Airetool DAS II 850 1250 CL Owner's manual

Airetool
Brand
Airetool
Model
DAS II 850 1250 CL
Type
Owner's manual

This manual is also suitable for

For additional product information visit our website at http://www.apextoolgroup.com
Instruction Manual
PL19-6010EN
11/21/2012
DAS II 850 Series
DAS II Dominator Rolling Motors
Airetool®
Page 2
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 efcient 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.•
Identication 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
Identication graphic:
¢ indicates a directional movement
ò 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 3
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Airetool®
Nomenclature
Model Number
Order
Number
Description
DAS II 850 1250 8405562 DAS II Dominator Rolling Motor - Push-to-start
DAS II 850 1250 CL 8405567 DAS II Dominator Rolling Motor - Push-to-start with cycle counter and lubricator
DAS II 850 600 8405569 DAS II Dominator Rolling Motor - Push-to-start
DAS II 850 600 CL 8405578 DAS II Dominator Rolling Motor - Push-to-start with cycle counter and lubricator
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Airetool®
Contents
1 Safety 6
1.1 Warning and notes ................................................................................................. 6
1.2 Basic requirements for safe working practices ......................................................7
1.3 Operator training ....................................................................................................7
1.4 Personal protective equipment ..............................................................................7
1.5 Designated use ......................................................................................................8
1.6 Codes and standards ............................................................................................ 8
1.7 Noise and vibration ................................................................................................ 8
2 Scope of supply, transport and storage 9
2.1 Items supplied .......................................................................................................9
2.2 Transport ............................................................................................................... 9
2.3 Storage ..................................................................................................................9
3 Product description 10
3.1 General description ............................................................................................. 10
3.2 Operation and functional elements ...................................................................... 10
4 Accessories 11
5 Before initial operation 12
5.1 Ambient conditions ..............................................................................................12
5.2 Air supply ............................................................................................................. 12
5.3 Connecting the air supply to the tool ................................................................... 12
5.3.1 Quick-Disconnect Couplers .................................................................................12
5.4 Tool set up ........................................................................................................... 13
5.4.1 Setting the torque ................................................................................................13
5.4.2 Loading an Expander .......................................................................................... 14
6 First operation 15
6.1 Puting into use .....................................................................................................15
6.2 DAS II 850 tube rolling .........................................................................................15
6.3 DAS II 850 operating notes ................................................................................. 15
6.4 DAS II 850 trip adjustment ................................................................................... 15
7 Troubleshooting 16
8 Maintenance 17
8.1 Service schedule .................................................................................................17
8.2 Lubrication ...........................................................................................................17
9 Repair instructions 18
9.1 DAS II 850 trip adjustment ................................................................................... 18
9.2 Control circuit diagram with cycle counter and expander lubricator .................... 19
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Airetool®
Contents
10 Spare parts
10.1 DAS II 850 600 Series Motor ............................................................................... 20
10.2 DAS II 850 600 Series Output .............................................................................22
10.3 DAS II 850 1250 Series Motor ............................................................................. 24
10.4 DAS II 850 1250 Series Output ...........................................................................26
10.5.1 DAS II 850 Series Motor Positioner ..................................................................... 28
10.5.2 DAS II 850 Series Motor Positioner ..................................................................... 30
10.6 DAS II 850 Series Cycle Counter - Lubricator .....................................................32
10.7 (Reference) DAS II Dominator - Lubricator ......................................................... 34
11 Technical data 36
11.1 DAS II 850 Series Rolling Motor Specications ................................................... 36
12 Service 37
12.1 Replacement parts .............................................................................................. 37
12.2 Tool repairs ..........................................................................................................37
12.3 Warranty repairs .................................................................................................. 37
13 Disposal 38
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Airetool®
Safety
1 Safety
1.1 Warnings and notes
Warning notes are identied 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.•
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WARNING identies a potentially hazardous situation which, if not avoided, may result in serious
injury.
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CAUTION identies a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or property and environmental damage.
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NOTE identies general information which may include application tips or useful information but no
hazardous situations.
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Important information that must be read and understood by all personnel installing, operating or
maintaining this equipment.
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Airetool®
Safety
1.2 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.
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Work Area:
ÚEnsure there is enough space in the work area.
ÚKeep the work area clean.
ÚKeep the work area well ventilated.
Personnel Safety:
ÚInspect the air supply hoses and ttings. Do not use damaged, frayed or deteriorated hoses.
ÚMake sure the air supply hose is securely attached to the tool.
ÚEnsure a secure standing position and maintain balance.
ÚMake sure the unit is positioned to provide unobstructed operator movement during the tube
rolling process and the Dominator arm has full movement.
ÚTo avoid unintended contact with the arm or rolling motor, always park and latch the arm in the
arm rest whenever the unit is unattended.
ÚKeep the tool clean and dry to provide the best possible grip.
ÚMaintain a rm grasp of the DAS II 850 during the tube rolling process.
Safety working with and around fastening tools:
ÚUse only condenser expanders available from Apex Tool Group.
ÚInspect condenser expander for visible damage and cracks. Replace damaged items immediately.
ÚDisconnect the air supply before installing or replacing the condenser expander.
ÚMake sure the condenser expander is fully assembled into the chuck and locked in postion.
Ú To avoid unintended motor startup, make sure the toggle switch is in the OFF position
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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 ying metal splinters.•
Wear hearing protection•
Danger of injury by being caught by moving equipment.
Wear a hairnet•
Wear close tting clothing•
Do not wear jewelry•
Page 8
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Airetool®
Safety
1.5 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.
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.•
1.6 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
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2 Scope of supply, transport and storage
2.1 Items supplied
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
Airetool®
Scope of Supply, Transport and Storage
Object Time Period Storage Temperature
Airetrol without air supply No guideline -13°F to 104°F (-25°C to 40°C)
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Airetool®
Product Description
3 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 General description
Torque control rolling motor with on-board pneumatic control logic•
Dial-a-torque adjustment collar for easy set up•
Push-to-start conguration runs only when activated, reducing noise and conserving shop air•
Cycle Counter tool option (C sufx)•
Expander Lubricator tool option (L sufx)•
3.2 Operation and functional elements
This section describes the operational and functional elements of the DAS II 850.
8
5
4
Ref. Description
1 Air Inlet
2 Exhaust Hose
3 DAS II 850 series rolling motor
4 Torque Adjusting Nut
5 Tube Expander
6 Rear and Front Handle Assemblies
7 Toggle Switch (Forward, Off, Reverse)
8 DAS II Dominator Articulating Arm
1
2
7
3
6
6
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Airetool®
Accessories
4 Accessories
Integral Cycle Counter
Model Sufx “C”
Lubricator Valve
Model Sufx “L”
Expanders
Application Specic (refer to product catalog)
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Airetool®
Before Initial Operation
5 Before initial operation
5.1 Ambient conditions
Ambient temperature: 41°F (5°C) to a maximum of 104°F (40°C)
Acceptable relative humidity: 25% to 90%, non-condensing
5.2 Air supply
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
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•
5.3 Connecting the air supply to the tool
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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.
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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 ow on and down to turn the air ow off.
Parameter Description
Air Hose Minimum inside diameter: 3/4" (19.1 mm)
Working pressure range 58 to 125 psi (400 to 860 kPa)
Recommended: 90 psi (620 kPa)
Compressed air
Air quality according to ISO 8573-1, quality class 2.4.3
The compressed air must be clean and dry.
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5.4 Tool set up
The tool must be congured for the application.
5.4.1 Setting the torque
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Danger of injury from accidental start up.
Turn off the compressed air before adjusting the clutch.
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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.
Airetool®
Before Initial Operation
Page 14
PL19-6010EN
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5.4.2 Loading an Expander
Using a 1/8” hex wrench, reach through the access hole (Figure 5.4.2.A) in the side of the Airtrol 1.
and loosen the set screw in the stop collar. Leave the hex wrench engaged with the set screw.
While holding the stop collar in place with the hex wrench, move the expander bracket far enough 2.
away from the chuck to allow installation of the expander. Retighten the set screw.
Select the correct adapter for the expander being used. Install the adapter into the expander 3.
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.
Connect the mandrel square to the Airetrol chuck and slide the thrust collar into the adapter until 4.
it stops against the lip in the back. Hand tighten the wing screw against the collar to hold it in
position.
Reference steps 1 and 2; adjust the collar position so there is approximately 1/16” gap between 5.
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.
Adjust the spring tension collar to provide enough force to return the collar but do not allow the 6.
spring to go solid when the mandrel is fully bottomed out in the cage.
Airetool®
Before Initial Operation
Adapter Order Number Expander Size
1-3/16 8567120 797-810
1-1/2 8567121 811-834, 841-842
1-5/8 8567122 835-840, 843-848, 853-854
1-3/4 8567123 849-852, 855-858, 865-866
1-7/8 8567124 859-864, 867-878, 887-888
2 8567125 879-886, 889-890
2-1/8 8567126 887-888, 891-900
Figure 5.4.2.A
Spring
Tension
Collar
Access Hole
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Airetool®
First Operation
6 First operation
6.1 Putting into use
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.
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Airetool®
Troubleshooting
7 Troubleshooting
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.
Push-to-start stop collar not set
correctly
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).
Exhaust muffler assembly saturated
with oil (on DAS2 Dominator)
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
Push-to-start stop collar not set
correctly
Refer to section 5.4.2 for stop collar set up
procedure.
Motor does not
start
Motor runs slow
Motor rolls okay,
but then shuts off
or will not reverse
Motor runs only in
reverse
Motor does not
shut off with switch
in ON position
Page 17
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Airetool®
Maintenance
8 Maintenance
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Danger of injury from accidental start up.
Turn off the compressed air before performing any maintenance.
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8.1 Service schedule
Only qualied 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.
8.2 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.
Maintenance
Interval
Hours of Use
Daily Daily
Visual inspection of air supply hose and connections
Inspect motor housing, expander bracket assembly and handles for loose
fasteners and retighten as necessary
Verify guards are intact and mounted as designed
Check the motor for excessive vibration or unusual noises
As required
10-12
continuous use
Grease gearing (refer to Section 8.2)
Preventative
Maintenance 1
~ 3000
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
Preventative
Maintenance 2
~ 6000
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
Preventative
Maintenance 3
~ 9000
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
Designation
Page 18
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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
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Airetool®
Repair Instructions
9.2 Control circuit diagram with cycle counter and expander lubricator options
MOTOR REV/FWD
REV FWD
1A1
1V5 (Optional)
Cycle
Counter
1V4
1V3
1V2
1V7
A B
A B
“FWD ON”
Signal
Port
To Expander
Lube Port
(Optional)
1V1
1S1
From
Lubricator
I O
I
O
Filtered
Air
VOL 1.0
IN3
Page 20
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Page 20
10.1 DAS II 850 600 Series Motor Models
DAS II 850 600 (8405569)
DAS II 850 600CL (8405578)
Airetool®
Space Parts
4
5
6
36
79
10
11
33
35
31
41
8
18
14
22
17
15
12
20
19
21
30
29
31
38
40
37
39
13
32
33 32
28
16
23
24
25
26
27
3
2
1
42
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Airetool DAS II 850 1250 CL Owner's manual

Airetool
Brand
Airetool
Model
DAS II 850 1250 CL
Type
Owner's manual
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