Stanley AV10 Kasutusjuhend

INSTRUCTION AND

SERVICE MANUAL

ORIGINAL INSTRUCTION

AV™10 Installation Tool – 73430-02000

Hydro-Electric Power Tool

EN Hydro-Electric Power Tool

BG Хидро-електрически електроинструмент

HR Hidroelektrični alat

CZ Hydraulicko-elektrické nářadí

RO Unealtă hidro-electro-pneumatică

HU Hidroelektromos szerszám

SK Hydro-elektrické náradie

SL Hidravlično električno orodje

RU Электрогидравлический электроинструмент

AR

LV Hidropneimatiskais elektroinstruments

LT Hidraulinis-elektrinis įrankis

ET Hüdroelektriline tööriist

EL Υδραυλικό-Ηλεκτρικό Εργαλείο Ισχύος

TR Elektro Hidrolik Elektrikli Alet

CONTENT

1. SAFETY DEFINITIONS 3

1.1 GENERAL SAFETY RULES 3

1.2 PROJECTILE HAZARDS 3

1.3 OPERATING HAZARDS 4

1.4 REPETITIVE MOTIONS HAZARDS 4

1.5 ACCESSORY HAZARDS 4

1.6 WORKPLACE HAZARDS 4

1.7 NOISE HAZARDS 4

1.8 VIBRATION HAZARDS 5

1.9 ADDITIONAL SAFETY INSTRUCTIONS FOR HYDRAULIC POWER TOOLS 5

2. SPECIFICATIONS 6

2.1 INTENT OF USE 6

2.2 PLACING TOOL SPECIFICATION 6

2.3 PLACING TOOL DIMENSIONS 7

3. PUTTING INTO SERVICE 8

3.1 PRINCIPLE OF OPERATION 8

3.2 PREPARATION FOR USE 9

4. OPERATING INSTRUCTIONS 10

4.1 TO INSTALL AN AVBOLT® FASTENER 10

4.2 TO INSTALL AN AVDELOK® FASTENER 10

5. SERVICING THE TOOL 11

5.1 DAILY 11

5.2 WEEKLY 11

5.3 ANNUALLY OR EVERY 250K OPERATIONS 11

5.4 SERVICE KIT 11

5.5 SERVICING TOOLS' 11

5.6 HYDRAULIC OIL 12

5.7 DISMANTLING INSTRUCTIONS 12

5.8 PROTECTING THE ENVIRONMENT 14

6. GENERAL ASSEMBLY OF INSTALLATION TOOL 73430-02000 15

7. PARTS LIST FOR INSTALLATION TOOL 73430-02000 17

8. SAFETY DATA 18

8.1 ENERPAC® HF HYDRAULIC OIL - SAFETY DATA 18

8.2 MOLYLITHIUM GREASE EP 3753 - SAFETY DATA 18

8.3 MOLYKOTE® 111 GREASE - SAFETY DATA 19

9. FAULT DIAGNOSIS 20

10. EC DECLARATION OF CONFORMITY 22

11. UK DECLARATION OF CONFORMITY 23

12. PROTECT YOUR INVESTMENT! 24

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 trade marks.

2

ENGLISH ORIGINAL INSTRUCTION

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 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.

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

safety regulations.

1. SAFETY DEFINITIONS

The definitions 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 hydraulic pump unit before performing any maintenance, attempting to adjust, fit 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 fixed.

• 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).

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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 fluid 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 fixed to asuspension device, make sure that the fixation is secure.

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

• 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 off-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 stiffness, these warning signs should not be ignored. The operator should tell the

employer and consult aqualified health professional.

1.5 ACCESSORY HAZARDS

• Disconnect the tool from the hydraulic and electrical supply before fitting 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.

4

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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.

• If you experience numbness, tingling, pain or whitening of the skin in your fingers 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 HYDRAULIC POWER TOOLS

• The operating hydraulic supply must not exceed 550bar (8000PSI).

• Oil under pressure can cause severe injury.

• Do not fit flexible hydraulic hoses rated at less than 700 bar (10,000 PSI) working pressure at a flow rate of 2.73 l/min

(200 in3/min).

• Never leave operating tool unattended. Disconnect hydraulic hose and electrical cable from the pump unit when tool is

not in use, before changing accessories or when making repairs.

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

• 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.

• 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 or electrical cable. Always use the placing tool handle.

• DO NOT pull or move the hydraulic pump unit using the hoses. Always use the pump unit handle or roll cage.

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

• Use only clean oil and filling equipment.

• Only recommended hydraulic fluids may be used.

• Power units require a free flow of air for cooling purposes and should therefore be positioned in a well ventilated area

free from hazardous fumes.

• Maximum temperature of the hydraulic fluid at the inlet is 110°C (230°F).

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

the right to change the specification of any product without prior notice.

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2. SPECIFICATIONS

2.1 INTENT OF USE

The AV™10 Installation Tool is principally a piston and cylinder assembly. When coupled hydraulically and electrically to

acompatible hydraulic power source and the relevant nose assembly is attached, it is then used to install 3/8” Avdelok®,

5/16” to 3/8” Avbolt® and Ø18mm Avseal® II in Industrial Environments.

The placing tool and hydraulic pump unit may only be used in accordance with the operating instructions for placing

Stanley Engineered Fastening structural rivets.

Refer to the table below for the list of applicable fasteners and associated nose equipment. Refer to the datasheets listed in

the table for the relevant nose assembly instructions.

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

FASTENER NOSE ASSEMBLY

NOSE ASSEMBLY

DATASHEET

TYPE SIZE PART NUMBER DIM. ‘A’ DIM. ‘B’ PART NUMBER

AVDELOK® 3/8” 73430-03100 87 mm 28 mm 07900-00919

AVBOLT® 5/16” 73430-03300 92 mm 27 mm 07900-00905

3/8” 73430-03200 92 mm 29 mm 07900-00905

AVSEAL® II

16 mm 73430-05000 95 mm 27 mm 07900-00840

16 mm flanged 73430-05000 95 mm 27 mm 07900-00840

18 mm 73430-05200 95 mm 27 mm 07900-00840

Refer to the illustration on page 7 for the identification of the nose assembly dimensions ‘A’ and ‘B’.

The safety instructions must be followed at all times.

2.2 PLACING TOOL SPECIFICATION

SPECIFICATION METRIC IMPERIAL

Force: Pull at stated pull pressure 55.0 kN 12364.0 lbf

Push O at stated return pressure 26.0 kN 5485.0 lbf

Pressure: Pull 510 bar 7397 PSI

Return 200 bar 2901 PSI

Stroke: Piston Stroke 25.0 mm 0.98 in

Weight: Without nose equipment 3.5 kg 7.7 lb

Hydraulic Oil: Enerpac® Hydraulic Oil – HF-95X

Product Range:

Avbolt® 10.0 mm 3/8 in

Avseal® II 18.0 mm

Avdelok® 10.0 mm 3/8 in

Additional Features:

Stem Ejection – Front or Rear Rear

Seal Arrangement Twin Lip and Wiper Seals

Hydraulic Bearing Rings Yes – Front and Rear

Protective Handle / Hose Gator Yes

Protective Hose Guard Yes

Hose

/

Cable Retention Clamps

Yes

6

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Noise values determined according to noise test code ISO 15744and ISO 3744. AV10

A-weighted sound power level dB(A), LWA Uncertainty noise: kWA = 3.0dB(A) 93.3 dB(A)

A-weighted emission sound pressure level at the work station

dB(A), LpA

Uncertainty noise: kpA = 3.0dB(A) 82.3 dB(A)

C-weighted peak emission sound pressure level dB(C), LpC, peak Uncertainty noise: kpC = 3.0dB(C) 127.7 dB(C)

Vibration values determined according to vibration test code ISO 20643and ISO 5349. AV10

Vibration emission level, ahd: Uncertainty vibration: k= 0.33m/s20.661 m/s2

Declared vibration emission values in accordance with EN 12096

2.3 PLACING TOOL DIMENSIONS

117

236

56

33

79

197

A

B

All dimensions are shown in millimetres.

The tool is fitted with two Hydraulic Hoses and an electrical Control Cable, 0.6m in length. Additional hydraulic hose

and cable extension lengths are available to order separately as required. Refer to the table below for the available hose

assembly lengths and associated part numbers.

HYDRAULIC HOSE ASSEMBLY

PART NUMBER HOSE LENGTH

07008–00448 5 Metre

07008–00449 10 Metre

07008–00450 15 Metre

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3. PUTTING INTO SERVICE

3.1 PRINCIPLE OF OPERATION

IMPORTANT - READ BOTH THE SAFETY RULES ON PAGES

3 – 5

AND THE PUMP UNIT INSTRUCTION MANUAL

CAREFULLY BEFORE PUTTING INTO SERVICE.

•

When both hoses and control cable are connected to the Avdel®

/

Enerpac® hydraulic pump unit, the pull and return

cycles of

the tool are controlled by depressing and releasing the trigger located in the handle.

• When the switch is depressed the solenoid valve, located in the hydraulic pump unit, is energised and directs the

pressurised oil flow to the pull side of the piston in the placing tool. This also allows the oil in the return side of the

placing tool to return to the reservoir.

•

During the pull cycles the piston/collet assembly moves towards the rear of the tool allowing the O-ring type cushion to push

the follower and jaws forward. If a fastener pin has been inserted in the nose assembly, the jaw set will clamp onto

the pintail

and assembly will commence.

•

For Avbolt® and Avdelok® the cycle of installation will first clamp the joint to be fastened and then as the anvil continues to

move forward the collar will be swaged into the locking grooves of the pin. At the end of the swaging cycle the anvil

will

come up against the joint and as movement continues the pintail will be broken off.

•

The trigger switch should be released immediately after pin break occurs. Releasing the trigger switch will cause the

solenoid

to de-energise and reverse the flow of pressurised oil.

•

If the trigger is not released, the placing tool piston will continue to move towards the rear of the tool until it reaches the end

of its stroke. The pressure in the pull side will then increase until a preset ‘High Pressure’ value is achieved at the pump.

At this point the solenoid valve will automatically de-energise and reverse the flow of pressurised oil to the return

side of the

placing tool.

•

In either case, pressurised oil will now flow into the return side of the placing tool, with the oil in the pull side returning

to the

reservoir.

• The forward movement of the piston/collet assembly will eject the installed fastener from the anvil.

•

At the point of releasing the trigger or when the ‘High Pressure’ value is achieved, the solenoid valve will de-energise and

activate a preset ‘Return Timer’. This controls the time that the pump motor will continue run before switching to the idle

mode. The timer can be manually set between 5 and 20 seconds to ensure that the placing tool piston always fully

returns to the forward position (refer to pump manual 07900-01030, pages 11 and 14).

•

When the piston returns to the fully forward position, the pressure will increase to preset low pressure value - c200bar.

The pump motor will continue to run until the Return Timer has expired. After this time period the motor will stop

automatically and valve will switch to the idle position. The solenoid valve will then automatically cycle to release

pressurised

oil to the reservoir from both the pull and return side of the placing tool.

•

This keeps the installation tool in the forward position. No pressure will be present in the hydraulic system at this point.

The

hydraulic pump unit will automatically start up on depression of the tool trigger switch.

8

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3.2 PREPARATION FOR USE

CAUTION - CORRECT PULL AND RETURN PRESSURES ARE IMPORTANT FOR PROPER FUNCTION OF THE ISTALLATION

TOOL. PERSONAL INJURY OR DAMAGE TO EQUIPMENT MAY OCCUR WITHOUT CORRECT PRESSURES. THE PULL AND

RETURN PRESSURES SUPPLIED BY THE HYDRAULIC PUMP UNIT MUST NOT EXCEED THOSE PRESSURES LISTED IN THE

PLACING TOOL SPECIFICATION.

IMPORTANT – BEFORE PUTTING THE PLACING TOOL AND HYDRAULIC HOSE SET INTO SERVICE:

ENSURE THAT THE PUMP PRESSURE RELIEF VALVES HAVE BEEN SET IN ACCORDANCE WITH THE PUMP INSTRUCTIONS

AND THE MAXIMUM PRESSURES SPECIFIED FOR THE PLACING TOOL AND HOSES.

ENSURE THAT THE HOSE KIT IS PRIMED WITH HYDRAULIC FLUID IN ACCORDANCE WITH THE PROCEDURE IN THE

PUMP INSTRUCTION MANUAL 07900-01030.

• Ensure the mains power supply to the hydraulic pump unit is switched off.

• Connect the placing tool hydraulic hose quick couplers directly to the pump unit before connecting the electrical

control cable. Hoses and control cable must be connected in this order and disconnected in reverse order.

• Switch on the mains supply to the hydraulic pump unit. Wait 5 seconds for the pump unit to complete the boot

sequence, before pressing the trigger switch. When all set the LCD screen on the pump unit will display ‘AVDEL’.

• During the boot sequence the pump control system identifies any trigger operation as a potential malfunction and

prevents the motor from starting. The LCD screen will display ‘BUTTON FAULT’ in this instance. Reset by switching off the

power supply for 10 seconds.

• Ensure that the placing tool is positioned below the pump reservoir tanks. Depress and release the placing tool trigger

switch a few times to almost the full stroke of the tool to circulate hydraulic fluid and expel any air from the tool.

• Observe action of tool. Check for fluid leaks and ensure that in the idler mode the piston is in the fully forward position.

The placing tool will now be primed.

• Switch off the mains power supply to the hydraulic pump unit and then disconnect the placing tool from the pump

unit in reverse order to that described above.

• Now connect the placing tool to the primed hydraulic hose kit and electrical control cable. Then connect hydraulic hose

kit quick couplers and the electrical control cable to the pump unit.

• Attach the nose assembly to the tool as per the instructions in the relevant nose assembly datasheet.

• Switch on the mains supply to the hydraulic pump unit as described above.

• Depress and release the placing tool trigger switch a few times to almost the full stroke of the tool to circulate hydraulic

fluid.

• The placing tool is now ready for use.

9

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4. OPERATING INSTRUCTIONS

4.1 TO INSTALL AN AVBOLT® FASTENER

• Check work and remove excessive gap. (Gap is the space between components of the Joint. Gap is excessive if not

enough pintail sticks through the collar for the nose assembly jaws to grab onto).

• Put Avbolt® fastener into hole.

• Push nose assembly onto the pin until the nose assembly anvil stops against the collar. Tool and nose assembly must be

held at right angles (90°) to the work.

• Depress tool trigger switch to start installation cycle.

• When the forward motion of the nose assembly anvil stops and the pintail breaks o, release the trigger. The tool will

go into its return stroke and push o the installed fastener. At the end of the return stroke the jaws will partially release

the expended pintail which can then be pushed through the jaws with the next installation and then ejected through

the rear of the tool.

• Once the installed fastener has been ejected, the tool and nose assembly is ready for the next installation.

4.2 TO INSTALL AN AVDELOK® FASTENER

• Check work and remove excessive gap. (Gap is the space between components of the Joint. Gap is excessive if not

enough pintail sticks through the collar for the nose assembly jaws to grab onto).

• Put Avdelok® fastener into hole.

• Slide Avdelok® collar over the pin. (The beveled end of the collar must be towards the nose assembly and tool.)

• Push nose assembly onto the pin until the nose assembly anvil stops against the collar. Tool and nose assembly must be

held at right angles (90°) to the work.

• Depress tool trigger switch to start installation cycle.

• When the forward motion of the nose assembly anvil stops and the pintail breaks off, release the trigger. The tool will

go into its return stroke and push off the installed fastener. At the end of the return stroke the jaws will partially release

the expended pintail which can then be pushed through the jaws with the next installation and then ejected through

the rear of the tool.

• Once the installed fastener been ejected, the tool and nose assembly is ready for the next installation.

CAUTION - DO NOT ATTEMPT TO BREAK OFF A PINTAIL WITHOUT THE INSTALLATION OF A COLLAR AS THIS WILL

CAUSE THE UNSECURED PORTION OF THE AVDELOK® OR AVBOLT® PINTAIL TO EJECT FROM THE NOSE AT A HIGH

SPEED AND FORCE.

10

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5. SERVICING THE TOOL

IMPORTANT - READ BOTH THE SAFETY RULES ON PAGES 3 – 5 AND THE PUMP UNIT INSTRUCTION MANUAL

CAREFULLY BEFORE PUTTING INTO SERVICE.

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 TOOL SHALL BE EXAMINED REGULARLY FOR DAMAGE AND MALFUNCTION.

5.1 DAILY

• Check placing tool, hoses and quick couplers for oil leaks.

• Worn or damaged hoses and couplings should be replaced.

• Check that the stroke of tool meets the specification.

• Check that the stem deflector is fitted.

• Check that the pump pull / advance pressure relief valve is functioning correctly.

• Check for worn anvil indicated by score marks on the installed collar. This can also be confirmed by referring to the

installed data in the fastener catalogue. Excessive wear can cause the anvil to rupture.

5.2 WEEKLY

• Dismantle and clean the nose assembly especially the jaws as described in the relevant nose assembly datasheet.

• Check for oil leaks in placing tool, hoses and quick couplers.

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 ANNUALLY OR EVERY 250K OPERATIONS

• Every 250,000 cycles the tool should be completely dismantled and new components should be used where worn,

damaged or as recommended. All O-rings, back-up rings and seals should be renewed and lubricated with MolyKote®

111 grease before assembling.

5.4 SERVICE KIT

For a complete service the following Service Kit is available:

SERVICE KIT: 73430-99990

PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION

07005-10118 Quick Coupler - Male 07900-00956 AV10 Piston Guide Sleeve

07005-10120 Quick Coupler - Female 07900-00957 AV10 End Cap Assembly Tool

07900-00951 AV10 Piston Bullet - Front 07992-00020 Grease – MolyLithium EP3753

07900-00952 AV10 Piston Bullet - Rear 07900-00755 Grease – Molykote 111

07900-00955 AV10 Front Gland Guide Rod 07900-00756 Loctite® 243 Threadlocker

5.5 SERVICING TOOLS'

The following standard tools are also required:

• Allen Key: 2.0 / 3.0 mm

• Open End Flat Spanner: 12 / 14 / 18 / 24 / 45 mm A/F

• PTFE Tape: 10 mm

• Engineers Vice with Jaw Guards – 150 mm

11

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5.6 HYDRAULIC OIL

CAUTION  USE ONLY ENERPAC® HF HYDRAULIC OIL  THE USE OF ANY OTHER OIL MAY CAUSE THE PLACING TOOL

AND PUMP TO MALFUNCTION AND WILL RENDER THE PLACING TOOL WARRANTY NULL AND VOID.

Hydraulic oil is available to order under the following part numbers.

HYDRAULIC OIL

PART NUMBER 07992-00081 07992-00082 07992-00083

Enerpac® Part Number HF-95X

HF-95Y HF-95T

Volume 1 Litre 5 Litres 20 Litres

Viscosity 32 mm2/s 32 mm2/s 32 mm2/s

5.7 DISMANTLING INSTRUCTIONS

IMPORTANT – ENSURE THE MAINS POWER SUPPLY TO THE HYDRAULIC PUMP UNIT IS SWITCHED OFF BEFORE

REMOVING THE NOSE ASSEMBLY OR DISMANTLING THE PLACING TOOL.

Before Dismantling:

• Uncouple the Quick Couplers 10 and 11 and the electrical Control Cable 14 between the placing tool and the Hydraulic

Hose Assembly.

• Remove the nose assembly from the placing tool as per the instructions in the relevant nose assembly datasheet.

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

removed before maintenance.

For a complete service of the tool, we advise that you proceed with dismantling the tool in the order shown on pages 12

to 14. After dismantling the tool we recommend that you replace all seals.

Head Piston Assembly:

• Remove the Deflector 3, from the End Cap 17.

• Clamp the tool handle in a vice with soft jaws so that the tool is pointing nose down. Insert the dowel pins on the *End

Cap Assembly Tool into the three holes in the End Cap 17.

• Using a 24 mm A/F spanner, unscrew and remove the End Cap 17, from the Body 2.

• Using a small flat screwdriver, remove O-Ring 33 from the End Cap 17 and discard.

• Connect the spare *Quick Coupler – Male to the Quick Coupler – Female 11 on the Hydraulic Hose - Return 18. This will

release any pressure from the return side of the Piston 1 and ease the removal of the Rear Seal Gland 16.

• Insert three M4 screws into the Rear Seal Gland 16, and use them to pull the part off the rear shaft of the Piston 1 and

out of the Body 2.

• Using a small flat screwdriver or similar tool, remove O-Ring 30 and Spiral Back-up Ring 36, from the external groove

on the Rear Seal Gland 16, and discard. When removing the seals, take care not to damage the surface of the Rear Seal

Gland with the screwdriver.

• Remove Rod Seal 28 and Wiper Seal 31, from the internal grooves on the Rear Seal Gland 16, and discard. When

removing the seals, take care not to damage the surface of the Rear Seal Gland with the screwdriver.

• Remove Rear Bearing Ring 29 and check the part for wear or damage. Discard if necessary.

• Remove the placing tool from the vice and empty the hydraulic oil from the rear of the tool. Remove the spare *Quick

Coupler – Male from the Quick Coupler – Female 11 on Hydraulic Hose - Return 18.

• Connect the spare *Quick Coupler - Female to the Quick Coupler – Male 10 on the Hydraulic Hose - Pull 19. This will

release any pressure from the pull side of the Piston 1 and ease the removal of the Piston.

• Screw the *Piston Bullet - Front on to the front of the Piston 1.

• Place the Body 2 nose up on a bench. Then using a soft mallet, tap the Piston 1 towards the rear of the Body and out the

back end, taking care not to damage the bore within the Body.

• Note that when removing the Piston 1, oil on the pull side of the Piston will leak from the front and rear of the Body 2.

• When removing the Piston 1, the Front Seal Gland 15 may be retained on the Piston shaft. If this is the case, unscrew

the *Piston Bullet - Front and pull the Front Seal Gland off of the Piston.

All numbers in bold refer to the General Assembly and Parts List on pages 15, 16 and 17.

*Service Kit on page 11

12

ENGLISH

• Using a small flat screwdriver remove Piston Seal 26 and the two Anti-Extrusion Rings 27, from the external groove

on the Piston 1, and discard. When removing the seals, take care not to damage the surface of the Piston with the

screwdriver.

• If the Front Seal Gland 15 is still retained in the Body 2. Place the Body nose up on a bench and then push the Front Seal

Gland from the front until it is free from the recess within Body. The Front Seal Gland can then be removed from the

back end of the Body. Take care not to damage the bore within the Body when doing so.

• Using a small flat screwdriver remove O-Ring 23 and Spiral Back-up Ring 34, from the external groove on the Front Seal

Gland 15, and discard. When removing the seals, take care not to damage the surface of the Front Seal Gland with the

screwdriver.

• Remove Rod Seal 25 and Wiper Seal 22, from the internal grooves on the Front Seal Gland 15, and discard. When

removing the seals, take care not to damage the surface of the Front Seal Gland with the screwdriver.

• Remove the Front Bearing Ring 24 and check the part for wear or damage. Discard if necessary.

• Using a small flat screwdriver, remove O-Ring 21 from the Body 2 and discard.

• Remove the spare *Quick Coupler - Female from the Quick Coupler - Male 10 on the Hydraulic Hose - Pull 19.

Assemble in reverse order to dismantling noting the following points:

• Clean all components before assembling.

• To aid assembly of seals apply a light coating of Molykote® 111 grease to all seals, seal grooves, back-up rings and the

assembly tools.

• Slide O-Ring 23 over the Front Seal Gland 15 and into the external groove. Insert the Spiral Back-up Ring 34 in the same

groove, in front of the installed O-Ring. Refer to the General Assembly and Parts List for the correct orientation of the

O-Ring and Spiral Back-up Ring.

• Press the Front Bearing Ring 24 into the internal recess within the Front Seal Gland 15 and then install Rod Seal 25

behind the Front Bearing Ring. Install the Wiper Seal 22 in the front recess of the Front Seal Gland. Refer to the General

Assembly to ensure the correct orientation of the Rod Seal and Wiper Seal.

• Lubricate the surface and leading edge of the Body 2 bore into which the Front Seal Gland 15 is to be installed with

Molykote® 111 grease.

• Lubricate the spigot on the *Front Gland Guide Rod tool and then place the Front Seal Gland 15, Rod Seal 25 end first,

fully over spigot. Insert *Front Gland Guide Rod into the rear of the Body 2 and then push the Front Seal Gland fully into

the bore within the Body. Reasonable force is required to insert Front Seal Gland into the Body, so the use of a press or

vice may be necessary. Remove the *Front Gland Guide Rod while ensuring that the Front Seal Gland stays in place.

• Lubricate the seal groove and major external diameter of the Piston 1 with Molykote® 111 grease. Slide the Piston Seal

26 over the front of the major Piston diameter and into the seal groove. Install two Anti-Extrusion Rings 27 into the

Piston seal groove, one either side of the Piston Seal.

• Screw the *Piston Bullet - Front onto the front of the Piston 1. Lubricate the *Piston Bullet - Front, Piston shaft and

Piston Seal 26 with Molykote® 111 grease.

• Screw the *Piston Guide Sleeve fully into the rear of the Body 2. Lubricate the bores in both the Body and the *Piston

Guide Sleeve with Molykote® 111 grease.

• Connect the spare *Quick Coupler - Female to the Quick Coupler - Male 10 on the Hydraulic Hose - Pull 19. This will

allow air to be released from the pull side of the Piston 1 when inserting the Piston.

• Insert the assembled Piston 1 into the rear of the Body 2 and through the assembled Front Seal Gland 15. Push the

Piston into the fully forward position until it stops against the Front Seal Gland. Hydraulic oil will be expelled from the

Hydraulic Hose - Pull 19.

• Remove the spare *Quick Coupler - Female from the Quick Coupler - Male 10 on the Hydraulic Hose - Pull 19. Remove

the *Piston Guide Sleeve from the rear of the Body 2.

• Slide O-Ring 30 over the Rear Seal Gland 16 and into the external groove. Insert the Spiral Back-up Ring 36 in the same

groove, behind the installed O-Ring. Refer to the General Assembly and Parts List for the correct orientation of the

O-Ring and Spiral Back-up Ring.

• Press the Rear Bearing Ring 29 into the internal recess within the Rear Seal Gland 16 and then install Rod Seal 28

behind the Rear Bearing Ring. Install the Wiper Seal 31 in the rear recess of the Rear Seal Gland. Refer to the General

Assembly to ensure the correct orientation of the Rod Seal and Wiper Seal.

• Clamp the tool handle in a vice with soft jaws so that the tool is pointing nose down.

All numbers in bold refer to the General Assembly and Parts List on pages 15, 16 and 17.

*Service Kit on page 11

13

ENGLISH

• Lubricate the surface and leading edge of the Body 2 bore into which the Rear Seal Gland 16 is to be installed with

Molykote® 111 grease. Lubricate the rear Piston 1 shaft with Molykote® 111 grease.

• Insert the *Piston Bullet - Rear into the rear Piston 1 shaft and Lubricate with Molykote® 111 grease.

• Fill the rear of the Body 2 with Enerpac® HF hydraulic oil. Oil level should be just above the rear inlet bore into the Body.

• Connect the spare *Quick Coupler - Male to the Quick Coupler - Female 11 on the Hydraulic Hose – Return 18. This will

allow air to be released from the return side of the Piston 1 when inserting the Rear Seal Gland 16.

• Place the Rear Seal Gland 16 over the *Piston Bullet - Rear. Then push the Rear Seal Gland over the Piston 1 shaft and

into the rear of the Body 2. Push the Rear Seal Gland into the Body until a few internal threads are exposed at the rear

of the Body. Take care not to damage the O-Ring 30 and Spiral Back-up Ring 36 on the threads when inserting the Rear

Seal Gland.

• Lubricate both the internal thread in the Body 2 and the external thread on End Cap 17 with MolyLithium Grease.

• Screw the End Cap 17 fully into the rear of the Body 2 using the *End Cap Assembly Tool. In doing so, the Rear Seal

Gland 16 will be pressed into position within the Body and a small amount of oil will be expelled from the Hydraulic

Hose - Return 18.

• Remove the spare *Quick Coupler - Male from the Quick Coupler - Female 11 on the Hydraulic Hose - Return 18.

• Push the Deflector 3, onto the End Cap 17.

• Prime the placing tool as described in Preparation for Use on page 9.

Hose Assembly:

• Remove the two Screws 9 from the Hose Clamp 13 using a 3.0mm Allen Key. Remove the Hose Clamp and Clamp Insert

20 from the Protective Sleeve 37 and Hydraulic Hoses - Return 18 and Pull 19.

• Using the small flat screwdriver prize the Handle Gator 8 from the handle of Body 2. Pull the Handle Gator over the

Protective Sleeve 37, Hydraulic Hoses-Return 18 and Pull 19 and remove.

• Cut the Cable Tie 35 and slide back the Protective Sleeve 37 to expose the fittings on the Hydraulic Hoses - Return 18

and Pull 19. The Hydraulic Hoses can be removed form the Body 2 using 12mm and 14mm spanners.

• The Quick Couplers - Male 10 and Female 11 can be removed from the Hydraulic Hoses - Return 18 and Pull 19 using

18mm and 24mm spanners.

• To remove Trigger Switch 7, first loosen Cable Gland 38, so that the Control Cable 14 is free to move within the Body 2.

Then undo M4 Set Screw 12 using a 2.0mm Allen Key.

• Push the Control Cable 14 into the Body 2 and simultaneously pull the Trigger Switch 7 out of the Body to expose the

solder joints on the Trigger Switch terminals. Unsolder the terminals to remove the Trigger Switch and Trigger Insert 39.

The Trigger Insert is bonded to the Trigger Switch and cannot be removed.

• The Control Cable 14 can now be pulled from the Body 2 and removed from the Protective Sleeve 37.

Assemble in reverse order to dismantling noting the following points:

• Prior to assembly clean all threads on the Quick Couplers - Male 10 and Female 11 and the Hydraulic Hoses - Return 18

and Pull 19. Then apply two to three layers of 10mm PTFE tape to the male threads on both of the Hydraulic Hoses.

• When replacing the Trigger Switch 7 apply *Loctite® 243 to the male thread on the Trigger Switch before assembling

the Trigger Insert 39.

• Apply *Loctite® 243 to M4 Set Screw 12 prior to assembly.

• Once assembled, prime the tool as per the instructions on page 9.

5.8 PROTECTING THE ENVIRONMENT

Assure conformity with applicable disposal regulations. Dispose all waste products at an approved waste facility or site so as

not to expose personnel and the environment to hazards.

All numbers in bold refer to the General Assembly and Parts List on pages 15, 16 and 17.

*Service Kit on page 11

14

ENGLISH

6. GENERAL ASSEMBLY OF INSTALLATION TOOL 73430-02000

34, 25 1

7

8

9

10

11

13

14

1

2

6

15

ENGLISH

115161721 22 34 23 24 25 26 27

39

20

28 29 30 36 31 33

35

37

38

B

C

E

D

18

19

DETAIL B

DETAIL C

DETAIL D

DETAIL E

GENERAL ASSEMBLY OF INSTALLATION TOOL 73430-02000

16

ENGLISH

7. PARTS LIST FOR INSTALLATION TOOL 73430-02000

73430-02000 Parts List

ITEM PART NUMBER DESCRIPTION QTY.

1 73430-02003 PISTON 1

2 73430-02001 BODY 1

3 73430-02011 DEFLECTOR 1

4 73425-02016 SAFETY LABEL 1

5 73430-02026 AV10 LABEL 2

6 07007-01504 CE & UKCA LABEL 1

7 07007-02103 TRIGGER SWITCH 1

8 73430-02020 HANDLE GATOR 1

9 07001-00686 M4 X 16 SKT CAP HD SCREW 2

10 07005-10118 QUICK COUPLER – MALE 1

11 07005-10120 QUICK COUPLER – FEMALE 1

12 07001-00479 M4 X 4 SKT SET SCREW 1

13 73430-02023 HOSE CLAMP 1

14 07007-02105 CONTROL CABLE 1

15 73430-02004 FRONT SEAL GLAND 1

16 73430-02006 REAR SEAL GLAND 1

17 73430-02005 END CAP 1

18 07005-10119 HYDRAULIC HOSE – RETURN 1

19 07005-10117 HYDRAULIC HOSE – PULL 1

20 73430-02024 CLAMP INSERT 1

21 07003-00457 O-RING 1

22 07003-00440 WIPER SEAL 1

23 07003-00458 O-RING 1

24 73430-02009 FRONT BEARING RING 1

25 07003-00439 ROD SEAL 1

26 07003-00443 PISTON SEAL 1

27 07003-00444 ANTI-EXTRUSION RING 2

28 07003-00441 ROD SEAL 1

29 73430-02010 REAR BEARING RING 1

30 07003-00459 O-RING 1

31 07003-00442 WIPER SEAL 1

32

33 07003-00460 O-RING 1

34 07003-00492 SPIRAL BACK-UP RING 1

35 07007-02032 CABLE TIE 1

36 07003-00493 SPIRAL BACK-UP RING 1

37 07005-10121 PROTECTIVE SLEEVE 0.6 m

38 07007-02104 CABLE GLAND 1

39 73430-02008 TRIGGER INSERT 1

- 07900-01020 AV10 TOOL INSTRUCTION MANUAL 1

17

ENGLISH

8. SAFETY DATA

8.1 ENERPAC® HF HYDRAULIC OIL - SAFETY DATA

FIRST AID

SKIN:

Unlikely to cause harm to the skin on brief or occasional contact but prolonged or exposure may lead to dermatitis. Wash

skin thoroughly with soap and water as soon as reasonably practicable. Remove heavily contaminated clothing and wash

underlying skin.

ORAL:

Unlikely to cause harm if accidentally swallowed in small doses, though larger quantities may cause nausea and diarrhea.

If contamination of the mouth occurs, wash out thoroughly with water. Except as a deliberate act, the ingestion of large

amounts of product is unlikely. If it should occur, do not induce vomiting; obtain medical advice. Take person to nearest

medical centre.

EYES:

Unlikely to cause more than transient stinging or redness if accidental eye contact occurs. Wash eyes thoroughly with

copious quantities of water, ensuring eyelids are held open. Obtain medical advice if any pain or redness develops or

persists.

MEDICAL ADVICE:

Treatment should in general be symptomatic and directed to relieving any effects. Note: High Pressure Applications:

Injections through the skin, resulting from contact with the product at high pressure, constitute a major medical emergency.

Injuries may not appear serious at first but within a few hours tissue becomes swollen, discolored and extremely painful with

extensive subcutaneous necrosis.

Surgical exploration should be undertaken without delay. Thorough and extensive debridement of the wound and

underlying tissue is necessary to minimize tissue loss and prevent or limit permanent damage. Note that high pressure may

force the product considerable distances along tissue planes.

DISPOSAL

Remove all spills with inert absorbent material. Ventilate spill area. Place contaminated materials in a disposable container

and dispose in a manner consistent with local regulations.

FIRE

FLASH POINT: 200°C.

Extinguish with either dry chemical, foam or carbon dioxide. Do not enter confined space without self contained breathing

apparatus.

HANDLING

Use barrier cream or oil resistant gloves.

STORAGE

Undercover and consistent with local regulations for inflammable material.

8.2 MOLYLITHIUM GREASE EP 3753 - SAFETY DATA

Grease can be ordered as a single item, the part number is shown in the Service Kit page 11.

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.

18

ENGLISH

FIRE

FLASH POINT: Above 220°C.

Not classified as flammable.

Suitable extinguishing media: CO2, Halon or water spray if applied by an experienced operator.

ENVIRONMENT

Scrape up for incineration or disposal on approved site.

HANDLING

Use barrier cream or oil resistant gloves

STORAGE

Away from heat and oxidising agent.

8.3 MOLYKOTE® 111 GREASE - SAFETY DATA

Grease can be ordered as a single item, the part number is shown in the Service Kit page 11.

FIRST AID

SKIN:

No first aid should be needed. INGESTION:

No first aid should be needed. EYES:

No first aid should be needed. INHALATION:

No first aid should be needed.

FIRE

FLASH POINT: Above 101.1°C. (closed cup) Explosive Properties: No

Suitable Extinguishing Media: Carbon Dioxide Foam, Dry Powder or fine water spray. Water can be used to cool fire exposed

containers.

ENVIRONMENT

No adverse effects are predicted.

HANDLING

General ventilation is recommended. Avoid eye contact.

STORAGE

Do not store with oxidizing agents. Keep container closed and store away from water or moisture

19

ENGLISH

9. FAULT DIAGNOSIS

SYMPTOMPOSSIBLE CAUSE REMEDY PAGE REF.

Placing Tool will not

operate

Inoperative pump unit Check pump power supply and refer to

pump unit instruction manual

Faulty Quick Couplers 10 and 11 Replace Quick Couplers 14

Trigger Control Cable 14 not

connected correctly

Check Control Cable is correctly connected

at pump and placing tool 9

Damaged Trigger Switch 7 or

Control Cable 14

Replace Trigger Switch and/or Control

Cable 14

Trigger Switch 7 does not

function

Pump in local mode Refer to pump instruction manual

Trigger Switch 7, Control Cable

14 or connector damaged

Replace Trigger Switch and/or Control

Cable 14

Pump running but

placing tools does not

function

Hydraulic Hoses not connected Check for correct connections at pump and

placing tool 9

Low oil level

Ensure placing tool is lled with oil and

correctly primed.

Refer to pump instruction manual

9

Placing tool external oil leak Inspect placing tool – replace worn or

damaged components 12–14

Hose Assembly external oil leak

Inspect Hose Assembly – ensure hose

connections are tight and/or replace

damaged hose connectors

14

Pump internal/external oil leak Refer to pump instruction manual

Placing tool operates

erratically

Low or erratic hydraulic pressure

supply Refer to pump instruction manual

Worn or damaged hydraulic seals in

placing tool

Inspect placing tool – replace worn or

damaged seals 12–14

Worn or damaged hydraulic

sealing surfaces in placing tool

Inspect placing tool – replace

worn or damaged components 12–14

Pump internal/external oil leak Refer to pump instruction manual

Pump builds full

pressure, but pintail does

not break

Breakload greater than placing tool

capacity at full pressure Refer to placing tool specication 6

Flow to placing tool blocked Check Quick Couplers 10 and 11

for full engagement 8

Pump pressure relief value set too

low

Adjust pressure relief valve settings – refer

to pump instruction manual

Pull grooves on fastener pintail

stripped See symptom on page 20 10

Improper tool operation 10

Placing tool Piston 1

will not return

Return ow restricted or blocked Check Quick Couplers 10 and 11 for full

engagement and/or fault 9

Hydraulic Hoses not connected Check for correct connections at pump and

placing tool 9

Pump valve malfunction Refer to pump instruction manual

20

ENGLISH

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