Aimco Brakes AcraDyne Gen 3 3000 Series Nutrunner Manual

							AcraDyne Gen III  
3000 Series Nutrunners
Operations Manual
PO Box 16460, Portland OR 97292-0460  • 800-852-1368 • Fax 800-582-9015
www.aimco-global.com 
						

							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 a s pipes, rad\
iators, 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 entangled cords increase the risk of electric shock.
 e) This tool is intended for indoor use only.
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 whil\
e 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 dut\
y 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 befo\
re 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 e\
lec-
tric 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\
 applica-
tions.  
2 
						

							OPERATION
Angle HeadTool Body
Multi Function 
Button
Start Lever
Cable 
Connection
Square/
Hex Drive
3
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 
A complete tool system consists of the following items:
ControllerPower cordToolTool Cable
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 automati-
cally 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 
						

							PAGE HEADER HEREGEN III 3000 SERIES ANGLE NUTRUNNERS 
Assembly for: AEN33060A and AEN33090A
ITEM # AEN  AEN       QTY. PART #  DESCRIPTION   33060A  33090A
1    X X       1  25057  NUTRUNNER HOUSING, G1-3K2    X X       1  25525  MOTOR ASSY, 9T, 3000 SERIES3    X X       1  25063  LED BOARD ASM.4    X X       2  25075  SCREW, SHC 4-40X.375, STEEL, BLACK OXIDE5    X X       2  25430  STAND-OFF, LED, 3000 SERIES6    X X       1  25073  SCREW, SET 4-40X.375, STEEL, BLACK OXIDE7    X X       1  25299  SPIRAL RETAINING RING8    X X       2  20058  BELLEVILLE WASHER9    X        1  25417  GEAR TRAIN ASSY, ANGLE HEAD     X       1 2014610    X X       2  20201  RETAINING PIN --- 3000 SERIES11    X X      A/R  25271 SHIM. - .00212    X X      A/R  25272 SHIM. - .00513    X X      A/R  25273 SHIM. - .01014    X X       1  25418  TOOL CONNECTOR ASM GEN III TOOLS15    X X       1  25102  Screw, BHC4-40X.188, STEEL, BLACK OXIDE16    X X       1  25402  T.I.D. BOARD ASM. - GEN III17    X X       2  24934  FLAT HEAD CAP SCREW18    X X       1  25071  SPRING, LEVER19    X X       1  25074  LEVER ASSEMBLY20    X X       2  20061  SCREW, LEVER21    X X       1  25072  O-RING, LED LIGHT RING COVER22    X X       1  20534  3000 SERIAL/MODEL LABEL23    X X       1  25058  LIGHT RING COVER, LED24    X X       1  25060  HANDLE COVER, REV. BUTTON25    X X       1  24706  REV BUTTON SUB-ASSEMBLY26    X X       1  24683  SPRING, REV BUTTON27    X X       1  24679  RETAINING RNG28    X X      10  24940  SCREW, FHSC 4-40 X .25 LG., STEEL, BLACK OXIDE29    X X       1  25059  HANDLE COVER30    X X       1  22141  SAFETY LABEL
4 
						

							PAGE HEADER HEREGEN III 3000 SERIES ANGLE NUTRUNNERS 
2
6 3
4
16 29
1523
21
20
18
19
28
27 22
24
26
30
25
1
10
7
9
28
17 1312 11
 
14
5
8
Assembly for: AEN33120A
ITEM #   
AEN      QTY. PART #  DESCRIPTION    33120A
1     X       1  25057  NUTRUNNER HOUSING, G1-3K2     X       1  25525  MOTOR ASSY, 9T, 3000 SERIES3     X       1  25063  LED BOARD ASM.4     X       2  25075  SCREW, SHC 4-40X.375, STEEL, BLACK OXIDE5     X       2  25430  STAND-OFF, LED, 3000 SERIES6     X       1  25073  SCREW, SET 4-40X.375, STEEL, BLACK OXIDE7     X       1  25299  SPIRAL RETAINING RING8     X       2  20058  BELLEVILLE WASHER9     X       1  24489  ANGLE HEAD/GEAR TRAIN ASM.10     X       2  20201  RETAINING PIN --- 3000 SERIES11     X      A/R  25271 SHIM. - .00212     X      A/R  25272 SHIM. - .00513     X      A/R  25273 SHIM. - .01014     X       1  25418  TOOL CONNECTOR ASM GEN III TOOLS15     X       1  25102  Screw, BHC4-40X.188, STEEL, BLACK OXIDE16     X       1  25402  T.I.D. BOARD ASM. - GEN III17     X       2  24934  FLAT HEAD CAP SCREW18     X       1  25071  SPRING, LEVER19     X       1  25074  LEVER ASSEMBLY20     X       2  20061  SCREW, LEVER21     X       1  25072  O-RING, LED LIGHT RING COVER22     X       1  20534  3000 SERIAL/MODEL LABEL23     X       1  25058  LIGHT RING COVER, LED24     X       1  25060  HANDLE COVER, REV. BUTTON25     X       1  24706  REV BUTTON SUB-ASSEMBLY26     X       1  24683  SPRING, REV BUTTON27     X       1  24679  RETAINING RNG28     X      10  24940  SCREW, FHSC 4-40 X .25 LG., STEEL, BLACK OXIDE29     X       1  25059  HANDLE COVER30     X       1  22141  SAFETY LABEL
5 
						

							6
PAGE HEADER HEREGEN III 3000 SERIES ANGLE NUTRUNNERS 
2
6 3
4
21 34
20 28
26 25
23
24
33
32 27
29
31
35
30
1
15
7 33
22 181716
 11 14
12
13
10 19
8
5
9
Assembly for: AEN33200A, AEN33300A and AEN33450A
ITEM #  AEN AEN  AEN      QTY. PART #  DESCRIPTION  33200A  33300A  33450A
1    X X  X     1  25057  NUTRUNNER HOUSING, G1-3K2    X X  X     1  25530  MOTOR / ID BOARD ASSY, 15 T, 3000 SERIES3    X X  X     1  25063  LED BOARD ASM.4    X X  X     2  25075  SCREW, SHC 4-40X.375, STEEL, BLACK OXIDE5    X X  X     2  25430  STAND-OFF, LED, 3000 SERIES6    X X  X     1  25073  SCREW, SET 4-40X.375, STEEL, BLACK OXIDE7    X X  X     1  25299  SPIRAL RETAINING RING8    X X  X     2  20058  BELLEVILLE WASHER9    X      1  21382  GEAR TRAIN ASSY, TRIPLE STEP, 13.94:1 RATIO      X      1  21381  GEAR TRAIN ASM. (20.74:1)       X     1  20921  GEAR TRAIN ASM. (30.87:1)10    X X  X     1  20912  WAVE SPRING --- 3000 SERIES11    X X  X     1  23461  ASSY, RIGHT ANGLE HEAD, 0.75 DRIVE, 200 NM12    X X  X     2  20911  BELLEVILLE WASHER13    X X  X     1  20924  ASSEMBLY, GEAR CARRIER, THIRD STAGE14    X X  X     2  20913  PIN, RETAINING15    X X  X     2  20201  RETAINING PIN --- 3000 SERIES16    X X  X    A/R  25271 SHIM. - .00217    X X  X    A/R  25272 SHIM. - .00518    X X  X    A/R  25273 SHIM. - .01019    X X  X     1  25418  TOOL CONNECTOR ASM GEN III TOOLS20    X X  X     1  25102  Screw, BHC4-40X.188, STEEL, BLACK OXIDE21    X X  X     1  25402  T.I.D. BOARD ASM. - GEN III22    X X  X     2  24934  FLAT HEAD CAP SCREW23    X X  X     1  25071  SPRING, LEVER24    X X  X     1  25074  LEVER ASSEMBLY25    X X  X     2  20061  SCREW, LEVER26    X X  X     1  25072  O-RING, LED LIGHT RING COVER27    X X  X     1  20534  3000 SERIAL/MODEL LABEL28    X X  X     1  25058  LIGHT RING COVER, LED29    X X  X     1  25060  HANDLE COVER, REV. BUTTON30    X X  X     1  24706  REV BUTTON SUB-ASSEMBLY31    X X  X     1  24683  SPRING, REV BUTTON32    X X  X     1  24679  RETAINING RNG33    X X  X    10  24940  SCREW, FHSC 4-40 X .25 LG., STEEL, BLACK OXIDE34    X X  X     1  25059  HANDLE COVER35    X X  X     1  22141  SAFETY LABEL  
						

							7
PAGE HEADER HEREGEN III 3000 SERIES IN-LINE NUTRUNNERS 
2
6 3
4
16
29
15 23
21
20
18
19
28
27 22
24
26
30
25
1
10
7
9
2817 1312
11
 
32
31 8
14
5
Assembly for: AES33040A and AES33060A
ITEM # 
AES  AES       QTY. PART #  DESCRIPTION   33040A  33060A
1    X X       1  25057  NUTRUNNER HOUSING, G1-3K2    X X       1  25525  MOTOR ASSY, 9T, 3000 SERIES3    X X       1  25063  LED BOARD ASM.4    X X       2  25075  SCREW, SHC 4-40X.375, STEEL, BLACK OXIDE5    X X       2  25430  STAND-OFF, LED, 3000 SERIES6    X X       1  25073  SCREW, SET 4-40X.375, STEEL, BLACK OXIDE7    X X       1  25299  SPIRAL RETAINING RING8    X X       2  20058  BELLEVILLE WASHER9    X        1  20129  INLINE GEAR TRAIN 1/2 DR. (20.74:1)      X       1  20128  INLINE GEAR TRAIN 1/2 DR. (30.87:1)10    X X       2  20201  RETAINING PIN --- 3000 SERIES11    X X      A/R  25271 SHIM. - .00212    X X      A/R  25272 SHIM. - .00513    X X      A/R  25273 SHIM. - .01014    X X       1  25418  TOOL CONNECTOR ASM GEN III TOOLS15    X X       1  25102  Screw, BHC4-40X.188, STEEL, BLACK OXIDE16    X X       1  25402  T.I.D. BOARD ASM. - GEN III17    X X       2  24934  FLAT HEAD CAP SCREW18    X X       1  25071  SPRING, LEVER19    X X       1  25074  LEVER ASSEMBLY20    X X       2  20061  SCREW, LEVER21    X X       1  25072  O-RING, LED LIGHT RING COVER22    X X       1  20534  3000 SERIAL/MODEL LABEL23    X X       1  25058  LIGHT RING COVER, LED24    X X       1  25060  HANDLE COVER, REV. BUTTON25    X X       1  24706  REV BUTTON SUB-ASSEMBLY26    X X       1  24683  SPRING, REV BUTTON27    X X       1  24679  RETAINING RNG28    X X      10  24940  SCREW, FHSC 4-40 X .25 LG., STEEL, BLACK OXIDE29    X X       1  25059  HANDLE COVER30    X X       1  22141  SAFETY LABEL31    X X       1  20455  FIXTURE NUT, INLINE --- 3000 SERIES32    X X       1  20847  REACTION BAR  
						

							8
PAGE HEADER HEREGEN III 3000 SERIES IN-LINE NUTRUNNERS
2
6 3
4
21
34
20 28
26 25
23
24
33
32 27
29
31
35
30
1
15
7 33
22 181716
 11 14
12
13
10
36
37 9
19
8
5
Assembly for: AES33100A, AES33150A and AES33230A
ITEM # 
AES AES  AES      QTY. PART #  DESCRIPTION  33100A  33150A  33230A
1    X X  X     1  25057  NUTRUNNER HOUSING, G1-3K2    X X  X     1  25530  MOTOR / ID BOARD ASSY, 15 T, 3000 SERIES3    X X  X     1  25063  LED BOARD ASM.4    X X  X     2  25075  SCREW, SHC 4-40X.375, STEEL, BLACK OXIDE5    X X  X     2  25430  STAND-OFF, LED, 3000 SERIES6    X X  X     1  25073  SCREW, SET 4-40X.375, STEEL, BLACK OXIDE7    X X  X     1  25299  SPIRAL RETAINING RING8    X X  X     2  20058  BELLEVILLE WASHER9    X      1  21382  GEAR TRAIN ASSY, TRIPLE STEP, 13.94:1 RATIO      X      1  21381  GEAR TRAIN ASM. (20.74:1)       X     10    X X  X     1  20912  WAVE SPRING --- 3000 SERIES11    X X  X     1  20923  INLINE HEAD ASSY - 1/2 IN DRIVE12    X X  X     2  20911  BELLEVILLE WASHER13    X X  X     1  20924  ASSEMBLY, GEAR CARRIER, THIRD STAGE14    X X  X     2  20913  PIN, RETAINING15    X X  X     2  20201  RETAINING PIN --- 3000 SERIES16    X X  X    A/R  25271 SHIM. - .00217    X X  X    A/R  25272 SHIM. - .00518    X X  X    A/R  25273 SHIM. - .01019    X X  X     1  25418  TOOL CONNECTOR ASM GEN III TOOLS20    X X  X     1  25102  Screw, BHC4-40X.188, STEEL, BLACK OXIDE21    X X  X     1  25402  T.I.D. BOARD ASM. - GEN III22    X X  X     2  24934  FLAT HEAD CAP SCREW23    X X  X     1  25071  SPRING, LEVER24    X X  X     1  25074  LEVER ASSEMBLY25    X X  X     2  20061  SCREW, LEVER26    X X  X     1  25072  O-RING, LED LIGHT RING COVER27    X X  X     1  20534  3000 SERIAL/MODEL LABEL28    X X  X     1  25058  LIGHT RING COVER, LED29    X X  X     1  25060  HANDLE COVER, REV. BUTTON30    X X  X     1  24706  REV BUTTON SUB-ASSEMBLY31    X X  X     1  24683  SPRING, REV BUTTON32    X X  X     1  24679  RETAINING RNG33    X X  X    10  24940  SCREW, FHSC 4-40 X .25 LG., STEEL, BLACK OXIDE34    X X  X     1  25059  HANDLE COVER35    X X  X     1  22141  SAFETY LABEL36    X X  X     1  20847  REACTION BAR37    X X  X     1  20455  FIXTURE NUT, INLINE --- 3000 SERIES  
						

							9
PAGE HEADER HEREGEN III 3000 SERIES IN-LINE NUTRUNNERS 
26
3 4 26
39
25
33
31
30
28
29
38
37 32
34
36
42
35
1
20
7 10
38
27 2322
 
9 11
40
41 17
14
12 13
1516 18
19
24
5
8
Assembly for: AES33400A and AES33600A
ITEM # 
AES  AES       QTY. PART #  DESCRIPTION   33400A  33600A
1    X X       1  25057  NUTRUNNER HOUSING, G1-3K2    X X       1  25530  MOTOR / ID BOARD ASSY, 15 T, 3000 SERIES3    X X       1  25063  LED BOARD ASM.4    X X       2  25075  SCREW, SHC 4-40X.375, STEEL, BLACK OXIDE5    X X       2  25430  STAND-OFF, LED, 3000 SERIES6    X X       1  25073  SCREW, SET 4-40X.375, STEEL, BLACK OXIDE7    X X       1  25299  SPIRAL RETAINING RING8    X X       2  20058  BELLEVILLE WASHER9    X        1  23790 AV  ASSY, GEARBOX, QUAD STAGE      X       1  23790  ASSY, GEARBOX, QUAD STAGE10    X X       1  20049  BALL BEARING, 1.120 X .4720 IN11    X X       1  20916  TRANSFER SHAFT, TRIPLE STAGE, 14T --- 3000 SERIES12    X X       1  20017  PINION BEARING RETAINER --- 3000 SERIES13    X X       1  21816  MYLAR WASHER14    X X       1  21941  2ND STAGE CARRIER ASSY, 3.73:1, 28 NM15    X X       1  20143  WAVE SPRING WASHER16    X X       1  20057  SPIRAL LOCK RING17    X X       1  20086  1ST STAGE CARRIER ASSY, 3.73:118    X X       1  20111  WAVE SPRING WASHER19    X X       1  20019  RETAINER, BEARING, 3000 SERIES20    X X       2  20201  RETAINING PIN --- 3000 SERIES21    X X       1  25271  SHIM. - .00222    X X       1  25272  SHIM. - .00523    X X       1  25273  SHIM. - .01024    X X       1  25418  TOOL CONNECTOR ASM GEN III TOOLS25    X X       1  25102  Screw, BHC4-40X.188, STEEL, BLACK OXIDE26    X X       1  25402  T.I.D. BOARD ASM. - GEN III27    X X       2  24934  FLAT HEAD CAP SCREW28    X X       1  25071  SPRING, LEVER29    X X       1  25074  LEVER ASSEMBLY30    X X       2  20061  SCREW, LEVER31    X X       1  25072  O-RING, LED LIGHT RING COVER32    X X       1  20534  3000 SERIAL/MODEL LABEL33    X X       1  25058  LIGHT RING COVER, LED34    X X       1  25060  HANDLE COVER, REV. BUTTON35    X X       1  24706  REV BUTTON SUB-ASSEMBLY36    X X       1  24683  SPRING, REV BUTTON37    X X       1  24679  RETAINING RNG38    X X      10  24940  SCREW, FHSC 4-40 X .25 LG., STEEL, BLACK OXIDE39    X X       1  25059  HANDLE COVER40    X X       1  23793  REACTION BAR41    X X       1  23792  RETAINING NUT, HEX42    X X       1  22141  SAFETY LABEL  
						

							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: 77 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 25%. 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
 • 5.50 lbs/2.49 kg - 9.70 lbs/4.39 kg
Performance
 • Torque range: 40 - 450 NM
 • Speed Range: 95 - 1240 RPM
   Note: Full speed 50% of rated for 3000 tools @ 120VAC.
10