (900-13)
2 Bearing (1000-64)
2 Needle Bearing (900-14)
Pressure Pad (900-11)
Pressure Pin (900-10)
Cam Case (900-2-A)
8 Lock Washer (#10)
8 Button Head Cap Screw (10-32 x 5/8)
2 Pin (1000-37)
Follower (900-17)
Trip (850-18)
3 Spring (1000-16)
2 Hex Nut (6-32)
2 Socket Head Set Screw (6-32 x 1/2)
2 Bearing (500-13)
2 Retaining Ring (900-6)
2 Retaining Ring (900-5)
Quick Change Chuck (850-375) (includes the following ** component parts)
Chuck Body (850-375-1)
Chrome Ball (3/32 CLS 25)
Chuck Sleeve (866-375-2)
Spring (866-375-3)
Lock Ring (5108-81)
2 Split Pin (1/8 x 7/8)
Adjusting Nut (900-43)
2 Nylon Tip Set Screw (8-32 x 3/16)
Name Plate (not shown)
Drive Screw (not shown)
1/16" Hex Wrench (not shown)
5/64" Hex Wrench (not shown)
1/8" Hex Wrench (not shown)
5/32" Hex Wrench (not shown)
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
Page 27
PL19-6010EN
Airetool®
11/21/2012
Spare Parts
10.5.1
DAS II 850 Series Motor Positioner
6
6
7
23
27
26
25
24
28 30
7
29
8
8
32
31
33
36
17
16 34
18
7
30
34 35
38
18
39
37
6
35
8
40 18
1
28
6
8
22
2
2
13
21
20
19
18
17
16
9
8
15
3
10
4
11
6
6
5
7
8
14
Page 28
12
PL19-6010EN
Airetool®
11/21/2012
Spare Parts
10.5.1
DAS II 850 Motor Positioner
EN
Description
Ref
Number
#
X
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
8567632
8010599
8567559
8567560
8567620
8010045
2901965
8567273
8567563
8010117
8567562
8567589
8567561
8010082
8010950
8010346
8567596
2992936
2901985
8567270
8010859
8566935
8567642
8011050
8010038
8011057
8011060
8010951PT
8010459
8566933
2992933
8567585
8008300
2992139
2992940
8567564
8567436
8007300PT
8007400
8566934
1
2
1
1
1
22
2
14
1
1
1
1
1
1
1
8
8
7
1
1
2
1
1
1
1
1
1
2
2
2
1
1
3
4
2
1
1
1
1
3
Rear Handle Assembly (DAS2 93/94)
Button Head Cap Screw (1/4-20 x 1/2)
Upper Back (DAS2 52)
Lower Back (DAS2 53)
Toggle Valve (DAS2 67)
22 Button Head Cap Screw (10-32 x 3/8)
4 Tube Elbow (10-32 x 1/16) (CL Series Motors = Quantity of 4)
14 Hose Barb (TC-720-21)
Exhaust Clamp (DAS2 56)
Socket Head Cap Screw (5/16-18 x 1-1/2)
Exhaust Post (DAS2 55)
Exhaust Adapter (DAS2 62)
Mounting Post (DAS2 54)
Jam Nut (3/4-16)
Jam Nut (7/8-14)
8 Socket Head Set Screw (10-32 x 1/2)
8 Spacer (10-32 x 1/4 x 7/8)
Straight Fitting Connector (1/8Q S x 10-32)
Valve (LFR 38)
Bracket Clip (TC-720-19)
4 Socket Head Cap Screw (10-32 x 1/4)
Roller Arm Clip (11925)
Air Tank (DAS2 102) (CL Series Motors)
Loop Clamp (5/8) (CL Series Motors)
Socket Head Cap Screw (10-32 x 1/2) (CL Series Motors)
Bracket (CLSeries Motors)
Socket Head Cap Screw (10-32 x 1-3/4) (CL Series Motors)
4 Nylon Spacer (10 x 1/2 x 1/8) (CL Series Motors = Quantity of 4)
4 Thin Elastic Nut (10-32)
Valve (MAV-4)
Tee (10-32 T)
Actuating Cylinder (DAS2 61)
6 Socket Head Cap Screw (10-32 x 3/8)
8 Fiber Gasket (Clip 117613)
Shuttle Valve (Clip MSV-1)
Cylinder Mounting Bracket (DAS2 57)
Valve Cup (850-F-1)
Socket Head Cap Screw (10-32 x 7/8)
Hex Nut (10-32)
Pilot (Clip MPA-3)
4
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
Page 29
PL19-6010EN
Airetool®
11/21/2012
10.5.2
Spare Parts
DAS II 850 Series Motor Positioner
57 57
58 59
60
67
61
62
61
60
64
65
66
63
57
56
45
46
47
41
42
49
43
48
43
49
44
55
43
50
44
54
51
52
53
Page 30
53
53
PL19-6010EN
Airetool®
11/21/2012
Spare Parts
10.5.2
DAS II 850 Motor Positioner
Ref
Number
#
41
42
43
44
45
46
47
48
49
50
2993026
2996872
8010980
8010282
8010763
8567591
8567590
8010966
8567129
8567567
8567120
8567121
8567122
8567123
8567615
8010105
8567586
8567616
8567612
8567135
8010967
8010984
8567128
8567127
8567565
8010103
8567566
8010295
8567136
8567558
2983276
2993024
2998991
8010147
1
2
4
2
2
1
1
1
2
1
1
1
1
1
1
4
1
3 ft.
1
3
1
1
4
4
2
2
1
1
1
1
4
6 ft.
1 ft.
1
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
EN
Description
X
4
2
2
2
4
8
Manifold Elbow (10-32 LM)
Swivel Fitting (Clip 15040)
Guard Clip (DAS2 65)
Button Head Cap Screw (10-32 x 3/16)
Hex Nut (10-32 x 5/16)
Back Guard (DAS2 64)
Front Guard (DAS2 63)
Pan Head Nylon Screw (10-32 x 1/8)
Rod (A-100-79-23)
Expander Adapter Bracket (DAS2 60) (CL Series Motors = Quantity of 0)
1-3/16 Expander Adapter (A-100-A 1-3/16)
1-1/2 Expander Adapter (A-100-A 1-1/2)
1-5/8 Expander Adapter (A-100-A 1-5/8)
1-3/4 Expander Adapter (A-100-A 1-3/4)
Front Loop Bracket (DAS2 46)
Socket Head Cap Screw (10-32 x 3/4)
Wing Screw (1/4-20 x 1-1/2)
Jacket (DAS2 92 J)
Front Handle (DAS2 92)
Collar (A-100-84)
Cushion Washer (17/32 x 1 x 3/32)
Crimp Clamp (7/8)
Seal (A-100-78)
1/2 Ball Bushing (A-100-77)
Bushing Tube (DAS2 58)
Socket Head Cap Screw (1/4-20 x 1-1/4)
Bushing Tube Block (DAS2 59)
Washer (1-1/16 x 17/32 x 3/32)
Spring (A-100-85)
Cover (DAS2 51) (CL Series Motors = Quantity of 0)
Wire Tie (ATS-8851) (not shown)
Tube (1/8)
Clear Tube (1/4) (not shown) (CL Series Motors = Quantity of 0)
Hex Key (1/8)
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
Page 31
PL19-6010EN
Airetool®
11/21/2012
10.6
Spare Parts
DAS II 850 Series Cycle Counter - Lubrcator
Models
DAS II 850 600CL (8405578)
DAS II 850 1250CL (8405567)
3
4
5
6
1
2
9
8
2
13
4
7
14
16
15
17
5
11
12
10
19
8
20
18
19
To Expander
Collar
To Expander
Collar
20
From
Lubricator
Page 32
In Expander
Adapters
PL19-6010EN
Airetool®
11/21/2012
Spare Parts
10.6
850 CL Series Cycle Counter - Lubricator
Ref
Number
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2902153
8010222
8567626
2992936
2993024
2902154
8567627
8006600
8567130
8565030
8010521
2992933
8567273
2992932
8566934
8566936
8010045
8566982
8567165
2901941
1
2
1
2
2 ft.
1
1
4
1
3
3
1
1
1
1
1
2
1
2
5 ft.
EN
Description
X
4
2
4
Cycle Counter (2-66)
Flat Head Cap Screw (4-40 x 1/4)
Cover (DAS2 51 CL)
Straight Fitting (1/8Q x 10-32)
Tubing (1/8) (Clip 3814-7 RD)
Barb Tee (1/16)
Expander Bracket (DAS2 60 OS)
Socket Head Set Screw (1/4-20 x 1/4)
Plunger (A-100-80)
Tubing Barbs (1100-48)
Teflon O-Ring (17-008)
Tee (10-32 T)
Hose Barb (TC-720-21)
Elbow (10-32 EL)
Pilot (Clip MPA-3)
Bracket (Clip 11918-1)
Button Head Cap Screw (10-32 x 3/8)
Valve (Clip MJV-2)
Male Tube Fitting (1/4Q x 1/8P ST)
Tubing (1/4 O.D.)
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
Page 33
PL19-6010EN
Airetool®
11/21/2012
10.7
Spare Parts
(Reference) DAS II Dominator - Lubrcator
Models
DAS II 850 600CL (8405578)
DAS II 850 1250CL (8405567)
3
4
2
5
2
8
6
7
1
12
11
10
14
6
15
9
10
To
Motor
18
12
11
14
14
14
11
16
15
10
11
17
13
10
Page 34
15
13
5
PL19-6010EN
Airetool®
11/21/2012
Spare Parts
10.7
(Reference) DAS II Dominator - Lubricator
Ref
Number
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
2902157
8011001
2992526
2902014
1715888
1716036
1712000
2990276
2902152
8010105
8010045
8010907
2902151
8010459
8010956
850178
2902015
2901941
1
2
1
1
2
2
1 ft.
1
2
4
4
2
2
8
4
1
1
10 ft.
EN
Description
X
Muffler Box (DAS2 35 Lub)
Muffler Clip and Screw (DAS2 47)
Quick Change Nipple (H3F)
Hex Reducer Bushing (1/2 x 1/4 G)
Barbed Insert (1/4 male)
Ferrule (KF-500-81)
Air Hose (1/4 1-1/4)
Street Elbow (1/4 90)
Hex Reducer Bushing (3/4 x 1/4 G)
Socket Head Cap Screw (10-32 x 3/4)
Button Head Cap Screw (10-32 x 3/8)
O-Ring (2-120)
Lubricator Bracket (DAS2 L1)
Locknut (10-32 Thin)
Nylon Spacer (10 x 1/2 x 3/8)
Lubricator
90 Degree Elbow (1/4Q x 1/4P)
Tubing (1/4 O.D.)
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
Page 35
PL19-6010EN
Airetool®
11/21/2012
Technical Data
11
Technical data
11.1
DAS II 850 Series Rolling Motor Specifications
Free
Speed CFM
RPM
DAS II 850 1250
8405562
1100
48
DAS II 850 1250 CL
8405567
1100
48
DAS II 850 600
8405569
500
48
DAS II 850 600 CL
8405578
500
48
No Suffix = Basic Airetrol, push-to-start (PTS)
C Suffix = PTS with Counter
L Suffix = PTS with Lubricator
Airetrol Dominator
Rolling Motor
Order
Number
Page 36
Minimum
Torque
ft. lbs.
Nm
1.8
2.4
1.8
2.4
2.6
3.5
2.6
3.5
Maximum
Torque
ft. lbs.
Nm
9.6
13.0
9.6
13.0
16.0
21.7
16.0
21.7
Quick Change
Chucks
Included Optional
3/8
1/2
3/8
1/2
3/8, 1/2
--3/8, 1/2
---
Airetool®
Service
12
Service
12.1
Replacement parts
PL19-6010EN
11/21/2012
Use only original Cleco replacement parts. Failure to comply can result in reduced power and increased
service requirements. The tool warranty may be voided if replacement parts are not manufactured or
approved by Apex Tool Group.
12.2
Tool repairs
Only qualified and trained personnel are to repair this equipment.
12.3
Warranty repairs
All warranty repairs are to be performed by an authorized Apex Tool Group service center. Contact your
local representative for assistance with warranty repair claims.
Page 37
PL19-6010EN
11/21/2012
13
Airetool®
Disposal
Disposal
--------------------------------------------------------------------------------------------------------------------------------------Injuries and environmental damage from improper disposal.
Components and auxillary materials of the tool pose risks to health and the environment.
Ú
Capture auxillary materials (oils, greases) when drained and dispose of them properly.
Ú
Separate the packaging components and dispose of them properly.
Ú
Comply with all applicable local regulations.
Observe local disposal guidelines for all components of this tool and its packaging.
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Page 38
PL19-6010EN
11/21/2012
Page 39
Sales & Service Centers
Note: All locations may not service all products. Please contact the nearest Sales & Service Center for
the appropriate facility to handle your service requirements.
Detroit, MI
Apex Tool Group
Sales & Service Center
2630 Superior Court
Auburn Hills, MI 48326
Tel: 248-393-5640
Fax: 248-391-6295
Houston, TX
Apex Tool Group
Sales & Service Center
6550 West Sam Houston
Parkway North, Suite 200
Houston, TX 77041
Tel: 713-849-2364
Fax: 713-849-2047
Lexington, SC
Apex Tool Group
670 Industrial Drive
Lexington, SC 29072
Tel: 800-845-5629
Tel: 803-951-7544
Fax: 803-358-7681
Los Angeles, CA
Apex Tool Group
Sales & Service Center
6881 Stanton Avenue
Unit B
Buena Park, CA 90621
Tel: 562-623-4457
Fax: 562-802-1718
Seattle, WA
York, PA
Canada
Apex Tool Group
Apex Tool Group
Apex Tool Group
Sales & Service Center
Sales & Service Center
Sales & Service Center
2865 152nd Avenue N.E.
3990 East Market Street
5925 McLaughlin Road
Redmond, WA 98052
York, PA 17402
Mississauga, Ont. L5R 1B8
Tel: 425-497-0476
Tel: 717-755-2933
Canada
Fax: 425-497-0496
Fax: 717-757-5063
Tel: 905-501-4785
Fax: 905-501-4786
England
France
China
Apex Tool Group
Apex Tool Group SAS
Cooper (China) Co., Ltd.
GmbH & Co. OHG
25 rue Maurice Chevalier
a company of
C/O Spline Gauges
B.P. 28
Apex Tool Group, LLC
Piccadilly, Tamworth
77831 Ozoir-La-Ferrière
955 Sheng Li Road,
Staffordshire B78 2ER
Cedex, France
Heqing Pudong, Shanghai
United Kingdom
Tel: +33 1 64 43 22 00
China 201201
Tel: +44 1827 8741 28
Fax: +33 1 64 43 17 17
Tel: +86-21-28994176
Fax: +44 1827 8741 28
Fax: +86-21-51118446
Germany
Apex Tool Group
GmbH & Co. OHG
Industriestraße 1
73463 Westhausen
Germany
Tel: +49 (0) 73 63 81 0
Fax: +49 (0) 73 63 81 222
Mexico
Cooper Tools
de México S.A. de C.V.
a company of
Apex Tool Group, LLC
Vialidad El Pueblito #103
Parque Industrial Querétaro
Querétaro, QRO 76220
Mexico
Tel: +52 (442) 211-3800
Fax: +52 (442) 103-0443
Brazil
Hungary
Cooper Tools Industrial Ltda. Apex Tool Group
a company of
Hungaria Kft
Apex Tool Group, LLC
Platànfa u.2
Av. Liberdade, 4055
9027 Györ
Zona Industrial - Iporanga
Hungary
18087-170 Sorocaba
Tel: +36 96 66 1383
SP Brazil
Fax: +36 96 66 1135
Tel: +55 15 2383929
Fax: +55 15 2383260
Apex Tool Group, LLC
1000 Lufkin Road
Apex, NC 27539
Phone: 919-387-0099
Fax:
919-387-2614
www.apextoolgroup.com
PL19-6010EN/Printed in USA 11/2012/Copyright © Apex Tool Group, LLC
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