STANLEY 07536 Hydro Pneumatic Power Tool Instruction Manual

STANLEY 07536 Hydro Pneumatic Power Tool Instruction Manual

©2021 Stanley Black & Decker inc.
All rights reserved.

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 specifications 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.

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

Always wear impact-resistant eye protection during operation of the tool. The grade of protection required should be assessed for each use.

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

Use of the tool can expose the operator’s hands to hazards, including crushing, impacts, cuts and abrasions and heat. Wear suitable gloves to protect hands.

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

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 qualified 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. Modifications can reduce the effectiveness of safety measures and increase the risks to the operator. Any modification 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 affects 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.

PROJECTILE HAZARDS

• Disconnect the tool from the air supply 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).

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.

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.

ACCESSORY HAZARDS

• Disconnect the tool from the air 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.

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.

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.

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.

ADDITIONAL SAFETY INSTRUCTIONS FOR PNEUMATIC & HYDRAULIC POWER TOOLS

• The operating supply air must not exceed 7 bar (100 PSI).
• Air under pressure can cause severe injury.
• Never leave operating tool unattended. Disconnect air hose when tool is not in use, before changing accessories or when making repairs.
• DO NOT let air exhaust opening on the mandrel collector face in the direction of the operator or other persons. Never direct air at yourself or anyone else.
• Whipping hoses can cause severe injury. Always check for damaged or loose hoses and fittings.
• Prior to use, inspect airlines for damage, all connections must be secure. Do not drop heavy objects on hoses. A sharp impact may cause internal damage and lead to premature hose failure.]
• Cold air shall be directed away from hands.
• Whenever universal twist couplings (claw couplings) are used, lock pins shall be installed and whipcheck safety cables shall be used to safeguard against possible hose-to-tool or hose-to-hose connection failure.
• DO NOT lift the placing tool by the hose. Always use the placing tool handle.
• Vent holes must not become blocked or covered.
• Keep dirt and foreign matter out of the hydraulic system of the tool as this will cause the tool to malfunction.
• Oil under pressure can cause severe injury.
• Prior to use, inspect hydraulic hoses for damage. All hydraulic connections must be clean, fully engaged and tight before operation. Do not drop heavy objects on hoses. A sharp impact may cause internal damage and lead to premature hose failure.
• DO NOT pull or move the intensifier unit using the hoses. Always use the unit handle.
• Use only clean oil and filling equipment.
• Only recommended hydraulic fluids may be used.
• Maximum temperature of the hydraulic fluid at the inlet is 100°C (212°F)

WARNING : While a small amount of wear and marking will naturally occur through normal and correct use of mandrels, they must be regularly examined for excessive wear and marking, with particular attention to the head diameter, the tail jaw gripping area of the shank or heavy pitting of the shank and any mandrel distortion. Mandrels which fail during use could forcibly exit the tool. It is the customer’s responsibility to ensure that mandrels are replaced before any excessive levels of wear and always before the maximum recommended number of placings. Contact your STANLEY Engineered Fastening representative who will let you know what that figure is by measuring the broach load of your application with our calibrated measuring tool.

STANLEY Engineered Fastening policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice.

SPECIFICATIONS

SPECIFICATION FOR 07536 TOOL

(0.09 ft3)
Stroke| Minimum| 25 mm (1 in)
Pull Force| @ 5.5 bar /80 lbf/in2| 3.89 kN (875 lbf)
Cycle time| Approximately| 1 second
Weight| Pistol| 1.2 kg (2.64 lb)

SPECIFICATION FOR 07531 INTENSIFIER

Noise values determined according to noise test code ISO 15744 and ISO 3744.| 07536
---|---
A-weighted sound power level dB(A), LWA| Uncertainty noise: kWA = 2.3 dB(A)| 79.5 dB(A)
A-weighted emission sound pressure level at the work stationdB(A), LpA| Uncertainty noise: kpA = 2.3 dB(A)| 68.5 dB(A)
C-weighted peak emission sound pressure level dB(C), LpC, peak| Uncertainty noise: kpC = 2.5 dB(C)| 96.9 dB(C)
Vibration values determined according to vibration test code ISO 20643 and ISO 5349.| 07536
---|---
Vibration emission level, ahd:| Uncertainty vibration: k = 0.25 m/s2| 0.97 m/s2
Declared vibration emission values in accordance with EN 12096

INTENT OF USE

The pneumatic 07536 tool is a hand held light weight tool designed to place 1/16” Avlug® making it ideal for batch or flowline assembly in a wide variety of applications throughout all industries.

The Hand Tool and Intensifier 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 9-12 for connection details. Part numbers are shown to order a complete tool but no nose equipment.

The tool number for the 07536 model is 07536-02200.
See the general assemblies on pages 15-22.

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

TOOL DIMENSIONS – 07536 MODEL

Part Number 07536-02100

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/filtering systems on the main air supply. To ensure maximum tool life and minimum tool maintenance they should be fitted 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.

• Follow the steps below when connecting the tool to the intensifier and main air supply:
  • Push the end of the large hydraulic hose from the tool into the quick release connector on the end of the intensifier.
  • On the front face of the intensifier (Refer to page 15):
  • Push the blue pneumatic (4mm OD) line into the reducer fitting which is located in the left hand bulkhead connector.
  • Push the black pneumatic (4mm OD) line into the plastic collet of the right hand bulkhead connector.
• On the front face of the control box (Refer to page 15):
  • Push the silver pneumatic (3mm OD) line into the reducer labelled ‘Cursor’ on the front face of the control box – LH side.
  • Push the green pneumatic (4mm OD) line into the reducer labelled ‘Tail Jaws’ on the front face of the control box – middle.
  • Push the white pneumatic (4mm OD) line into the reducer labelled ‘Signal’ on the front face of the control box – RH side.
• Fit a pneumatic hose between the male connector at the rear of the intensifier and main air supply

AIR CURSORS

Air Cursor Selection
See separate data sheet 07900-00863 for nose assembly components.

CURSOR

IMPORTANT
If fitted incorrectly, the cursor will not allow the loading of the tool and feeding of the fasteners.

before fitting the nose equipment. The slightly concave end of the cursor should point towards the front of the tool as shown in the illustration.

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

Extreme caution must be exercised whe undertaking the following procedure. Care must be taken to avoid the barrel and protruding mandre

• Remove the Nose Assembly if there is one.
• Insert an empty mandrel fully into the tool.
• Close the Tail Jaws 32, by switching on the tail jaw switch (items 18 and 19).
• The cursor will pop out of the barrel after a short delay.
• Open the Tail Jaws 32, by switching off the tail jaw switch (items 18 and 19), this will release the mandrel.
• Remove the cursor from the mandrel and insert the cursor into the barrel.
  

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

If you have been supplied with a nose jaw, mandrels and mandrel follower springs proceed with loading the tool and fitting the nose equipment as shown below.

Loading the Tool

• Connect the air supply to the tool.

• Open Tail Jaws 32 which grip the mandrel, by switching off the tail jaw switch (items 18 and 19).

• Screw selected nose jaws onto Barrel 44 of the tool.

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

• Slide the mandrel follower spring onto the mandrel ensuring correct orientation
  

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

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

• Insert the previously assembled mandrel, mandrel follower spring and fasteners into the nose jaws until the first fastener to be placed is protruding from the nose jaw.

• Close the nose jaws and adjust so that the first fastener protrudes by 1.5mm – 3mm (1/16” to 1/8”), as shown in the illustration below right.

• Close the Tail Jaws 32 to ensure the mandrel is gripped, by switching on the tail jaw switch (items 18 and 19)
  
  

Re-loading the Tool

• Open Tail Jaws 32 of tool, by switching off the tail jaws (items 18 and 19).
• 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 •*.

Setting the Tool – Adjustable Nose Assemblies Only

Insert the previously assembled mandrel (see Loading the Tool •*) or the disposable mandrel against the stop within the Tail Jaw Piston Assembly 60.

While holding the mandrel, close the Tail Jaws 32, which grip the mandrel, by switching on the tail jaw switch (18 and 19).

Screw the lock nut onto the Barrel 44 of the tool.

Rotate the nose assembly onto the Barrel 44.

Adjust the nose assembly so that the first fastener protrudes by 1,5mm-3mm (1/16”-1/8”), as shown in the illustration on page 11.

Tighten the lock nut against the nose assembly to prevent the nose jaw assembly from moving

Re-loading the Tool

Open the tail jaws of the tool, by switching off the tail jaw switch (18-19).

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

Insert the new mandrel against the stop within the too, and close the Tail Jaws 32 which grip the mandrel, by switching on the tail jaw switch (18 and 19).

Close the Tail Jaws 32.

OPERATING PROCEDURE

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

• Push the fastener, protruding from the nose jaws, fully into the application holes ensuring that the tool is held square.
• Operate the trigger without releasing – the mandrel head is pulled through the fastener, forming the fastener into the application.
• Remove the tool.
• Release the trigger. The next fastener will be automatically presented through the nose jaws, ready for placing.

SERVICING THE TOOL

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

IMPORTANT
The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel. The operator should not be involved in maintenance or repair of the tool unless properly trained.

PNEUMATIC CONTROL BOX

IMPORTANT
Under no circumstances must the pneumatic box be opened. The box is a closed item. The internal adjustments are preset and must not be altered or tampered with. Only Authorised STANLEY Engineered Fastening personnel may dismantle this control box.

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.

DAILY

• Daily, before use or when first putting the tool into service. Pour a few drops of clean lubricating oil into the air inlet of the intensifier if no lubricator is fitted on air supply. If the tool is in continuous use, the air hose should be disconnected from the main air supply and the tool lubricated every two to three hours.
• Check for air and oil leaks. If damaged, hoses and couplings should be replaced.
• If there is no filter on the pressure regulator, bleed the airline to clear it of accumulated dirt or water before connectingthe air hose to the intensifier. If there is a filter, drain it.
• Check that the nose equipment is correct.
• Check mandrels regularly for signs of wear or damage monitoring the number of placings (read the safety instructions on page 4-6).

WEEKLY

• Conduct the full “Daily” procedures as described above.
• Remove, inspect, clean and grease the Tail Jaws (refer to “Tail Jaw Cylinder” in the “Maintenance Section” page 16).
• Check oil level in the intensifier Unit reservoir is approximately 12mm (1/2”) below the transparent cover plate.

MOLY LITHIUM GREASE EP 3753 SAFETY DATA
Grease can be ordered as a single item, the part number is shown in the Service Kit page 14. First Aid

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

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

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

FLASH POINT: Above 220°C.
Not classified as flammable.
Suitable extinguishing media: CO2
, Halon or water spray if applied by an experienced operator.

Environment
Scrape up for burning or disposal on approved site.

Handling
Use barrier cream or oil resistant gloves.

Storage
Away from heat and oxidising agent.

SERVICE KIT
For all servicing we recommend the use of the Service Kit (part number 07900-05300)

SERVICE KIT

ITEM PART Nº| DESCRIPTION| Nº OFF| ITEM PART Nº| DESCRIPTION| Nº OFF
07900-00157| CIRCLIP PLIERS| 1| 07900-00352| SEAL REMOVAL HOOK| 1
07900-00006| SPATULA| 1| 07900-00710| BARREL PLUG REMOVAL SPAN-NER| 1
07900-00446| EXTRACTOR| 1| 07900-00725| BULLET| 1
07900-00603| BARREL VICE JAWS| 1| 07900-00243| SCREWDRIVER| 1
07900-00520| 3/8″ ROD| 1| 07900-00717| INTENSIFIER SPANNER| 1
07900-00521| 1/4″ ROD| 1| 07900-00013| 1/8″ ALLEN KEY| 1
07900-00602| ‘O’ RING ASSEMBLY BULLET| 1| 07900-00617| LOCTITE® MULTI-GASKET 574 50ml PACK| 1
07900-00595| 18mm SPANNER| 1| 07900-00469| 2.5mm ALLEN KEY| 1
07900-00434| 32mm SPANNER| 1| 07900-00351| 3mm ALLEN KEY| 1
07900-00237| 3/8″ × 5/16″ B.S.W. SPANNER| 1| 07900-00224| 4mm ALLEN KEY| 1
07900-00012| 9/16″ × 5/8″ SPANNER| 1| 07900-00225| 5mm ALLEN KEY| 1
07900-00008| 7/16″ × 1/2″ SPANNER| 1| 07992-00020| 80g TIN MOLY LITHIUM GREASE EP 3753| 1

Note : Spanner sizes are measured ‘across flats’ unless otherwise specified.

AIR CURSOR TOOL, INTENSIFIER & CONTROL BOX ASSEMBLY 07536-02100

MAINTENANCE

Every 500,000 cycles the tool should be completely dismantled and new components should be used where worn, damaged or when recommended. All ‘O’ rings and seals should be renewed and lubricated with Moly Lithium grease EP 3753 before assembling.

IMPORTANT
Safety Instructions appear on page 4. The employer is responsible for ensuring that tool maintenance instructions are given to the appropriate personnel. The operator should not be involved in maintenance or repair of the tool unless properly trained.

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

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

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 intensifier unit, air lines from the intensifier and control box, thus separating the pistol unit from the intensifier unit.

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

DISMANTLING 07536-02200

TAIL JAW CYLINDER

• Manually flip the retaining Clip 53 up and remove the End Cap 59.
• Using an Allen Key*, remove one Cap Head Screw 6 ensuring that any trapped air in the tail jaw cylinder is exhausted. Remove the second Cap Head Screw 6.
• Pull out Rear Plug 50. Note: To aid extraction there is a 5mm thread on the rear face of the plug.
• Extract air tail jaw components, comprising Tail Jaw Piston Assembly 60, Stop 52, ‘O’ Ring 12 and Jaws 32.
• Extract the remaining components, comprising of Spring 36 and Jaw Housing 42.
• Free length of spring 36 should be 38.1mm (1.5”). Replace if necessary.
• Remove piston assembly seal ‘O’ Ring 11.
• Disconnect Air Cursor Concertina Tube (Green) 49 from Elbow Connector 22.
• Disconnect Air Cursor Concertina Tube (Silver) 38 from Barb Elbow 30.
• Using an Allen Key*, remove all five handle moulding securing Screws 3, 4 and all four Nuts 8 from the tool handle.
• Grip Barrel 44 in a vice using soft jaws* to avoid damage.
• Using a box spanner, unscrew Barrel Plug 46, preventing Barrel 44 turning by using an open ended spanner.
• Pull the Tail Jaw Cylinder 47 from the tool.
• Remove ‘O’ Ring 14, Rubbing Strip 41 and Barrel Return Spring 37.
• Coat the face of Tail Jaws 32 with Moly Lithium grease, in contact with Jaw Housing 42, before assembling.
• Assemble in reverse order of dismantling.

HYDRAULIC PISTON

• Remove Tail Jaw Cylinder 47 as described earlier.
• Grip Body 45 in vice using soft jaws* to avoid damage, undo Stroke Limiter 40.
• Using an Allen Key*, loosen Screw 5 that is clamping the Switch Block 54 to the barrel 44
• Hold the tool firmly and pull the Barrel 44 from the Body 45 (a small quantity of hydraulic oil may be ejected from inside the head assembly).
• Remove Piston 39 carefully so as not to damage head bore.
• Remove Seal 16.
• Seal 17 is difficult to remove without damaging, but can remain in place during cleaning (provided it is not affected by cleaning process). If however, Seal 17 requires renewing proceed as follows:
• Using spatula*, prise out Seal 17 from Body 45, taking care not to damage body cavity and bores. The removed Seal 17 MUST be discarded.
• To replace Seal 17, unscrew Bleed Plug Assembly 43 until inside face is level with internal bore of the Body 45. This will provide a smooth passage for insertion of a new Seal 17 through rear of Body 45.
• Ensure the Seal 17 is well greased and the correct way round with the open end of the seal facing the rear tail jaws.
• Complete assembly in reverse order of dismantling.

TRIGGER ASSEMBLY

• To dismantle/service assembly, remove covers from the tool as described earlier.
• Disconnect all air hoses from assembly, taking care not to damage them. Remove assembly.
• Using a spanner*, unscrew the Retainer 34 and remove. Take care to keep the Spring 31.
• Prise off the ‘O’ Ring 10 taking care not to damage the Spindle 35 and Retainer 34 seatings.
• Clean and re-assemble using a new ‘O’ Ring 10.
• Check length of Spring 31 which must be 12.7mm (0.5”) free length – replace if necessary.
• Assembly in reverse order of dismantling.

TAIL JAW ON/OFF VALVE

• The unit is designed so that minimum of servicing is required during the life of the tool.
• If it is necessary to dismantle the valve, proceed as follows:
• Remove Trigger Housing 56 as described in section “Hydraulic Piston”.
• Using a screwdriver*, carefully remove the Chrome Star-lock Washer 18 from Air Tail Jaw Spool 55 and discard washer.
• Extract Air Tail Jaw Spool 55 from Switch Block 54.
• Taking care not to damage the Air Tail Jaw Spool 55, remove the ‘O’ Rings 12.
• Clean spool and refit new ‘O’ Rings 12 using assembly bullet* and insert into Switch Block 54, noting its orientation.
• Fit New Chrome Star-lock Washer 18 by clamping in a soft jaw 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 cursor assembly occasionally with a little light oil.

IMPORTANT
Check the tool against daily and weekly servicing. Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.

GENERAL ASSEMBLY OF BASE TOOL 07536-02200

PARTS LIST FOR BASE TOOL 07536-02200

07536-02200 PARTS LISTS

ITEM| PART N°| DESCRIPTION| QTY| SPARES| ITEM| PART N°| DESCRIPTION| QTY| SPARES
1| 07007-00392| CABLE TIE (NOT SHOWN)| 1| –| 34| 07220-00803| RETAINER| 1| –
2| 07001-00499| M3×5 LONG SOCKET SET SCREW| 3| –| 35| 07241-00208| SPINDLE| 1| –
3| 07001-00262| M4×22 LONG SOCKET HEAD CAP SCREW| 1| –| 36| 07154-00404| SPRING| 1| –
4| 07001-00401| M4×10 LONG SOCKET HEAD CAP SCREW| 4| –| 37| 07490-03002| BARREL RETURN SPRING| 1| –
5| 07001-00404| M5×6 LONG SOCKET HEAD SET SCREW| 1| –| 38| 07536-02211| 3MM AIR CURSOR CON- CERTINA TUBE – SILVER| 1| –
6| 07001-00504| M4×6 LONG SOCKET HEAD CAP SCREW| 2| 2| 39| 07536-00203| PISTON| 1| –
7| | | | | 40| 07530-00204| STROKE LIMITER| 1| –
8| 07002-00134| M4 HEX NUT| 4| –| 41| 07530-00206| RUBBING STRIP| 1| 1
9| 07002-00153| M4 WASHER [PLASTIC]| 2| –| 42| 07536-00208| JAW HOUSING| 1| –
10| 07003-00022| ‘O’ RING| 1| –| 43| 07530-00500| BLEED PLUG ASSEMBLY [ITEMS 62 TO 65] ●| 1| –
11| 07003-00113| ‘O’ RING| 3| 3| 44| 07536-02201| BARREL| 1| –
12| 07003-00121| ‘O’ RING| 3| 3| 45| 07530-02202| BODY| 1| –
13| 07003-00142| 1/8″ BSP BONDED SEAL| 1| 1| 46| 07530-02205| BARREL PLUG| 1| –
14| 07003-00167| ‘O’ RING| 1| 1| 47| 07536-02207| TAIL JAW CYLINDER| 1| –
15| 07003-00386| ‘O’ RING| 2| –| 48| 07530-02210| LABEL| 2| –
16| 07003-00236| SEAL [DYNAMIC]| 1| 1| 49| 07536-02212| 4MM AIR CURSOR CON- CERTINA TUBE – GREEN| 1| –
17| 07003-00237| SEAL [STATIC]| 1| –| 50| 07536-02213| REAR PLUG| 1| –
18| 07004-00058| 1/8″ STARLOCK WASHER CHROME| 1| –| 51| 07530-00310| BLANKING PLUG| 2| –
19| 07004-00059| 1/8″ STARLOCK WASHER BLACK| 1| –| 52| 07536-02214| STOP| 1| –
20| 07005-10073| 3MM CONNECTOR| 1| –| 53| 07530-02220| CLIP| 1| –
21| 07005-01357| COLLET TYPE CON- NECTOR| 1| –| 54| 07530-02301| SWITCH BLOCK| 1| –
22| 07005-01571| ELBOW CONNECTOR| 3| –| 55| 07530-02302| AIR TAIL JAW SPOOL| 1| –
23| 07536-02216| LOCKNUT| 1| –| 56| 07530-02311| TRIGGER HOUSING| 1| –
24| 07005-10074| 2MM CONNECTOR| 1| –| 57| 07536-02601| HANDLE MOULDING AS- SEMBLY RIGHT HAND| 1| –
25| 07007-00017| DUST CAP| 1| –| 58| 07536-02602| HANDLE MOULDING AS- SEMBLY LEFT HAND| 1| –
26| 07007-00300| TRIGGER BUTTON| 1| –| 59| 07530-02603| END CAP| 1| –
27| 73200-02022| SAFETY LABEL| 1| –| 60| 07536-02800| TAIL JAW PISTON ASSEM- BLY| 1| –
28| 07007-01504| CE MARK LABEL| 1| –| 61| 07536-02215| FITTING ADAPTER| 1| –
29| 07008-00438| FLEXIBLE HOSE ASSEM- BLY| 1| –| 62| 07003-00142| ●  BONDED SEAL (NOT SHOWN)| 1| 1
30| 07005-01323| M3 BARB ELBOW| 1| –| 63| 07003-00194| ●  BONDED SEAL (NOT SHOWN)| 1| 1
31| 07125-00215| SPRING| 1| –| 64| 07001-00442| ●  SCREW (NOT SHOWN)| 1| 1
32| 07151-00403| TAIL JAWS| 1pair| 2| 65| 07530-00501| ●  PLUG (NOT SHOWN)| 1| –
33| 07003-00016| ‘O’ RING| 1| | | | | |

DISMANTLING INSTRUCTIONS

• When dismantling the intensifier assembly, first disconnect the air supply hose to intensifier inlet Connector 22.
• Using an Allen Key* undo four Screws 27 and remove Protection Plate 24.
• Disconnect the trigger hose 47 from the intensifier Valve 43 or 48 by depressing the outlet collet and withdrawing the hose.
• Remove Cover Plate 4 and Gasket 35 by removing Screws 37 and Washers 36 using Allen Key*.
• Ensure that gasket is not damaged to ensure a proper seal on assembly.
• Invert intensifier assembly and drain oil from reservoir into a suitable container.
• Remove Quick Release Connector 32 together with Connector 31 and Seals 33 with suitable spanner*.
• Remove intensifier Valve 43 or 48 by removing the fixing screws with a suitable spanner taking care to retain ‘O’ Ring 21 located in the Intensifier Body Casting.
• Remove Screw 19 using a suitable Allen Key* and remove Silencer Cover 16, Foam Silencer 15, Spacer 18 and Retaining Plate 20.
• Pull off the 6mm Plastic Tube 41 from Vacuum Connectors 42.
• From the base of the intensifier insert a 3mm Allen Key * through the two holes and unscrew the Vacuum Connectors 42. Note:
• Care must be taken as the vacuum connectors are locked and sealed in place using Loctite® 574.
• If difficult to remove, the vacuum connectors can be drilled out using a 3/16” or 4.7mm diameter drill.
• To reassemble the Vacuum Connectors 42, the following procedure must be followed: –
• Soak the vacuum connectors in a suitable primer, i.e. Perma Bond A905
• Place a drop of Loctite® 574 in the intensifier threaded hole.
• From the base of the intensifier insert the Allen Key through the hole. Ensure that the Allen Key is free from Loctite® 574 before inserting into the vacuum connector.
• Rotate the Allen Key while applying Loctite® 574 to the base of the vacuum connector.
• Screw the Vacuum connector into the intensifier, ensuring that there is sufficient Loctite® 574 at the base of the fitting such the thread is not visible.
• Using a screwdriver, carefully remove internal Retaining Ring 14. Clean and inspect groove for sign of damage.
• Using Extractor*, insert male threaded end into End Cover 12 and withdraw it along with intensifier Sleeve 28 and ‘O’ Rings 10 and 13.
• Insert Rod* through the connector orifice at the front of the intensifier body and tap out Piston Rod 9 and Piston Assembly.
• Using a suitable Allen Key*, unscrew two Screws 25 and remove End Cover 12 from intensifier Sleeve 28.
• Remove Seal Plug 7 with spanner*.
• Insert rod* through connector orifice at the front of the intensifier body and push out Seal Housing 5 and associated ‘O’ rings and lip seals.
• Remove Valve Housing Assembly 34 from the main body with a suitable spanner*. Clean by blowing through with a low-pressure air jet.
• Remove Piston Rod 9 from intensifier Air Piston 11 by gripping the first 20 mm (3/4”) of the rod in a vice fitted with soft jaws, taking care not to damage or mark the working surface.
• Unscrew locking Nut 17 with a suitable spanner*.
• Assemble in the reverse order of dismantling, observing the following:
• Clean all parts and renew all ‘O’ rings.
• Lubricate all seals using Moly Lithium grease.
• Valve Housing Assembly 34 must be refitted using a thread sealing adhesive.
• Assemble the Piston Assembly using a new Nut 17.
• End Cover 12 must be fitted correctly inside Retaining Ring 14. The tool must not be operated if the end cover has been omitted.

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

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.

INTENSIFIER 07531-02200

07531-02200 PARTS LIST

ITEM| PART N°| DESCRIPTION| QTY SPARES ITEM| PART N°| DESCRIPTION| QTY SPARES
1| 07003-00037| SEAL| 1| 1| 28| 07531-00201| SLEEVE| 1| –
2| 07240-00211| FILLER SCREW| 1| –| 29| 07003-00337| LIP SEAL| 1| 1
3| 07001-00418| BLEED SCREW| 1| 1| 30| 07003-00336| LIP SEAL| 2| 2
4| 07240-00210| COVER PLATE| 1| –| 31| 07005-00406| CONNECTOR| 1| –
5| 71420-02006| SEAL HOUSING| 1| –| 32| 07005-00759| QUICK RELEASE CON-NECTOR| 1| –
6| 07003-00153| ‘O’ RING| 2| –| 33| 07003-00142| SEAL| 2| 1
7| 71420-02007| SEAL PLUG| 1| –| 34| 07240-00400| VALVE HOUSING AS-SEMBLY| 1| –
8| 71420-02300| BODY ASSEMBLY| 1| –| 35| 07240-00209| GASKET| 1| 1
9| 71420-02008| PISTON ROD| 1| –| 36| 07002-00073| WASHER| 4| 1
10| 07003-00182| ‘O’ RING| 1| 1| 37| 07001-00554| SCREW| 4| 1
11| 07531-00202| AIR PISTON| 1| –| 38| 07007-01504| LABEL| 1| –
12| 07531-00204| END COVER| 1| –| 39| 07240-00217| LABEL| 1| –
13| 07003-00183| ‘O’ RING| 1| 1| 40| 07531-00205| LABEL| 2| –
14| 07004-00069| RETAINING RING| 1| 1| 41| 07005-00596| 6mm PLASTIC TUBE| –| –
15| 07240-00213| FOAM SILENCER| 1| 1| 42| 07245-00103| VACUUM CONNECTOR| 2| –
16| 07240-00214| SILENCER COVER| 1| –| 43| 07005-00590| COMPAIR VALVE| 1| 1
17| 07002-00017| NUT| 1| 1| 44| 07005-01431| BULKHEAD CONNECTOR| 1| 1
18| 07240-00215| SPACER| 1| –| 45| 07005-00668| M5 PLUG| 1| –
19| 07001-00417| SCREW| 1| 1| 46| 07005-00670| M5 SEALING RING| 1| –
20| 07240-00216| RETAINING PLATE| 1| –| 47| 07005-01084| 4mm PLASTIC TUBE (150mm)| –| –
21| *07003-00042| ‘O’ RING| 1| 1| 48| 07005-01524| FESTO VALVE| 1| –
22| 07005-00041| CONNECTOR| 1| –| 49| 07001-00176| SCREW| 3| –
23| 07003-00065| WASHER| 1| –| 50| 07007-00292| 1/4″ BSP REDCAP| 1| –
24| 07240-00220| PROTECTION PLATE| 1| –| 51| 07005-00647| CONNECTOR| 1| –
25| 07001-00375| SCREW| 2| –| 52| 07005-01085| 6mm PLASTIC TUBE (150mm)| –| –
26| 07003-00238| ‘O’ RING| 1| 1| 53| 07005-00855| BULKHEAD UNION| 1| –
27| 07001-00396| SCREW| 4| –| 54| 73200-02022| SAFETY LABEL| 1| –

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 and AWS 32 available in 0.5l (part number 07992-00002) or one gallon containers (part number 07992-00006). Please see safety data below.

HYSPIN® VG32 AND AWS 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.

PRIMING PROCEDURE

IMPORTANT
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 Screw 2 and Seal 1 from Plastic Cover plate 4 on the intensifier reservoir.
• Pour the priming oil into the reservoir until it is approximately 1/2” (12mm) from the top.
• Replace Screw 2 and Seal 1.
• Connect the intensifier unit to the air supply. Remove screw from reservoir.
• With the 07536 pistol unit fitted to the intensifier unit and held below the level of the intensifier unit, unscrew Bleed Screw 64 from Bleed Plug Assembly 43 on the 07536 tool two turns and allow oil to flow out of the tool.
• When the oil runs freely and free of air bubbles, tighten the bleed screw.
• Top up the reservoir on the intensifier unit with priming oil.
• Cycle the tool until any air bubbles present in the oil are expelled into the oil reservoir.

FAULT DIAGNOSIS

Check for correct size mandrel
Tail jaws switched of| Switch on tail jaws
Air in hydraulic system.| See ‘Priming Procedure’
‘Mandrel Slip’ – jaws will not grip mandrel| Worn or dirty tail jaws.| Clean or renew as necessary
’ Insufficient air pressure/volume| Increase air pressure/volume
Tail jaw switch inoperable| Replace switch
’ Air leaks to tail jaws| Renew ‘O’ rings on piston 11
Mandrel broken and not reaching tail jaws.| Replace mandrel
Fault in pneumatic contro  box.| Contact Stanley Engineered Fastening personnel
Jaws will not release mandrel| Dirty tail jaws or jaw housing.| Clean and lubricate
Faulty tail jaw switch.| Replace ‘O’ ring
Trapped air signal| Check pneumatic lines
Fault in pneumatic control box| Contact Stanley Engineered Fastening personnel
Fasteners will not feed through nose jaws| Tail jaws not switched on.| Switch on tail jaws
Worn tail jaws.| Renew tail jaws
Cursor orientation incorrect.| Refit, ensuring correct orientation
Incorrect cursor| Fit correct cursor
Incorrect nose jaws| Fit correct nose jaws
Mandrel follower spring not fitted| Fit correct mandrel follower spring
Mandrel follower length| Fit correct mandrel follow
Incorrect gap between fastener head and nose jaws when loaded.| Set gap to 1.5mm – 3mm (1/16” – 1/8”) See ‘Loading the Tool’
Cursor sticking.| Clean and oil cursor
worn air cursor| Renew curso
Incorrect mandrel follower spring fitted| Fit correct mandrel follower spring
Worn or broken barrel return spring| Replace barrel return s
Excessive tail jaw wear| High broach load| Check application hole size and thickness and fastener grip capa-bility
Feeding more than one fastener at a time| Mandrel slip| Check as for ‘Mandrel Slip’, stage 2
Incorrect gap between fastener head and nose jaws when| Set gap to 1.5mm – 3mm (1/16” – 1/8”) See ‘Loading the Tool’ on pag

EC DECLARATION OF CONFORMITY

We, Stanley Engineered Fastening, Stanley House, Works Road, Letchworth Garden City, Hertfordshire, SG6 1JY UNITED KINGDOM, declare under our sole responsibility that the product:

Description : Hydro-Pneumatic Repetition Tool for Speed Rivets
Model : 07536

to which this declaration relates is in conformity with the following harmonized standards:

Technical documentation is compiled in accordance with Annex VII, in accordance with the following Directive: 2006/42/EC

The Machinery Directive ( Statutory Instruments 2008 No 1597 – The Supply of Machinery (Safety) Regulations refers).

The undersigned makes this declaration on behalf of STANLEY Engineered Fastening

A. K. Seewraj
Director of Engineering, UK
Avdel UK Limited, Stanley House, Works Road, Letchworth Garden City, Hertfordshire,
SG6 1JY UNITED KING

Place of issue : Letchworth Garden City, UK
Date of issue : 01-01-2021

The undersigned is responsible for compilation of the technical file for products sold in the European Union and makes this declaration on behalf of Stanley Engineered Fastening.

Matthias Appel
Team Leader Technical Documentation
Stanley Engineered Fastening, Tucker GmbH, Max-Eyth-Str.1,
35394 Gießen, Germany

This machinery is in conformity with Machinery Directive 2006/42/EC

UK DECLARATION OF CONFORMITY

We, Stanley Engineered Fastening, Stanley House, Works Road, Letchworth Garden City, Hertfordshire, SG6 1JY UNITED KINGDOM, declare under our sole responsibility that the product:

Description : Hydro-Pneumatic Repetition Tool for Speed Rivets
Model: 07536

to which this declaration relates is in conformity with the following designated standards:

Technical documentation is compiled in accordance with the Supply of Machinery (Safety) Regulations 2008, S.I. 2008/1597 (as amended).

The undersigned makes this declaration on behalf of STANLEY Engineered Fastening

A. K. Seewraj
Director of Engineering, UK
Avdel UK Limited, Stanley House, Works Road, Letchworth Garden City, Hertfordshire,
SG6 1JY UNITED KINGDOM

Place of issue : Letchworth Garden City, UK
Date of issue: 01-01-2021

This machinery is in conformity with
Supply of Machinery (Safety) Regulations 2008,
S.I. 2008/1597 (as amended)

References

• STANLEY® Engineered Fastening | Precision Fastening and Assembly Solutions
• STANLEY® Engineered Fastening | Precision Fastening and Assembly Solutions
• Contact Us | STANLEY® Engineered Fastening
• Find A Fastener Distributor | STANLEY® Engineered Fastening
• Warranty Registration Form for POP® Avdel® STANLEY Asssemblie Technologies Tools | STANLEY® Engineered Fastening

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