Aimco Brakes AcraDyne Gen 3 1000 Series Nutrunner Manual

							PO Box 16460, Portland OR 97292-0460  • 800-852-1368 • Fax 800-582\
-9015
www.aimco-global.com
AcraDyne  
1000 Series Nutrunners
 Operations Manual 
						

							Introduction
SAVE THESE INSTRUCTIONS
1) WORK AREA
 a) Keep work area clean and well lit. Cluttered and dark areas invite accid\
ents.
 b)  Do not operate power tools in explosive atmospheres, such as the presenc\
e of flammable liquids, gases or dust. Power tools create sparks which may ignite  
    the dust or fumes.
 c) Keep children and bystanders away while operating a power tool. Distract\
ions can cause you to lose control.
2) ELECTRICAL SAFETY
 a) Power tool plugs must match the outlet. Never modify the plug in any way\
. Do not use any adapter plugs with earthed (grounded) power tools.    
    Unmodified plugs and matching outlets will reduce risk of electric shock\
. 
 b) Avoid body contact with earthed or grounded surfaces such as pipes, radi\
ators, ranges and refrigerators. There is an increased risk of   electric shock if your  
    body is earthed or grounded.
 c) Do not expose power tools to rain or wet conditions. Water entering a po\
wer tool will increase the risk of electric shock.
 d) Do not abuse the cord. Never use the cord for carrying, pulling or unplu\
gging the power tool.  
    Keep cord away from heat, oil, sharp edges or moving parts. Damaged or e\
ntangled cords increase the risk of electric shock.
 e)  When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable of outdoor use reduces \
the risk of electric  
  shock
  f) It is not recommended to use AcraDyne controllers or tools outside or to\
 use an extension cord to connect the controller to a power source.
3) PERSONAL SAFETY
 a) Stay alert, watch what you are doing and use common sense when operating\
 a power tool. Do not use a power tool while you are tired or under the 
    influence of drugs, alcohol or medication. A moment of inattention while\
 operating power tools may result in serious personal injury.
 b)  Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for  
    appropriate conditions will reduce personal injuries.  If the maximum du\
ty cycle of the attached tool is exceeded or the tool temperature exceeds 50° C.,  
   then the operator should wear protective hand wear (gloves).
 c)  Avoid accidental starting. Ensure the switch is in the off-position before plugging in. Carrying power tools with your finger on the switch or plugging in  
    power tools that have the switch on invites accidents.
 d)  Remove any adjusting key or wrench before turning the power tool on. A w\
rench or a key left attached to a rotating part of the power tool may result in  
  personal injury.
  e) Do not overreach. Keep proper footing and balance at all times. This ena\
bles better control of the power tool in unexpected situations. 
 f) Dress properly. Do no wear loose clothing or jewelry. Keep your hair, cl\
othing and gloves away from moving parts. Loose clothes, jewelry or long hair  
    can be caught in moving parts.
 g)  If devices are provided for the connection of dust extraction and collec\
tion facilities, ensure these are connected and properly used. Use of these devices  
    can reduce dust-related hazards.
4) POWER TOOL USE AND CARE
 a) Do not force the power tool. Use the correct power tool for your applica\
tion. The correct power tool will do the job better  
    and safer at the rate for which it was designed.
 b) Do not use the power tool if the switch does not turn it on and off. Any\
 power tool that cannot be controlled with the switch  
    is dangerous and must be repaired.
 c) This product is designed to be used in combination with the AcraDyne iEC\
 DC tool controller for intermittent hand-held or fixtured assembly processes.
 
 
 
 
 
 Safety Information
Thank you for purchasing this AcraDyne DC electric assembly tool, one of the lightest and fastest DC electric 
assembly tools on the market.  When used with the AcraDyne iEC tool controller, this tool will provide excellent 
productivity, ergonomics, reliability and quality on a wide range of industrial assembly applications.  
2 
						

							OPERATIONS
Angle HeadTool Body
Start Lever
Cable 
Connection
Square/
Hex Drive
3
Multi Function 
Button
1. Connect tool cable to the iEC controller and the tool: 
The tool cable has curved alignment tabs and slots 
built into the connectors at each end to ensure proper  
alignment and connection with the tool and controller.
Make sure that power is not turned on at the controller 
before making any connections. Align the female connec-
tor on the cable with the male connector on the tool and insert 
the cable onto the tool, then slide the connector nut onto the 
threads on the cable and turn clockwise until hand-tight.
Align the male connector tab on the other end of the tool 
cable with the female slot on the controller and insert the 
cable into the connector, then slide the metal outer cover 
onto the connection threads on the controller and turn clock-
wise until hand-tight.
2. Multifunction Button Operation: 
The tool will flash all LED lights three times when power is 
first turned on at the controller. After the controller finishes 
initializing and displays a target toque value, the multifunction 
button (MFB) is used to toggle the tool from clockwise mode 
(FWD) to counter-clockwise operation mode (REV). The MFB 
is the small button opposite the trigger.  
The tool will initially start in clockwise mode and will have no 
LED lights turned on. If the trigger is pressed, the tool will 
turn on the blue LED meaning the tightening operation is 
underway. Pressing the MFB will cause the tool to flash yel-
low and red LED lights.  Pressing the MFB again will switch 
the tool back FWD mode and will indicate this with no LED 
lights turned on.
3. Start Lever Operation:
To start the tool, depress the start lever. Blue LED lights will 
be displayed while tightening a bolt. The tool will stop auto-
matically when it senses its target torque value or if no torque 
is sensed in a specified time period. After a cycle is complete, 
the tool will display green LED lights for a success, or red 
LED lights for failure to reach torque/angle.
Light Ring Light Assignment
The Buzzer and Multi-Function Button are programmable in the 
DSP Menu of ToolWare.
Light ColorMeaning
Green SolidOK
Red FlashingTorque Low
Red SolidTorque High
Yellow FlashingAngle Low
Yellow SolidAngle High
Blue SolidTool In-Cycle/Tool Armed
Blue FlashingP-Set Change thru MFB
All On FlashingTool in Disassembly
BuzzerBad Assembly/Tool in Disassembly/Power Up
A complete tool system consists of the following items:
ControllerPower cordToolTool Cable 
						

							4
PAGE HEADER HERE1000 SERIES ANGLE NUTRUNNERS 
6
3
2
1
5
7
8
SEE NOTE # 1
APPLY LOCTITE 243 (BLUE) PRIORTO INSTALLATION INTO ITEM # 7TIGHTEN TO 40 Nm (29.5 FT-LBS)APPLY LOCTITE 242 (BLUE) PRIORTO INSTALLATION OF ITEM # 7
34.9MM (1-3/8) FLATS40Nm (30 FT-LBS.)
4
PRESS INTO ITEM 2UNTIL FLUSH WITH SURFACE
11 10 9SHIM AS REQUIREDWITH ITEMS 9-11 TO ALIGN ANGLE HEAD TO LEVER
B
Assembly for: AEN4B12004A, AEN4C12008A, AEN4C12014A, AEN4C12018A, AEN4C12022A
4
ITEM# 
AEN4B  AEN4C AEN4C AEN4C AEN4C      QTY. PART #  DESCRIPTION   12004A  12008A 12014A 12018A 12022A     1  X  X  X X X      1 24703  HANDLE ASSEMBLY- 1000 SERIES 2  X  X X X X     1 24719  TRANSDUCER ADAPTOR 3  X  X X X X     1 24729  KEY 4  X  X  X X X      1 24688  ROLL PIN, 1/16 x 5/16” LONG 5  X  X X X X     1 24780  MOTOR COUPLER SUB-ASM. 6  X  X            1 24778  TRANSDUCER SUB-ASM., 8Nm             X X X      1 24779  TRANSDUCER SUB-ASM., 20Nm 7  X              1 25531  ASSY, GEAR CASE, 4 Nm ANGLEHEAD       X            1 24860  GEAR CASE SUB-ASM 6T         X          1 24709  GEAR CASE SUB-ASM, 14T/14T           X       1 24792  GEAR CASE SUB-ASM., 12T/12T             X     1 24710  GEAR CASE SUB-ASM, 8T/14T 8  X              1 4A9116  ASSY, ANGLE HEAD, 4 Nm       X X X X      1 24890  ANGLE HEAD ASM, STUBBY, 3/8”” SQ. DR. 9  X  X  X X X      A/R 24855  SHIM .1MM, 14MM ID X 20MM OD 10  X  X  X X X      A/R 24856  SHIM .2MM, 14MM ID X 20MM OD 11  X  X  X X X      A/R 24857  SHIM .3MM, 14MM ID X 20MM OD  
						

							5
PAGE HEADER HERE1000 SERIES IN-LINE NUTRUNNERS 
1
2
3
45
6
7
APPLY LOCTITE   #242 BLUE
 
 
TIGHTEN TO GEAR CASETO 40Nm (30 FT.LBS.)
SEE NOTE 1
34.9mm (1 3/8) FLATS  40Nm (30 FT.LBS.) SEE NOTE 1
 APPLY LOCTITE   #242 BLUE
 
 
TIGHTEN TO GEAR CASETO 40Nm (30 FT.LBS.)
8
30.2mm (1 3/16) HEX25Nm (18 FT.LBS.)
 
APPLY LOCTITE   #242 BLUE
   
9PRESS INTO ITEM 2 FLUSH WITH SURFACE
Assembly for: AES4A12003A, AES4A12006A, AES4A12011A, AES4A12014A, AES4A12018A, AES4A12022A
ITEM# 
AES4A  AES4A AES4A AES4A AES4A  AES4A   QTY. PART #  DESCRIPTION   12003A  12006A 12011A 12014A 12018A  12022A   1 X  X  X X X X    1 24703  HANDLE ASSEMBLY- 1000 SERIES 2  X  X X X X  X  1 24719  TRANSDUCER ADAPTOR 3  X        1 24777  TRANSDUCER SUB-ASM., 3Nm       X            1 24778  TRANSDUCER SUB-ASM., 8Nm         X X X X    1 24779  TRANSDUCER SUB-ASM., 20Nm 4  X  X X X X  X  1 24729  KEY 5  X  X X X X  X  1 24780  MOTOR COUPLER SUB-ASM. 6  X  X            1 24860  GEAR CASE SUB-ASM 6T         X          1 24709  GEAR CASE SUB-ASM, 14T/14T           X       1 24792  GEAR CASE SUB-ASM., 12T/12T             X     1 24710  GEAR CASE SUB-ASM, 8T/14T               X   1 24781  GEAR CASE ASM, 6T/14T 7  X  X  X X X X    1 24896  STRAIGHT OUTPUT ASM, 1/4”” HEX Q.C. 8      X X X X    1 24696  REACTION BAR, ALUMINUM, 1000 SERIES 9  X  X  X X X X    1 24688  ROLL PIN, 1/16 x 5/16” LONG  
						

							PAGE HEADER HERE1000 SERIES PUSH-TO-START NUTRUNNERS 
6
74
3
5
1
9
10
11
ALIGN CABLE CONNECTOR WITH SLOT ON GEAR CASEHOUSING THEN GLUE TO SHOULDERON GEAR CASE HOUSINGWITH RTV
8
13
14
12
HOLD FLATS SECURE WITH TOOL # 1354WHILE TIGHTENING ITEM #11
38.1mm  (1½) FLATSTIGHTEN TO MOTOR WITH LOCTITE 24240 Nm (30 Ft*LBS)
2
38.1mm (1½) FLATSTIGHTEN TO ITEM #8 WITH LOCTITE 242PRIOR TO INSTALLING ITEMS 12-1440 Nm (30 FT*lbs)SEE NOTE 3 SEE NOTE 1
Assembly for: AEL4A12003A, AEL4A12006A, AEL4A12011A, AEL4A12014A, AEL4A12018A, AEL4A12022A
6
ITEM# 
AEL4A  AEL4A AEL4A AEL4A AEL4A  AEL4A   QTY. PART #  DESCRIPTION   12003A  12006A 12011A 12014A 12018A  12022A   1 X  X  X X X X    1 24703  HANDLE ASSEMBLY- 1000 SERIES 2  X  X X X X  X  1 24762  PTS FLEX CIRCUIT 3  X  X X X X  X  1 24719  TRANSDUCER ADAPTOR 4  X  X X X X  X  1 24729  KEY 5  X  X  X X X X    1 24688  ROLL PIN, 1/16 x 5/16” LONG 6  X  X X X X  X  1 24780  MOTOR COUPLER SUB-ASM. 7  X  X            1 24778  TRANSDUCER SUB-ASM., 8Nm         X X X X    1 24779  TRANSDUCER SUB-ASM., 20Nm 8  X  X  X X    X   1 25521  ADAPTER, PTS GEAR HOUSING 9  X  X            1 24786  GEAR CASE ASSEMBLY, P-T-S, S.S., 8         X          1 24791  GEAR CASE ASSEMBLY, P-T-S, 14/14           X       1 24807  GEAR CASE ASSY, P-T-S, D.S. 12/12             X     1 24784  GEAR CASE ASM, P-T-S,  8/14               X   1 24776  GEAR CASE ASM, P-T-S, 6T/14T 10  X  X  X X X X    1 24566  P-T-S LIGHT RING ASM. 11  X  X            1 24744  P-T-S G.C. HSG COVER- S.S.         X X X X    1 24757  GEAR CASE HOUSING COVER, P-T-S, D.S. 12  X  X  X X X X    1 25590  O-RING, Ø13/16 X Ø1/16 13  X  X  X X X X    1 25591  O-RING, Ø1¼ X Ø1/16 14  X  X  X X X X    1 24753  P-T-S LIGHT RING LENS 
						

							PAGE HEADER HERE1000 SERIES FIXTURED NUTRUNNERS 
1
2
3
45
6
7
APPLY LOCTITE   #242 BLUE
 
 
TIGHTEN TO GEAR CASETO 40Nm (30 FT.LBS.)
SEE NOTE 1
34.9mm (1 3/8) FLATS  40Nm (30 FT.LBS.) SEE NOTE 1
 APPLY LOCTITE   #242 BLUE
 
 
TIGHTEN TO GEAR CASETO 40Nm (30 FT.LBS.)
8
30.2mm (1 3/16) HEX25Nm (18 FT.LBS.)
 
APPLY LOCTITE   #242 BLUE
   
9PRESS INTO ITEM 2 FLUSH WITH SURFACE
Assembly for: AEF4A12003A, AEF4A12006A, AEF4A12011A, AEF4A12014A, AEF4A12018A, AEF4A12022A
7
ITEM# 
AEF4A  AEF4A AEF4A AEF4A AEF4A  AEF4A   QTY. PART #  DESCRIPTION   12003A  12006A 12011A 12014A 12018A  12022A   1 X  X X X X  X  1 24888  TID BOARD ASM 2  X  X  X X X X    1 24913  CIRCUIT BOARD MOUNTING PLATE 3  X  X  X X X X    2 24914  BHCS, #4-40 x .25 LG 4  X  X X X X  X  1 24912  COVER, CIRCUIT BOARD 5  X  X  X X X X    2 24917  BHCS, #4 x .38 LG TAP-TITE 6  X  X  X X X X    1 24863  PISTOL MOTOR ASM., 1000 SERIES 7  X  X X X X  X  2 24930  SCREW, AMP BOARD 8  X  X  X X X X    1 24886  CIRCUIT BOARD ASM - PISTOL/ FIXTURED TOOLS 9  X  X X X X  X  1 24873  LIGHT RING 10  X  X  X X X X    1 24909  STRAIGHT ADAPTOR, PISTOL TOOL CONNECTOR 11  X  X X X X  X  1 24677  TOOL CONNECTOR ASSEMBLY 12  X  X  X X X X    1 25419  SCREW, PHM 4-40 X .188 , STEEL, PLAIN 13  X  X  X X X X    4 24933  FLAT HEAD CAP SCREW 14  X  X  X X X X    1 24687  O-RING, LIGHT RING, LEVER 15  X  X            1 24860  GEAR CASE SUB-ASM 6T         X          1 24709  GEAR CASE SUB-ASM, 14T/14T           X       1 24792  GEAR CASE SUB-ASM., 12T/12T                X     1 24710  GEAR CASE SUB-ASM, 8T/14T               X   1 24781  GEAR CASE ASM, 6T/14T 16   X X X X  X  1 24719  TRANSDUCER ADAPTOR 17    X X X X X    1 24688  ROLL PIN, 1/16 x 5/16” LONG 18   X X X X  X  1 24729  KEY 19  X        1 24777  TRANSDUCER SUB-ASM., 3Nm       X            1 24778  TRANSDUCER SUB-ASM., 8Nm         X X X X    1 24779  TRANSDUCER SUB-ASM., 20Nm 20  X  X X X X  X  1 24780  MOTOR COUPLER SUB-ASM. 21  X  X  X X X X    1 24918  RETRACTABLE OUTPUT SPINDLE ASM, 3/8 SQ 22  X  X X X X  X  1 24924  MOUNTING FLANGE 23  X  X  X X X X    2 24934  FLAT HEAD CAP SCREW 24  X  X  X X X X    1 24686  RETAINING RING, LEVER LIGHT RING 
						

							ADJUSTING THE THROTTLE LEVER TO ANGLE HEAD LOCATION
(REQUIRES OPTIONAL P/N 25444)
1. REMOVE THE ANGLE HEAD
 1.1. Hold the angle head and with a 1-3/8" crows foot loosen and remove the g\
ear casing    
      from the angle head.
 
2. INSTALL ADJUSTMENT SHIMS
 2.1. Shim kit part number 25444 is needed for the 1000 series.
 2.2. Add adjustment shims as needed to align the angle head with the throttle\
 lever.
3. REINSTALL THE ANGLE HEAD
 3.1. Apply Loctite 243 to the threads on the angle head.
 3.2. Hold the angle head and tighten the gear casing to 40NM using the 1-3/8"\
 crows foot.
8
6
3
2
1
5
7
8
SEE NOTE # 1
APPLY LOCTITE 243 (BLUE) PRIORTO INSTALLATION INTO ITEM # 7TIGHTEN TO 40 Nm (29.5 FT-LBS)
APPLY LOCTITE 242 (BLUE) PRIORTO INSTALLATION OF ITEM # 7
34.9MM (1-3/8) FLATS40Nm (30 FT-LBS.)
4
PRESS INTO ITEM 2UNTIL FLUSH WITH SURFACE
11 10 9
SHIM AS REQUIREDWITH ITEMS 9-11 TO ALIGN ANGLE HEAD TO LEVER
B 
						

							9
Specifications
Environmental
 • Operating Temperature: 0°C to 32°C 
 • Storage Temperature: 0°C to 65°C 
 • Humidity: 
   o  5% to 90% RH, Non-Condensing, for temperatures 0°C  to 40°C 
   o  5% to 60% RH, Non-Condensing, for temperatures 0°C to 65°C 
 •  Maximum Altitude of Operation: 3000m
 • Maximum decibel level: 73 dB(A)
 
Electrical
 • Motor Type: BLDC
   o Motor Phase Voltage: 160 Volts Pulse DC @ Controller Supply Voltage of    
        120 RMS, or 320 Volts Pulse DC @ Controller Supply Voltage of 230 RMS
 • Duty Cycle: The Nutrunner tools are intended for intermittent operation with recommended  
    maximum duty cycles not to exceed 33%. Note: actual maximum duty cycles are dependant  
   upon several factors including:  Ambient Temperature, Tool selection, Jo\
int conditions,    
   Fastening-parameter programming, and different applications and strategi\
es. For optimum  
   duty cycle determination, please contact your AcraDyne sales representat\
ive.
Physical
 • 1.5 lbs/.68 kg - 2.6 lbs/1.18 kg
Performance
 • Torque Range: 3 - 22 NM
 • Speed Range: 560 - 2625 RPM 
						

							
Notes: