Instruction Manual. Hydro-Pneumatic Power Tool model

Transcription

1 Instruction Manual 7531 Hydroneumatic ower Tool model

2

3 Contents CONTENTS Safety Rules 4 Specifications Specification for Type Tool 5 Specification for Intensifier 5 Intent of Use Tool Capability 6 utting into Service Air Supply Bench Mounted Guard Assembly 8 and neumatic Circuit Bench Mounted Guard Assembly 9 Modular Head Bush Stops 10 Cursor 11 Loading and Reloading the Tool 1112 Operating rocedure 12 Mandrel Follower Springs Identification 13 and Orientation Nose Assemblies Nose Jaws 14 Selecting a Nose Jaw 15 Nose Jaw Selection Imperial 16 Nose Jaw Selection Metric 17 Mandrels and Mandrel Follower Springs 18 Chobert and Grovit Selection Imperial 18 Chobert and Grovit Selection Metric 19 Briv Selection Imperial 20 Briv Selection Metric 21 Mandrel Head Types and '' Length 21 Avlug, Avsert, Avtronic and Rivscrew 22 Selection Imperial Avlug, Avsert, Avtronic and Rivscrew 22 Selection Metric Servicing the Tool Daily / Weekly 23 Moly Lithium Grease E 3735 Safety Data 23 Service Kit 24 Bench Mounted Module and Guard Assembly (s) Maintenance Dismantling the Hydraulic Module Assembly Maintenance Dismantling Module Dismantling Tail Jaws Assembly 27 Dismantling Hydraulic Body Assembly 27 Reassembling Hydraulic Body Assembly 27 Dismantling Barrel Assembly 27 Repetition Module Assembly (s) Exploded View 28 arts List 29 Bench Mounted CFrame Guard (s) Assembly View 30 arts List 31 Intensifier Maintenance Dismantling Instructions 32 Intensifier General Assembly 33 arts List 33 riming Oil Details Hyspin VG 32 and AWS 32 Oil 34 Safety Data riming rocedure 34 Fault Diagnosis Symptom, ossible Cause & Remedy 3536 Warranty Textron Fastening Systems installation tools carry a 12 month warranty against defects caused by faulty materials or workmanship, the warranty period commencing from the date of delivery confirmed by invoice or delivery note. The warranty applies to the user/purchaser when sold through an authorised outlet, and only when used for the intended purpose. The warranty is invalidated if the installation tool is not serviced, maintained and operated according to the instructions contained in the Instruction and Service Manuals. In the event of a defect or failure, and at its sole discretion, Textron Fastening Systems undertakes only to repair or replace faulty components. Textron Fastening Systems policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice. 3

4 Safety Rules This instruction manual must be read with particular attention to the following safety rules, by any person installing, operating, or servicing this tool. 1 Do not use outside the design intent. 2 Do not use equipment with this tool/machine other than that recommended and supplied by Textron Fastening Systems. 3 Any modification undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Textron Fastening Systems or their representatives, shall be the customer s entire responsibility. Textron Fastening Systems will be pleased to advise upon any proposed modification. 4 The tool/machine must be maintained in a safe working condition at all times and examined at regular intervals for damage and function by trained competent personnel. Any dismantling procedure shall be undertaken only by personnel trained in Textron Fastening Systems procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. lease contact Textron Fastening Systems with your training requirements. 5 The tool/machine shall at all times be operated in accordance with relevant Health and Safety legislation. In the U.K. the Health and Safety at Work etc. Act 1974 applies. Any question regarding the correct operation of the tool/machine and operator safety should be directed to Textron Fastening Systems. 6 The precautions to be observed when using this tool/machine must be explained by the customer to all operators. 7 Always disconnect the airline from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly. 8 Do not operate a tool/machine that is directed towards any person(s) or the operator. 9 Always adopt a firm footing or a stable position before operating the tool/machine. 10 Ensure that vent holes do not become blocked or covered and that hoses are always in good condition. 11 The operating pressure shall not exceed 5 bar (72.5 lbf/in 2 ). 12 The combination of fastener, mandrel, hole size and sheet thickness shall be in accordance with Textron Fastening Systems Specifications. 13 Do not operate the tool if it is not fitted with a complete nose assembly unless specifically instructed otherwise. 14 Bench mounted tools must not be used without a 'Bench Mounted Guard' with the shield in position above the tool barrel and they should not be operated if the guard is damaged in any way. 15 Do not contaminate the transparent shield with solvents or alkaline substances. These will reduce the strength of the shield. 16 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against fastener ejection, should a fastener be placed in air. We recommend wearing gloves if there are sharp edges or corners on the application. 17 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should be kept dry and clean for best possible grip. 18 Excessive contact with hydraulic oil should be avoided. To minimize the possibility of rashes, care should be taken to wash thoroughly. IMORTANT 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 or wear and always before the maximum recommended number of placings. Contact your Textron Fastening Systems representative who will let you know what that figure is by measuring the broach load of your application with a calibrated test tool. These tools can also be purchased under art Number , supplied with all necessary information for testing in this manual. 4

5 Specifications SECIFICATION FOR TYE TOOL Air ressure Minimum Maximum 45 bar ( lbf/in 2 ) Free Air Volume 5 bar /72.5 lbf/in litres (0.09 ft 3 ) Stroke Minimum 30.0 mm (1.18 in) With 3 buffer stops as standard 21.0 mm (0.83 in) ull 5 bar /72.5 lbf/in kn (788 lbf) Cycle time Approximately 1 second Noise Level Less than 70 db(a) SECIFICATION FOR INTENSIFIER Air ressure Minimum Maximum 45 bar ( lbf/in 2 ) Intensification Ratio 32:1 5

6 Intent of Use TOOL CAABILITY The pneumatic type tool is designed to place Avdel speed fasteners (except 1 /16" Avlug ) making it ideal for batch flowline assembly in a wide variety of applications throughout all industries. Reference must be made to the nose equipment section of the manual when selecting compatible components for the type of fastener used in the application (see pages 1822). Nose jaw dimensions are shown on page 15 and stated on pages 16 and 17. FASTENER NAME CHOBERT GROVIT AVLUG BRIV RIVSCREW AVTRONIC AVSERT FASTENER 2.5mm M2.5 M3 3 /32" 1 /8" 5 /32" 3 /16" 1 /4" 3mm 3.5mm 4mm 6mm 2.8mm UNC UNC 6

7 2 utting into Service AIR SULY All tools are operated with compressed air at an optimum pressure of 5 bar. We recommend the use of pressure regulators and automatic oiling/filtering systems on the main air supply. To ensure maximum tool life and minimum tool maintenance, these should be fitted within 3 metres of the air inlet point on the tool itself for the and Guard. See diagram below. Air supply hoses should have a minimum working effective pressure rating of 150% of the maximum pressure in the system or 10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasive resistant exterior and should be armoured where operating conditions may result in hoses being damaged. All air hoses MUST have a minimum bore of 6.4 millimetres or 1 /4 inch. Read daily servicing details on page 23. STO COCK (USED DURING MAINTENANCE OF FILTER/REGULATOR OR LUBRICATION UNITS) 3 METRES MAXIMUM TAKE OFF OINT FROM MAIN SULY LUBRICATOR RESSURE REGULATOR AND FILTER (DRAIN DAILY) MAIN SULY DRAIN OINT

8 utting into Service BENCH MOUNTED GUARD ASSEMBLY Refer to illustration opposite (page 9) From the CFrame Guard, connect the Black 6mm pneumatic tube (Connected to the 5/2 Roller Valve on the upright section) to the fitting at the rear of the module (Tail Jaws On). This pipe comes through the sidewall of the main umbilical. From the CFrame Guard, connect the Black 4mm pneumatic tube (Connected to the 5/2 Roller Valve on the upright section) to the fitting at the middle of the module (Tail Jaws Off). This pipe comes through the sidewall of the main umbilical. From the CFrame Guard, connect the Blue 6mm pneumatic tube (Connected to the 5/2 Roller Valve on the upright section) to the left hand fitting on the front face of the intensifier. From the CFrame Guard, connect the Blue 4mm pneumatic tube (Connected to the 3/2 Roller Valve on the upright section) to the right hand fitting on the front face of the intensifier. From the CFrame Guard, connect the Green 4mm pneumatic tube (Connected to the 3/2 Roller Valve on the upright section) to the foot pedal. Note: Substitute item 56 ( Attached to Bench Mounted Guard) banjo connector in place of existing fitting on the foot pedal. Fit a hose between the intensifier and the main air supply BENCH MOUNTED GUARD NEUMATIC CIRCUIT INTENSIFIER MODULE Y 6 BLUE X NONRETURN VALVE BLACK INTENSIFIER VALVE 6 BLACK 4(A) 2(B) 5 3 1() FOOT EDAL GUARD ASSEMBLY GREEN BLUE 8

9 utting into Service BENCH MOUNTED GUARD ASSEMBLY 4mm Blue Tube 4mm Green Tube 6mm Blue Tube 100mm Guidance Information Only 4 off holes ø6mm Mounting Hole Layout 300mm Guidance Information Only 120mm pitch Module neumatic Hose Assembly 4mm Black Tube 6mm Black Tube 7531 Foot edal 4mm Green Tube 9

10 utting into Service MODULAR BUSH STOS IMORTANT Bush stops are fitted to reduce the stroke length of the tool thus the tool cycle time and shock loads. Minimising shock loads will increase the efficiency of the tool and will prolong the life of the mandrel. Each tool is supplied with three buffer stops already fitted. It may be necessary to remove one or more of these to match the length of the fasteners to be placed so that when in the fully back position, the mandrel head lies just inside the nose jaws. Use the table below to ascertain the number of buffer stops recommended for your fastener. First find the relevant diameter and within that section select the correct length code. These two digits are the last two of the fastener part number. Read the corresponding number of buffer stops in the table below. Fastener Diameter 03 ( 3 /32, 2.5mm and 2.8mm) 04 ( 1 /8 ) Code Fastener length code Number of fill buffer stops Fastener Diameter 05 ( 5 /32 ) 06 ( 3 /16 ) 08 ( 1 /4, 6mm) Code Fastener length code 05/06 07/08 09/10 11/12 13/14 15/ Number of fill buffer stops For extra buffer stops, 1 /8 thick, order part number Adjusting the number of Buffer Stops 48 Ensure that the air supply to the tool is disconnected. Remove Modular Head Assembly from the mounting plate/machine Top late. Hold Body 38 in a pair of soft vice jaws and unscrew Tail Jaw Housing 42. This exposes the iston Nut 47 and Locknut 46. Add or remove, as applicable, Buffer Stops 48 in accordance with the table opposite. Refit Tail Jaw Housing 42, tightening it onto Body 38. Remove from vice and refit Modular Head Assembly into position. Note: No oil loss will be expected during the above operation, therefore repriming is not necessary. Item numbers in bold refer to the general assembly drawing and parts list for (pages 2829). 10

11 utting into Service CURSOR IMORTANT If fitted incorrectly, the cursor will not allow feeding of the fasteners. While the cursor will be fitted the correct way round when the tool is supplied, we recommend that you check its orientation before fitting 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 fitted 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: Remove the Screw 3 and from the body 38. Remove barrel assembly from Body 38. Remove Grub Screw 2 from Barrel Nut 32. Note: When replacing screw. Secure using Loctite Screwloc 222. Hold Barrel 33 securely and remove Barrel Nut 32. Exercise caution as the Barrel Return Spring 36 is under compression. Insert a mandrel into the hole in the rear end of Barrel 33 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 Cursor Assembly 20 into the front of the barrel, correct way round. CURSOR ASSEMBLY SRING LOADED END NOSE JAWS TOOL BARREL LOADING AND RELOADING THE TOOL IMORTANT The procedure for loading the tool and for fitting 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, on pages If you have been supplied with a nose jaw, mandrels and mandrel follower springs proceed with loading the tool and fitting the nose equipment as shown overleaf. Item numbers in bold refer to the general assembly drawing and parts list for (pages 2829). 11

12 utting into Service Loading the Tool Connect the air supply to the tool. Open tail jaws which grip the mandrel, by: Bench Mounted Guard: ush the guard away from the operator. Screw selected nose jaws onto barrel 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 table on page 13. Gripping the tail end of the mandrel, tear off 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 first fastener to be placed is protruding from the nose jaw. Close the nose jaws and adjust so that the first fastener protrudes by 1.5mm 3mm ( 1 /16 to 1 /8 ), as shown in the illustration below right. Close the tail jaws to ensure the mandrel is gripped, by: Bench Mounted Guard: ull the guard towards the operator. 1.5mm 3mm ( 1 /16" 1 /8") Reloading the Tool Open tail jaws 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. OERATING ROCEDURE IMORTANT You must check that the cursor orientation and the nose equipment are correct before attempting to operate the tool. ush the fastener, protruding from the nose jaws, fully into the application holes ensuring that the application is held square. Operate the foot pedal without releasing the mandrel head is pulled through the fastener, forming the fastener into the application. Remove the application. Release the foot pedal. The next fastener will be automatically presented through the nose jaws, ready for placing. 12

13 utting into Service FOLLOWER SRINGS IDENTIFICATION AND ORIENTATION FASTENER NAME NOSE JAW (SEE NOSE EQUIMENT SECTION) / FOLLOWER SRING AND FASTENER ASSEMBLY FOLLOWER SRING 3 /32" STANDARD TAERED FERRULE SRING BRIV 3 /32" LIMITED ACCESS & LIMITED ACCESS CAM OERATED 1 /8" 5 /32" 3 /16" 6mm STANDARD EXCET 3rd OVER CHOBERT AVLUG GROVIT 3 /32" 3 /32" EXCET STANDARD TAERED, LIMITED ACCESS STANDARD TAERED, LIMITED ACCESS 1 /8" 5 /32" EXCET 3rd OVER CHOBERT GROVIT 5 /32" 3 /16" 3rd OVER EXCET 2nd OVER 3 /16" 2nd OVER CHOBERT 1 /4" RIVSCREW 2.8mm 3mm 3.5mm 4mm AVSERT 2.5mm 4 x 40 UNC 3mm 6 x 32 UNC 2.5mm AVTRONIC 2.8mm EXCET LIMITED ACCESS 2.8mm LIMITED ACCESS 13

14 Nose Assemblies On speed fastening tools such as 70510, the nose equipment always consists of three elements: a Nose Jaw, a Mandrel and a Mandrel Follower Spring. All three items are matched to the fastener being placed and to the hole size in the application. IMORTANT To avoid complete dismantling of the tool it is essential to check the orientation of the cursor before fitting the nose equipment to the tool. See CURSOR section on page 11. It is essential that the correct nose equipment is fitted to the tool to ensure both effective placing of the fastener and SAFE operation of the tool. READ THE SAFETY INSTRUCTIONS page 4 carefully. To identify the correct combination of nose equipment to fit your tool first select a nose jaw by reading the section below then read the mandrel section to select part numbers both for the mandrel itself and for the mandrel follower spring. Mandrels and mandrel follower springs are illustrated on page 13. To fit the nose equipment, follow the Loading and Reloading the Tool procedure page 11. NOSE JAWS IMORTANT The wrong nose jaw could result in an incorrectly placed fastener or unsatisfactory clench. Nose Jaws can be categorised into four different basic shapes as illustrated on page 15. Even though internal dimensions will vary according to the intended fastener. Exact dimensions referring to the letters in the illustrations opposite are indicated in the Nose Jaw Selection Tables on pages For a particular shape, there may be several options of end form giving access benefits or fastener placing enhancement. Flat Normal end form of all nose jaws. Suitable on all applications with no access restrictions. Universal Designed for use with universal head Chobert fasteners. Can also be used with Briv fasteners to obtain the highest possible clench. Note this reduces the maximum grip range of the Briv fastener by approximately 0.4mm (0.015 ). Recessed For use with Briv fasteners ONLY. It gives a higher clench than a flat end form but less than a universal end form, with no reduction of the grip range of the fastener. Tapered Available as shown in the Nose Jaw Selection Tables. Allows greater accessibility than a flat end form and places the same range. Head Forming For use with Rivscrew fasteners ONLY. Deforms the head of the fastener to achieve good clench. 14

15 Nose Assemblies SELECTING A NOSE JAW List the name, size and material of the fastener to be placed. Look for this fastener in the first column of the nose jaw selection tables on page 16 if using imperial measurements and on page 17 if using metric units. Looking right across the table, take note of which nose jaws are available. ONLY those shown are available. Select which is most suitable for your application by referring to the respective nose jaw drawing. If your application has no access restriction, you should select the standard shape with a flat end form with or without cam. STANDARD LIMITED ACCESS 'B' 'B' 'D' 'E' 'D' 'E' FLAT UNIVERSAL RECESSED TAERED FLAT Available in 4 different end forms to place all fasteners (except Rivscrew). Suitable on applications with no or little access restriction. Available as shown in NOSE JAW SELECTION TABLE. Allows access into very restrictive applications. STANDARD CAM OERATED 'B' LIMITED ACCESS CAM OERATED 'B' 'E' 'E' 'D' 'D' FLAT FORMING (HF) FLAT Available as shown in NOSE JAW SELECTION TABLE overleaf. Equivalent functions to the Standard and Limited Access above with the addition of a cam to ease and speed up the nose jaw opening thus the pod reloading procedure. 15

16 Nose Assemblies NOSE JAW SELECTION IMERIAL The REF Nº column cross references with the REF Nº columns in the mandrel section. It identifies both the mandrel and mandrel follower spring required for a particular nose jaw with a specific fastener. FASTENER 3/32" CHOBERT REF. Nº TYE AND END FORM STANDARD FLAT STD. CAM OERATED FLAT STANDARD TAERED NOSE JAW DIMENSIONS 'B' 'D' 'E' REF. Nº NOSE JAW TYE AND END FORM # STANDARD UNIVERSAL LTD. ACCESS CAM OERATED LIMITED ACCESS DIMENSIONS 'B' 'D' 'E' /8" CHOBERT 4 4 STANDARD FLAT STANDARD TAERED # STANDARD UNIVERSAL STD. CAM OERATED FLAT /32" CHOBERT 5 5 STANDARD FLAT STANDARD TAERED # STANDARD UNIVERSAL STD. CAM OERATED FLAT /16" CHOBERT 6 6 STANDARD FLAT STANDARD TAERED # STANDARD UNIVERSAL STD. CAM OERATED FLAT /4" CHOBERT 7 STANDARD FLAT STD. CAM OERATED FLAT /32" BRIV Brass only 8 9 STANDARD TAERED LIMITED ACCESS LTD. ACCESS CAM OERATED /8" BRIV Al. Alloy, Brass, Steel 5/32" BRIV Al. Alloy, Brass, Steel STANDARD FLAT STANDARD TAERED STANDARD FLAT STANDARD RECESSED STANDARD RECESSED /32" BRIV St.Steel only 3/16" BRIV Al. Alloy, Brass, Steel STANDARD FLAT STANDARD FLAT STANDARD RECESSED STANDARD RECESSED /16" BRIV St.Steel only 14 STANDARD FLAT STANDARD RECESSED mm BRIV Al. Alloy, Steel 15 STD. CAM OERATED STANDARD FLAT /32" AVLUG STANDARD FLAT STD. CAM OERATED FLAT STANDARD TAERED /8" AVLUG 2.5mm AVTRONIC 2.8mm AVTRONIC STANDARD FLAT STD. CAM OERATED FLAT STANDARD FLAT STANDARD FLAT STANDARD TAERED LTD. ACCESS CAM OERATED LTD. ACCESS CAM OERATED mm RIVSCREW 21 STD. CAM OERATED HF mm RIVSCREW 3.5mm RIVSCREW 4.0mm RIVSCREW STD. CAM OERATED HF STD. CAM OERATED HF STD. CAM OERATED HF # These nose jaws are suitable for placing Chobert fasteners with a Universal Head Form. When used on the equivalent size of Briv, the highest possible clench is achieved. Note that when using Briv fasteners, the maximum grip is reduced by approximately (0.4 mm). 16

17 Nose Assemblies NOSE JAW SELECTION METRIC FASTENER 3/32" CHOBERT 1/8" CHOBERT 5/32" CHOBERT 3/16" CHOBERT 1/4" CHOBERT 3/32" BRIV Brass only 1/8" BRIV Al. Alloy, Brass, Steel 5/32" BRIV Al. Alloy, Brass, Steel REF. Nº TYE AND END FORM STANDARD FLAT STD. CAM OERATED FLAT STANDARD TAERED STANDARD FLAT STANDARD TAERED STANDARD FLAT STANDARD TAERED STANDARD FLAT STANDARD TAERED STANDARD FLAT STANDARD TAERED LIMITED ACCESS STANDARD FLAT STANDARD TAERED STANDARD FLAT NOSE JAW DIMENSIONS 'B' 'D' 'E' REF. Nº NOSE JAW TYE AND END FORM # STANDARD UNIVERSAL LTD. ACCESS CAM OERATED LIMITED ACCESS # STANDARD UNIVERSAL STD. CAM OERATED FLAT # STANDARD UNIVERSAL STD. CAM OERATED FLAT # STANDARD UNIVERSAL STD. CAM OERATED FLAT STD. CAM OERATED FLAT LTD. ACCESS CAM OERATED STANDARD RECESSED STANDARD RECESSED DIMENSIONS 'B' 'D' 'E' /32" BRIV St.Steel only 12 STANDARD FLAT STANDARD RECESSED /16" BRIV Al. Alloy, Brass, Steel 13 STANDARD FLAT STANDARD RECESSED /16" BRIV St.Steel only 14 STANDARD FLAT STANDARD RECESSED mm BRIV Al. Alloy, Steel 15 STD. CAM OERATED STANDARD FLAT /32" AVLUG 1/8" AVLUG 2.5mm AVTRONIC 2.8mm AVTRONIC 2.8mm RIVSCREW 3.0mm RIVSCREW 3.5mm RIVSCREW 4.0mm RIVSCREW STANDARD FLAT STD. CAM OERATED FLAT STANDARD FLAT STD. CAM OERATED FLAT STANDARD FLAT STANDARD FLAT STD. CAM OERATED HF STD. CAM OERATED HF STD. CAM OERATED HF STD. CAM OERATED HF STANDARD TAERED STANDARD TAERED LTD. ACCESS CAM OERATED LTD. ACCESS CAM OERATED # These nose jaws are suitable for placing Chobert fasteners with a Universal Head Form. When used on the equivalent size of Briv, the highest possible clench is achieved. Note that when using Briv fasteners, the maximum grip is reduced by approximately (0.4 mm). 17

18 Nose Assemblies S AND FOLLOWER SRINGS Mandrels and mandrel follower springs, illustrated on page 13 need to be selected to suit the fastener type and size as well as the size of the hole in the application. Use of the wrong mandrel could increase the risk of breakage and the wear of the mandrel head. Feeding problems could occur if the wrong mandrel follower spring is used. IMORTANT READ THE SAFETY INSTRUCTIONS page 4 carefully. 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 Textron Fastening Systems representative who will let you know what that figure is by measuring the broach load of your application with our calibrated measuring tool. These tools can also be purchased under part number , supplied with all necessary information for testing. CHOBERT AND GROVIT IMERIAL For mandrel or mandrel follower spring selection, follow instructions above. FASTENER REF. Nº STANDARD GREEN # S/R ST OVER YELLOW # S/R SRING /32" CHOBERT /8" CHOBERT /32" CHOBERT 3/16" CHOBERT 1/4" CHOBERT FASTENER REF. Nº ND OVER BLUE # S/R 3RD OVER RED # S/R SRING /32" CHOBERT /8" CHOBERT /32" CHOBERT /16" CHOBERT

19 Nose Assemblies The tables on pages 1822 list the part numbers of all mandrels and mandrel follower springs per fastener group of fasteners, i.e. for Chobert and Grovit. While fastener sizes are always shown in their specified units, each table has been produced twice to offer dimensions in imperial and metric. These Mandrel Selection tables crossreference with the Nose Jaw Selection tables on pages 16 and 17 through the Ref. No. column. It is the diameter of the head at the end of a mandrel which when pulled through controls the expansion of the fastener body. While there are different head shapes to suit different type of fasteners (see illustration on page 21), progressive head sizes are needed to reflect manufacturing tolerances on the diameter of the hole in your application so that the fastener always expands sufficiently to fill the hole. Too large a mandrel head would over stress the mandrel and mandrels that fail during use could forcibly exit the tool. Selection tables are arranged into four mandrel size sections, ranging from standard to 3rd oversize, each being colour coded as per the end of the mandrel heads themselves. CHOBERT AND GROVIT METRIC FASTENER REF. Nº STANDARD GREEN # S/R ST OVER YELLOW # S/R SRING /32" CHOBERT /8" CHOBERT /32" CHOBERT 3/16" CHOBERT 1/4" CHOBERT FASTENER REF. Nº ND OVER BLUE # S/R 3RD OVER RED # S/R SRING /32" CHOBERT /8" CHOBERT /32" CHOBERT /16" CHOBERT

20 Nose Assemblies To find the correct part number of a mandrel for a particular application, read the instructions below after you have gathered the following information as per example alongside. Answers for the example are shown in grey italic. FASTENER NAME example Chobert FASTENER 1/8 DATASHEET Series 1125 ALICATION CLEARANCE BEHIND ALICATION Infinite REF.Nº FROM NOSE JAW SELECTION TABLE 5 (standard flat) Subtract the minimum hole size recommended () in the fastener datasheet from the actual application hole size. example: Turn to the page with the Mandrel Selection table for your fastener, selecting either the imperial or the metric dimensions table (pages 18 to 20). example: page 18. Staring with the Standard Mandrel Green section, find your fastener size in the lefthand column. example 1 /8 Chobert & Grovit. If you selected a nose jaw with which to place your fastener, you should now be able to find a line within your fastener section with the same Ref No. as that from the Nose Jaw Selection table. example: 5. This is your line Ref. No. in which you will find both your mandrel and mandrel follower spring part number. This line continues into the second half of the table for the 2nd and 3rd oversize mandrels. Scan along the line to the hole size columns and select which ever is the nearest or equal to the figure calculated in step one. You may now read the mandrel part number next to the hole size. example: For Chobert and Grovit only, most mandrels are also available in a short reach version (see illustration on page 21). Short reach mandrels are used to minimise the possibility of the mandrel head contacting a read obstruction. This would result in the underside of the fastener head not seating properly on the application surface, causing a lack on clench in the joint. Whichever size mandrel you settle on, you will also need to check the figure against that mandrel is adequate. is the clearance required for the mandrel head at the back of the application IN ADDITION to the length of the fastener protruding through the application, as shown in the illustration on page 21. You may now read the corresponding mandrel follower spring part number in the righthand column of the table. example: In all cases, satisfactory clenching of the joint should be assessed particularly if the size of the hole in your application is very close to the next oversize hole condition, when it will be safe to select the greater size of mandrel to obtain a higher clench. REMEMBER that this will increase the broach load and reduce the mandrel life. BRIV IMERIAL For mandrel or mandrel follower spring selection, follow instructions on page 18. FASTENER 3/32" BRIV Brass only REF. Nº STANDARD GREEN ST OVER YELLOW SRING /8" BRIV Al. Alloy, Brass, Steel /32" BRIV Al. Alloy, Brass, Steel 5/32" BRIV St.Steel only 3/16" BRIV Al. Alloy, Brass, Steel 3/16" BRIV St.Steel only 6mm BRIV Al. Alloy, Steel FASTENER 3/32" BRIV Brass only REF. Nº ND OVER BLUE RD OVER RED SRING /8" BRIV Al. Alloy, Brass, Steel 5/32" BRIV Al. Alloy, Brass, Steel 3/16" BRIV Al. Alloy, Brass, Steel mm BRIV Al. Alloy, Steel

21 Nose Assemblies TYES AND '' LENGTH Mandrels for stainless steel Briv are easily identifiable by a V cut in the end of the mandrel heads. When using curved nose jaws, mandrels have to be bent by hand to match the curvature of the nose jaw, thus ensuring good feed of fasteners. CHOBERT, GROVIT, AVSERT, AVTRONIC SHORT REACH (CHOBERT & GROVIT ONLY) BRIV BRIV (STAINLESS STEEL) RIVSCREW AVLUG BRIV METRIC FASTENER 3/32" BRIV Brass only REF. Nº STANDARD GREEN ST OVER YELLOW SRING /8" BRIV Al. Alloy, Brass, Steel /32" BRIV Al. Alloy, Brass, Steel /32" BRIV St.Steel only /16" BRIV Al. Alloy, Brass, Steel 3/16" BRIV St.Steel only 6mm BRIV Al. Alloy, Steel FASTENER REF. Nº 2ND OVER BLUE 3RD OVER RED SRING 3/32" BRIV Brass only /8" BRIV Al. Alloy, Brass, Steel 5/32" BRIV Al. Alloy, Brass, Steel 3/16" BRIV Al. Alloy, Brass, Steel mm BRIV Al. Alloy, Steel

22 Nose Assemblies AVLUG, AVSERT, AVTRONIC & RIVSCREW IMERIAL For mandrel or mandrel follower spring selection, follow instructions on page 18. FASTENER 3/32" AVLUG LINE Nº STANDARD GREEN ST OVER YELLOW SRING /8" AVLUG mm AVTRONIC mm AVTRONIC mm RIVSCREW 21 * mm RIVSCREW 22 * mm RIVSCREW 23 * mm RIVSCREW 24 * * These Dimensions are Across Flats FASTENER 2.5mm AVTRONIC LINE Nº ND OVER BLUE RD OVER RED SRING mm AVTRONIC AVLUG, AVSERT, AVTRONIC & RIVSCREW METRIC FASTENER 3/32" AVLUG LINE Nº STANDARD GREEN ST OVER YELLOW SRING /8" AVLUG mm AVTRONIC mm AVTRONIC mm RIVSCREW 21 * mm RIVSCREW 22 * mm RIVSCREW 23 * mm RIVSCREW 24 * * These Dimensions are Across Flats FASTENER 2.5mm AVTRONIC LINE Nº ND OVER BLUE RD OVER RED SRING mm AVTRONIC

23 Servicing the Tool Regular servicing should be carried out and a comprehensive inspection performed annually or every 500,000 cycles, whichever is sooner. IMORTANT 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. DAILY Daily, before use or when first putting the tool into service. our a few drops of clean lubricating oil into the air inlet of the intensifier if no lubricator is fitted 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 filter on the pressure regulator, bleed the airline to clear it of accumulated dirt or water before connecting the air hose to the intensifier. If there is a filter, 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). Ensure the guard is undamaged and functions correctly. Ensure the stroke of the modular head is sufficient for the fastener being placed. Reprime if necessary. WEEKLY Conduct the full Daily procedures as described above. Remove, inspect, clean and grease the Tail Jaws (refer to Dismantling Tail Jaws page 27). Check oil level in the intensifier Unit reservoir is approximately 12mm ( 1 /2 ) below the transparent cover plate, top up if necessary. MOLY LITHIUM GREASE E 3753 SAFETY DATA Grease can be ordered as a single item, the part number is shown in the service kit page 24. 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 OINT: Above 220 C. Not classified as flammable. Suitable extinguishing media: CO 2, 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. 23

24 Servicing the Tool SERVICE KIT For all servicing we recommend the use of the service kit (part number (S)). SERVICE KIT ITEM DESCRITION Nº OFF ITEM DESCRITION Nº OFF SANNER ASSEMBLY ASSEMBLY SANNER FOR ISTON SATULA SANNER 24 & 26mm OEN ENDED /16in X 1/2in A/F SANNER SANNER 32 & 30mm OEN ENDED /16 X 5/8 A/F SANNER (1/18in thick) EXTRACTOR HEXAGON WRENCH 1/8" A/F SANNER ASSEMBLY JAW HOUSING KEY HEXAGONAL WRENCH 2.5mm A/F HEXAGON WRENCH 0.050in A/F /8 DIAMETER ROD HEXAGON WRENCH 4mm A/F /4in DIAMETER ROD HEXAGON WRENCH 5mm A/F ASSEMBLY SANNER FOR ISTON HEXAGON WRENCH 6mm A/F ASSSEMBLY BULLET /8 B.S.W SANNER ISTON ASSEMBLY ROD HEXAGON WRENCH 3mm A/F SLEEVE mm A/F SANNER USH ROD mm x 14mm A/F SANNER ASSEMBLY BULLET (ISTON) mm A/F SANNER gm MOLYLITHIUM GREASE E tin mm x 13mm A/F SANNER 1 Note: Spanner sizes are measured 'across flats' unless otherwise specified. 24

25 Bench Mounted Module & Guard Assembly (S) 10 ITEM DESCRITION QTY DOWTY SEAL HYDRAULIC ADATOR 1 3 NOT USED FOOT EDAL HYDRAULIC HOSE ASSEMBLY LABEL (FOOT EDAL) INTENSIFIER MANUAL (NOT SHOWN) MODULE GUARD ASSEMBLY

26 Maintenance Every 500,000 cycles the tool should be completely dismantled and components should be replaced where worn, damaged or when recommended. All O rings and seals should be renewed and lubricated with Moly Lithium grease E 3753 before assembling. IMORTANT Safety Instructions appear on page 4. 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 specifically instructed otherwise. It is recommended that any dismantling operation be carried out in clean conditions. DISMANTLING THE Separating the Module from the Assembly Remove the nose jaw equipment from the Modular Head Assembly Remove the Modular Head Assembly & Tool Mounting Block from the guard, by using the appropriate Allen Key*. Remove the Mounting Block from the Module by using the appropriate Spanner*. Disconnect nipple from selfclosing coupling at the intensifier Remove the 6mm Tube by depressing the collar on the swivel elbow fitting. Using a Spanner* remove swivel elbow from module. Remove the 4mm Tube by depressing the collar on the swivel elbow fitting. Using a Spanner* remove swivel elbow from module. Using a spanner* remove the hydraulic hose assembly, compact elbow, hydraulic adaptor and dowty seals from the module Bench Mounted Guard Assembly Compact Elbow Hydraulic Adaptor Dowty Seals Modular Head Assembly neumatic Hose Assembly Swivel Elbow & 4mm Tube Hydraulic Hose Assembly Swivel Elbow & 6mm Tube 7531 Nipple & Self Closing Coupling * Refers to items included in the service kit, see page

27 Hydraulic Module Assembly Maintenance DISMANTLING THE TAIL JAWS With the aid of Spanners*, remove Adaptor 24 and Tail Jaw Assembly from Tail Jaw Housing 42. The Turret 22 and the Turret Jaws 19 will be exposed. Care should be taken not to misplace the Jaws. Clean and inspect Jaw Housing 45. It will be necessary to remove the Jaw Housing only if damaged. To remove the Jaw Housing 45 use Jaw Housing Key* and Spanners. Clean all items, clean and replace as necessary. Regrease using Molylithium based grease. DISMANTLING TAIL JAWS ASSEMBLY Remove Adaptor 24 and Tail Jaws Assembly. Remove Adaptor 24 from Front Cylinder 44 using Spanner*. Remove Banjo 43 and 'O' Rings 9. With the aid of Spanners* remove Turret 22 from Front iston Rod 49. With the aid of Spanners* remove Front Cylinder 44 from Rear Cylinder 28. Remove Front iston Rod 49 and iston 26. Remove Circlip 16 and remove iston 26 from iston Rod 27. Remove 'O' Ring 4 from Front Cylinder 44. Note: Removal of 'O' Rings from internal recesses requires the use of a pointed probe. Care must be taken not to damage sealing surfaces. Remove 'O' Ring 8 from iston. Remove 'O' Ring 10 from iston using Spatula *. Remove Seal Retainer 30, with the aid of spanner* remove Front Rear Cylinder 28 from Back Rear Cylinder 28. Remove iston Rod 27, Circlip 16, iston 26, and 'O' Ring Seals as described. Remove Seal Retainer 30. With the aid of spanner * remove Back Rear Cylinder 28 from Rear lug 29. Remove Seal Retainer 30. Remove iston Rod, Circlip, iston and 'O' Ring Seals as described. Replace worn or damaged parts as required. Clean all parts thoroughly, lubricate Seals and Cylinder Bores with Molylithium grease. Reassemble in reverse order. DISMANTLING HYDRAULIC BODY ASSEMBLY Using Hexagon Wrench* remove Button Head Bleed Screws 1 and Seals 6 from Body 38. Allow hydraulic fluid to drain from Cylinder Body. Using Hexagon Wrench* remove Barrel Assembly 2, 11, 13, 20, 21, 23, 25, 31, 32, 33, 34, 35, 36, 37. Using spanners* to prevent the Body 38 rotating, and with the aid of spanners* remove the Tail Jaw Housing 42 and Tail Jaw Assembly. With the aid of spanners* remove Locknut 46 and iston Nut 47. Remove Buffer Stops 48. Note: It is important that the same number of Buffer Stops removed, are replaced on reassembly. Remove iston 41. Remove Hydraulic Seal 15 and iston Guidance Tape 39, clean all parts thoroughly, inspect for damage and replace if necessary. Remove Hydraulic Seal 14 and iston Guidance Tape 40 from Body 38, clean and inspect for damage and replace if necessary. Note: Extreme care must be taken when removing Seals, to avoid damage to sealing surfaces. Inspect iston diameters, and Body Cylinder bore, for wear and damage. Replace Hydraulic Seals and iston Guidance Tape in the correct relative positions. For Hydraulic Seals 14 use assembly tools*. Insert Seal in tapered end of Sleeve*. Ensure seal is orientated correctly. Insert sleeve into bore of Body 38. Using ush Rod*, push Seal out of sleeve into body groove. Lubricate Seals and Cylinder Bores with Molylithium grease. REASSEMBLING HYDRAULIC BODY Using Assembly Bullet*, positioned on the thread of iston 41 and with the aid of iston Assembly Rod*, push the piston through the bore of the Body 38 until it reaches the shoulder of the Body, remove the Assembly Bullet*. Assemble Buffer Stops 48, ensure the same number are assembled as were removed. Screw iston Nut 47 and Lock Nut 46 onto the Thread of the iston 41. Using Spanners*, lock the Nuts together, ensuring that the front face of Locknut 46 is flush with the front face of iston 41. Fit Barrel Assembly 2, 11, 13, 20, 21, 23, 25, 31, 32, 33, 34, 35, 36, 37 to Body 38. Secure using Screw 3, lock screw using Hexagon Wrench*. Fit Tail Jaw Housing 42 and Tail Jaw Assembly to Body 38 and tighten using Spanners*. DISMANTLING BARREL ASSEMBLY Using hexagon Wrench*, remove Button Head Bleed Screws 1 and Seals 6 from Body 38. Remove Barrel Assembly from Body 38. Using Hexagon Wrench*, remove Screw 2 from Barrel Nut 32. Replace O Ring 25. Note: When Replacing Screw, secure using Locktite Screwloc 222. With the aid of Spanners* hold Barrel 33 and remove Barrel Nut 32 using Spanners*. Remove Barrel Spring 36, Barrel Spring Retainer 35. Remove Spring Guide 21, remove Spacer 37 and remove Seal Spring Guide 34. Remove O Rings 11 and 13. Clean and inspect all parts. Replace if damaged or worn. Assemble in reverse order. * Refers to items included in the service kit, see page 24. Item numbers in bold refer to the general assembly and parts list on pages

28 28 Repetition Module Assembly (s)