OPERATION MANUAL / SPARE PARTS LIST

PNEUMATIC TENSIONER
MODEL A452.0001
13.4210.01

13421001.en/MAS/ 05.06

CE Declaration of conformity
We declare that the machine A452
is in conformity with the following standard or
standardised documents:
98/37/EEC
FROMM Holding AG
Hinterbergstrasse 26
CH - 6330 Cham
27.03 2001

R.Fromm
Director

INDEX

PAGE

SAFETY INSTRUCTIONS

WARRANTY CONDITIONS AND LIABILITY

APPROPRIATE USE

TECHNICAL DATA

INSTALLATION

OPERATING CONTROLS

OPERATION

SPARE PARTS LIST 13.4210.01

11

EXCHANGE OF WEARING PARTS

13

10

ADJUSTMENTS

14

11

ASSEMBLING INSTRUCTIONS

15

12

MAINTENANCE

16

SAFETY INSTRUCTIONS

Read these instructions carefully. Failure to follow these instructions can result in severe personal injury.

Eye injury hazard

Failure to wear safety glasses with side shields can result in severe eye injury or blindness. Always wear
safety glasses with side shields which conform to ANSI Standard Z87.1.

Operation
Tool must not be used by persons not properly trained in their use. Before tensioning strap, read and
understand the tool operating instructions. Failure to follow the operating instructions or improper load
positioning could result in strap breakage.
Become familiar with your tool and keep fingers away from areas that can pinch or cut.

Joints
You are fully responsible to review the joints made by your tool. Become familiar with the seal control and seal
adjustment described in this operation manual. Misformed joints may not secure the load and could cause
serious injury. Never handle or ship any load with improperly formed joints.
Dispensing strap
Only dispense strap from a dispenser specifically designed for strap.
Tuck strap end back into dispenser when not in use.
Protective gloves
When handling strap, always wear protective gloves.

Strap warnings
Never use strap as a means of pulling or lifting loads. Failure to follow these warnings can result in severe
personal injury.
Strap breakage hazard
Improper operation of the tool, excessive tensioning, using strap not recommended for this tool or sharp
corners on the load can result in a sudden loss of strap tension or in strap breakage during tensioning, which
could result in the following:
A sudden loss of balance causing you to fall.
Both tool and strap flying violently towards your face.
Note as follows:
If the load corners are sharp, use edge protectors.
Place the strap correctly around a properly positioned load.
Positioning yourself in-line with the strap, during tensioning and sealing, can result in severe personal
injury from flying strap or tool. When tensioning or sealing, position yourself to one side of the strap and
keep all bystanders away.
Use the correct strap quality, strap width, strap gauge and strap tensile strength recommended in this
manual for your tool. Using strap not recommended for this tool can result in strap breakage during
tensioning.
Cutting tensioned strap
When cutting strapping, use the proper strapping cutter and keep other personnel and yourself at a safe
distance from the strap. Always stand to side of the strap, away from the direction the loosened strap end will
fly. Use only cutters designed for strap and never hammers, pliers, hacksaws, axes, etc.
Fall hazard
Keep your working area tidy. Untidiness of your working area may cause a risk of injury. Maintaining improper
footing and/or balance when operating the tool can cause you to fall. Before tensioning and especially in
elevated areas, always establish good balance. Both feet should be securely placed on a flat, solid surface,
especially when working in elevated areas. Do not use the tool when you are in an awkward position.
Pay attention to the rules and regulations for preventions of accident which are valid for the work place.
Tool hazards
A well maintained tool is a safe tool!
Check tool regularly for broken or worn parts. Do not operate a tool with broken or worn parts.
Never modify any tool. Modification can result in severe bodily injury.

WARRANTY CONDITIONS AND LIABILITY

FROMM Holding AG warrants all its strapping tools and machine heads during a period of 90 days from the
date of sale. The warranty includes all deficiencies clearly resulting from poor manufacturing or faulty materials.
Damage claims as a result of production shutdowns and claims for damage to persons and to property resulting
from warranty deficiencies cannot be asserted by the customer.
The warranty excludes:

wearing parts

deficiencies resulting from improper installing, incorrect handling and maintaining the tool

deficiencies resulting from using the tool without or with defective security- and safety devices

disregard of directions in the operation manual

arbitrary modifications of the tool

deficient control of wearing parts

deficient repair works of the tool

Use of consumable products not recommended by FROMM Holding AG

We reserve the right to modify the product at any time in order to improve its quality.

APPROPRIATE USE

The tool model A452 has been designed to strap packages with steel strapping exclusively.
The warranty / liability excludes:
non appropriate use of the tool,
disregard of directions in the operation manual,
disregard of control- and maintenance instructions.

TECHNICAL DATA

Item-No.:

13.4210

Dimensions
Tool:

Package:

Length:

329 mm / 13"

460 mm / 18"

Width:

135 mm / 5.3"

272 mm / 10.7"

Height:

158 mm / 6.2"

180 mm / 7"

Weight:

4.35 kg / 9.6 lbs

1.1 kg / 2.4 lbs

Performance
Max. strap tension:

8.5 KN / 1900 lbs at 6 bar / 87 psi

Tensioning speed:

150 mm/s / 5.9 inch/s

Compressed air
Max. air pressure:

6.0 bar / 87 psi

Joining thread:

G 1/4 or G 3/8" (inside)

Min. inside diam. of air-tube:

8mm / 5/16"

Air consumption:

14.5 Nl/sec. / 0.51cu. ft./sec.

A4520001enT1.man.fm

Steel strap
Width:

19 - 32 mm / 3/4 - 1 1/4"

Thickness:

0.63 - 1.27 mm / .025 - .05"

Tensioning strength:

600 - 1100 N/mm2 / 87 000 - 160 000 psi

Finish:

Waxed, smooth edges

Sound information
The A-weighted equivalent continuous sound level at the work place of the machine operator is
typical 81 dB (A).
This value was determined according to DIN 45 635 T3 (11.85).

Vibration information
The weighted effective value of the acceleration typically amounts to less than 2,5m/s2.
This value was determined according to DIN EN 28 662 T1 (01.93).

INSTALLATION

Compressed air connection

The compressed air is to be connected to the tool preferably by a quick disconnecter.
It is very important to clean the compressed air with an air unit
consisting of a separator for water and dirt, a pressure regulator with a
manometer and a lubricator.
The maximum length of the air tube between air unit and tool has to be 5m/15 ft.

Suspension of tool
The tool can be suspended at the ring nut N1.5924.

A4520001enT1.man.fm

OPERATING CONTROLS
Handle

Air motor
Switch ring

Safety button

OPERATION
When handling strap, always wear
protective gloves and safety glasses with
side shields which conform to
ANSI Standard Z87.1.

Feeding the strap

Feed the strap through the seal around the package
to be strapped;
Push the strap through the seal again;
Bend it;
Pretension the loose strap loop manually.
The bent strap end has to be adjacent to the object
to be strapped!

Introducing the tool

Lift the air motor against the handle;
Introduce the tool from right to left and from rear to
front;
Lower the air motor on the strap.

A4520001enT1.man.fm

Tensioning the strap

Turn the switch ring counter clockwise.
Tensioning is completed when the air motor stalls.
The tension force can be adjusted by the
connected air pressure.
Important! Never exceed 87 psi / 6,0 bar!
Releasing of the switch ring interrupts the
tensioning process.
The reached tension remains.
The unsealed strap can be released by pressing
the safety button.

Sealing the strap

Seal the tensioned strap loop with a suitable sealer
(e.g. Fromm Model A461).

Cutting the strap

Swing the tensioner a maximum of 90 forward
and backward.
If necessary repeat the swing.

Lift the air motor,

remove the strap from the tool.

A4520001enT1.man.fm

N1.5924

N1.1113

A45.1319

N1.6223

N1.6221

N1.1103
N2.4902

N4.9159
N41.9128
N41.9129

N2.5827

N2.5826

N2.2451

A45.1315

A45.1314
A45.1312
A45.1316

A45.0101

N3.2603
N1.1583

N1.1816

A45.1301

N3.2321

A38.3210

A45.0103

N1.3421

A45.1317
A45.1320

N1.6223

N3.2602

N3.2319

N2.2126

N1.1113

13421001.z

A45.1313

6
A45.1304

7
N1.1816
A45.0102

N6.6276

N3.2320

N2.3206

A45.1303

A38.1303

N3.4310

N1.3516

N2.4902

N41.9120

L2.2101
N3.4107

N3.4309

N3.2314

A45.1307
N3.4510
A45.1305

N3.4511

A45.1309
A45.1310

N1.6337

N3.1146

N2.5219

A45.1308

N1.6338

N2.2102

A45.1311

N1.1816

Molycote BR2 plus

Klber Isoflex Alltime SL2
Mobilux EP2

Orientation
Loctite 222

10

L2.2101.z

L2.2218

L2.2217

N3.1169

L2.1308

16 x L2.1402

L2.1403

L2.2219

L2.1404

L2.1404

N6.6285

N3.1170

10

(L2.1203)

L2.2215

L2.1208

N6.6205

L2.1313

L2.2206
L2.2203

L2.1505

N3.1109

L2.2209
N6.6206
N2.5102

L2.2201

L2.2216

N1.6701

N3.1170

L2.1320

N3.1170

16 x L2.1402

L2.1403

16 x L2.1402

L2.1403

L2.1312

L2.1312

L2.1310

L2.1501

L2.1310

L2.1501

L2.1504

L2.2220

N6.6207

L2.2213

12

L2.2101

L2.2204

L2.1302

5 x L2.2205

N1.6321

L2.2212

L2.2210

L2.2211

L2.2214

L2.2202

L2.2208

11

L2.1206

i

Mobilux EP2
ESSO Spinesso 10 C
Molycote BR2 plus
/
50 Nm
/
40 Nm
/
50 Nm
/
20 Nm

N3.1185

N6.6284

L2.2207

13

SPARE PARTS LIST 13.4210.01

13.4210.01

A452/19-32/0.63-1.27/8.5

A452.0001.01

Item-No.

in group

Description

A38.1303

Pcs.

20.04.00
Dimension

Field

1 WORM WHEEL

B6

A38.3210

1 PIVOT PIN

D2

[A45.0101]

1 GEAR BODY

C3

[A45.0102]

1 END COVER

A7

[A45.0103]

1 END COVER

D1

[A45.1301]

A45.0101

A45.1303
A45.1304

A45.0102

1 GEAR BODY

D4

1 TENSION SHAFT

B5

1 END COVER

A6

A45.1305

1 WORM

D5

A45.1307

1 DRIVER

C6

A45.1308

1 RATCHET

D7

A45.1309

1 BUTTON

D4

A45.1310

1 PAWL

D4

A45.1311

1 COVER

E4

A45.1312

1 TENSIONING BODY

C2

A45.1313

1 SLIDE PLATE

E3

A45.1314

1 PAWL

C1

A45.1315

1 DOWEL

C1

A45.1316

1 COVER

C1

1 END COVER

D1

1 HANDLE

A4

[A45.1317]

A45.0103

A45.1319
A45.1320

1 TENSIONING WHEEL

D3

L2.1203

L2.2215

1 PLASTIC JACKET

B10

L2.1206

L2.2207

1 ADAPTOR

B13

L2.1208

L2.2207

1 SEALING SCREW

A10

L2.1302

L2.2201

1 PARALLEL PIN

D12

L2.1308

L2.2101

1 SILENCER

A8

L2.1310

L2.2220

2 NEEDLE CAGE

A9+

L2.1312

L2.2220

2 SHAFT

A9+

L2.1313

L2.2101

1 BEARING RING

D10

L2.1320

L2.2101

1 WASHER

B10

L2.1402

L2.2218

L2.1403

L2.2218

48 BEARING NEEDLE

C9+

3 GEAR WHEEL

C9

L2.1404

L2.2218

3 SHAFT

C9+

L2.1501

L2.2220

2 GEAR WHEEL

A9+

L2.1504

L2.2220

1 PLANET SHAFT

B9

L2.1505

L2.2201

1 KEY

B11

[L2.2101]

1 AIR MOTOR

C7+

1 MOTOR CELL

C10

L2.2201

1 ROTOR

C12

L2.2201

1 CYLINDER

C11

L2.2201

1 END PLATE

D12

L2.2201

5 VANE

C12

[L2.2201]

L2.2101

L2.2202
L2.2203
L2.2204
L2.2205

L2.2206

L2.2201

1 END PLATE

C11

[L2.2207]

L2.2101

1 VALVE HEAD

A13

L2.2208

L2.2207

1 VALVE BODY

A11

L2.2209

L2.2207

1 VALVE PISTON

A11

L2.2210

L2.2207

1 TORSION SPRING

A12

L2.2211

L2.2207

1 DOWEL

A12

L2.2212

L2.2207

1 PARALLEL PIN

L2.2213

L2.2207

1 SWITCH RING

L2.2214

L2.2207

1 BEARING NEEDLE

[ ] = Group
13421001.een.fm

2.5 X 12

B12
B12

2.5 X 17.8

A12

* = Wearing parts
11

13.4210.01

A452/19-32/0.63-1.27/8.5

A452.0001.01

Item-No.

in group

Description

Pcs.

20.04.00
Dimension

Field

[L2.2215]

L2.2101

1 HOUSING

B10

L2.2216

L2.2101

1 EXHAUST RING

D10

L2.2217

L2.2101

1 BEARING RING

C8

[L2.2218]

L2.2101

1 IDLER STEP

D8

L2.2219

L2.2218

1 PLANET SHAFT

C9

[L2.2220]

L2.2101

1 IDLER STEP

A9

N1.1103

1 SCREW

M8 X 25

B3

N1.1113

4 SCREW

M5 X 20

A3+

N1.1583

1 HEXAGON SCREW

M5 X 16

C2

N1.1816

8 SCREW

M4 X 16

A7+

N1.3421

1 SOCKET SET SCREW

M4 X 8

D3

N1.3516

1 SOCKET SET SCREW

M6 X 16

B4

N1.5924

1 RING NUT

M8

A3

N1.6221

1 SPRING LOCK WASHER

M8

B4

N1.6223

4 SPRING LOCK WASHER

M5

A3+

N1.6321

L2.2207

N1.6337
N1.6338
N1.6701

L2.2101

N2.2102
N2.2126

A45.0103

1 SPACER WASHER

20 X 28 X 1

B12

1 SPACER WASHER

17 X 24 X 0.5

D7

1 SPACER WASHER

28 X 40 X 0.5

D7

2 CUP SPRING

C10

1 PARALLEL PIN

5 m6 X 16

E5

1 PARALLEL PIN

5 m6 X 26

E1

N2.2451

1 DOWEL PIN

5 X 45 MM

C2

N2.3206

1 WOODRUFF KEY

6 X 9 X 21.63

A5

4 HAMMER HEAD BOLT

1.85 X 4.76

B4+

1 PRESSURE SPRING

0.6 X 8 X 14/6

A10

N2.5219

1 PRESSURE SPRING

0,7X5,7X12/6

D5

N2.5826

1 TORSION SPRING

3.5/40.0

C3

N2.5827

1 TORSION SPRING

2.0/16.5

N2.4902
N2.5102

N3.1109

L2.2207

L2.2201

N3.1146

C1

1 BALL BEARING

B11

1 BALL BEARING

D6

N3.1169

L2.2101

1 BALL BEARING

B8

N3.1170

L2.2101

3 BALL BEARING

B10+

N3.1185

L2.2201

1 BALL BEARING

C13

N3.2314

A45.0101

1 NEEDLE CASE

C5

N3.2319

A45.0103

1 NEEDLE CASE

E2

N3.2320

A45.0102

1 NEEDLE CASE

A5

N3.2321

A45.0101

1 NEEDLE BUSH

D4

N3.2602

A45.0103

1 PACKING RING

E2

N3.2603

A45.0101

1 PACKING RING

D4

N3.4107

1 THRUST BEARING CAGE

C5

N3.4309

1 THRUST RACE

C6

N3.4310

2 THRUST RACE

B5

N3.4510

1 FREE-WHEELING

D6

N3.4511

1 ROLLER BEARING

D7

N41.9120

1 TYPE PLATE

N41.9128

1 ADHESIVE LABEL

N41.9129

1 ADHESIVE LABEL

N4.9159

1 LABEL

<<A452>>

B4
B3
C4

<<CE>>

B4

N6.6205

L2.2207

1 O-RING

9.2 X 1.78

A10

N6.6206

L2.2207

1 O-RING

4.3 X 2.4

A10

N6.6207

L2.2207

1 O-RING

3.1 X 1.6

A11

N6.6276

A45.0102

1 O-RING

48.9 X 2.62

A5

N6.6284

L2.2207

2 O-RING

14.1 X 1.6

B13

N6.6285

L2.2101

1 O-RING

39.4 X 1.6

D10

[ ] = Group
12

* = Wearing parts
13421001.een.fm

EXCHANGE OF WEARING PARTS

9.1

Exchange of tension wheel and sliding plate

Unscrew end cover.
Pull off tension wheel A45.1320 from tension shaft.
Loose lock screw N1.3421.
Unscrew sliding plate A45.1313 to the bottom.
Assemble in opposite order (attend to the assembling direction of the tension wheel).

If the sliding plate or the tension wheel have been changed, they have to be adjusted after assembling!
(see 10.1)

N1.3516

A45.1320

N1.3421

A45.1313

A4520001enT2.man.fm

13

10 ADJUSTMENTS
10.1 Adjustment of sliding plate/ tension wheel

~ 0.5mm

~ 0.05mm

N1.3516

Screw the sliding plate in the tensioning body from the bottom until it raises 0,5mm above the surface of the
tensioning body.
Screw the lock screw N1.3421 in the nearest possible gap of the sliding plate.
Adjust the gap between sliding plate and tension wheel to 0,05mm with the adjustment screw N1.3516.
The rotating tension wheel must not touch the sliding plate in any case.!

10.2 Adjustment of the pawl

N1.1583

1.5mm

Ex works the maximum opening of the pawl

A45.1314 is adjusted to 1,5mm.
If necessary the opening angle can be
reduced with the adjustment screw
N1.1583.

14

A4520001enT2.man.fm

11 ASSEMBLING INSTRUCTIONS
Free-wheeling N3.4510

A45.1307

The driverA45.1307 has to be turned in

the freewheeling in arrow direction.

N3.4510

Ball bearing N3.1169

The thicker side of the outside ring of the ball bearing must
face towards the air motor.

N3.1169

Cup springs N1.6701

The two cup springs has to be assembled in the air motor
as shown.

N1.6701

Bearing needle L2.2214

When assembling the bearing needle L2.2214 in the
valve body L2.2208 the mentioned pressing in dimension
must be observed.

L2.2214

L2.2208

A4520001enT2.man.fm

15

12 MAINTENANCE
Depending on the working conditions and the use of the tool the following maintenance has to be made
periodically:

12.1 Air unit

Checking the air-pressure daily (never exceed 87psi / 6 bar)

Checking oil-level daily
The water separator must be emptied before it is full (unless automatic).
The filter has to be cleaned following the instructions of the manufacturer of the air- unit.

Oil for air unit

HL or CL ISO-VG 10

12.2 Cleaning
If impact of dirt and dust is considerable and if painted or zinc coated straps are used the tension wheel must
be cleaned regularly. Normally it is sufficient to blow it out by the use of an air gun.

12.3 Lubrication
The worm gear is lubricated with MOLYKOTE BR2 PLUS. For relubrication purposes after possible repairs
only this type of grease must be used.
The free wheeling N3.4510 and the roller bearing N3.4511 have to be lubricated with Klber Isoflex Alltime
SL2 when being assembled.
When being exchanged, all movable parts have to be greased with grease of type MOBILUX EP2 or with any
equivalent product.

16

A4520001enT2.man.fm