Stanley 07530 Manual de utilizare

INSTRUCTION AND

SERVICE MANUAL

ORIGINAL INSTRUCTION

0753 MKII Type - Repetition Tool for Speed Rivets - 07530 / 07531 / 07532

Hydro-Pneumatic Power Tool

EN

Hydro-Pneumatic Power Tool

BG

Хидро-пневматичен електроинструмент

HR

Hidro-pneumatski električni alat

CZ

Hydropneumatické nářadí

RO

Unealtă hidro-pneumatică

HU

Hidropneumatikus szerszámgép

SK

Hydro-pneumatické elektrické náradie

SL

Hidro-pnevmatsko električno orodje

RU

Гидропневматический электроинструмент

AR



LV

Hidropneimatiskais elektroinstruments

LT

Hidraulinis-pneumatinis elektrinis įrankis

ET

Hüdropneumaatiline tööriist

EL

Υδροπνευματικό εργαλείο ισχύος

TR

Hidro-Pnömatik Elektrikli Alet

The information provided may not be reproduced and/or made public in any way and through any means (electronically

or mechanically) without prior explicit and written permission from STANLEY Engineered Fastening. The information

provided is based on the data known at the moment of the introduction of this product. STANLEY Engineered Fastening

pursues apolicy of continuous product improvement and therefore the products may be subject to change. The information

provided is applicable to the product as delivered by STANLEY Engineered Fastening. Therefore, STANLEY Engineered

Fastening cannot be held liable for any damage resulting from deviations from the original specications of the product.

The information available has been composed with the utmost care. However, STANLEY Engineered Fastening will not

accept any liability with respect to any faults in the information nor for the consequences thereof. STANLEY Engineered

Fastening will not accept any liability for damage resulting from activities carried out by third parties. The working names,

trade names, registered trademarks, etc. used by STANLEY Engineered Fastening should not be considered as being free,

pursuant to the legislation with respect to the protection of trademarks.

2

ENGLISH ORIGINAL INSTRUCTION

CONTENT

1. SAFETY DEFINITIONS ................................................................................................................................................... 4

1.1 GENERAL SAFETY RULES .......................................................................................................................................................................... 4

1.2 PROJECTILE HAZARDS .............................................................................................................................................................................. 4

1.3 OPERATING HAZARDS ............................................................................................................................................................................... 5

1.4 REPETITIVE MOTIONS HAZARDS............................................................................................................................................................ 5

1.5 ACCESSORY HAZARDS .............................................................................................................................................................................. 5

1.6 WORKPLACE HAZARDS ............................................................................................................................................................................. 5

1.7 NOISE HAZARDS .......................................................................................................................................................................................... 5

1.8 VIBRATION HAZARDS................................................................................................................................................................................. 5

1.9 ADDITIONAL SAFETY INSTRUCTIONS FOR PNUEMATIC AND HYDRAULIC TOOLS .............................................................. 6

2. SPECIFICATIONS ............................................................................................................................................................ 7

2.1 SPECIFICATION FOR 0753 MK II TYPE TOOL ....................................................................................................................................... 7

2.2 SPECIFICATION FOR 07531 INTENSIFIER ............................................................................................................................................. 7

3. INTENT OF USE .............................................................................................................................................................. 8

3.1 TOOL DIMENSIONS - 07530 MKII MODEL ........................................................................................................................................... 9

3.2 TOOL DIMENSIONS - 07532 MKII MODEL ........................................................................................................................................... 9

4. PUTTING INTO SERVICE ..............................................................................................................................................10

4.1 AIR SUPPLY ..................................................................................................................................................................................................10

4.2 CURSOR ........................................................................................................................................................................................................12

4.3 LOADING AND RELOADING THE TOOL ..............................................................................................................................................12

4.4 OPERATING PROCEDURE ........................................................................................................................................................................13

4.5 PLACING EQUIPMENT .............................................................................................................................................................................. 13

5. SERVICING THE TOOL..................................................................................................................................................14

5.1 DAILY .............................................................................................................................................................................................................14

5.2 WEEKLY .........................................................................................................................................................................................................14

5.3 MOLY LITHIUM GREASE EP 3753 SAFETY DATA..............................................................................................................................14

5.4 SERVICE KIT ..................................................................................................................................................................................................15

6. MAINTENANCE ............................................................................................................................................................16

6.1 DISMANTLING 07530-02200 MKII .......................................................................................................................................................16

6.2 DISMANTLING 07532-02200 MKII .......................................................................................................................................................18

6.3 GENERAL ASSEMBLY OF BASE TOOL 07530-02200 MKII ............................................................................................................. 20

6.4 PARTS LIST FOR BASE TOOL 07530-02200 MKII ..............................................................................................................................21

6.5 GENERAL ASSEMBLY OF BASE TOOL 07532-02200 MKII ............................................................................................................. 22

6.6 PARTS LIST FOR BASE TOOL 07532-02200 MKII ..............................................................................................................................23

6.7 INTENSIFIER 07531-02200 - MAINTENANCE ....................................................................................................................................24

6.8 INTENSIFIER 07531-02200 ......................................................................................................................................................................25

6.9 PILOT VALVE 07005-00590 - MAINTENANCE ...................................................................................................................................27

6.10 PROTECTING THE ENVIRONMENT .......................................................................................................................................................27

6.11 PILOT VALVE 07005-00590 - SPARES INFORMATION .....................................................................................................................28

7. PRIMING ......................................................................................................................................................................29

7.1 OIL DETAILS ................................................................................................................................................................................................. 29

7.2 HYSPIN VG 32 AND AWS 32 OIL SAFETY DAT ..................................................................................................................................29

7.3 PRIMING PROCEDURE..............................................................................................................................................................................29

8. FAULT DIAGNOSIS ....................................................................................................................................................... 30

9. EC DECLARATION OF CONFORMITY .......................................................................................................................... 32

10. UK DECLARATION OF CONFORMITY........................................................................................................................33

11. PROTECT YOUR INVESTMENT! ...................................................................................................................................34

3

ORIGINAL INSTRUCTION ENGLISH

This instruction manual must be read by any person installing or operating this tool with particular attention to the

following safety rules.

Always wear impact-resistant eye protection during operation of the tool. The grade of protection required should

be assessed for each use.

Use hearing protection in accordance with employer’sinstructions and as required by occupational health and

safety regulations.

Use of the tool can expose the operator’shands to hazards, including crushing, impacts, cuts and abrasions and

heat. Wear suitable gloves to protect hands.

1. SAFETY DEFINITIONS

The denitions below describe the level of severity for each signal word. Please read the manual and pay attention to these

symbols.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING: Indicates apotentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION: Indicates apotentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol indicates apotentially hazardous situation which, if not avoided, may

result in property damage.

Improper operation or maintenance of this product could result in serious injury and property damage. Read and

understand all warnings and operating instructions before using this equipment. When using power tools, basic safety

precautions must always be followed to reduce the risk of personal injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

1.1 GENERAL SAFETY RULES

• For multiple hazards, read and understand the safety instructions before installing, operating, repairing, maintaining,

changing accessories on, or working near the tool. Failure to do so can result in serious bodily injury.

• Only qualied and trained operators must install, adjust or use the tool.

• DO NOT use outside the design intent of placing STANLEY Engineered Fastening Blind Rivets.

• Use only parts, fasteners, and accessories recommended by the manufacturer.

• DO NOT modify the tool. Modications can reduce the eectiveness of safety measures and increase the risks to the

operator. Any modication to the tool undertaken by the customer will be the customer’sentire responsibility and void

any applicable warranties.

• Do not discard the safety instructions; give them to the operator.

• Do not use the tool if it has been damaged.

• Prior to use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that aects

the tool’soperation. If damaged, have the tool serviced before using. Remove any adjusting key or wrench before use.

• Tools shall be inspected periodically to verify that the ratings and markings required by this part of ISO 11148 are legibly

marked on the tool. The employer/user shall contact the manufacturer to obtain replacement marking labels when

necessary.

• The tool must be maintained in asafe working condition at all times and examined at regular intervals for damage

and function by trained personnel. Any dismantling procedure will be undertaken only by trained personnel. Do not

dismantle this tool without prior reference to the maintenance instructions.

1.2 PROJECTILE HAZARDS

• Disconnect the tool from the air supply before performing any maintenance, attempting to adjust, t or remove anose

assembly or accessories.

• Be aware that failure of the workpiece or accessories, or even of the inserted tool itself can generate high-velocity

projectiles.

• Always wear impact-resistant eye protection during operation of the tool. The grade of protection required should be

assessed for each use.

• The risks to others should also be assessed at this time.

• Ensure that the workpiece is securely xed.

• Check that the means of protection from ejection of fastener and/or mandrel is in place and is operative.

• Warn against the possible forcible ejection of mandrels from the front of the tool.

• DO NOT operate atool that is directed towards any person(s).

4

ENGLISH ORIGINAL INSTRUCTION

1.3 OPERATING HAZARDS

• Use of the tool can expose the operator’shands to hazards, including crushing, impacts, cuts and abrasions and heat.

Wear suitable gloves to protect hands.

• Operators and maintenance personnel shall be physically able to handle the bulk, weight and power of the tool.

• Hold the tool correctly; be ready to counteract normal or sudden movements and have both hands available.

• Keep tool handles dry, clean, and free from oil and grease.

• Maintain abalanced body position and secure footing when operating the tool.

• Release the start-and-stop device in the case of an interruption of the hydraulic supply.

• Use only lubricants recommended by the manufacturer.

• Contact with hydraulic uid should be avoided. To minimise the possibility of rashes, care should be taken to wash

thoroughly if contact occurs.

• Material Safety Data Sheets for all hydraulic oils and lubricants is available on request from your tool supplier.

• Avoid unsuitable postures as it is likely for these positions not to allow counteracting of normal or unexpected

movement of the tool.

• If the tool is xed to asuspension device, make sure that the xation is secure.

• Beware of the risk of crushing or pinching if nose equipment is not tted.

• DO NOT operate tool with the nose casing removed.

• Adequate clearance is required for the tool operator’shands before proceeding.

• When carrying the tool from place to place keep hands away from the trigger to avoid inadvertent activation.

• DO NOT abuse the tool by dropping or using it as ahammer.

• Care should be taken to ensure that spent mandrels do not create ahazard.

1.4 REPETITIVE MOTIONS HAZARDS

• When using the tool, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of the

body.

• While using the tool, the operator should adopt acomfortable posture whilst maintaining asecure footing and

avoiding awkward or o-balance postures. The operator should change posture during extended tasks; this can help

avoid discomfort and fatigue.

• If the operator experiences symptoms such as persistent or recurring discomfort, pain, throbbing, aching, tingling,

numbness, burning sensations or stiness, these warning signs should not be ignored. The operator should tell the

employer and consult aqualied health professional.

1.5 ACCESSORY HAZARDS

• Disconnect the tool from the air supply before tting or removing the nose assembly or accessory.

• Use only sizes and types of accessories and consumables that are recommended by the manufacturer of the tool; do

not use other types or sizes of accessories or consumables.

1.6 WORKPLACE HAZARDS

• Slips, trips and falls are major causes of workplace injury. Be aware of slippery surfaces caused by use of the tool and

also of trip hazards caused by the air line or hydraulic hose.

• Proceed with care in unfamiliar surroundings. There can be hidden hazards, such as electricity or other utility lines.

• The tool is not intended for use in potentially explosive atmospheres and is not insulated against contact with electric

power.

• Ensure that there are no electrical cables, gas pipes, etc., which can cause ahazard if damaged by use of the tool.

• Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts.

Loose clothes, jewellery or long hair can be caught in moving parts.

• Care should be taken to ensure that spent mandrels do not create ahazard.

1.7 NOISE HAZARDS

• Exposure to high noise levels can cause permanent, disabling hearing loss and other problems, such as tinnitus

(ringing, buzzing, whistling or humming in the ears). Therefore, risk assessment and the implementation of appropriate

controls for these hazards are essential.

• Appropriate controls to reduce the risk may include actions such as damping materials to prevent workpieces from

“ringing”.

• Use hearing protection in accordance with employer’sinstructions and as required by occupational health and safety

regulations.

• Operate and maintain the tool as recommended in the instruction manual, to prevent an unnecessary increase in the

noise level.

1.8 VIBRATION HAZARDS

• Exposure to vibration can cause disabling damage to the nerves and blood supply of the hands and arms.

• Wear warm clothing when working in cold conditions and keep your hands warm and dry.

5

ORIGINAL INSTRUCTION ENGLISH

• If you experience numbness, tingling, pain or whitening of the skin in your ngers or hands, stop using the tool, tell

your employer and consult aphysician.

• Where possible Support the weight of the tool in astand, tensioner or balancer, because alighter grip can then be used

to support the tool.

1.9 ADDITIONAL SAFETY INSTRUCTIONS FOR PNEUMATIC & HYDRAULIC POWER TOOLS

• The operating supply air must not exceed 7 bar (100 PSI).

• Air under pressure can cause severe injury.

• Never leave operating tool unattended. Disconnect air hose when tool is not in use, before changing accessories or

when making repairs.

• DO NOT let air exhaust opening on the mandrel collector face in the direction of the operator or other persons. Never

direct air at yourself or anyone else.

• Whipping hoses can cause severe injury. Always check for damaged or loose hoses and ttings.

• Prior to use, inspect airlines for damage, all connections must be secure. Do not drop heavy objects on hoses. A sharp

impact may cause internal damage and lead to premature hose failure.]

• Cold air shall be directed away from hands.

• Whenever universal twist couplings (claw couplings) are used, lock pins shall be installed and whipcheck safety cables

shall be used to safeguard against possible hose-to-tool or hose-to-hose connection failure.

• DO NOT lift the placing tool by the hose. Always use the placing tool handle.

• Vent holes must not become blocked or covered.

• Keep dirt and foreign matter out of the hydraulic system of the tool as this will cause the tool to malfunction.

• Oil under pressure can cause severe injury.

• Prior to use, inspect hydraulic hoses for damage. All hydraulic connections must be clean, fully engaged and tight

before operation. Do not drop heavy objects on hoses. A sharp impact may cause internal damage and lead to

premature hose failure.

• DO NOT pull or move the intensier unit using the hoses. Always use the unit handle.

• Use only clean oil and lling equipment.

• Only recommended hydraulic uids may be used.

• Maximum temperature of the hydraulic uid at the inlet is 100°C (212°F).

WARNING: While a small amount of wear and marking will naturally occur through normal and correct use of mandrels,

they must be regularly examined for excessive wear and marking, with particular attention to the head diameter, the

tail jaw gripping area of the shank or heavy pitting of the shank and any mandrel distortion. Mandrels which fail during

use could forcibly exit the tool. It is the customer’s responsibility to ensure that mandrels are replaced before any

excessive levels of wear and always before the maximum recommended number of placings. Contact your STANLEY

Engineered Fastening representative who will let you know what that gure is by measuring the broach load of your

application with our calibrated measuring tool.

STANLEY Engineered Fastening policy is one of continuous product development and improvement and we reserve

the right to change the specication of any product without prior notice.

6

ENGLISH ORIGINAL INSTRUCTION

2. SPECIFICATIONS

2.1 SPECIFICATION FOR 0753 MK II TYPE TOOL

Air Pressure Minimum - Maximum 5-7 bar (70-100 lbf/in2)

Free Air Volume Required @ 5.1 bar /75 lbf/in22.6 litres (0.09 ft3)

Stroke Minimum 30.0 mm (1.18 in)

Pull Force @ 5.5 bar /80 lbf/in23.89 kN (875 lbf)

Cycle time Approximately 1 second

Weight Pistol 1.2 kg (2.64 lb)

2.2 SPECIFICATION FOR 07531 INTENSIFIER

Air Pressure Minimum - Maximum 5-7 bar (70-100 lbf/in2)

Intensication Ratio 32:1

Noise values determined according to noise test code ISO 15744 and ISO 3744. 0753

A-weighted sound power level dB(A), LWA Uncertainty noise: kWA = 2.3 dB(A) 85.7 dB(A)

A-weighted emission sound pressure level at the work station

dB(A), LpA

Uncertainty noise: kpA = 2.3 dB(A) 74.8 dB(A)

C-weighted peak emission sound pressure level dB(C), LpC, peak Uncertainty noise: kpC = 2.5 dB(C) 97.9 dB(C)

Vibration values determined according to vibration test code ISO 20643 and ISO 5349. 0753

Vibration emission level, ahd:Uncertainty vibration: k = 0.19 m/s 0.73 m/s

Declared vibration emission values in accordance with EN 12096

7

ORIGINAL INSTRUCTION ENGLISH

3. INTENT OF USE

The pneumatic 0753 MkII type tool is designed to place Stanley Engineered Fastening speed fasteners (except /” Avlug®)

making it ideal for batch or owline assembly in a wide variety of applications throughout all industries.

The Hand Tool and Intensier have been tested as separate items and combined. They must only be used together and for

no other purposes. Refer to "Putting into Service" on page 10 for connection details.

Both models, the 07530 MkII and 07532 MkII are hand-held lightweight tools. Their only dierence lies in the location of the

hose entry.

The top entry on the 07532 MkII tool allows suspension from an added mounting plate, see drawing opposite. Part numbers

are shown to order a complete tool including the intensier and all hoses but no nose equipment.

The pistol number for the 07530 MkII model is 07530-02200 and is 07532-02200 for the 07532 MkII model. See the general

assemblies on pages 20-23.

Both models will place the same fasteners and both will place most repetition fasteners, as shown in the table below.

Both models make use of the same nose equipment. Reference must be made to the Accessories manual (07900-09508)

when selecting compatible components for the type and size of fastener used in your application.

DO NOT use under wet conditions or in the presence of ammable liquids or gases.

FASTENER

NAME

FASTENER SIZE

/"/"/"/"/"2.5mm

2.8mm 3mm 3.5mm 4mm 6mm M2.5 4-40 UNC M3 6-32 UNC

CHOBERT® 

GROVIT® 

AVLUG®  

BRIV®  

RIVSCREW® 

AVTRONIC® 

AVSERT®  

NEOSPEED(R) 

8

ENGLISH ORIGINAL INSTRUCTION

3.1 TOOL DIMENSIONS - 07530 MKII MODEL

Part Number 07530-02100

0753

60

2.36

28

1.10

98

3.85

200

7.87

130

5.12

420

16.54

475

18.70 338

13.30

51

2

163

6.41

140

5.51

50

1.96

3.2 TOOL DIMENSIONS - 07532 MKII MODEL

Part Number 07532-02100

60

2.36

28

1.10

98

3.85

163

6.41

140

5.51

0753

475

18.70

338

13.30

51

2

50

1.96

130

5.12

200

7.87

420

16.54

Dimensions shown in bold are millimetres. Other dimensions are in inches.

9

ORIGINAL INSTRUCTION ENGLISH

4. PUTTING INTO SERVICE

4.1 AIR SUPPLY

All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators

and automatic oiling/ltering systems on the main air supply. To ensure maximum tool life and minimum tool maintenance

they should be tted within 3 metres of the tool (see diagram below).

Air supply hoses should have a minimum working eective pressure rating of 150% of the maximum pressure produced

in the system or 10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and

should be armoured where operating conditions may result in hoses being damaged. All air supply hoses MUST have a

minimum bore diameter of 6.4 millimetres or 1/4 inch.

Read daily servicing details page 14.

8

6

4

2

0

10

12

14

16

TAKE OFF POINT

FROM MAIN SUPPLY

STOP COCK

(USED DURING MAINTENANCE

OF FILTER/REGULATOR

OR LUBRICATION UNITS)

MAIN SUPPLY

DRAIN POINT

PRESSURE REGULATOR

AND FILTER

(DRAIN DAILY)

LUBRICATOR

3

M

E

T

R

E

S

M

A

X

I

M

U

M

0 7 5 3

TYPE

Follow the steps below when connecting the tool to the intensier and main air supply:

• Push the end of the large hydraulic hose from the tool into the quick release connector on the end of the intensier.

• On the front face of the intensier:

• Push the blue pneumatic (4mm OD) line into the reducer tting which is located in the left hand bulkhead

connector.

• Push the black pneumatic (4mm OD) line into the plastic collet of the right hand bulkhead connector.

• Fit a pneumatic hose between the male connector at the rear of the intensier and main air supply.

10

ENGLISH ORIGINAL INSTRUCTION

NOSE

JAWS

TOOL

BARREL

CURSOR

SPRING

LOADED END

For reference there are three dierent mechanical cursor types:

• 07271-01100 Used for Standard mandrels and /” Disposable mandrels

• 07279-05843 Used for /” Disposable mandrels

• 07279-05845 Used for /” Disposable mandrels

The dierence in the above assemblies is the internal diameter of the End Plug.

END PLUG

These are colour coded see below:

MECHANICAL CURSOR

PART NO. END PLUG PART NO. COLOUR HOLE DIAMETER (mm)

07271-01100 07150-00402 PLAIN STEEL 2.7

07279-05843 07159-05844 GOLD 2.2

07279-05845 07159-05846 SILVER 3.3

11

ORIGINAL INSTRUCTION ENGLISH

4.2 CURSOR

IMPORTANT

If tted incorrectly, the cursor will not allow feeding of the fasteners.

While the cursor will be tted the correct way round when the tool is supplied, we recommend that you check its orientation

before tting the nose equipment. The sprung loaded, slightly concave, end of the cursor should point towards the front of

the tool as shown in the illustration.

When tted the correct way round, the cursor will easily slide out of the barrel when a mandrel is pushed into its centre then

pulled back.

To reverse the orientation of the cursor, follow these steps:

Item numbers in bold refer to the general assembly and parts list for

the 07530-02200 MkII type on pages 20-21. For the 07532-02200

MkII type, the procedure is the same but the part numbers must be

taken from the general assembly and parts list on pages 22-23.

• Remove the clip 47 and slide o end cap 38.

• Using an Allen Key, remove one cap head screw 44 ensuring

that any trapped air is exhausted. remove the second cap head

screw 44.

• Pull out rear plug 46.

• Pull out tail jaw piston assembly 14 together with jaws 9.

• Lift out spring 13 and jaw housing 8.

• Insert a mandrel into the hole in the rear end of barrel 25 until it protrudes through the front of the barrel, then pull out

the mandrel and cursor together through the front.

• Reassemble components in reverse order.

• Insert Mechanical Cursor Assembly 5 into the front of the barrel, correct way round.

4.3 LOADING AND RELOADING THE TOOL

IMPORTANT

The procedure for loading the tool and for tting the nose equipment to the tool is integral.

When ordering a complete tool or system you will normally be supplied with all the nose equipment required for the

fastener to be placed.

To identify nose equipment components or to select the correct elements, read the nose equipment section, in the

accessories manual (07900-09508).

If you have been supplied with a nose jaw, mandrels and mandrel follower springs proceed with loading the tool and tting

the nose equipment as shown overleaf.

NOSE

JAWS

TOOL

BARREL

CURSOR

SPRING

LOADED END

Item numbers in bold refer to the general assembly and parts list for the 07530-02200 MkII type on pages 20-21. For the

07532-02200 MkII type, the procedure is the same but the part numbers must be taken from the general assembly and parts

list on pages 22-23.

12

ENGLISH ORIGINAL INSTRUCTION

Loading the Tool

• Connect the air supply to the tool.

• Open tail jaws 9 which grip the mandrel, by switching o the tail jaw switch (items 26 and 30).

• Screw selected nose jaws onto barrel 25 of the tool.

• Insert a mandrel into the tail end of the fasteners through the paper pod.

• Slide the mandrel follower spring onto the mandrel ensuring correct orientation, as shown in the accessories manual

(part number 07900-09508).

• Gripping the tail end of the mandrel, tear o the paper pod from around the fasteners.

• Open the nose jaws either by rotating the outer ring on Cam operated jaws or by pushing outwards on the jaw ends, as

illustrated below left.

• Insert the previously assembled mandrel, mandrel follower spring and fasteners into the nose jaws until the rst

fastener to be placed is protruding from the nose jaw.

• Close the nose jaws and adjust so that the rst fastener protrudes by 1.5mm - 3mm (/” to /”), as shown in the

illustration below right.

• Close the tail jaws to ensure the mandrel is gripped, by switching on the tail jaw switch (items 26 and 30).

1.5mm - 3mm

(1/16 " - 1/8 ")

Reloading the Tool

• Open tail jaws 9 of tool.

• Open the nose jaws and pull the empty mandrel and mandrel follower spring out of the tool.

• Reload the tool by following the above instructions, starting at stage.

4.4 OPERATING PROCEDURE

IMPORTANT

You must check that the cursor orientation and the nose equipment are correct before attempting to operate the tool.

• Push the fastener, protruding from the nose jaws, fully into the application holes ensuring that the tool is held square.

• Operate the trigger without releasing - the mandrel head is pulled through the fastener, forming the fastener into the

application.

• Remove the tool.

• Release the trigger. The next fastener will be automatically presented through the nose jaws, ready for placing.

4.5 PLACING EQUIPMENT

All nose equipment, mandrels, follower springs and other accessories can be found in the accessories manual (part number

07900-09508).

Item numbers in bold refer to the general assembly and parts list for the 07530-02200 MkII type on pages 20-21. For the

07532-02200 MkII type, the procedure is the same but the part numbers must be taken from the general assembly and parts

list on pages 22-23.

13

ORIGINAL INSTRUCTION ENGLISH

5. SERVICING THE TOOL

Regular servicing should be carried out and a comprehensive inspection performed annually or every 500,000 cycles,

whichever is sooner.

IMPORTANT

The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel.

The operator should not be involved in maintenance or repair of the tool unless properly trained.

5.1 DAILY

• Daily, before use or when rst putting the tool into service. Pour a few drops of clean lubricating oil into the air inlet of

the intensier if no lubricator is tted on air supply. If the tool is in continuous use, the air hose should be disconnected

from the main air supply and the tool lubricated every two to three hours.

• Check for air and oil leaks. If damaged, hoses and couplings should be replaced.

• If there is no lter on the pressure regulator, bleed the airline to clear it of accumulated dirt or water before connecting

the air hose to the intensier. If there is a lter, drain it.

• Check that the nose equipment is correct.

• Check mandrels regularly for signs of wear or damage monitoring the number of placings (read the safety instructions

on page 4 - 6).

5.2 WEEKLY

• Conduct the full “Daily” procedures as described above.

• Remove, inspect, clean and grease the Tail Jaws (refer to “Tail Jaw Cylinder” in the "Maintenance Section" page 16).

• Check oil level in the intensier Unit reservoir is approximately 12mm (/”) below the transparent cover plate.

CAUTION: Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals

may weaken the materials used in these parts

5.3 MOLY LITHIUM GREASE EP 3753 SAFETY DATA

Grease can be ordered as a single item, the part number is shown in the service kit page 15.

First Aid

SKIN:

As the grease is completely water resistant it is best removed with an approved emulsifying skin cleaner.

INGESTION:

Ensure the individual drinks 30ml Milk of Magnesia, preferably in a cup of milk.

EYES:

Irritant but not harmful. Irrigate with water and seek medical attention.

Fire

FLASH POINT: Above 220°C.

Not classied as ammable.

Suitable extinguishing media: CO, Halon or water spray if applied by an experienced operator.

Environment

Scrape up for burning or disposal on approved site.

Handling

Use barrier cream or oil resistant gloves

Storage

Away from heat and oxidising agent.

14

ENGLISH ORIGINAL INSTRUCTION

5.4 SERVICE KIT

For all servicing we recommend the use of the service kit (part number 07900-05300).

SERVICE KIT

ITEM PART Nº DESCRIPTION Nº OFF ITEM PART Nº DESCRIPTION Nº OFF

07900-00157 CIRCLIP PLIERS 1 07900-00352 SEAL REMOVAL HOOK 1

07900-00006 SPATULA 1 07900-00710 BARREL PLUG REMOVAL SPANNER 1

07900-00446 EXTRACTOR 1 07900-00725 BULLET 1

07900-00603 BARREL VICE JAWS 1 07900-00243 SCREWDRIVER 1

07900-00520 ⁄" ROD 1 07900-00717 INTENSIFIER SPANNER 1

07900-00521 ⁄" ROD 1 07900-00013 ⁄" ALLEN KEY 1

07900-00602 'O' RING ASSEMBLY BULLET 1 07900-00617 LOCTITE MULTI-GASKET 574 50ml PACK 1

07900-00595 18mm SPANNER 1 07900-00469 2.5mm ALLEN KEY 1

07900-00434 32mm SPANNER 1 07900-00351 3mm ALLEN KEY 1

07900-00237 ⁄" × ⁄" BSW SPANNER 1 07900-00224 4mm ALLEN KEY 1

07900-00012 ⁄" × ⁄" SPANNER 1 07900-00225 5mm ALLEN KEY 1

07900-00008 ⁄" × ⁄" SPANNER 1 07992-00020 80g TIN MOLY LITHIUM GREASE EP 3753 1

Note: Spanner sizes are measured 'across ats' unless otherwise specied.

15

ORIGINAL INSTRUCTION ENGLISH

6. MAINTENANCE

Every 500,000 cycles the tool should be completely dismantled and new components should be used where worn, damaged

or when recommended. All ‘O’ rings and seals should be renewed and lubricated with Moly Lithium grease EP 3753 before

assembling.

IMPORTANT

Safety Instructions appear on page 4 - 6.

The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel.

The operator should not be involved in maintenance or repair of the tool unless properly trained.

The airline must be disconnected before any servicing or dismantling is attempted, unless specically instructed otherwise.

It is recommended that any dismantling operation be carried out in clean conditions.

Dismantling of the 07530 MkII and 07532 MkII are covered separately. For the 07530 MkII refer to the dismantling procedures

below and for the 07532 MkII refer to pages 16-18. Item numbers in bold refer to the general assemblies and parts lists

for the respective model on pages 20-23.

Prior to dismantling the tool, you will need to remove the nose equipment.

For total tool servicing we advise that you proceed with the dismantling of sub-assemblies in the order shown below after

having disconnected the hydraulic hose from the intensier unit and the trigger air line from the intensier valve, thus

separating the pistol unit from the intensier unit.

The potentially dangerous substances that could have deposited on the machine as a result of work processes must be

removed before maintenance.

6.1 DISMANTLING 07530-02200 MKII

To dismantle the 07532-02200 MkII refer to pages 18-19.

TAIL JAW CYLINDER

• Manually ip the Clip 47 up and remove the End Cap 38.

• Using an Allen Key*, remove one Cap Head Screw 44 ensuring that any trapped air in the tail jaw cylinder is exhausted.

Remove the second Cap Head Screw 44.

• Pull out Rear Plug 46.

• Extract air tail jaw components, comprising Tail Jaw Piston Assembly 14, Spring 13, Jaws 9 and Jaw Housing 8.

• Remove plug at rear of piston assembly using an Allen Key* and a bar through the large slot in the turret.

• Clean out turret using a 4.7mm (/”) drill and replace plug using a non-hardening sealing compound, e.g. Loctite Multi-

gasket 574*.

• Remove piston seal ‘O’ Ring 10.

• Using an Allen Key*, remove all ve handle moulding securing Screws 34, 39 and Nuts 33 from the tool handle.

• Grip Barrel 25 in a vice using soft jaws* to avoid damage.

• Using a box spanner*, unscrew Barrel Plug 7, preventing Barrel 25 turning by using an open ended spanner*.

• Disconnect Air Tail Jaw Concertina Tube 12 from Switch Block 28 and pull Tail Jaw Cylinder 6 from tool.

• Remove ‘O’ Ring 4, Rubbing Strip 15 and Barrel Return Spring 16.

• Free length of Spring 13 should be 38.1mm (1.5”). Replace if necessary.

• Coat the tail jaws with Moly Lithium grease before assembling.

• Assemble in reverse order of dismantling.

* Refers to items included in the 0753 Mkll service kit. For complete list see page 15.

Item numbers in bold refer to the general assemblies and parts lists on pages 22-23.

16

ENGLISH ORIGINAL INSTRUCTION

HYDRAULIC PISTON

• Remove Tail Jaw Cylinder 6 as described earlier.

• Grip Body 19 in vice using soft jaws* to avoid damage, undo Stroke Limiter 17.

• Grip Barrel 25 in soft jaw vice, pull Body 19 from Barrel 25 (a small quantity of hydraulic oil will be ejected from inside

body).

• Remove Piston 18 carefully so as not to damage body bore.

• Remove Seal 3.

• Seal 1 is dicult to remove without damaging, but can remain in place during cleaning (provided it is not aected by

cleaning process). If however, Seal 1 requires renewing proceed as follows:

• Using spatula*, prise out Seal 1 from Body 19, taking care not to damage body cavity and bores. The removed Seal 1

MUST be discarded.

• To replace Seal 1, unscrew Hydraulic Hose Assembly 22 and t a spare Bleed Plug Assembly 2 screwing it in to bring

inside face level with internal bore.

• Unscrew existing bleed plug until inside face is level with internal bore. This will provide a smooth passage for insertion

of new Seal 1 through rear of body.

• Ensure the seal is well greased and the correct way round with the open end of the seal facing the rear tail jaws.

• Complete assembly in reverse order of dismantling.

TRIGGER ASSEMBLY

• To dismantle/service assembly, remove covers from the tool as described earlier.

• Disconnect all air hoses from assembly, taking care not to damage them. Remove assembly.

• Using a spanner*, unscrew the Retainer 49 and remove. Take care to keep the Spring 50.

• Prise o the ‘O’ Ring 53 taking care not to damage the Spindle 54 and Retainer 49 seatings.

• Clean and re-assemble using a new ‘O’ Ring 53.

• Check length of Spring 50 which must be 12.7mm (0.5”) free length – replace if necessary.

• Assembly in reverse order of dismantling.

TAIL JAW ON/OFF VALVE

• The unit is designed so that minimum of servicing is required during the life of the tool.

• If it is necessary to dismantle valve, proceed as follows:

• Disconnect air hose from assembly, taking care not to damage them. Remove assembly.

• Using an Allen Key*, loosen Screw 27 clamping assembly to Barrel 25 and remove assembly.

• Using a screwdriver*, carefully remove the Chrome Star-lock Washer 26 from Air Tail Jaw Spool 29 and discard washer.

• Extract Air Tail Jaw Spool 29 from Switch Block 28.

• Taking care not to damage the Air Tail Jaw Spool 29, remove the ‘O’ Rings 31.

• Clean spool and ret new ‘O’ Rings 31 using assembly bullet* and insert into Switch Block 28, noting its orientation.

• Fit New Chrome Star-lock Washer 26 by clamping in vice using a soft jaw vice to prevent damage. DO NOT USE UNDUE

FORCE.

• Complete assembly in reverse order of dismantling.

TAIL JAW PRESSURE NON-RETURN VALVE

• The Non-return Valve 21 is located in the tool handle.

• To remove/replace the Non-return Valve 21 depress the bulk head ttings and withdraw the Blue Plastic Tube 23 from

both ends.

• When replacing the Non-return Valve 21, note the orientation.

* Refers to items included in the 0753 Mkll service kit. For complete list see page 15.

Item numbers in bold refer to the general assemblies and parts lists on pages 22-23.

17

ORIGINAL INSTRUCTION ENGLISH

HANDLE & END CAP

• Clean and inspect mouldings for cracks or other damage.

CURSOR

• Clean and oil Mechanical Cursor Assembly 5 occasionally with a little light oil.

IMPORTANT

Check the tool against daily and weekly servicing.

Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.

6.2 DISMANTLING 07532-02200 MKII

To dismantle the 07530-02200 MkII refer to pages 16-18.

TAIL JAW CYLINDER

• Manually ip the Clip 54 up and remove the End Cap 45.

• Using an Allen Key*, remove one cap head Screw 51 ensuring that any trapped air in the tail jaw cylinder is exhausted.

Remove the second cap head Screw 51.

• Push forward Rear Plug 53 against Spring 20 and release quickly to allow Rear Plug 53 to fall away.

• Extract air tail jaw components, comprising Tail Jaw Piston Assembly 21, Spring 20, Jaws 16 and Jaw Housing 15.

• Remove plug at rear of piston assembly using an Allen Key* and a bar through the large slot in the turret.

• Clean out turret using a 4.7mm (/”) drill and replace plug using a non-hardening sealing compound, e.g. Loctite Multi-

gasket 574*.

• Remove piston seal ‘O’ Ring 17.

• Using an Allen Key*, remove all ve handle moulding securing Screws 41, 46 and Nuts 40 from the tool handle.

• Grip Barrel 31 in a vice using soft jaws* to avoid damage.

• Using a box spanner*, unscrew Barrel Plug 14, preventing Barrel 31 turning by using an open ended spanner*.

• Disconnect Air Tail Jaw Concertina Tube 19 from Switch Block 35 and pull Tail Jaw Cylinder 12 from tool.

• Remove ‘O’ Ring 10, Rubbing Strip 22 and Barrel Return Spring 13.

• Free length of Spring 20 should be 38.1mm (1.5”). Replace if necessary.

• Coat the tail jaws with Moly Lithium grease before assembling.

• Assemble in reverse order of dismantling.

HYDRAULIC PISTON

• Remove Tail Jaw Cylinder 12 as described earlier.

• Grip Body 25 in vice using soft jaws* to avoid damage, undo Stroke Limiter 23.

• Grip Barrel 31 in soft jaw vice, pull Body 25 from Barrel 31 (a small quantity of hydraulic oil will be ejected from inside

body).

• Remove Piston 24 carefully so as not to damage body bore.

• Remove Seal 9.

• Seal 1 is dicult to remove without damaging, but can remain in place during cleaning (provided it is not aected by

cleaning process). If however, Seal 1 requires renewing proceed as follows:

• Using spatula*, prise out Seal 1 from Body 25, taking care not to damage body cavity and bores. The removed Seal 1

MUST be discarded.

* Refers to items included in the 0753 Mkll service kit. For complete list see page 15.

Item numbers in bold refer to the general assemblies and parts lists on pages 22-23.

18

ENGLISH ORIGINAL INSTRUCTION

• To replace Seal 1, disconnect Hydraulic Hose Assembly 63 and all the associated air pipes. Unscrew Self Closing Coupler

6, remove Suspension Mounting Plate 4, unscrew the Adapter Top Hose 2 and t a spare Bleed Plug Assembly 30

screwing it into bring the inside face level with the internal bore.

• Unscrew existing bleed plug until inside face is level with internal bore. This will provide a smooth passage for insertion

of new Seal 1 through rear of body.

• Ensure the seal is well greased and the correct way round with the open end of the seal facing the rear tail jaws.

• Complete assembly in reverse order of dismantling.

TRIGGER ASSEMBLY

• To dismantle/service assembly, remove covers from the tool as described earlier.

• Disconnect all air hoses from assembly, taking care not to damage them. Remove assembly.

• Using a spanner*, unscrew the Retainer 56 and remove. Take care to keep the Spring 57.

• Prise o the ‘O’ Ring 60 taking care not to damage the Spindle 61 and Retainer 56 seatings.

• Clean and re-assemble using a new ‘O’ Ring 60.

• Check length of Spring 57 which must be 12.7mm (0.5”) free length – replace if necessary.

• Assembly in reverse order of dismantling.

TAIL JAW ON/OFF VALVE

• The unit is designed so that minimum of servicing is required during the life of the tool.

• If it is necessary to dismantle valve, proceed as follows:

• Disconnect air hose from assembly, taking care not to damage them. Remove assembly.

• Using an Allen Key*, loosen Screw 34 clamping assembly to Barrel 31 and remove assembly.

• Using a screwdriver*, carefully remove the Chrome Star-lock Washer 33 from Air Tail Jaw Spool 36 and discard washer.

• Extract Air Tail Jaw Spool 36 from Switch Block 35.

• Taking care not to damage the Air Tail Jaw Spool 36, remove the ‘O’ Rings 38.

• Clean spool and ret new ‘O’ Rings 38 using assembly bullet* and insert into Switch Block 35, noting its orientation.

• Fit New Chrome Star-lock Washer 33 by clamping in vice using soft Jaws to prevent damage. DO NOT USE UNDUE

FORCE.

• Complete assembly in reverse order of dismantling.

TAIL JAW PRESSURE NON-RETURN VALVE

• The Non-return Valve 26 is located in the tool handle.

• To remove/replace the Non-return Valve 26 depress the bulk head ttings and withdraw Blue Plastic Tube 27 from both

ends.

• When replacing the Non-return Valve 26, note the orientation.

HANDLE & END CAP

• Clean and inspect mouldings for cracks or other damage.

CURSOR

• Clean and oil Mechanical Cursor Assembly 11 occasionally with a little light oil.

IMPORTANT

Check the tool against daily and weekly servicing.

Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.

* Refers to items included in the 0753 Mkll service kit. For complete list see page 15.

Item numbers in bold refer to the general assemblies and parts lists on pages 22-23.

19

ORIGINAL INSTRUCTION ENGLISH

6.3 GENERAL ASSEMBLY OF BASE TOOL 07530-02200 MKII

25

24

TRIGGER VALVE DETAIL

27

60

26

SECTION 'X'-'X'

PART SECTION 'W'-'W'

W

29

30

31

53

54

32

34

33

34

33

34

33

39

33

39

33

35

HANDLE COVER DETAILS

28

X

24

78 1096531

20 18 1516 13

11

12

1417

22

21

23

44

43

46

45

44 45

47

19

36 37

38

40

41

48

52

49 50

20

51

20

ENGLISH ORIGINAL INSTRUCTION

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