Paoli DP05-34B Operating Instructions Manual
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Paoli DP05-34B Operating Instructions Manual

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Summary of Contents for Paoli DP05-34B

  • Page 1 Operating instructions Read the manual carefully before use! Keep for future use!
  • Page 3 Illustrations in this manual serve to provide a basic understanding and may differ from the actual design. This manual is valid for the following battery nutrunners and soft- ware: Versions BATTERY NUTRUNNERS DP05-34B DP10-34B DP20-10B DP30-10B DP36-10B DP48-15B DP80-15B...

  • Page 5: Table Of Contents

    Table of contents Table of contents Unpacking................7 Getting to know the nutrunner........... 9 2.1 Illustration of the nutrunner........... 9 2.2 Brief description............10 2.3 Rating plate..............11 2.4 Performance variables..........11 2.5 Nutrunner controls............12 2.6 Overview of functions..........16 2.7 Accessories..............
  • Page 6 Table of contents Performing maintenance..........55 11.1 Having the nutrunner maintained by the user... 55 11.2 Having the nutrunner maintained by the user... 57 11.3 Having service tasks performed by the manufac- turer................58 Troubleshooting..............60 12.1 Identifying faults............60 12.2 Performing troubleshooting........

  • Page 7: Unpacking

    Unpacking Unpacking Delivery The nutrunner is delivered in a plastic transport case together with the other items in the scope of delivery. The transport case is packed in a cardboard box upon delivery. The transport case is fitted with a foam inlay. The recesses in the inlay enable precision storage of the scope of delivery.
  • Page 8 Unpacking Handling packaging material The individual packages are packed according to the expected transport conditions. Only environmentally friendly materials are used for the packaging. The packaging should provide protection against transport damage, corrosion and other damage. For this reason, do not destroy the packaging and do not remove it until shortly before use.

  • Page 9: Getting To Know The Nutrunner

    Getting to know the nutrunner Getting to know the nutrunner 2.1 Illustration of the nutrunner Fig. 2: Illustration of the nutrunners Reaction arm Drive motor Square drive (tool holder) Ventilation slot Reaction arm circlip Direction of rotation setting Safety swivel joint Handle Gear setting Battery...

  • Page 10: Brief Description

    Getting to know the nutrunner Battery Battery release button Electrical contacts and guide rail Battery charge status indicator button 4 LEDs for battery charge status indicator Fig. 3: Illustration of battery Battery charger LED display Battery connection Power cable (not shown) Fig.

  • Page 11: Rating Plate

    Name of the manufacturer including their full address Machine designation Type designation Article/serial number Maximum torque Year of construction Weight CE mark 2.4 Performance variables Overview of available performance variables for the nutrunner ver- sions: BATTERY NUTRUNNERS DP05-34B DP10-34B DP20-10B DP30-10B DP36-10B DP48-15B DP80-15B...

  • Page 12: Nutrunner Controls

    Getting to know the nutrunner 2.5 Nutrunner controls Fig. 5: Controls Gear setting Battery charge status indicator button Setting levels 4 LEDs for battery charge status indicator Direction of rotation setting Battery release button Handle Trigger Battery charge status indicator...
  • Page 13 Getting to know the nutrunner The nutrunner features the following controls: Gear setting and setting levels Gear setting Marking for setting level Setting levels The torque is selected using a combination of gear and setting level. Note the enclosed torque chart. Gear: Gear 1 to 4 The gearbox gears are adjusted manually.
  • Page 14 Getting to know the nutrunner Direction of rota- Direction of rotation tion setting Left-hand side is Counterclockwise (CCW) pressed. Loosening in counterclockwise direc- tion Handle The nutrunner can be gripped securely and carried by the handle (Fig. 5/4). Ergonomic use of the trigger is possible. Battery charge status indicator Battery charge status indicator Button and 4 LEDs for charge status indicator...
  • Page 15 Getting to know the nutrunner Button and LEDs for charge status indicator The battery charge status can only be displayed correctly when the drive motor is switched off. The battery charge status is displayed (as a percentage) by pressing the button. Fig.

  • Page 16: Overview Of Functions

    Getting to know the nutrunner LED display for battery charger LED display Meaning Continuous yellow light The battery charger is operational. Mains voltage is available. Flashing green light Quick charging is active. Continuous green light Quick charging has concluded. Flashing red light Charging is not possible.

  • Page 17: Accessories

    Reaction arm with circlip Special reaction arm Nose extension “Torque Control TC1” mobile measuring unit Impact wrench sockets in various designs Certificate Technical, more detailed supplement to the torque chart Offset heads for long studs Special accessories Contact PAOLI service.

  • Page 18: Before You Begin

    Before you begin Before you begin This section provides an overview of all safety aspects that are essential to the best possible protection of the personnel and the safe and trouble-free operation of the machine. Additional safety instructions for specific work tasks are contained in the sections regarding the individual life stages of the machine.
  • Page 19 Before you begin Safety instructions in specific Safety instructions may refer to specific, individual instructions. instructions Such safety instructions are integrated into the instruction so that they do not interrupt the flow of reading when carrying out the task. The signal words described above are used. Example: Loosen the screw.

  • Page 20: Symbols On The Nutrunner

    Before you begin 3.2 Symbols on the nutrunner Illustration Fig. 11: Symbols Nutrunner rating plate Programming adapter rating plate Test badges DTS receiver rating plate Reaction arm Battery rating plate Battery charger rating plate Illegible signage WARNING! Danger in the event of illegible signage! Over time, signs and stickers can become dirty or be rendered unrecognisable by other means, such that hazards cannot be recognised and necessary...
  • Page 21 Before you begin The following symbols and information notices are located on the nutrunner: Voltage The equipment marked in this way is supplied with electrical energy. Do not open the nutrunner. Danger of crushing Keep your hands away from areas bearing this warning. There is a danger of body parts being crushed, pulled in or other- wise injured.

  • Page 22: Intended Use

    Before you begin Date of the next PAOLI service. For nutrunners with certificate: Date of the last torque test. Reaction arm The stated value indicates the maximum permissible torque for the reaction arm. 3.3 Intended use The battery nutrunner is a hand-held tool and may only be used for tightening and loosening bolted connections within the Ä...

  • Page 23: Misuse

    Before you begin 3.4 Misuse Any use beyond the intended use as well as any other use is con- sidered misuse. WARNING! Danger in the event of misuse! Misuse of the nutrunner can lead to dangerous sit- uations. – Never operate without the reaction arm. –...

  • Page 24: Workplace Safety

    Before you begin 3.5.1 Workplace safety Keep your work area clean and well lit. Untidiness and unlit work areas can cause accidents. Do not work with the electric tool in potentially explosive envi- ronments in which there are flammable liquids, gases or dusts. Electric tools generate sparks that could ignite the dust or fumes.

  • Page 25: Personal Safety

    Before you begin 3.5.3 Personal safety Be attentive, pay attention to what you are doing, and take the utmost care when working with an electric tool. Do not use any electric tools if you are tired or are under the influence of drugs, alcohol or medicines.

  • Page 26: Service

    Before you begin Store unused electric tools out of reach from children. Do not allow any person to use the electric tool if the person in question is not familiar with the electric tool or if they have not read the instructions.

  • Page 27: Electrical Dangers

    Before you begin 3.6.1 Electrical dangers Electrical current DANGER! Danger of death due to electric shock! If contact is made with live parts, there is an imme- diate danger of death due to electric shock. Damage to the insulation or individual components can be life-threatening.
  • Page 28 Before you begin Batteries WARNING! Danger of death due to fire, explosion, smoke and toxic gases if batteries are handled incor- rectly! Incorrect handling of rechargeable batteries can result in fire, explosions and electric shock. Escaping gases or smoke can lead to poisoning and suffocation.

  • Page 29: Mechanical Dangers

    Before you begin WARNING! Danger of injury due to very strong electromag- netic radiation! Very strong electromagnetic radiation can cause the nutrunner to malfunction, resulting in serious injuries and major property damage. – Do not operate in the immediate vicinity of strong transmitting antennas.
  • Page 30 – Brace the reaction arm correctly. – Do not operate the nutrunner in continuous ope-ration and do not use it as a drive unit. – Use only PAOLI original parts. Reaction arm The reaction arms are designed for a maximum permissible load.
  • Page 31 Before you begin Dirt and scattered objects CAUTION! Danger of injury from falling over dirt and scat- tered objects! People may slip on or stumble over dirt and scat- tered objects. Falling may cause injuries. – Always keep the work area clean. –...

  • Page 32: Noise And Ergonomics

    Before you begin Conserving materials In order to prevent premature damage to tools and accessories, only use the nutrunner up to 80% of the maximum torque of the nutrunner during con- tinuous use, if possible to do so. Especially during loosening, loads could occur that have adversely effect durability.
  • Page 33 Before you begin Inadequate ergonomics CAUTION! Damage to the musculoskeletal system due to the high weight of the nutrunner! Lifting and carrying heavy loads can cause perma- nent damage to the musculoskeletal system. – Ensure stable footing and sufficient room for movement.

  • Page 34: Reaction Arm Circlip

    Before you begin Faulty safety devices WARNING! Danger of death due to inoperative safety devices! If safety devices or safety functions are inoperative or disabled, there is a danger of serious injuries. – Prior to commencing work, check that all safety devices are operative and correctly installed.

  • Page 35: Operator's Obligations

    Before you begin 3.7 Operator's obligations The nutrunner is used in the commercial sector. The operator of the nutrunner is therefore subject to the statutory obligations per- taining to occupational safety. In addition to the safety instructions in this manual, the applicable safety, occupational safety and environmental protection regula- tions for the nutrunner’s area of application must be adhered to.

  • Page 36: Who Is Permitted To Use The Nutrunner

    Before you begin 3.8 Who is permitted to use the nutrunner? WARNING! Danger of injury if personnel are insufficiently qualified! If unqualified personnel perform work on or with the nutrunner or if such persons loiter in the danger zone while work is being performed, dan- gers arise that could cause serious injuries and considerable property damage.
  • Page 37 PAOLI service Certain work may only be performed by PAOLI service or by personnel authorised by Maschinenfabrik Wagner GmbH & Co. KG. Other personnel are not authorised to perform this work. Con- tact PAOLI service or authorised PAOLI partners regarding performance of the work that is due.

  • Page 38: Personal Protective Equipment

    Before you begin 3.9 Personal protective equipment Safety gloves Safety gloves are used to protect the hands from friction, abra- sions, punctures or deeper injuries and from contact with hot sur- faces. Safety shoes Safety shoes protect the feet from crushing, falling parts and from slipping on slippery ground.

  • Page 39: Environmental Protection

    Before you begin 3.10 Environmental protection ENVIRONMENT! Danger for the environment due to incorrect handling of environmentally hazardous sub- stances! If environmentally hazardous substances are han- dled incorrectly, especially if such substances are disposed of incorrectly, this could cause significant damage to the environment.

  • Page 40: Determining The Bolting Process

    Determining the bolting process Determining the bolting process Information about bolted connec- The nutrunner reacts differently to “soft” and “hard” bolted connec- tions tions. Even “soft” and “hard” bolted connections react individually to each other, as the thread and lubrication state can vary from bolted connection to bolted connection.

  • Page 41: Preparing The Nutrunner

    Preparing the nutrunner Preparing the nutrunner Unsecured or overloaded compo- nents WARNING! Danger of injury due to unsecured or over- loaded components! Unsecured components or components subjected to loads exceeding the intended use could result in uncontrolled nutrunner behaviour, outward ejection of components or breakage and thereby cause serious injuries.
  • Page 42 Preparing the nutrunner Slide on the circlip (Fig. 13/1) with the aid of the circlip pliers (Fig. 14) and clamp it. ð The reaction arm is secured. Fig. 14: Circlip pliers Attach the impact wrench socket (nut) to the square drive on the nutrunner and secure it.

  • Page 43: Supplying With Energy

    Supplying with energy Supplying with energy 6.1 Battery care Battery care instructions In order to obtain the full performance, lithium-ion batteries (Li-Ion) require care. Battery care rules The first charging process is crucial. Charge the battery fully prior to first use. Each battery has a limited number of charge cycles.
  • Page 44 Supplying with energy Even when the device is switched off, a small current can flow that leads to a deep discharge after a prolonged period of time. Deep discharge damages the battery and, in extreme cases, will destroy Self-discharge A charge loss of 3% to 5% per month is possible for lithium-ion bat- teries.

  • Page 45: Charging The Battery

    Supplying with energy 6.2 Charging the battery The first time Charge the battery fully prior to first-time use. Electrical current DANGER! Danger of death due to electric shock! If contact is made with live parts, there is an imme- diate danger of death due to electric shock. Damage to the insulation or individual components can be life-threatening.

  • Page 46: Connecting The Nutrunner To The Battery

    Supplying with energy Battery charger The batteries (Fig. 16/2) can be charged using the battery charger (Fig. 16/1) included in the scope of delivery. Fig. 16: Charging the battery Setting up the charger Set up the battery charger in a cool, dry place and connect it to a power socket.

  • Page 47: Setting The Torque Levels

    Setting the torque levels Setting the torque levels Gear setting and setting levels NOTICE! Property damage due to gear and setting level adjustment! Changing the setting during operation causes property damage including destruction of the nutrunner. Changing the gear causes mechanical damage to the gearbox.

  • Page 48: Bracing The Reaction Arm

    Do not use the reaction arm if it is dam- aged. – Brace the reaction arm correctly. Note the fol- lowing instructions regarding bracing. – Always ensure that the reaction arm is in full contact with the surface. – Use only PAOLI original reaction arms.
  • Page 49 (Fig. 19/3) and cannot slip out of place. Note the starting angle of rotation (Fig. 19/2). If the standard reaction arm is not suitable for this, use a suit- able reaction arm. If you have questions, contact PAOLI service. Fig. 20: Reaction arm braced incorrectly...

  • Page 50: Tightening

    Do not use the reaction arm if it is dam- aged. – Brace the reaction arm correctly. Starting the bolting process Contact PAOLI service prior to operation at temperatures below 0°C. Ensure that the nutrunner has been properly prepared and that the bolting process is known.
  • Page 51 Tightening Ensure that the reaction arm (Fig. 21/1) is braced against a bracing surface (Fig. 21/3) on its side facing the nutrunner’s desired direction of rotation. Ensure that there is full contact. Do not retighten. Do not repeat correctly completed bolting processes.
  • Page 52 Tightening Trigger NOTICE! Property damage due to pulsing! Press and hold the trigger (Fig. 22/3) until the bolting process has concluded and an acoustic signal sounds. Do not pulse (press and release the trigger in quick succession). ð If the bolting process was successful, a longer one-off acoustic signal sounds and the next bolting process can be started.

  • Page 53: Loosening

    This can cause breakages. – Do not overload components. Starting the loosening process Contact PAOLI service prior to operation at temperatures below 0°C. Ensure that the nutrunner has been properly prepared and that the bolting process is known.
  • Page 54 Loosening Standard direction of rotation: Right-hand thread To tighten in counterclockwise direction (CCW), push the direction of rotation lever (Fig. 23/2) to the left. ð An acoustic signal sounds if torque levels are blocked. Fig. 23: Direction of rotation Tightening in clockwise direction Loosening in counterclockwise direction Trigger...

  • Page 55: Performing Maintenance

    – Have all repairs performed by the manufacturer. – Never open the nutrunner. – Use only PAOLI original parts. Faultless operation The following sections describe the maintenance tasks that are required in order to ensure optimum and faultless operation of the nutrunner.
  • Page 56 Spare parts must meet the technical requirements specified by parts PAOLI. This is always ensured by original spare parts. A war-ranty can only be provided for original spare parts supplied by PAOLI. The installation or use of other spare parts can, under certain cir- cumstances, adversely alter the specified design properties and, consequently, impair active or passive safety.

  • Page 57: Having The Nutrunner Maintained By The User

    Client Serial number of the nutrunner Desired spare part Desired quantity Desired mode of shipping Ä “PAOLI service” on page 4 11.2 Having the nutrunner maintained by the user Personnel: User Perform the following maintenance steps before and after every...

  • Page 58: Having Service Tasks Performed By The Manufacturer

    Improperly performed service tasks can cause incorrect bolted connections, destruction of the nutrunner and to injuries. – Do not perform service tasks yourself. Contact PAOLI service in good time regarding the fol- lowing service tasks. Service tasks PAOLI service Personnel:...
  • Page 59 Performing maintenance Torque chart The torques need to be checked after repairs and, in the event of deviations, a new torque chart or a new torque selection diagram needs to be created. Newly determined values need to be stored in the nutrunner.

  • Page 60: Troubleshooting

    First note the list of typical errors and issues. Nutrunner, battery or accessory is faulty or shows signs of damage. Contact Ä “PAOLI service” on page 4. FAQs Below is a summary of typical malfunctions, issues and answers. This is intended to provide rapid assistance. For problems that Ä...

  • Page 61: Performing Troubleshooting

    – Never open the nutrunner. – Use only PAOLI original parts. Device damage Contact PAOLI service on page 4 if there is any damage to the nutrunner. Battery Replace a faulty or uncharged battery. Do not put faulty bat- teries into service.

  • Page 62: Disposing Of The Nutrunner

    Disposing of the nutrunner Disposing of the nutrunner The nutrunner must be disposed of in an environmentally sound manner at the end of its service life. Disassembly WARNING! Danger of injury due to short circuit and stored residual energy! If components are damaged, there is a danger of injury due to short circuit or the continued pres- ence of stored residual energy.

  • Page 63: Technical Data

    Technical data Technical data Dimensions and weight Dimensions and weight are dependent on the version. See the technical data sheet in the document folder regarding specific values for the nutrunner. Data Value Unit Weight* 5.4 – 13.5 kg Length 365 – 522 mm Width 68 –...
  • Page 64 Values based on a fully charged 6.0 Ah battery. Type Number of pos- Bolting Torque [Nm] sible bolted con- process nections M 24x95 DP05-34B M 27x95 DP10-34B M 27x95 1,400 DP20-10B M 36x95 2,100 DP30-10B M 36x95...
  • Page 65 Appendix The following documents are supplied with the nutrunner in a docu- ment folder in addition to this manual. EU declaration of conformity USB stick Torque chart Certificates (option) Technical data sheet...
  • Page 66 NOTES...

This manual is also suitable for:

Dp10-34bDp20-10bDp30-10bDp36-10bDp48-15bDp80-15b

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