Model AST -101 STUNNER TESTER EQUIPMENT SELECTION... Ordering No. TABLE OF CONTENTS... Page Stunner Tester, 115V... 4016004 Stunner Tester, 230V... 4016005 Notice to Employer and Safety Director... 2 Notice to Operators, Maintenance and Cleanup Personnel... 3 Parts Diagram and List... 4 Operation Diagram... 7 Specifications... 7 Installation Instructions... 7 Operation Instructions... 8 Maintenance Instructions... 8
noticetoemployer and safety director Model AST--101 page 2 of 8 Keep body parts clear NOTICE TO EMPLOYER AND SAFETY DIRECTOR AVOID INJURY 1. Remove and repair any tool that malfunctions. All personnel must be instructed to remove any malfunctioning equipment. 2. Ensure that all employees who use this tester are trained in the proper use of the USSS -1 Stunner and are aware of the dangers that may arise if they do not follow procedures outlined in this brochure. 3. Ensure that all employees are instructed to stand clear of the tester during its use, and to never put fingers, hands or other parts of the body directly in front of the USSS -1 Stunner. 4. Enclosed are four (4) copies of NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PER- SONNEL. Post one copy on the employees bulletin board; give one copy to the operator(s); give one copy to the maintenance foreman; and give one copy to the sub -contract cleanup / internal cleanup foreman. Additional copies will be provided upon request. 5. The USSS -1 Stunner is designed and intended to be powerful. This fact should be obvious to your employees, but you must emphasize it to them. 6. Ensure eye and ear protection is worn at all times when operating the USSS -1 Stunner. 7. Never make modifications or alterations to the tester. Replace any missing or illegible labels. 8. Ensure that proper procedures are established in accordance with OSHA s lockout/tagout procedures (29 CFR 1910.147) to prevent accidental startup or release of stored energy. 9. Follow our installation and maintenance instructions for proper installation and care of the tester. 10. Avoid injury. Do not permit the tester to be misused. 11. If you resell or distribute a Jarvis product, you must provide the purchaser with the appropriate safety sheets and tool brochure. Additional copies of safety sheets and tool brochures will be provided upon request.
6 notice to operators, maintenance and cleanup personnel page 3 of 8 Model AST--101 Keep body parts clear NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PERSONNEL ANY MALFUNCTIONING TOOL MUST BE REMOVED FROM SERVICE REPORT ANY PROBLEMS TO YOUR SUPERVISOR 1. Disconnect the power in accordance with OSHA s lockout/tagout procedures (29 CFR 1910.147) before performing any repair or maintenance. 2. Disconnect the power - or have the air hose disconnected - in accordance with OSHA s lockout/tagout procedures (29 CFR 1910.147) before performing any cleanup. 3. Never put fingers, hands or other parts of the body directly in front of the USSS -1 Stunner. 4. Always wear eye and ear protection when operating the tester. 5. Always keep all body parts away from the stunning rod guide when triggers are activated. 6. Never squeeze the triggers while inserting the USSS -1 Stunner into the tester. The USSS -1 Stunner could fire if the stunning rod guide is displaced by contact with the tester while both triggers are depressed. 7. Never make modifications or alterations to the tool. Replace any missing or illegible labels.
parts diagram and list Model AST--101 page 4 of 8 Stunner Tester 3061364 Figure A ITEM PART NO. PART NAME QTY 1 1055234 Socket Head Cap Screw 4 2 1058197 Guide 1 3 1016673 Housing 1 4 1017390 Nameplate Label 1 5 1055274 Drive Screw 6 6 1017400 Name and Info Label 1 7 1005156 Proximity Switch 2 8 1032701 Safety Plate 1
6 parts diagram and list page 5 of 8 Model AST--101 Electric Control Box Current Configuration Figure B * QTY = 115V/230V ITEM PART NO. PART NAME QTY 9 1001198 Cable with Molded Plug 2 10 1012113 Cable Tie with Marker 2 11 1011364 Strain Relief Connector 2 12 1007385 Locking Nut 2 13 1032691 Mounting Plate 1 14 1017392 Wiring Diagram (115V) 1 1017393 Wiring Diagram (230V) 15 1016692 Electrical Enclosure 1 16 1042471 Terminal Rail 1 17 1063496 Yellow/Green Terminal Block 2 18 1055010 Pan Head Screw 2 19 1004022 Internal Lock Washer 2 20 1063494 Grey Terminal Block *5/4 21 1063363 Terminal Marker 14 22 1072070 Timer 1 ITEM PART NO. PART NAME QTY 23 1017384 On/Off Label 1 24 1005174 Selector Switch 1 25 1063456 Terminal Marker 2 26 1063352 Time Delay Fuse (115V) 1 1063826 Time Delay Fuse (230V) 27 1063455 Fuse Term. Block (115V) 1 1063390 Fuse Term. Block (230V) 28 1063495 Blue Terminal Block *0/1 29 1007249 Locking Nut 1 30 1011248 Strain Relief Connector 1 31 1001194 Power Cord (115V) 1 3001078 Power Cord (230V) 3063350 Control Box Assy (115V) 3063351 Control Box Assy (230V)
parts diagram and list Model AST--101 page 6 of 8 Electric Control Box Original Configuration Figure C * QTY = 115V/ 230V ITEM PART NO. PART NAME QTY ITEM PART NO. PART NAME QTY 5 1055274 Drive Screw 4 38 1063970 Electrical Connector, 3 term. 1 9 1001198 Cable with Molded Plug 2 39 1063971 Female Terminal Disconnect 1 10 1012113 Cable Tie with Marker 2 40 1063822 Terminal Block Base 5 11 1011364 Strain Relief Connector 2 41 1063490 Diode 2 12 1007385 Locking Nut 2 42 1063972 Terminal Bridge 5 17 1063496 Green/Yellow Terminal Block 2 43 1063823 Terminal Block Plug 5 18 1055010 Pan Head Screw 2 44 1063973 Resistor 2 19 1004022 Internal Lock Washer 2 45 1063974 Resistor 1 20 1063494 Grey Terminal Block 4 46 1042313 Terminal Rail 1 21 1063363 Terminal Marker 27 47 1032644 Mounting Plate 1 23 1017384 Off/On Label 1 48 1016652 Electrical Enclosure 1 24 1005174 Selector Switch 1 49 1063455 Fuse Block Terminal 1 25 1063456 Terminal Marker 2 50 1063975 Fuse 1 28 1063495 Blue Terminal Block *0/1 51 1005175 Push Button Switch 1 29 1007249 Locking Nut 1 52 1017385 Clear Label 1 30 1011248 Cord Connector 1 53 1063976 Timer 1 31 3001078 Line Cord (230V) 1 54 1071016 Ferrule 5 1001194 Line Cord (115V) 1 55 1061512 Ferrule *4/1 32 1063967 Electrical Connector, 6 term. 1 56 1063728 Terminal Strip 4 33 1063968 Crimp Terminal 5 57 1017061 Model/Serial Number Label 1 34 1063969 Power Supply 1 58 1017388 Wiring Diagram (230V) 1 35 1055482 Pan Head Screw 4 1017383 Wiring Diagram (115V) 1 36 1004006 Internal Lock Washer 8 3063314 Control Box Assy (115V) 37 1061475 Hex Spacer 4 3063333 Control Box Assy (230V)
6 operation diagram, specifications and installation instructions page 7 of 8 Model AST--101 SPECIFICATIONS Power Requirements 10 W Operating Voltage 115 V, 1 phase, 60 Hz 230 V, 1 phase, 50/60 Hz Overall Dimensions (l x w x h) TestStand 6.0x6.3x8.0in 152x160x203mm Control 10x6.5x6.25in 254x165x159mm Weight Test Stand 17.6 lbs 8.0 kg Control 6.6 lbs 3.0 kg INSTALLATION INSTRUCTIONS IMPORTANT: ALWAYS TURN THE POWER OFF IN ACCOR- DANCE WITH OSHA S LOCKOUT/TAGOUT PROCEDURES (29 CFR 1910.147) BEFORE PERFORMING ANY MAINTE- NANCE OR REPAIRS. 1 Mount the Model AST -101 tester securely on a bench or table top in the vicinity of where the Model USSS -1 Stunner is being used and/or maintained. Be sure to mount the safety plate (item 8) between the Model AST-101 and the bench. 1.1 Use the four (5/16) clearance holes to secure the housing and safety plate. 1.2 Make sure that the top of the housing is at a convenient height to facilitate insertion and extraction of the USSS -1 Stunner. 2 Mount the control box in the vicinity of the tester housing. Two cords, two meters long with connectors are provided. 3 The power requirement for the tester is 10 Watts at 115VAC, 60 Hz or 230VAC, 50 Hz.
installation, operation and maintenance instructions Model AST--101 page 8 of 8 4 Connect the control box to the proximity switches (item 7) using the two cables (item 9) provided with the control box. 4.1 The top and bottom cables are clearly identified (top or bottom) with cable ties (item 10) and must be connected to the appropriate (top or bottom) connector. OPERATION INSTRUCTIONS Refer to the operation diagram on page 7 to identify the two triggers. Note: It is not necessary to test the USSS -1 Stunner before every use, but the tool should be checked at least once per shift to ensure effectiveness of the stunner. 1 Connect the power cord (item 31) to the power supply. 2 Turn selector switch (item 24) on. 3 Verify that the pressure regulator for the air supply to the USSS -1 Stunner is set for 175 psi. 4 Place the USSS -1 Stunner into the tester. 4.1 Be careful to align the slot in the top of the tester housing with the rib on the nose housing of the USSS -1 Stunner. 4.2 Never insert the tool into the housing while depressing both the main and the auxiliary triggers. The tool could actuate before the stunning rod is in the proper orientation, causing damage to the tool and/or tester. 5 After the USSS -1 Stunner is resting in the tester housing, hold the tool firmly to reduce and contain the recoil. 6 To prime the tool, first depress and hold the main trigger. Then depress the auxiliary trigger to fire the stunning rod. 7 The display will read directly in microseconds the time it takes for the stunning rod to pass by both proximity switches. A reading of 1650 equals 0.00165 seconds. 7.1 A reading below 1650 indicates an acceptable stunning speed. A reading above 1650 indicates a repair is necessary. MAINTENANCE INSTRUCTIONS ALWAYS TURN THE POWER OFF IN ACCORDANCE WITH OSHA S LOCKOUT/TAGOUT PROCEDURES (29 CFR 1910.147) BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS. 1 DAILY: 1.1 Check that the proximity switches (item 7) are securely attached to the tester housing. 1.2 Check that the two cables (item 9) from the control box are securely attached to the proximity switches in the tester housing. 2 REPLACING THE PROXIMITY SWITCHES: 2.1 Remove the cable from the control box. 2.2 Loosen the locking nut on the proximity switch (item 7) and unthread the switch from the tester housing. 2.3 Thread the new switch into the tester housing. 2.4 Locate the front end of the switch 1 / 16 inch recessed from the inside diameter of the guide (item 2). The end of the switch must not protrude into the guide bore. 2.5 Tighten the locking nut after the switch has been properly located. 3 REPLACING THE GUIDE: 3.1 Remove the proximity switches (item 7) as described in section 2. 3.2 Remove four socket head cap screws (item 1). 3.3 Push guide out from top of tester housing. 3.4 To reassemble, reverse steps 3.1 to 3.3. 3.4.1 Use Loctite 262 on the four socket head cap screws (item 1).