10 Always adopt a rm footing or a stable position before operating the tool/machine. 11 Ensure that vent holes do not become blocked or covered and that hoses are always in good condition. 12 The operating pressure shall not exceed 7 bar (100 lbf/in2). 13 The combination of fastener, mandrel, hole size and sheet thickness shall be in accordance with Avdel UK Limited Specications. 14 Do not operate the tool if it is not tted with a complete nose assembly unless specically instructed otherwise. 15 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. 16 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. 17 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent startup. 18 Excessive contact with hydraulic oil should be avoided. To minimize the possibility of rashes, care should be taken to wash thoroughly. I M P O R TA N T 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 Avdel 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 Part Number 07900-09080, supplied with all necessary information for testing in this manual.

Specifications

S p e c i f i c a t i o n f o r M k I I Ty p e To o l
Air Pressure Free Air Volume Required Stroke Pull Force Cycle time Noise Level Weight Vibration
Minimum - Maximum @ 5.1 bar /75 lbf/in2 Minimum @ 5.5 bar /80 lbf/in Approximately Less than Pistol Less than
5-7 bar (70-100 lbf/in2) 2.6 litres (0.09 ft3) 30.0 mm (1.18 in) 3.89 kN (875 lbf) 1 second 70 dB(A) 1.2 kg (2.64 lb) 2.5 m/s2 (8 ft/s2)

Specification for 07531 Intensifier
Air Pressure Intensification Ratio Minimum - Maximum 5-7 bar (70-100 lbf/in2) 32:1

Intent of Use

The pneumatic 0753 MkII type tool is designed to place Avdel speed fasteners (except 1/16 Avlug) making it ideal for batch or owline assembly in a wide variety of applications throughout all industries. The Hand Tool and Intensier have been tested as separate items and combined. They must only be used together and for no other purposes. Refer to "Putting into Service" on page 8 for connection details. Both models, the 07530 MkII and 07532 MkII are hand-held lightweight tools. Their only difference lies in the location of the hose entry. The top entry on the 07532 MkII tool allows suspension from an added mounting plate, see drawing opposite. Part numbers are shown to order a complete tool including the intensier and all hoses but no nose equipment. The pistol number for the 07530 MkII model is 07530-02200 and is 07532-02200 for the 07532 MkII model. See the general assemblies on pages 28-31. Both models will place the same fasteners and both will place most repetition fasteners, as shown in the table below. Both models make use of the same nose equipment. Reference must be made to the Nose Equipment section of the manual when selecting compatible components for the type and size of fastener used in your application (see pages 13-21). Nose jaw dimensions are shown on page 14.
FASTENER SIZE FASTENER NAME
CHOBERT GROVIT AVLUG BRIV RIVSCREW AVTRONIC AVSERT
3/32" 1/8" 5/32" 3/16" 1/4" 2.5mm 2.8mm 3mm 3.5mm 4mm 6mm M2.5 4-40 UNC M3 6-32 UNC
To o l D i m e n s i o n s - 0 M k I I M o d e l

Part Number 07530-02100

60 2.18.13.30

50 1.96

6.41 5.51

98 3.85

28 1.5.16.54

200 7.87

To o l D i m e n s i o n s - 2 M k I I M o d e l

Part Number 07532-02100

130 5.16.54

60 2.36

98 3.13.30

28 1.10

475 18.70
Dimensions shown in bold are millimetres. Other dimensions are in inches.

Putting into Service

Air Supply
All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and automatic oiling/ltering systems on the main air supply. To ensure maximum tool life and minimum tool maintenance they should be tted within 3 metres of the tool (see diagram below). Air supply hoses should have a minimum working effective pressure rating of 150% of the maximum pressure produced in the system or 10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and should be armoured where operating conditions may result in hoses being damaged. All air supply hoses MUST have a minimum bore diameter of 6.4 millimetres or 1/4 inch. Read daily servicing details page 22.

Push the fastener, protruding from the nose jaws, fully into the application holes ensuring that the tool is held square. Operate the trigger without releasing - the mandrel head is pulled through the fastener, forming the fastener into the application. Remove the tool. Release the trigger. The next fastener will be automatically presented through the nose jaws, ready for placing.
MANDREL FOLLOWER SPRINGS IDENTIFICATION AND ORIENTATION
FASTENER NAME SIZE NOSE JAW
(SEE NOSE EQUIPMENT SECTION)

MANDREL SIZE

MANDREL/MANDREL FOLLOWER SPRING AND FASTENER ASSEMBLY

MANDREL FOLLOWER SPRING

3/32"
MANDREL HEAD STANDARD TAPERED ALL

FERRULE SPRING

MANDREL
LIMITED ACCESS & LIMITED ACCESS CAM OPERATED

1/8"

5/32"

3/16"

ALL ALL EXCEPT 3rd OVERSIZE ALL
STANDARD ALL EXCEPT STANDARD TAPERED, LIMITED ACCESS STANDARD TAPERED, LIMITED ACCESS

CHOBERT AVLUG GROVIT

ALL ALL EXCEPT 3rd OVERSIZE 3rd OVERSIZE ALL EXCEPT 2nd OVERSIZE 2nd OVERSIZE

CHOBERT GROVIT

3/16" ALL

CHOBERT

1/4"

RIVSCREW

3mm 3.5mm

4mm 2.5mm

AVSERT
4 x 40 UNC 3mm 6 x 32 UNC

AVTRONIC

ALL EXCEPT LIMITED ACCESS

LIMITED ACCESS

Nose Assemblies
On speed fastening tools such as 0753 MkII type, 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.
I M P O R TA N T To avoid complete dismantling of the tool it is essential to check the orientation of the cursor before tting the nose equipment to the tool. See CURSOR section on page 10. It is essential that the correct nose equipment is tted to the tool to ensure both effective placing of the fastener and SAFE operation of the tool. READ THE SAFETY INSTRUCTIONS page 4 carefully.

REF. N 27 28

NOSE JAW TYPE AND END FORM # STANDARD - UNIVERSAL LTD. ACCESS CAM OPERATED LIMITED ACCESS LONG CURVED - FLAT # STANDARD - UNIVERSAL STD. CAM OPERATED - FLAT # LONG - UNIVERSAL LONG CAM OPERATED - FLAT # STANDARD - UNIVERSAL STD. CAM OPERATED - FLAT # LONG - UNIVERSAL LONG CAM OPERATED - FLAT # STANDARD - UNIVERSAL STD. CAM OPERATED - FLAT # LONG - UNIVERSAL LONG CAM OPERATED - FLAT STD. CAM OPERATED - FLAT LONG CAM OPERATED - FLAT LTD. ACCESS CAM OPERATED STANDARD - RECESSED LONG - FLAT LONG CURVED - FLAT STANDARD - RECESSED LONG - RECESSED LONG CURVED - RECESSED STANDARD - RECESSED LONG - RECESSED LONG CURVED - RECESSED STANDARD - RECESSED LONG - RECESSED LONG CURVED - RECESSED STANDARD - RECESSED LONG - RECESSED LONG CURVED - RECESSED STANDARD - FLAT LONG - FLAT STANDARD - TAPERED LONG - FLAT PART N 07150-03203 07177-03003 07274-01000 07150-05003 07150-03204 07170-04600 07150-04204 07170-05000 07150-03205 07170-04700 07150-04205 07170-05100 07150-03206 07170-04800 07150-04206 07170-05200 07170-04900 07170-05300 07177-03003 07170-03004 07150-04004 07150-05004 07170-03005 07170-03205 07170-03305 07170-03005 07170-03205 07170-03305 07170-03006 07170-03206 07170-03306 07170-03006 07170-03206 07170-03306 07170-05800 07170-05900 07150-03103 07150-04003 07170-03104 07150-04004 07170-05000 07170-04600 07271-08000 07271-08100 DIMENSIONS 'B' 'D' 'E'.36.20.22.41.41.41.41.41.48.48.48.48.56.56.56.56.64.64.20.41.41.41.48.48.48.48.48.48.56.56.56.56.56.56.64.64.36.41.41.41.41.41.41.40 1.33 1.18 1.07 2.28 1.22 1.18 2.22 2.18 1.35 1.30 2.35 2.30 1.24 1.18 2.39 2.30 1.18 2.18 1.18 1.20 2.18 2.12 1.32 2.30 2.23 1.32 2.30 2.23 1.20 2.30 2.21 1.20 2.30 2.21 1.21 2.19 1.30 2.30 1.19 2.18 2.18 1.18 1.18 1.18.24.16.16.16.32.20.30.20.41.24.42.24.47.33.48.33.39.39.16.30.20.20.41.41.41.41.41.41.47.47.47.47.47.47.52.52.16.16.20.20.20.20.16.16 -
STANDARD - TAPERED LONG - FLAT LONG CAM OPERATED - FLAT STD. CAM OPERATED - FLAT LTD. ACCESS CAM OPERATED LTD. ACCESS CAM OPERATED -

2.5mm AVTRONIC

2.8mm AVTRONIC 2.8mm RIVSCREW 3.0mm RIVSCREW 3.5mm RIVSCREW 4.0mm RIVSCREW
# These nose jaws are suitable for placing Chobert rivets with a Universal Head Form. When used on the equivalent size of Briv, the highest possible clench is achieved. Note when using Briv fasteners, the maximum grip is reduced by approximately 0.015" (0.4mm). possible clench is achieved. Note that when using Briv fasteners, the maximum grip is reduced by approximately 0.015 (0.4 mm).

Nose Jaw Selection - Metric

FASTENER

REF. N 1
NOSE JAW TYPE AND END FORM STANDARD - FLAT STD. CAM OPERATED - FLAT STANDARD - TAPERED LONG - FLAT STANDARD - FLAT STANDARD - TAPERED LONG - FLAT LONG CURVED - FLAT STANDARD - FLAT STANDARD - TAPERED LONG - FLAT LONG CURVED - FLAT STANDARD - FLAT STANDARD - TAPERED LONG - FLAT LONG CURVED - FLAT STANDARD - FLAT LONG - FLAT STANDARD - TAPERED LIMITED ACCESS STANDARD - FLAT STANDARD - TAPERED LONG - RECESSED LONG CURVED - RECESSED STANDARD - FLAT LONG - FLAT LONG CURVED - FLAT STANDARD - FLAT LONG - FLAT LONG CURVED - FLAT STANDARD - FLAT LONG - FLAT LONG CURVED - FLAT STANDARD - FLAT LONG - FLAT LONG CURVED - FLAT STD. CAM OPERATED LONG CAM OPERATED STANDARD - FLAT STD. CAM OPERATED - FLAT LONG CURVED - FLAT STANDARD - FLAT STD. CAM OPERATED - FLAT LONG CURVED - FLAT STANDARD - FLAT STANDARD - FLAT STANDARD - FLAT LONG - FLAT STANDARD - FLAT LONG - FLAT STD. CAM OPERATED - HF STD. CAM OPERATED - HF STD. CAM OPERATED - HF STD. CAM OPERATED - HF PART N 07150-03003 07170-04500 07170-03103 07150-04003 07150-03004 07170-03104 07150-04004 07150-05004 07150-03005 07150-03105 07150-04005 07150-05005 07150-03006 07150-03106 07150-04006 07150-05006 07150-03008 07150-04008 07170-03103 07274-01000 07150-03004 07170-03104 07170-03204 07170-03304 07150-03005 07150-04005 07150-05005 07150-03005 07150-04005 07150-05005 07150-03006 07150-04006 07150-05006 07150-03006 07150-04006 07150-05006 07170-05600 07170-05700 07150-03003 07170-04500 07150-05003 07150-03004 07170-04600 07150-05004 07150-03003 07150-03004 07150-03003 07150-04003 07271-05600 07271-05900 07271-03000 07271-03000 07271-03500 07271-04000 DIMENSIONS 'B' 'D' 'E' 9.14 33.02 4.06 9.14 33.02 4.06 9.14 33.02 4.06 10.41 58.42 4.06 10.41 29.97 5.08 10.41 30.23 5.08 10.41 55.37 5.08 10.41 53.85 5.08 12.19 33.02 6.10 11.18 33.02 6.10 12.19 58.42 6.10 12.19 56.64 6.10 14.22 29.97 8.38 14.22 29.97 8.38 14.22 58.42 8.38 14.22 56.13 8.38 16.26 29.97 9.91 16.26 55.37 9.91 9.14 33.02 3.81 5.59 27.18 4.06 10.41 29.97 5.08 10.41 30.23 5.08 10.41 55.37 7.62 10.41 53.85 7.62 12.19 33.02 6.10 12.19 58.42 6.10 12.19 56.64 6.10 12.19 33.02 6.10 12.19 58.42 6.10 12.19 56.64 6.10 14.22 29.97 8.38 14.22 58.42 8.38 14.22 56.13 8.38 14.22 29.97 8.38 14.22 58.42 8.38 14.22 56.13 8.38 16.33 30.65 13.14 16.33 55.65 13.14 9.14 33.02 4.06 9.14 33.02 4.06 10.41 57.91 4.06 10.41 29.97 5.08 10.41 29.97 5.08 10.41 53.85 5.08 9.14 33.02 4.06 10.41 29.97 5.08 9.14 33.02 4.06 10.41 58.42 4.06 9.14 33.02 4.06 10.41 58.42 4.06 10.41 29.97 6.10 10.41 29.97 6.10 10.41 29.97 6.10 10.41 29.97 6.35

HEAD 1.93 1.93 1.93 1.93 2.49 2.49 3.10 3.10 3.96 3.96 -
2ND OVERSIZE MANDREL - BLUE P P MANDREL # S/R MANDREL MAX. MAX. PART N PART N 4.70 07150-06103 07150-06103 07150-06103 07150-07103 07150-06204 07150-07204 07150-06205 07150-07205 07150-06206 07150-07206 4.70 4.70 4.70 6.81 6.81 8.13 8.13 9.45 9.45 07150-08204 07150-09204 07150-08205 07150-09205 07150-08206 07150-09206 2.79 2.79 3.30 3.30 3.81 3.81 -
HEAD 2.59 2.59 3.35 3.35 -
3RD OVERSIZE MANDREL - RED P P MANDREL # S/R MANDREL MAX. MAX. PART N PART N 07150-06304 07150-07304 07150-06305 07150-07305 7.32 7.32 9.45 9.45 07150-08304 07150-09304 07150-08305 07150-09305 3.00 3.00 3.81 3.81 -
To nd 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 FASTENER SIZE DATASHEET APPLICATION HOLE SIZE CLEARANCE BEHIND APPLICATION REF.N FROM NOSE JAW SELECTION TABLE

example

Chobert
Series 1125 0.1335 Innite 5 (standard at)
Subtract the minimum hole size recommended (AS REC.) in the fastener datasheet from the actual application hole size. -example: 0.005. Turn to the page with the Mandrel Selection table for your fastener, selecting either the imperial or the metric dimensions table (pages 17-21). -example: page 17. Staring with the Standard Mandrel - Green section, nd your fastener size in the left-hand column. -example 1/8 Chobert & Grovit. If you selected a nose jaw which place you fastener, you should now be able to nd 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 nd 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 gure calculated in step one. You may now read the mandrel part number next to the hole size. -example: 07150-06104 For Chobert and Grovit only, most mandrels are also available in a short reach version (see illustration on page 20). 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 P gure against that mandrel is adequate. P 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 20. You may now read the corresponding mandrel follower spring part number in the right-hand column of the table. -example: 07150-06804.

M a n d r e l H e a d Ty p e s a n d P L e n g t h
Mandrels for stainless steel Briv are easily identiable 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.
P CHOBERT, GROVIT, AVSERT, AVTRONIC SHORT REACH (CHOBERT & GROVIT ONLY) P BRIV BRIV (STAINLESS STEEL) P P

P RIVSCREW AVLUG

Briv - Metric
REF. N HOLE SIZE AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC AS REC STANDARD MANDREL - GREEN MANDREL PART N 07150-06013 07150-06013 07271-06414 07271-07414 07150-06015 07150-07015 07170-06805 07170-07805 07150-06016 07150-07016 07170-06806 07170-07806 07150-06018 07150-07018 HOLE SIZE +.10 +.10 +.13 +.13 +.13 +.13 +.13 +.13 +.13 +.13 +.13 +.13 +.13 +.13 1ST OVERSIZE MANDREL - YELLOW MANDREL P PART N MAX. 07150-06113 3.12 07150-06113 07271-06514 07271-07514 07150-06115 07150-07115 07170-06825 07170-07825 07150-06116 07150-07116 07170-06826 07170-07826 07150-06118 07150-07118 3RD OVERSIZE MANDREL - RED MANDREL PART N 07150-06316 07150-07316 3.12 3.20 3.20 3.61 3.61 3.35 3.35 4.17 4.17 3.96 3.96 4.34 4.34 SPRING PART N 07170-06873 07170-06903 07150-06814 07150-07814 07170-06875 07170-07875 07170-06875 07170-07875 07170-06876 07170-07876 07170-06876 07170-07876 07150-06846 07150-07846
HEAD 1.83 1.83 2.34 2.34 2.79 2.79 3.05 3.05 3.58 3.58 3.89 3.89 4.54 4.54
P MAX. 3.02 3.02 3.05 3.05 3.45 3.45 3.20 3.20 3.99 3.99 3.81 3.81 4.18 4.18
HEAD 1.93 1.93 2.46 2.46 2.92 2.92 3.18 3.18 3.71 3.71 4.01 4.01 4.67 4.67
HOLE SIZE +.20 +.20 +.25 +.25 +.25 +.25 +.25 +.25 +.25 +.25
HEAD 2.01 2.01 2.59 2.59 3.05 3.05 3.84 3.84 4.79 4.79
2ND OVERSIZE MANDREL - BLUE P MANDREL MAX. PART N 07150-06213 3.20 07150-06213 07271-06614 07271-07614 07150-06215 07150-07215 07150-06216 07150-07216 07150-06218 07150-07218 3.20 3.38 3.38 3.78 3.78 4.32 4.32 4.49 4.49

HOLE SIZE +.30 +.30 -

HEAD 3.85 3.85 -

P MAX. 4.39 4.39 -

SPRING PART N 07170-06873 07170-06903 07150-06814 07150-07814 07170-06875 07170-07875 07170-06876 07170-07876 07150-06846 07150-07846
A v l u g , A v s e r t , A v t ro n i c & R i v s c r e w - I m p e r i a l & M e t r i c

Service Kit

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

SERVICE KIT

ITEM PART N 07900-00157 07900-00006 07900-00446 07900-00603 07900-00520 07900-00521 07900-00602 07900-00595 07900-00434 07900-00237 07900-00012 07900-00008 DESCRIPTION CIRCLIP PLIERS SPATULA EXTRACTOR BARREL VICE JAWS 3 /8" ROD 1 /4" ROD 'O' RING ASSEMBLY BULLET 18mm SPANNER 32mm SPANNER 3/8" x 5/16" B.S.W. SPANNER 9/16" x 5/8" SPANNER 7/16" x 1/2" SPANNER N OFF ITEM PART N 07900-00352 07900-00710 07900-00725 07900-00243 07900-00717 07900-00013 07900-00617 07900-00469 07900-00351 07900-00224 07900-00225 07992-00020 DESCRIPTION SEAL REMOVAL HOOK BARREL PLUG REMOVAL SPANNER BULLET SCREWDRIVER INTENSIFIER SPANNER 1/8" ALLEN KEY LOCTITE MULTI-GASKET 574 50ml PACK 2.5mm ALLEN KEY 3mm ALLEN KEY 4mm ALLEN KEY 5mm ALLEN KEY 80g TIN MOLY LITHIUM GREASE EP 3753 N OFF 1 1
Note: Spanner sizes are measured 'across ats' unless otherwise specied.

Maintenance

Every 500,000 cycles the tool should be completely dismantled and new components should be used where worn, damaged or when recommended. All O rings and seals should be renewed and lubricated with Moly Lithium grease EP 3753 before assembling. I M P O R TA N T 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 specically instructed otherwise. It is recommended that any dismantling operation be carried out in clean conditions. Dismantling of the 07530 MkII and 07532 MkII are covered separately. For the 07530 MkII refer to the dismantling procedures below and for the 07532 MkII refer to pages 26-27. Item numbers in bold refer to the general assemblies and parts lists for the respective model on pages 28-31. Prior to dismantling the tool, you will need to remove the nose equipment. For total tool servicing we advise that you proceed with the dismantling of sub-assemblies in the order shown below after having disconnected the hydraulic hose from the intensier unit and the trigger air line from the intensier valve, thus separating the pistol unit from the intensier unit.
Dismantling 07530-02200 MkII
To dismantle the 07532-02200 MkII refer to pages 26-27. TAIL JAW CYLINDER

Manually ip the Clip 47 up and remove the End Cap 38. Using an Allen Key*, remove one Cap Head Screw 44 ensuring that any trapped air in the tail jaw cylinder is exhausted. Remove the second Cap Head Screw 44. Pull out Rear Plug 46. Extract air tail jaw components, comprising Tail Jaw Piston Assembly 14, Spring 13, Jaws 9 and Jaw Housing 8. Remove plug at rear of piston assembly using an Allen Key* and a bar through the large slot in the turret. Clean out turret using a 4.7mm (3/16) drill and replace plug using a non-hardening sealing compound, e.g. Loctite Multi-gasket 574*. Remove piston seal O Ring 10. Using an Allen Key*, remove all ve handle moulding securing Screws 34, 39 and Nuts 33 from the tool handle. Grip Barrel 25 in a vice using soft jaws* to avoid damage. Using a box spanner*, unscrew Barrel Plug 7, preventing Barrel 25 turning by using an open ended spanner*. Disconnect Air Tail Jaw Concertina Tube 12 from Switch Block 28 and pull Tail Jaw Cylinder 6 from tool. Remove O Ring 4, Rubbing Strip 15 and Barrel Return Spring 16. Free length of Spring 13 should be 38.1mm (1.5). Replace if necessary. Coat the tail jaws with Moly Lithium grease before assembling. Assemble in reverse order of dismantling.

* Refers to items included in the 0753 Mkll service kit. For complete list see page 23. Item numbers in bold refer to the general assemblies and parts lists on pages 30-31.
To dismantle/service assembly, remove covers from the tool as described earlier. Disconnect all air hoses from assembly, taking care not to damage them. Remove assembly. Using a spanner*, unscrew the Retainer 56 and remove. Take care to keep the Spring 57. Prise off the O Ring 60 taking care not to damage the Spindle 61 and Retainer 56 seatings. Clean and re-assemble using a new O Ring 60. Check length of Spring 57 which must be 12.7mm (0.5) free length replace if necessary. Assembly in reverse order of dismantling.
The unit is designed so that minimum of servicing is required during the life of the tool. If it is necessary to dismantle valve, proceed as follows: Disconnect air hose from assembly, taking care not to damage them. Remove assembly. Using an Allen Key*, loosen Screw 34 clamping assembly to Barrel 31 and remove assembly. Using a screwdriver*, carefully remove the Chrome Star-lock Washer 33 from Air Tail Jaw Spool 36 and discard washer. Extract Air Tail Jaw Spool 36 from Switch Block 35. Taking care not to damage the Air Tail Jaw Spool 36, remove the O Rings 38. Clean spool and ret new O Rings 38 using assembly bullet* and insert into Switch Block 35, noting its orientation. Fit New Chrome Star-lock Washer 33 by clamping in vice using soft Jaws to prevent damage. DO NOT USE UNDUE FORCE. Complete assembly in reverse order of dismantling.
The Non-return Valve 26 is located in the tool handle. To remove/replace the Non-return Valve 26 depress the bulk head ttings and withdraw Blue Plastic Tube 27 from both ends. When replacing the Non-return Valve 26, note the orientation.
Clean and oil Mechanical Cursor Assembly 11 occasionally with a little light oil.
W W 33 HANDLE COVER DETAILS X X PART SECTION 'W'-'W'

SECTION 'X'-'X'

52 TRIGGER VALVE DETAIL
G e n e r a l A s s e m b l y o f B a s e To o l 0 - 0 M k I I

07530-02200 PARTS LIST

QTY SPARES ITEM 60mm 60 07530-02302 07004-00059 07003-00121 07005-01571 07002-00134 07001-00401 07530-02210 07007-01504 07007-01503 07530-02603 07001-00262 07530-02601 07530-02602 07003-00113 07001-00504 07002-00153 07530-02213 07530-02220 07007-00300 07220-00803 07125-00215 07530-02311 07005-01357 07003-00022 07241-00208 07003-00142 07003-00194 07001-00442 07530-00501 07530-00310 AIR TAIL JAW SPOOL 1/8" STARLOCK WASHER BLACK 'O' RING ELBOW CONNECTOR M4 HEX NUT M4 X 10 LONG SOCKET HEAD CAP SCREW LABEL CE MARK LABEL BOOK SYMBOL LABEL END CAP M4 X 22 LONG SOCKET HEAD CAP SCREW MODIFIED HANDLE MOULDING (RIGHT) MODIFIED HANDLE MOULDING (LEFT) 'O' RING M4 X 6 LONG SOCKET HEAD CAP SCREW M4 WASHER PLASTIC REAR PLUG CLIP TRIGGER BUTTON RETAINER SPRING TRIGGER HOUSING COLLET TYPE CONNECTOR 'O' RING SPINDLE BONDED SEAL BONDED SEAL SCREW PLUG BLANKING PLUGS PART N DESCRIPTION QTY SPARES

PART N

DESCRIPTION
P a r t s L i s t f o r B a s e To o l 0 - 0 M k I I
07003-00237 07530-00500 07003-00236 07003-00167 07271-01100 07530-02207 07530-02205 07530-00208 07151-00403 07003-00113 07005-01972 07530-02211 07154-00404 07530-02800 07530-00206 07490-03002 07530-00204 07530-00203 07530-02202 07003-00142 07005-01973 07008-00423 07005-01083 07007-00017 07530-02201 07004-00058 07001-00404 07530-02301
SEAL (STATIC) BLEED PLUG ASSEMBLY (ITEMS 56 to 59) SEAL (DYNAMIC) 'O' RING MECHANICAL CURSOR ASSEMBLY TAIL JAW CYLINDER BARREL PLUG JAW HOUSING JAWS 'O' RING L TYPE THREADED NIPPLE AIR TAIL JAW CONCERTINA TUBE SPRING TAIL JAW PISTON ASSEMBLY RUBBING STRIP BARREL RETURN SPRING STROKE LIMITER PISTON BODY 1/8" BSP BONDED SEAL NON-RETURN VALVE HYDRAULIC HOSE ASSEMBLY 4mm O/D BLUE PLASTIC TUBE DUST CAP BARREL 1/8" STARLOCK WASHER CHROME M5 X 6 LONG SOCKET HEAD SCREW SWITCH BLOCK
W W HANDLE COVER DETAILS PART SECTION 'W'-'W' 29
G e n e r a l A s s e m b l y o f B a s e To o l 2 - 0 M k I I

7 TRIGGER VALVE DETAIL

07532-02200 PARTS LIST

QTY SPARES ITEM 1 1

ITEM PART N DESCRIPTION QTY SPARES
P a r t s L i s t f o r B a s e To o l 2 - 0 M k I I
07004-00058 07001-00404 07530-02301 07530-02302 07004-00059 07003-00121 07005-01571 07002-00134 07001-00401 07530-02210 07007-01504 07007-01503 07530-02603 07001-00262 07532-02208 07532-02209 07003-00113 07001-00504 07002-00153 07530-02213 07530-02220 07007-00300 07220-00803 07125-00215 07530-02311 07003-00022 07241-00208 07008-00414 07003-00142 07003-00194 07001-00442 07530-00501 07530-00310 1/8" STARLOCK WASHER CHROME M5 X 6 LONG SOCKET HEAD SCREW SWITCH BLOCK AIR TAIL JAW SPOOL 1/8" STARLOCK WASHER BLACK 'O' RING ELBOW CONNECTOR M4 HEX NUT M4 X 10 LONG SOCKET HEAD CAP SCREW LABEL CE MARK LABEL BOOK SYMBOL LABEL END CAP M4 X 22 LONG SOCKET HEAD CAP SCREW MODIFIED HANDLE MOULDING (RIGHT) MODIFIED HANDLE MOULDING (LEFT) 'O' RING M4 X 6 LONG SOCKET HEAD CAP SCREW M4 WASHER PLASTIC REAR PLUG CLIP TRIGGER BUTTON RETAINER SPRING TRIGGER HOUSING 'O' RING SPINDLE HYDRAULIC HOSE ASSEMBLY BONDED SEAL BONDED SEAL SCREW PLUG BLANKING PLATE 1 -

I M P O R TA N T Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.
* Refers to items included in the 0753 MkII service kit. For complete list see page 23. Item numbers in bold refer to the illustration and parts list opposite.

Intensifier 07531-02200

*Some units will not include these items
19 'B' 41 (The required link is achieved via internal porting)

21* 48 'A' 22

VIEW ON ARROW 'B' 43
VIEW ON ARROW 'A' VIEW ILLUSTRATING FESTO VALVE VIEW ILLUSTRATING COMPAIR VALVE

07531-02200 PARTS LIST

ITEM 27 PART N 07003-00037 07240-00211 07001-00418 07240-00210 71420-02006 07003-00153 71420-02007 71420-02300 71420-02008 07003-00182 07531-00202 07531-00204 07003-00183 07004-00069 07240-00213 07240-00214 07002-00017 07240-00215 07001-00417 07240-00216 * 07003-00042 07005-00041 07003-00065 07240-00220 07001-00375 07003-00238 07001-00396 DESCRIPTION SEAL FILLER SCREW BLEED SCREW COVER PLATE SEAL HOUSING 'O' RING SEAL PLUG BODY ASSEMBLY PISTON ROD 'O' RING AIR PISTON END COVER 'O' RING RETAINING RING FOAM SILENCER SILENCER COVER NUT SPACER SCREW RETAINING PLATE 'O' RING CONNECTOR WASHER PROTECTION PLATE SCREW 'O' RING SCREW QTY SPARES ITEM PART N 07531-00201 07003-00337 07003-00336 07005-00406 07005-00759 07003-00142 07240-00400 07240-00209 07002-00073 07001-00554 07007-01504 07240-00217 07531-00205 07005-00596 07245-00103 07005-00590 07005-01431 07005-00668 07005-00670 07005-01084 07005-01524 07001-00176 07007-00292 07005-00647 07005-01085 07005-00855 07007-01503 DESCRIPTION SLEEVE LIP SEAL LIP SEAL CONNECTOR QUICK RELEASE CONNECTOR SEAL VALVE HOUSING ASSEMBLY GASKET WASHER SCREW LABEL LABEL LABEL * 6mm PLASTIC TUBE * VACUUM CONNECTOR COMPAIR VALVE BULKHEAD CONNECTOR M5 PLUG M5 SEALING RING 4mm PLASTIC TUBE (150mm) FESTO VALVE SCREW 1/4" BSP REDCAP CONNECTOR 6mm PLASTIC TUBE (150mm) BULKHEAD UNION LABEL QTY SPARES -
P i l o t Va l v e 5 - 0 - M a i n t e n a n c e
Please note that these service instructions refer to the Compair valve where tted. Servicing of the valve is limited to the removal/replacement of O rings.
Remove Screws 24 and remove pilot assembly. Remove Piston 11 and discard O Rings 3, 10, 4 and 5. Remove Screws 26 and 21 and remove End Caps 22 and 25. Withdraw Pistons 12 and 18 and remove O Rings 7 and 9 from pistons. Withdraw Spool 16 from bore, taking care not to damage surface of spool and remove location Washers 14 and 17, O Ring 8, Spacers 15 and O Ring 6 from each end of valve body. Remove ve interface O Rings 4. Discard ALL O rings removed. Clean all parts with paraffin or white spirit. DO NOT USE SOLVENTS. Dry all parts. Lightly smear bores of valve Body 23, pilot valve Body 19, both End Caps 22 and 25 and all replacement O rings with CENTOPLEX 2 grease. Fit new O Rings 10, 4 and 5 to Piston 11 and insert into pilot valve body. Fit new O Rings 3, 10 and 6 to pilot valve body, place Top Cap 20 in position and secure pilot valve assembly to main valve Body 23 with Screws 24. Ensure that the interface seal housing faces upward with the G1/4 at the bottom. Ensure orientation of Piston 11 is correct. With main valve Body 23 in the same position, t green location Washer 17 to the left hand side of the valve assembly. Starting from the right hand side of the valve, assemble alternately O Rings 8 and Spacers 15 (6 seals and 5 spacers) and nally complete the stack assembly with white location Washer 14. Lightly smear Spool 16 with CENTOPLEX 2 grease, supplied with the service kit, and slide spool through seal/spacer stack. Fit O Rings 9 and 7 to respective Pistons 18 and 12, t O Rings 6 to ends of main valve Body 23. Insert pistons into End Caps 25 and 22 and assemble end caps to valve, taking care to locate piston shafts into holes in the ends of Spool 16. Secure end cap assemblies to main valve Body 23 with Screws 26 and 21. Fit interface O Rings 4 into their housings in the main valve body. If the pipe connection to the pilot assembly is damaged, replace Plastic Collet 2 and lift out the O Ring 1 from Cartridge 27. Fit new O Ring 1 and insert Plastic Collet 2 into Cartridge 27.

Check as for Mandrel Slip, stage 2 Set gap to 1.5mm - 3mm (1/16 - 1/8) See Loading the Tool 10
Other symptoms or failures should be reported to your local Avdel authorised distributor or repair centre.
Declaration of Conformity
We, Avdel UK Limited, Watchmead Industrial Estate, Welwyn Garden City, Herts, AL7 1LY declare under our sole responsibility that the product:
Model 0753 MkII type 07530 - 07532 models
Hand Tool Serial No. Intensier Serial No.
to which this declaration relates is in conformity with the following standards:
EN ISO 12100 - parts 1 & 2 BS EN ISO 8662 - part 6 BS EN ISO 3744 ISO EN 792 part 13 - 2000 BS EN ISO 11202 BS EN 982 BS EN 983
following the provisions of the Machine Directive 98/37/EC
A. Seewraj - Product Engineering Manager - Automation Tools

Date of issue

This box contains a power tool which is in conformity with Machines Directive 98/37/EC. The Declaration of Conformity is contained within.
Acument Australia Pty Ltd. 891 Wellington Road Rowville, Victoria 3178 Tel: +Fax: +Email: info@acument.com.au CANADA Avdel Canada, a Division of Acument Canada Limited. 87 Disco Road Rexdale Ontario M9W 1M3 Tel: +Fax: +Email: infoAvdel-Canada@acument.com CHINA Acument China Ltd. RM 1708, 17/F., Nanyang Plaza, 57 Hung To Rd., Kwun Tong Hong Kong Tel: +0631 Fax: +0022 Email: infochina@acument.com
Avdel Deutschland GmbH Klusriede Langenhagen Tel: +49 (0) 0 Fax: +49 (0) 133 Email: AvdelDeutschland@acument.com ITALY Avdel Italia S.r.l. Viale Lombardia 51/Brugherio (MI) Tel: +289911 Fax: +2873079 Email: vendite@acument.com JAPAN Acument Japan Kabushiki Kaisha Center Minami SKY, 3-1 Chigasaki-Chuo, Tsuzuki-ku, Yokohama-city, Kanagawa Prefecture Japan 224-0032 Tel: +Fax: +Email: info@acument.co.jp SINGAPORE
Acument Korea Ltd. 212-4, Suyang-Ri, Silchon-Eup, Kwangju-City, Kyunggi-Do, Korea, 464-874 Tel: +Fax: +Email: info@acumentkorea.com SPAIN Avdel Spain S.A. C/ Puerto de la Morcuera, 14 Poligono Industrial Prado Overa Ctra. de Toledo, km 7,Legans (Madrid) Tel: +34 (0) Fax: +34 (0) Email: ventas@acument.com UNITED KINGDOM Avdel UK Limited Pacic House 2 Swiftelds Watchmead Industrial Estate Welwyn Garden City Hertfordshire AL7 1LY Tel: +44 (0) Fax: +44 (0) Email: enquiries@acument.com USA Avdel USA LLC 614 NC Highway 200 South Staneld, North Carolina 28163 Tel: +888-7100 Fax: +888-0258 Email: infoAvdel-USA@acument.com

Instruction Manual

07535 MkII type

H y d ro - P n e u m a t i c P o w e r To o l

Contents

Safety Rules Specications Specication for 07535 MkII Type Tool Specication for 07531 Intensier Intent of Use Tool Dimensions Putting into Service Air Supply Cursor Loading and Re-loading the Tool Operating Procedure Mandrel Follower Springs Identication and Orientation Nose Assemblies Nose Jaws Selecting a Nose Jaw Nose Jaw Selection Tables Mandrels and Mandrel Follower Springs Chobert and Grovit Selection Tables Briv Selection Tables Mandrel Head Types and 'P' Length Avlug, Avsert, Avtronic and Rivscrew Selection Tables Servicing the Tool Daily / Weekly Moly Lithium Grease EP 3735 Safety Data Service Kit
Maintenance Dismantling 07535-02500 MkII General Assembly and Parts List 07535-02500 MkII General Assembly and Parts List Pantograph Intensier 07531-02200 Integral Handle and Trigger Assembly Pilot valve 07005-00590 Priming Oil Details & Safety Data Priming Procedure Fault Diagnosis Symptom, Possible Cause & Remedy
24-25 26-27 28-29 30-31 32-33 34-35

14-16-17 18-20-21

LIMITED WARRANTY Avdel makes the limited warranty that its products will be free of defects in workmanship and materials which occur under normal operating conditions. This Limited Warranty is contingent upon: (1) the product being installed, maintained and operated in accordance with product literature and instructions, and (2) conrmation by Avdel of such defect, upon inspection and testing. Avdel makes the foregoing limited warranty for a period of twelve (12) months following Avdels delivery of the product to the direct purchaser from Avdel. In the event of any breach of the foregoing warranty, the sole remedy shall be to return the defective Goods for replacement or refund for the purchase price at Avdels option. THE FOREGOING EXPRESS LIMITED WARRANTY AND REMEDY ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES. ANY IMPLIED WARRANTY AS TO QUALITY, FITNESS FOR PURPOSE, OR MERCHANTABILITY ARE HEREBY SPECIFICALLY DISCLAIMED AND EXCLUDED BY AVDEL.
Avdel UK Limited policy is one of continuous product development and improvement and we reserve the right to change the specication of any product without prior notice.

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.
3 Do not use outside the design intent. Do not use equipment with this tool/machine other than that recommended and supplied by Avdel UK Limited. Any modication undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by Avdel UK Limited or their representatives, shall be the customers entire responsibility. Avdel UK Limited will be pleased to advise upon any proposed modication. 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 Avdel UK Limited procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact Avdel UK Limited 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 Avdel UK Limited. The precautions to be observed when using this tool/machine must be explained by the customer to all operators. Always disconnect the airline from the tool/machine inlet before attempting to adjust, t or remove a nose assembly. Do not operate a tool/machine that is directed towards any person(s) or the operator. Always adopt a rm footing or a stable position before operating the tool/machine.

To reverse the orientation of the cursor, follow these steps: Item numbers in bold refer to the general assembly and parts list for the 07535-02500 MkII type on pages 26-27. CURSOR SPRING LOADED END
Remove the Clip 46 and slide off End Cap 38. Using an Allen Key, remove one cap head screw 43 ensuring that any trapped air is exhausted. Remove the second Cap Head Screw 43. Pull out Rear Plug 45. Pull out Tail Jaw Piston Assembly 14 together with Jaws 9. Lift out Spring 13 and Jaw Housing 8.

TOOL BARREL NOSE JAWS

Insert a mandrel into the hole in the rear end of Barrel 25 until it protrudes through the front of the barrel, then pull out the mandrel and cursor together through the front. Reassemble components in reverse order. Insert Mechanical Cursor Assembly 5 into the front of the barrel, correct way round.
L o a d i n g a n d R e l o a d i n g t h e To o l
IMPORTANT The procedure for loading the tool and for tting the nose equipment to the tool is integral.
When ordering a complete tool or system you will normally be supplied with all the nose equipment required for the fastener to be placed. To identify nose equipment components or to select the correct elements, read the nose equipment section, on pages 12-21. If you have been supplied with a nose jaw, mandrels and mandrel follower springs proceed with loading the tool and tting the nose equipment as shown overleaf.
Item numbers in bold refer to the general assembly and parts list for the 07535-02500 MkII type on pages 26-27.
L o a d i n g t h e To o l
Connect the air supply to the tool. Open tail Jaws 9 which grip the mandrel, by switching off the tail jaw switch (items 26, 29 and 30). Screw selected nose jaws onto Barrel 25 of the tool.
I 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 11. 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 rst fastener to be placed is protruding from the nose jaw. Close the nose jaws and adjust so that the rst fastener protrudes by 1.5mm - 3mm (1/16 to 1/8), as shown in the illustration below right. Close the tail jaws to ensure the mandrel is gripped, by switching on the tail jaw switch (items 26, 29 and 30).

1.5mm - 3mm (1/16" - 1/8")
R e l o a d i n g t h e To o l
Open tail Jaws 9 of tool. Open the nose jaws and pull the empty mandrel and mandrel follower spring out of the tool. Reload the tool by following the above instructions, starting at stage I.
O p e r a t i n g P ro c e d u r e
IMPORTANT You must check that the cursor orientation and the nose equipment are correct before attempting to operate the tool.
Push the fastener, protruding from the nose jaws, fully into the application holes ensuring that the tool is held square. Operate the trigger without releasing - the mandrel head is pulled through the fastener, forming the fastener into the application. Remove the tool. Release the trigger. The next fastener will be automatically presented through the nose jaws, ready for placing.
MANDREL FOLLOWER SPRINGS IDENTIFICATION AND ORIENTATION
FASTENER NAME SIZE NOSE JAW
(SEE NOSE EQUIPMENT SECTION)

MANDREL SIZE

MANDREL/MANDREL FOLLOWER SPRING AND FASTENER ASSEMBLY

MANDREL FOLLOWER SPRING

3/32"
MANDREL HEAD STANDARD TAPERED ALL

FERRULE SPRING

MANDREL
LIMITED ACCESS & LIMITED ACCESS CAM OPERATED

1/8"

5/32"

3/16"

ALL ALL EXCEPT 3rd OVERSIZE ALL
STANDARD ALL EXCEPT STANDARD TAPERED, LIMITED ACCESS STANDARD TAPERED, LIMITED ACCESS

CHOBERT AVLUG GROVIT

ALL ALL EXCEPT 3rd OVERSIZE 3rd OVERSIZE ALL EXCEPT 2nd OVERSIZE 2nd OVERSIZE

CHOBERT GROVIT

3/16" ALL

CHOBERT

1/4"

RIVSCREW

3mm 3.5mm 4mm 2.5mm

AVSERT

4 x 40 UNC 3mm 6 x 32 UNC

AVTRONIC

ALL EXCEPT LIMITED ACCESS

LIMITED ACCESS

Nose Assemblies
On speed fastening tools such as 07535 MkII type, 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.
I M P O R TA N T To avoid complete dismantling of the tool it is essential to check the orientation of the cursor before tting the nose equipment to the tool. See CURSOR section on page 9. It is essential that the correct nose equipment is tted 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 t your tool rst 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 11. To t the nose equipment, follow the Loading the Tool procedure page 9-10.

5/32" BRIV St.Steel only
3/16" BRIV Al. Alloy, Brass, Steel
3/16" BRIV St.Steel only 6mm BRIV Al. Alloy, Steel

3/32" AVLUG

07150-04003 10.41 58.42 4.06 -
07170-03104 10.41 30.23 5.08 07150-04004 10.41 55.37 5.08 07170-05000 10.41 55.37 5.08 -

1/8" AVLUG

07170-04600 10.41 29.97 5.08 07271-08000 10.41 29.97 4.06 -
07271-08100 10.16 29.97 4.06 -
Mandrels and Mandrel Follower Springs
Mandrels and mandrel follower springs, illustrated on page 11 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. I M P O R TA N T 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 customers responsibility to ensure that mandrels are replaced before any excessive levels of wear and always before the maximum recommended number of placings. Contact your Avdel representative who will let you know what that gure is by measuring the broach load of your application with our calibrated measuring tool. These tools can also be purchased under part number 07900-09080, supplied with all necessary information for testing.
C h o b e r t a n d G ro v i t - I m p e r i a l
For mandrel or mandrel follower spring selection, follow instructions on page 18.
REF. N 2 3/32" CHOBERT & GROVIT 1/8" CHOBERT & GROVIT 7 5/32" CHOBERT & GROVIT 3/16" CHOBERT & GROVIT 10 1/4" CHOBERT REF. N 2 3/32" CHOBERT & GROVIT 1/8" CHOBERT & GROVIT 7 5/32" CHOBERT & GROVIT 3/16" CHOBERT & GROVIT 10 1/4" CHOBERT HOLE SIZE STANDARD MANDREL - GREEN P P MANDREL # S/R MANDREL MAX. MAX. PART N PART N.166.071 07150-06003 07150-08003 07150-06003 07150-06003 07150-07003 07150-06004 07150-07004 07150-06005 07150-07005 07150-06006 07150-07006 07150-06008 07150-07008.166.166.166.216.216.244.244.247.247.268.268 07150-08003 07150-08003 07150-09003 07150-08004 07150-09004 07150-08005 07150-09005 07150-08006 07150-09006 07150-08008 07150-09008.071.071.071.090.090.100.100.102.102.110.110 HOLE SIZE +.0015 +.0035 +.0015 +.0035 +.0015 +.0035 +.0035 +.004 +.004 +.008 +.008 +.014 +.014 +.012 +.012 HOLE SIZE +.014 +.014 +.025 +.025 1ST OVERSIZE MANDREL - YELLOW P P MANDREL # S/R MANDREL MAX. MAX. PART N PART N.174 07150-06303 07150-06303 07150-06303 07150-06104 07150-07104 07150-06105 07150-07105 07150-06106 07150-07106 07150-06108 07150-07108.174.174.237.237.284.284.320.320.330.330 07150-08103 07150-08103 07150-08103 07150-09103 07150-08104 07150-09104 07150-08105 07150-09105 07150-08106 07150-09106 07150-08108 07150-09108.078.078.078.078.098.098.116.116.130.130.134.134 SPRING PART N 07150-06803 07150-06803 07170-06873 07170-06873 07170-06903 07170-06903 07150-07803 07150-06804 07150-07804 07170-06875 07170-07875 07170-06876 07170-07876 07150-06808 07150-07808 SPRING PART N 07150-06803 07170-06873 07170-06903 07150-07803 07150-06804 07150-07804 07170-06875 07150-06805 07170-07875 07150-07805 07150-06806 07150-07806 -

HEAD 1.93 1.93 1.93 1.93 2.49 2.49 3.10 3.10 3.96 3.96 -
2ND OVERSIZE MANDREL - BLUE P P MANDREL # S/R MANDREL MAX. MAX. PART N PART N 4.70 07150-06103 07150-06103 07150-06103 07150-07103 07150-06204 07150-07204 07150-06205 07150-07205 07150-06206 07150-07206 4.70 4.70 4.70 6.81 6.81 8.13 8.13 9.45 9.45 07150-08204 07150-09204 07150-08205 07150-09205 07150-08206 07150-09206 2.79 2.79 3.30 3.30 3.81 3.81 -
HEAD 2.59 2.59 3.35 3.35 -
3RD OVERSIZE MANDREL - RED P P MANDREL # S/R MANDREL MAX. MAX. PART N PART N 07150-06304 07150-07304 07150-06305 07150-07305 7.32 7.32 9.45 9.45 07150-08304 07150-09304 07150-08305 07150-09305 3.00 3.00 3.81 3.81 -
To nd 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 FASTENER SIZE DATASHEET APPLICATION HOLE SIZE CLEARANCE BEHIND APPLICATION REF.N FROM NOSE JAW SELECTION TABLE

example

Chobert
Series 1125 0.1335 Innite 5 (standard at)
Subtract the minimum hole size recommended (AS REC.) in the fastener datasheet from the actual application hole size. -example: 0.005. Turn to the page with the Mandrel Selection table for your fastener, selecting either the imperial or the metric dimensions table (pages 16-21). -example: page 16. Staring with the Standard Mandrel - Green section, nd your fastener size in the left-hand column. -example 1/8 Chobert & Grovit. If you selected a nose jaw which place you fastener, you should now be able to nd 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 nd 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 gure calculated in step one. You may now read the mandrel part number next to the hole size. -example: 07150-06104 For Chobert and Grovit only, most mandrels are also available in a short reach version (see illustration on page 19). 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 P gure against that mandrel is adequate. P 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 19. You may now read the corresponding mandrel follower spring part number in the right-hand column of the table. -example: 07150-06804.

2.8mm AVTRONIC

2.8mm RIVSCREW 3.0mm RIVSCREW 3.5mm RIVSCREW 4.0mm RIVSCREW
* These Dimensions are Across Flats 2ND OVERSIZE MANDREL - BLUE P MANDREL MAX. PART N 07170-06225 07170-07225 07170-06228 07170-06228 07170-07228.140.140.150.150.150 3RD OVERSIZE MANDREL - RED MANDREL PART N -
HOLE SIZE +.006 +.006 +.006 +.006 +.006 -
HEAD .076.076.085.085.085 -

HOLE SIZE -

HEAD -

P MAX. -

SPRING PART N 07150-06803 07150-07803 07170-06528 07170-06873 07170-07528 -
A v l u g , A v s e r t , A v t ro n i c & R i v s c r e w - M e t r i c
AV L U G , AV S E R T , AV T R O N I C & R I V S C R E W - M E T R I C

LINE N 27

HOLE SIZE AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC. AS REC AS REC. AS REC. AS REC.
HEAD 1.93 1.93 2.49 2.49 1.84 2.24 1.78 1.78 2.01 2.01 2.01 * 1.65 * 1.65 * 2.10 * 2.62
P MAX. 8.97 8.97 15.06 15.06 3.68 4.70 3.56 3.56 3.81 3.81 3.81 3.23 3.23 3.35 3.81
HOLE SIZE +.10 +.10 +.07 +.07 +.07 +.07 +.07 -
HEAD 2.06 2.01 1.85 1.85 2.08 2.08 2.08 -
1ST OVERSIZE MANDREL - YELLOW P MANDREL MAX. PART N 12.14 07150-06703 07150-07703 07170-06125 07170-07125 07170-06128 07170-06128 07170-07128 9.35 3.56 3.56 3.81 3.81 3.81 -
* These Dimensions are Across Flats LINE N 27
HOLE SIZE +.15 +.15 +.15 +.15 +.15 -
HEAD 1.93 1.93 2.16 2.16 2.16 -
2ND OVERSIZE MANDREL - BLUE P MANDREL MAX. PART N 07170-06225 07170-07225 07170-06228 07170-06228 07170-07228 3.56 3.56 3.81 3.81 3.81 -
3RD OVERSIZE MANDREL - RED MANDREL PART N -
S e r v i c i n g t h e To o l
Regular servicing should be carried out and a comprehensive inspection performed annually or every 500,000 cycles, whichever is sooner.
I M P O R TA N T 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, before use or when rst putting the tool into service. Pour a few drops of clean lubricating oil into the air inlet of the intensier if no lubricator is tted on air supply. If the tool is in continuous use, the air hose should be disconnected from the main air supply and the tool lubricated every two to three hours. Check for air and oil leaks. If damaged, hoses and couplings should be replaced. If there is no lter on the pressure regulator, bleed the airline to clear it of accumulated dirt or water before connecting the air hose to the intensier. If there is a lter, drain it. Check that the nose equipment is correct. Check mandrels regularly for signs of wear or damage monitoring the number of placings (read the safety instructions on page 4).

We e k l y

Conduct the full "Daily" procedures as described above. Remove, inspect, clean and grease the Tail Jaws (refer to Tail Jaw Cylinder in the "Maintenance Section" page 25). Check oil level in the intensier Unit reservoir is approximately 12mm (1/2) below the transparent cover plate.

REASSEMBLY

Clean all parts and replace as necessary. Assembly is the reverse of the dismantling procedure.
* Refers to items included in the 0753 Mkll service kit. For complete list see page 23. Item numbers in bold refer to the general assembly and parts list for the 07535-02600 Pantograph Arm on pages 28-29.
Dismantling 07535-02500 MkII

TAIL JAW CYLINDER

Manually ip the Clip 46 up and remove the End Cap 38. Using an Allen Key*, remove one Screw 43 and Washer 44 ensuring that any trapped air in the tail jaw cylinder is exhausted. Remove the second Screw 43 and Washer 44. Pull out Rear Plug 45. Extract air tail jaw components, comprising Tail Jaw Piston Assembly 14, Spring 13, Jaws 9 and Jaw Housing 8. Remove plug at rear of piston assembly using an Allen Key* and a bar through the large slot in the turret. Clean out turret using a 4.7mm (3/16) drill and replace plug using a non-hardening sealing compound, e.g. Loctite Multi-gasket 574*. Remove piston seal O Ring 10. Using an Allen Key*, remove all ve handle moulding securing Screws 34, 39 and Nuts 33 from the tool handle. Grip Barrel 25 in a vice using soft jaws to avoid damage. Using a box spanner*, unscrew Barrel Plug 7, preventing Barrel 25 turning by using an open ended spanner*. Disconnect Air Tail Jaw Concertina Tube 12 from Switch Block 28 and pull Tail Jaw Cylinder 6 from tool. Remove O Ring 4, Rubbing Strip 15 and Barrel Return Spring 16. Free length of Spring 13 should be 38.1mm (1.5). Replace if necessary. Coat the tail jaws with Moly Lithium grease before assembling. Assemble in reverse order of dismantling.

HYDRAULIC PISTON

Remove Tail Jaw Cylinder 6 as described earlier. Grip Body 19 in vice using soft jaws to avoid damage, undo Stroke Limiter 17. Grip Barrel 25 in soft jaw vice, pull Body 19 from Barrel 25 (a small quantity of hydraulic oil will be ejected from inside body). Remove Piston 18 carefully so as not to damage body bore. Remove Seal 3. Seal 1 is difficult to remove without damaging, but can remain in place during cleaning (provided it is not affected by cleaning process). If however, Seal 1 requires renewing proceed as follows: Using spatula*, prise out Seal 1 from Body 19, taking care not to damage body cavity and bores. The removed Seal 1 MUST be discarded. To replace Seal 1, unscrew Hydraulic Connector 49 to bring inside face level with internal bore. Unscrew existing bleed plug until inside face is level with internal bore. This will provide a smooth passage for insertion of new Seal 1 through rear of body. Ensure the seal is well greased and the correct way round with the open end of the seal facing the rear tail jaws. Complete assembly in reverse order of dismantling.

TAIL JAW ON/OFF VALVE

The unit is designed so that minimum of servicing is required during the life of the tool. If it is necessary to dismantle valve, proceed as follows: Disconnect air hose from assembly, taking care not to damage them. Remove assembly. Using an Allen Key*, loosen Screw 27 clamping assembly to Barrel 25 and remove assembly. Using a screwdriver*, carefully remove the Chrome Star-lock Washer 26 from Air Tail Jaw Spool 29 and discard washer. Extract Air Tail Jaw Spool 29 from Switch Block 28. Taking care not to damage the Air Tail Jaw Spool 29, remove the O Rings 31. Clean spool and ret new O Rings 31 using assembly bullet* and insert into Switch Block 28, noting its orientation. Fit New Chrome Star-lock Washer 26 by clamping in vice using soft jaws vice to prevent damage. DO NOT USE UNDUE FORCE. Complete assembly in reverse order of dismantling.

HANDLE & END CAP

Clean and inspect mouldings for cracks or other damage.

CURSOR

Clean and oil Mechanical Cursor Assembly 5 occasionally with a little light oil.
I M P O R TA N T Check the tool against daily and weekly servicing. Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.
* Refers to items included in the 0753 Mkll service kit. For complete list see page 23. Item numbers in bold refer to the general assemblies and parts lists on pages 26-27.
37 W 38 W HANDLE COVER DETAILS X X PART SECTION 'W'-'W'

SECTION 'X'-'X'

G e n e r a l A s s e m b l y o f B a s e To o l 5 - 0 M k I I
07535-02500 (S) PARTS LIST
QTY SPARES ITEM 200mm 07530-02302 07004-00059 07003-00121 07005-01571 07002-00134 07001-00401 07530-02210 07007-01504 07007-01503 07530-02603 07001-00262 07535-02502 07535-02503 01810-02136 07001-00504 07002-00153 07530-02213 07530-02220 07535-00203 07535-00201 07535-02501 07530-00310 07001-00514 07003-00142 07003-00194 07001-00442 07530-00501 AIR TAIL JAW SPOOL 1/8" STARLOCK WASHER BLACK 'O' RING ELBOW CONNECTOR M4 HEX NUT M4 X 10 LONG SOCKET HEAD CAP SCREW LABEL CE MARK LABEL BOOK SYMBOL LABEL END CAP M4 X 22 LONG SOCKET HEAD CAP SCREW MODIFIED HANDLE MOULDING (RIGHT) MODIFIED HANDLE MOULDING (LEFT) BRIV RIVET M4 X 6 LONG SOCKET HEAD CAP SCREW M4 WASHER PLASTIC REAR PLUG CLIP WASHER CAM HYDRAULIC CONNECTEOR BLANKING PLUG M4 X 5 LONG SOCKET SET SCREW BONDED SEAL BONDED SEAL SCREW PLUG 2 PART N DESCRIPTION QTY SPARES

PART N

DESCRIPTION
P a r t s L i s t f o r B a s e To o l 5 - 0 M k I I
07003-00237 07530-00500 07003-00236 07003-00167 07271-01100 07530-02207 07530-02205 07530-00208 07151-00403 07003-00113 07005-01972 07530-02211 07154-00404 07530-02800 07530-00206 07490-03002 07530-00204 07530-00203 07530-02202 07003-00142 07002-00151 07005-00760 07005-01981 07007-00017 07530-02201 07004-00058 07001-00404 07530-02301
SEAL (STATIC) BLEED PLUG ASSEMBLY (ITEMS 52 to 55) SEAL (DYNAMIC) 'O' RING MECHANICAL CURSOR ASSEMBLY TAIL JAW CYLINDER BARREL PLUG JAW HOUSING JAWS 'O' RING L TYPE THREADED NIPPLE AIR TAIL JAW CONCERTINA TUBE SPRING TAIL JAW PISTON ASSEMBLY RUBBING STRIP BARREL RETURN SPRING STROKE LIMITER PISTON BODY 1/8" BSP BONDED SEAL M20 LOCKNUT 1/8" BSP QUICK RELEASE COUPLING 4mm O/D BLUE PLASTIC TUBE DUST CAP BARREL 1/8" STARLOCK WASHER CHROME M5 X 6 LONG SOCKET HEAD SET SCREW SWITCH BLOCK

I M P O R TA N T Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.
* Refers to items included in the 07535 Mkll service kit. For complete list see page 23. Item numbers in bold refer to the illustration and parts list opposite.

Intensifier 07531-02200

144 146

163 136

'B' 171 168

160 159

155 'A' VIEW ON ARROW 'B'
VIEW ILLUSTRATING COMPAIR VALVE VIEW ILLUSTRATING FESTO VALVE VIEW ON ARROW 'A'

07531-02200 PARTS LIST

ITEM 157 PART N 07003-00037 07240-00211 07001-00418 07240-00210 71420-02006 07003-00153 71420-02007 71420-02300 71420-02008 07003-00182 07531-00202 07531-00204 07003-00183 07004-00069 07240-00213 07240-00214 07002-00017 07240-00215 07001-00417 07240-00216 07001-00042 07005-00041 07003-00065 07240-00220 07001-00375 07003-00238 07001-00396 DESCRIPTION SEAL FILLER SCREW BLEED SCREW COVER PLATE SEAL HOUSING 'O' RING SEAL PLUG BODY ASSEMBLY PISTON ROD 'O' RING AIR PISTON END COVER 'O' RING RETAINING RING FOAM SILENCER SILENCER COVER NUT SPACER SCREW RETAINING PLATE 'O' RING CONNECTOR WASHER PROTECTION PLATE SCREW 'O' RING SCREW QTY SPARES ITEM PART N 07531-00201 07003-00337 07003-00336 07005-00406 07005-00759 07003-00142 07240-00400 07240-00209 07002-00073 07001-00554 07007-01504 07240-00217 07531-00205 07005-00596 07245-00103 07005-00590 07005-01431 07005-00668 07005-00670 07005-01084 07005-01524 07001-00176 07007-00292 07005-00647 07005-01085 07005-00855 07007-01503 DESCRIPTION SLEEVE LIP SEAL LIP SEAL CONNECTOR QUICK RELEASE CONNECTOR SEAL VALVE HOUSING ASSEMBLY GASKET WASHER SCREW LABEL LABEL LABEL 6mm PLASTIC TUBE VACUUM CONNECTOR COMPAIR VALVE BULKHEAD CONNECTOR M5 PLUG M5 SEALING RING 4mm PLASTIC TUBE FESTO VALVE SCREW 1/4" BSP REDCAP CONNECTOR 6mm PLASTIC TUBE BULKHEAD UNION LABEL QTY SPARES -
I n t e g r a l H a n d l e a n d Tr i g g e r A s s e m b l y
Refer to drawing 07535-02700 (S) opposite
Remove the Mandrel and Follower Spring from the tool. Disconnect the air supply. Remove the Nose Jaw Assembly. Insert a 2mm A/F Hex Wrench into the ange of the pantograph Handle 197. Rotate the handle until the Hex Wrench enters set Screw 191. Loosen the screw one turn. Repeat for the other set screw. (The set screws are at 90 to one another.) Slide the pantograph handle downwards, and off of the tool barrel. Slide the Trigger Actuating Sleeve 198 out of the pantograph Handle 197. Hold the pantograph handle in a vice, using a 2.5mm diameter pin gently tap out the Dowel Pin 195. Care must be taken in retaining the Compressions Spring 196. Using a 2mm A/F Hex Wrench loosen set Screw 192 one turn. Repeat for the other set screw. (The set screws are at 180 to one another.) Remove the pipe from the Male Fitting 194 and slide the Trigger Collar 200 off the tool barrel. Using a 2mm A/F Hex Wrench loosen the set Screw 191 from the Trigger Collar 200. Remove the Valve Housing 201 together with the Valve 193 and Male Fitting 194 from the Trigger Collar 200. Remove the Valve 193 and Male Fitting 194 from the Valve Housing 201.

Assembly Instructions

Assembly is the same procedures in reverse noting the following points.
Assembly the Valve 193 and Male Fitting 194 to the Valve Housing 201. Screw the assembled parts into the Trigger Collar 200 such that the actuating pin of the valve is within 0.25mm of the Trigger Actuating Sleeve 198 when in the assembled position. The Trigger Collar 200 should be rm against the plastic housing of the Placing Tool. The Retaining Collar 199 should be secured using the two set Screws 191 so that the pantograph Handle 197 is free to rotate.
Item numbers in bold refer to the illustration and parts list opposite.
I n t e g r a l H a n d l e a n d Tr i g g e r A s s e m b l y 07535-02700(s)

196 S ec t i o n A - A

07535-02700(S) INTEGRAL HANDLE AND TRIGGER ASSEMBLY PARTS LIST
ITEM PART N 07001-00514 07001-00599 07005-00088 07005-01960 07007-01799 07474-03044 DESCRIPTION SCREW SCREW VALVE MALE FITTING DOWEL PIN COMPRESSION SPRING QTY SPARES ITEM PART N 07535-02401 07535-02402 07535-02405 07535-02701 07535-02702 07535-02703 DESCRIPTION HANDLE TRIGGER ACTUATING SLEEVE RETAINING COLLAR TRIGGER COLLAR VALVE HOUSING TRIGGER QTY SPARES -
P i l o t Va l v e 5 - 0 - M a i n t e n a n c e
Please note that these service instructions refer to the Compair valve where tted. (The Festo valve is not serviceable.) Servicing of the valve is limited to the removal/replacement of O rings.
Remove Screws 24 and remove pilot assembly. Remove Piston 11 and discard O Rings 3, 10, 4 and 5. Remove Screws 26 and 21 and remove End Caps 22 and 25. Withdraw Pistons 12 and 18 and remove O Rings 7 and 9 from pistons. Withdraw Spool 16 from bore, taking care not to damage surface of spool and remove location Washers 14 and 17, O Ring 8, Spacers 15 and O Ring 6 from each end of valve body. Remove ve interface O Rings 4. Discard ALL O rings removed. Clean all parts with paraffin or white spirit. DO NOT USE SOLVENTS. Dry all parts. Lightly smear bores of valve Body 23, pilot valve Body 19, both End Caps 22 and 25 and all replacement O rings with CENTOPLEX 2 grease. Fit new O Rings 10, 4 and 5 to Piston 11 and insert into pilot valve body. Fit new O Rings 3, 10 and 6 to pilot valve Body 19, place Top Cap 20 in position and secure pilot valve assembly to main valve Body 23 with Screws 24. Ensure that the interface seal housing faces upward with the G1/4 at the bottom. Ensure orientation of Piston 11 is correct. With main valve Body 23 in the same position, t green location Washer 17 to the left hand side of the Valve Assembly 13. Starting from the right hand side of the valve, assemble alternately O Rings 8 and Spacers 15 (6 seals and 5 spacers) and nally complete the stack assembly with white location Washer 14. Lightly smear Spool 16 with CENTOPLEX 2 grease, supplied with the service kit, and slide spool through seal/spacer stack. Fit O Rings 9 and 7 to respective Pistons 18 and 12, t O Rings 6 to ends of main valve Body 23. Insert pistons into End Caps 25 and 22 and assemble end caps to valve, taking care to locate piston shafts into holes in the ends of Spool 16. Secure end cap assemblies to main valve Body 23 with Screws 26 and 21. Fit interface O Rings 4 into their housings in the main valve Body 23. If the pipe connection to the pilot assembly is damaged, replace Plastic Collet 2 and lift out the O Ring 1 from Cartridge 27. Fit new O Ring 1 and insert Plastic Collet 2 into Cartridge 27.

P i l o t Va l v e 5 - 0

13 VIEW ON ARROW 'A' 7 INTERFACE 'O' RINGS

24 'A'

07005-00590 VALVE PARTS LIST
ITEM PART N 07005-00599 07005-00598 07003-00204 07003-00103 07003-00042 07003-00121 08005-00127 07003-00105 07003-00178 07003-00017 07005-00590 DESCRIPTION * 'O' RING * PLASTIC COLLET * 'O' RING * 'O' RING * 'O' RING * 'O' RING * 'O' RING * 'O' RING * 'O' RING * 'O' RING PISTON PISTON VALVE ASSEMBLY WASHER QTY SPARES ITEM PART N DESCRIPTION SPACER SPOOL WASHER PISTON BODY TOP CAP SCREW END CAP BODY SCREW END CAP SCREW CARTRIDGE QTY SPARES 1 -
* Together these items make up a Service Kit for the valve with the addition of one Centoplex 2 tube of grease, the kit is available from Avdel, part number 07005-01538.

Priming

Priming is ALWAYS necessary after the tool has been dismantled and prior to operating. It may also be necessary to restore the full stroke after considerable use, when the stroke may be reduced and fasteners are not fully placed by one operation of the trigger.

Oil Details

The recommended oil for priming is Hyspin VG32 available in 0.5l (part number 07992-00002) or one gallon containers (part number 07992-00006). Please see safety data below.
Hyspin VG 32 Oil Safety Data
First Aid SKIN: Wash thoroughly with soap and water as soon as possible. Casual contact requires no immediate attention. Short term contact requires no immediate attention. INGESTION: Seek medical attention immediately. DO NOT induce vomiting. EYES: Irrigate immediately with water for several minutes. Although NOT a primary irritant, minor irritation may occur following contact. Fire Suitable extinguishing media: CO2, dry powder, foam or water fog. DO NOT use water jets. Environment WASTE DISPOSAL: Through authorised contractor to a licensed site. May be incinerated. Used product may be sent for reclamation. SPILLAGE: Prevent entry into drains, sewers and water courses. Soak up with absorbent material. Handling Wear eye protection, impervious gloves (e.g. of PVC) and a plastic apron. Use in well ventilated area. Storage No special precautions.
P r i m i n g P ro c e d u r e
I M P O R TA N T DO NOT OPERATE THE TRIGGER WHILE THE BLEED SCREW IS REMOVED All operations should be carried out on a clean bench, with clean hands in a clean area. Ensure that the new oil is perfectly clean and free from air bubbles. Care MUST be taken at all times, to ensure that no foreign matter enters the tool, or serious damage may result.
Remove Filler Screw 132 and Seal 131 from Plastic Cover Plate 134 on the intensier reservoir. Pour the priming oil into the reservoir until it is approximately 1/2 (12mm) from the top. Replace Filler Screw 132 and Seal 131. Connect the intensier unit to the air supply. Remove screw from reservoir. With the pistol unit tted to the intensier unit and held below the level of the intensier unit, unscrew Bleed Screw 54 from Bleed Plug Assembly 2 on the 07535 MkII tool two turns and allow oil to ow out of the tool. When the oil runs freely and free of air bubbles, tighten the Bleed Screw 54 from Bleed Plug Assembly 2. Top up the reservoir on the intensier unit with priming oil. Cycle the tool until any air bubbles present in the oil are expelled into the oil reservoir.

Item numbers in bold refer to the general assemblies and parts lists pages 26-27 and 31.

Fault Diagnosis

Symptom
Tool will not place fastener

Possible Cause

Low air pressure. Lack of lubrication. High broach load. Check for correct size mandrel. Worn or broken tail jaws. Tail jaws switched off. Air in hydraulic system.

Remedy

Increase air pressure Lubricate tool at air inlet point Check fastener grip and application hole size New tail jaws Switch on tail jaws See Priming Procedure

Page Ref

Mandrel Slip jaws will not grip mandrel
Worn or dirty tail jaws. Insufficient air pressure/volume. Tail jaw switch inoperable. Air leaks to tail jaws. Mandrel broken and not reaching tail jaws. Defective non-return valve.
Clean or renew as necessary Increase air pressure/volume Replace switch Renew O rings on piston 8 Replace mandrel Replace non-return valve
Jaws will not release mandrel
Dirty tail jaws or jaw housing. Faulty tail jaw switch.
Clean and lubricate Replace O rings
Fasteners will not feed through nose jaws
Tail jaws not switched on. Worn tail jaws. Cursor orientation incorrect. Incorrect nose jaws. Mandrel follower spring not tted. Incorrect gap between fastener head and nose jaws when loaded. Cursor sticking. Weak outer spring around cursor. Incorrect mandrel follower spring tted.
Switch on tail jaws Renew tail jaws Ret, ensuring correct orientation Fit correct nose jaws Fit correct mandrel follower spring Set gap to 1.5mm - 3mm (1/16 - 1/8) See Loading the Tool Clean and oil cursor Renew cursor Fit correct mandrel follower spring 9-10

Excessive tail jaw wear

High broach load.
Check application hole size and thickness and fastener grip capability
Feeding more than one fastener at a time
Mandrel slip. Incorrect gap between fastener head and nose jaws when loaded
Check as for Mandrel Slip, above Set gap to 1.5mm - 3mm (1/16 - 1/8) See Loading the Tool 9-10
Item numbers in bold refer to the general assemblies and parts lists pages 26-27. Other symptoms or failures should be reported to your local Avdel authorised distributor or repair centre.