STANLEY 07530 Hydro Pneumatic Power Tool Instruction Manual

STANLEY 07530 Hydro Pneumatic Power Tool

Product Information

• Product Name: 0753 MKII Type – Repetition Tool for Speed Rivets
• Model Numbers: 07530 / 07531 / 07532
• Type: Hydro-Pneumatic Power Tool
• Language: English

Product Usage Instructions

1. Ensure you have read and understood the safety definitions provided in the manual.
2. Wear impact-resistant eye protection at all times during operation. Assess the grade of protection required for each use.
3. Follow employer’s instructions and comply with occupational health and safety regulations regarding the use of hearing protection.
4. To put the tool into service, refer to section 4 of the manual.
5. If servicing is required, follow the instructions provided in section 5 of the manual.
6. Maintain the tool as per the guidelines mentioned in section 6 of the manual.
7. For priming instructions, refer to section 7 of the manual.
8. If any faults occur, consult the fault diagnosis guide in section 8 of the manual.
9. The EC Declaration of Conformity can be found in section 9 of the manual.
10. The UK Declaration of Conformity is available in section 10 of the manual.
11. Protect your investment by following the recommendations in section 11 of the manual.

Note: For detailed specifications and dimensions of the tool, refer to the corresponding sections in the manual.

©2021 STANLEY Black & Decker
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 trademarks.

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 0753 MK II TYPE TOOL

• Air Pressure Minimum – Maximum 5-7 bar (70-100 lbf/in2)
• Free Air Volume Required @ 5.1 bar /75 lbf/in2 2.6 litres (0.09 ft3)
• Stroke Minimum 30.0 mm (1.18 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

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

Noise values determined according to noise test code ISO 15744 and ISO 3744.| 0753
---|---
A-weighted sound power level dB(A), LWA| Uncertainty noise: kWA = 2.3 dB(A)| 85.7 dB(A)
A-weighted emission sound pressure level at the work station

dB(A), LpA

| Uncertainty noise: kpA = 2.3 dB(A)| 74.8 dB(A)
C-weighted peak emission sound pressure level dB(C), LpC, peak| Uncertainty noise: kpC = 2.5 dB(C)| 97.9 dB(C)
Vibration values determined according to vibration test code ISO 20643 and ISO 5349.| 0753
---|---
Vibration emission level, ahd:| Uncertainty vibration: k = 0.19 m/s2| 0.73 m/s2
Declared vibration emission values in accordance with EN 12096

INTENT OF USE

• The pneumatic 0753 MkII type tool is designed to place Stanley Engineered Fastening speed fasteners (except 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 10 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 intensifier 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 20-23.
• 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 Accessories manual (07900-09508) when selecting compatible components for the type and size of fastener used in your application.
• DO NOT use under wet conditions or in the presence of flammable liquids or gases.

2.8mm

| 3mm| 3.5mm| 4mm| 6mm| M2.5 4-40 UNC| M3 6-32 UNC
CHOBERT®| ⚫| ⚫| ⚫| ⚫| ⚫| | | | | | |
GROVIT®| ⚫| ⚫| ⚫| ⚫| | | | | | | |
AVLUG®| ⚫| ⚫| | | | | | | | | |
BRIV®| ⚫| ⚫| ⚫| ⚫| | | | | | ⚫| |
RIVSCREW®| | | | | | ⚫| ⚫| ⚫| ⚫| | |
AVTRONIC®| | | | | | ⚫| | | | | |
AVSERT®| | | | | | | | | | | ⚫| ⚫
NEOSPEED(R)| | ⚫| ⚫| ⚫| | | | | | | |

TOOL DIMENSIONS – 07530 MKII MODEL
Part Number 07530-02100

TOOL DIMENSIONS – 07532 MKII MODEL
Part Number 07532-02100

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/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

millimetres or 1/4 inch.
Read daily servicing details page 14.

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:
• 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.
• Fit a pneumatic hose between the male connector at the rear of the intensifier and main air supply.

For reference there are three different mechanical cursor types:

• 07271-01100 Used for Standard mandrels and 5/32” Disposable mandrels
• 07279-05843 Used for 1/8” Disposable mandrels
• 07279-05845 Used for 3/16” Disposable mandrels

The difference in the above assemblies is the internal diameter of the End Plug.

These are colour coded see below:

MECHANICAL CURSOR

PART NO.

| END PLUG PART NO.| COLOUR| HOLE DIAMETER (mm)
---|---|---|---
07271-01100| 07150-00402| PLAIN STEEL| 2.7
07279-05843| 07159-05844| GOLD| 2.2
07279-05845| 07159-05846| SILVER| 3.3

CURSOR
IMPORTANT
If fitted incorrectly, the cursor will not allow feeding of the fasteners.

While the cursor will be fitted the correct way round when the tool is supplied, we recommend that you check its orientation before fitting the nose equipment. The sprung loaded, slightly concave, end of the cursor should point towards the front of the tool as shown in the illustration.
When fitted the correct way round, the cursor will easily slide out of the barrel when a mandrel is pushed into its centre then pulled back.

To reverse the orientation of the cursor, follow these steps:
Item numbers in bold refer to the general assembly and parts list for the 07530-02200 MkII type on pages 20-21. For the 07532-02200 MkII type, the procedure is the same but the part numbers must be taken from the general assembly and parts list on pages 22-23.

• Remove the clip 47 and slide off end cap 38.

• Using an Allen Key, remove one cap head screw 44 ensuring that any trapped air is exhausted. remove the second cap head screw 44.

• Pull out rear plug 46.

• Pull out tail jaw piston assembly 14 together with jaws 9.

• Lift out spring 13 and jaw housing 8.

• 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.

LOADING AND RELOADING THE TOOL

• IMPORTANT
  The procedure for loading the tool and for fitting the nose equipment to the tool is integral.

When ordering a complete tool or system you will normally be supplied with all the nose equipment required for the fastener to be placed.
To identify nose equipment components or to select the correct elements, read the nose equipment section, in the accessories manual (07900-09508).
If you have been supplied with a nose jaw, mandrels and mandrel follower springs proceed with loading the tool and fitting the nose equipment as shown overleaf.

Item numbers in bold refer to the general assembly and parts list for the 07530-02200 MkII type on pages 20-21. For the 07532-02200 MkII type, the procedure is the same but the part numbers must be taken from the general assembly and parts list on pages 22-23.

Loading the Tool

• Connect the air supply to the tool.
• Open tail jaws 9 which grip the mandrel, by switching off the tail jaw switch (items 26 and 30).
• Screw selected nose jaws onto barrel 25 of the tool.
• Insert a mandrel into the tail end of the fasteners through the paper pod.
• Slide the mandrel follower spring onto the mandrel ensuring correct orientation, as shown in the accessories manual (part number 07900-09508).
• Gripping the tail end of the mandrel, tear off the paper pod from around the fasteners.
• Open the nose jaws either by rotating the outer ring on Cam operated jaws or by pushing outwards on the jaw ends, as illustrated below left.
• Insert the previously assembled mandrel, mandrel follower spring and fasteners into the nose jaws until the first fastener to be placed is protruding from the nose jaw.
• Close the nose jaws and adjust so that the first fastener protrudes by 1.5mm – 3mm (1/16” to 1/8”), as shown in the illustration below right.
• Close the tail jaws to ensure the mandrel is gripped, by switching on the tail jaw switch (items 26 and 30).

Reloading the Tool

• 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.

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.

PLACING EQUIPMENT
All nose equipment, mandrels, follower springs and other accessories can be found in the accessories manual (part number 07900-09508).

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.

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 connecting the air hose to the intensifier. If there is a filter, drain it.
• Check that the nose equipment is correct.
• Check mandrels regularly for signs of wear or damage monitoring the number of placings (read the safety instructions on page 4 – 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.
  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

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 15.

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 SPANNER| 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.

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

The airline must be disconnected before any servicing or dismantling is attempted, unless specifically instructed otherwise.
It is recommended that any dismantling operation be carried out in clean conditions.
Dismantling 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 16-18. Item numbers in bold refer to the general assemblies and parts lists for the respective model on pages 20-23.
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 and the trigger air line from the intensifier valve, 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 07530-02200 MKII
To dismantle the 07532-02200 MkII refer to pages 18-19.

TAIL JAW CYLINDER

• Manually flip 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 five 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 15. Item numbers in bold refer to the general assemblies and parts lists on pages 22-23.

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 Hose Assembly 22 and fit a spare Bleed Plug Assembly 2 screwing it in 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.

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 49 and remove. Take care to keep the Spring 50.
• Prise off the ‘O’ Ring 53 taking care not to damage the Spindle 54 and Retainer 49 seatings.
• Clean and re-assemble using a new ‘O’ Ring 53.
• Check length of Spring 50 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 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 refit 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 a soft jaw vice to prevent damage. DO NOT USE UNDUE FORCE.
• Complete assembly in reverse order of dismantling.

TAIL JAW PRESSURE NON-RETURN VALVE

• The Non-return Valve 21 is located in the tool handle.
  To remove/replace the Non-return Valve 21 depress the bulk head fittings and withdraw the Blue Plastic Tube 23 from both ends.

• When replacing the Non-return Valve 21, note the orientation.

• Refers to items included in the 0753 Mkll service kit. For complete list see page 15. Item numbers in bold refer to the general assemblies and parts lists on pages 22-23.

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.

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

DISMANTLING 07532-02200 MKII
To dismantle the 07530-02200 MkII refer to pages 16-18.

TAIL JAW CYLINDER

• Manually flip the Clip 54 up and remove the End Cap 45.
• Using an Allen Key*, remove one cap head Screw 51 ensuring that any trapped air in the tail jaw cylinder is exhausted. Remove the second cap head Screw 51.
• Push forward Rear Plug 53 against Spring 20 and release quickly to allow Rear Plug 53 to fall away.
• Extract air tail jaw components, comprising Tail Jaw Piston Assembly 21, Spring 20, Jaws 16 and Jaw Housing 15.
• 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 17.
• Using an Allen Key*, remove all five handle moulding securing Screws 41, 46 and Nuts 40 from the tool handle.
• Grip Barrel 31 in a vice using soft jaws* to avoid damage.
• Using a box spanner, unscrew Barrel Plug 14, preventing Barrel 31 turning by using an open ended spanner.
• Disconnect Air Tail Jaw Concertina Tube 19 from Switch Block 35 and pull Tail Jaw Cylinder 12 from tool.
• Remove ‘O’ Ring 10, Rubbing Strip 22 and Barrel Return Spring 13.
• Free length of Spring 20 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 12 as described earlier.

• Grip Body 25 in vice using soft jaws* to avoid damage, undo Stroke Limiter 23.

• Grip Barrel 31 in soft jaw vice, pull Body 25 from Barrel 31 (a small quantity of hydraulic oil will be ejected from inside body).

• Remove Piston 24 carefully so as not to damage body bore.

• Remove Seal 9.

• 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 25, taking care not to damage body cavity and bores. The removed Seal 1 MUST be discarded.

• Refers to items included in the 0753 Mkll service kit. For complete list see page 15. Item numbers in bold refer to the general assemblies and parts lists on pages 22-23.

  • To replace Seal 1, disconnect Hydraulic Hose Assembly 63 and all the associated air pipes. Unscrew Self Closing Coupler 6, remove Suspension Mounting Plate 4, unscrew the Adapter Top Hose 2 and fit a spare Bleed Plug Assembly 30 screwing it into bring the inside face level with the 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.

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 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.

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 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 refit 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.

TAIL JAW PRESSURE NON-RETURN VALVE

• The Non-return Valve 26 is located in the tool handle.
• To remove/replace the Non-return Valve 26 depress the bulk head fittings and withdraw Blue Plastic Tube 27 from both ends.
• When replacing the Non-return Valve 26, note the orientation.

HANDLE & END CAP

• Clean and inspect mouldings for cracks or other damage.

CURSOR

• Clean and oil Mechanical Cursor Assembly 11 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 07530-02200 MKII

PARTS LIST FOR BASE TOOL 07530-02200 MKII

07530-02200 PARTS LIST

ITEM PART N° DESCRIPTION QTY SPARES ITEM         PART N° DESCRIPTION                   QTY SPARES
1| 07003-00237| SEAL (STATIC)| 1| –| 30| 07004-00059| 1/8“ STARLOCK WASHER BLACK| 1| –
2| 07530-00500| BLEED PLUG ASSEMBLY (ITEMS 56 to 59)| 1| –| 31| 07003-00121| ‘O’ RING| 2| 3
3| 07003-00236| SEAL (DYNAMIC)| 1| 1| 32| 07005-01571| ELBOW CONNECTOR| 2| –
4| 07003-00167| ‘O’ RING| 1| 1| 33| 07002-00134| M4 HEX NUT| 5| –
5| 07271-01100| MECHANICAL CURSOR ASSEMBLY| 1| –| 34| 07001-00401| M4 × 10 LONG SOCKET HEAD CAP SCREW| 3| –
6| 07530-02207| TAIL JAW CYLINDER| 1| –| 35| 07530-02210| LABEL| 2| –
7| 07530-02205| BARREL PLUG| 1| –| 36| 07007-01504| CE MARK LABEL| 1| –
8| 07530-00208| JAW HOUSING| 1| –| 37| 73200-02022| SAFETY LABEL| 1| –
9| 07151-00403| JAWS| 2| 2| 38| 07530-02603| END CAP| 1| –
10| 07003-00113| ‘O’ RING| 1| 2| 39| 07001-00262| M4 × 22 LONG SOCKET HEAD CAP SCREW| 2| –
11| 07005-01972| L TYPE THREADED NIPPLE| 1| –| 40| 07530-02601| MODIFIED HANDLE MOULDING (RIGHT)| 1| –
12| 07530-02211| AIR TAIL JAW CONCERTINA TUBE| 1| –| 41| 07530-02602| MODIFIED HANDLE MOULDING (LEFT)| 1| –
13| 07154-00404| SPRING| 1| –| 43| 07003-00113| ‘O’ RING| 1| –
14| 07530-02800| TAIL JAW PISTON ASSEMBLY| 1| –| 44| 07001-00504| M4 × 6 LONG SOCKET HEAD CAP SCREW| 2| 2
15| 07530-00206| RUBBING STRIP| 1| 1| 45| 07002-00153| M4 WASHER PLASTIC| 2| –
16| 07490-03002| BARREL RETURN SPRING| 1| –| 46| 07530-02213| REAR PLUG| 1| –
17| 07530-00204| STROKE LIMITER| 1| –| 47| 07530-02220| CLIP| 1| –
18| 07530-00203| PISTON| 1| –| 48| 07007-00300| TRIGGER BUTTON| 1| –
19| 07530-02202| BODY| 1| –| 49| 07220-00803| RETAINER| 1| –
20| 07003-00142| 1/8″ BSP BONDED SEAL| 2| 2| 50| 07125-00215| SPRING| 1| –
21| 07005-01973| NON-RETURN VALVE| 1| –| 51| 07530-02311| TRIGGER HOUSING| 1| –
22| 07008-00423| HYDRAULIC HOSE ASSEMBLY| 1| –| 52| 07005-01357| COLLET TYPE CONNECTOR| 1| –
23| 07005-01083| 4mm O/D BLUE PLASTIC TUBE| 60

mm

| –| 53| 07003-00022| ‘O’ RING| 1| –
24| 07007-00017| DUST CAP| 1| –| 54| 07241-00208| SPINDLE| 1| –
25| 07530-02201| BARREL| 1| –| 56| 07003-00142| ˜ BONDED SEAL| 1| 1
26| 07004-00058| 1/8″ STARLOCK WASHER CHROME| 1| –| 57| 07003-00194| ˜ BONDED SEAL| 1| 1
27| 07001-00404| M5 × 6 LONG SOCKET HEAD SCREW| 1| –| 58| 07001-00442| ˜ SCREW| 1| –
28| 07530-02301| SWITCH BLOCK| 1| –| 59| 07530-00501| ˜ PLUG| 1| –
29| 07530-02302| AIR TAIL JAW SPOOL| 1| –| 60| 07530-00310| BLANKING PLUGS| 2|

GENERAL ASSEMBLY OF BASE TOOL 07532-02200 MKII

PARTS LIST FOR BASE TOOL 07532-02200 MKII

07532-02200 PARTS LIST

ITEM PART N° DESCRIPTION QTY SPARES ITEM         PART N° DESCRIPTION                   QTY SPARES
1| 07003-00237| SEAL (STATIC)| 1| –| 34| 07001-00404| M5 × 6 LONG SOCKET HEAD SCREW| 1| –
2| 07532-00203| ADAPTOR TOP HOSE| 1| –| 35| 07530-02301| SWITCH BLOCK| 1| –
3| 07003-00142| 1/8″ BSP BONDED SEAL| 4| 2| 36| 07530-02302| AIR TAIL JAW SPOOL| 1| –
4| 07532-02202| SUSPENSION MOUNTING PLATE| 1| –| 37| 07004-00059| 1/8“ STARLOCK WASHER BLACK| 1| –
5| 07532-00205| MODIFIED SCREW| 1| –| 38| 07003-00121| ‘O’ RING| 2| 3
6| 07005-00759| SELF CLOSING COUPLER| 1| –| 39| 07005-01571| ELBOW CONNECTOR| 2| –
7| 07005-01357| COLLET TYPE CONNECTOR| 3| –| 40| 07002-00134| M4 HEX NUT| 5| –
8| 07005-01325| BARBED STRAIGHT CONNECTOR| 2| –| 41| 07001-00401| M4 × 10 LONG SOCKET HEAD CAP SCREW| 3| –
9| 07003-00236| SEAL (DYNAMIC)| 1| 1| 42| 07530-02210| LABEL| 2| –
10| 07003-00167| ‘O’ RING| 1| 1| 43| 07007-01504| CE MARK LABEL| 1| –
11| 07271-01100| MECHANICAL CURSOR ASSEMBLY| 1| –| 44| 73200-02022| SAFETY LABEL| 1| –
12| 07530-02207| TAIL JAW CYLINDER| 1| –| 45| 07530-02603| END CAP| 1| –
13| 07490-03002| BARREL RETURN SPRING| 1| –| 46| 07001-00262| M4 × 22 LONG SOCKET HEAD CAP SCREW| 2| –
14| 07530-02205| BARREL PLUG| 1| –| 47| 07532-02208| MODIFIED HANDLE MOULDING (RIGHT)| 1| –
15| 07530-00208| JAW HOUSING| 1| –| 48| 07532-02209| MODIFIED HANDLE MOULDING (LEFT)| 1| –
16| 07151-00403| JAWS| 2| 2| 50| 07003-00113| ‘O’ RING| 1| –
17| 07003-00113| ‘O’ RING| 1| 2| 51| 07001-00504| M4 × 6 LONG SOCKET HEAD CAP SCREW| 2| 2
18| 07005-01972| L TYPE THREADED NIPPLE| 1| –| 52| 07002-00153| M4 WASHER PLASTIC| 2| –
19| 07530-02211| AIR TAIL JAW CONCERTINA TUBE| 1| –| 53| 07530-02213| REAR PLUG| 1| –
20| 07154-00404| SPRING| 1| –| 54| 07530-02220| CLIP| 1| –
21| 07530-02800| TAIL JAW PISTON ASSEMBLY| 1| –| 55| 07007-00300| TRIGGER BUTTON| 1| –
22| 07530-00206| RUBBING STRIP| 1| 1| 56| 07220-00803| RETAINER| 1| –
23| 07530-00204| STROKE LIMITER| 1| –| 57| 07125-00215| SPRING| 1| –
24| 07530-00203| PISTON| 1| –| 58| 07530-02311| TRIGGER HOUSING| 1| –
25| 07530-02202| BODY| 1| –| 60| 07003-00022| ‘O’ RING| 1| –
26| 07005-01973| NON-RETURN VALVE| 1| –| 61| 07241-00208| SPINDLE| 1| –
27| 07005-01083| 4mm O/D BLUE PLASTIC TUBE| 350

mm

| –| 63| 07008-00414| HYDRAULIC HOSE ASSEMBLY| 1| –
28| 07532-02215| SEALING PLUG| 1| –| 64| 07003-00142| ˜ BONDED SEAL| 1| 1
29| 07005-01084| 4mm O/D BLACK PLASTIC TUBE| 220

mm

| –| 65| 07003-00194| ˜ BONDED SEAL| 1| 1
30| 07530-00500| BLEED PLUG ASSEMBLY (ITEMS 64 to 67)| 1| –| 66| 07001-00442| ˜ SCREW| 1| –
31| 07530-02201| BARREL| 1| –| 67| 07530-00501| ˜ PLUG| 1| –
32| 07007-00017| DUST CAP| 1| –| 68| 07530-00310| BLANKING PLATE| 2|
33| 07004-00058| 1/8“ STARLOCK WASHER CHROME| 1| –| | | | |

INTENSIFIER 07531-02200 – MAINTENANCE

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 (item 22 on page 20 or item 29 on page 22) 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

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.

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 CONNECTOR| 1| –
6| 07003-00153| ‘O’ RING| 2| –| 33| 07003-00142| SEAL| 2| 1
7| 71420-02007| SEAL PLUG| 1| –| 34| 07240-00400| VALVE HOUSING ASSEMBLY| 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| –

PILOT VALVE 07005-00590 – MAINTENANCE

Dismantling Instructions
Please note that these service instructions refer to the Compair valve where fitted.
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 five 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, fit 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 finally 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, fit ‘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.

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.

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

Item numbers in bold refer to the illustration and parts list opposite.

PILOT VALVE 07005-00590 – SPARES INFORMATION

07005-00590 VALVE PARTS LIST

ITEM| PART N°| DESCRIPTION| QTY| SPARES| ITEM| PART N°| DESCRIPTION| QTY| SPARES
1| 07005-00599| ‘O’ RING| –| –| 15| –| † SPACER| 5| –
2| 07005-00598| PLASTIC COLLET| –| –| 16| –| † SPOOL| 1| –
3| 07003-00204| ‘O’ RING| 1| –| 17| –| † WASHER| 1| –
4| 07003-00103| ‘O’ RING| 6| –| 18| –| † PISTON| 1| –
5| 07003-00042| ‘O’ RING| 1| –| 19| –| † BODY| 1| –
6| 07003-00121| ‘O’ RING| 4| –| 20| –| † TOP CAP| 1| –
7| 08005-00127| ‘O’ RING| 1| –| 21| –| † SCREW| 2| –
8| 07003-00105| ‘O’ RING| 6| –| 22| –| † END CAP| 1| –
9| 07003-00178| ‘O’ RING| 1| –| 23| –| † BODY| 1| –
10| 07003-00017| ‘O’ RING| 2| –| 24| –| † SCREW| 2| –
11| –| † PISTON| 1| –| 25| –| † END CAP| 1| –
12| –| † PISTON| 1| –| 26| –| † SCREW| 2| –
13| 07005-00590| VALVE ASSEMBLY| –| –| 27| –| † CARTRIDGE| 1| –
14| –| † WASHER| 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. † Not available as a spare

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 VG 32 AND AWS 32 OIL SAFETY DAT

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 pistol unit fitted to the intensifier unit and held below the level of the intensifier unit, unscrew Bleed Screw 58 from Bleed Plug Assembly 2 on the 07530 Mk II tool or Bleed Screw 66 from Bleed Plug Assembly 30 on the 07532 Mk II 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

Other symptoms or failures should be reported to your local Avdel authorized distributor or repair centre.

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: 07530 / 07531 / 07532

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 KINGDOM

Place of issue:  Letchworth Garden City, UK

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

CE: 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: 07530 / 07531 / 07532

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: 27/08/2021

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

PROTECT YOUR INVESTMENT!
Stanley® Engineered Fastening BLIND RIVET TOOL WARRANTY
STANLEY® Engineered Fastening warrants that all power tools have been carefully manufactured and that they will be free from defect in material and workmanship under normal use and service for a period of one (1) year.
This warranty applies to the first time purchaser of the tool for original use only.

Exclusions:
Normal wear and tear.
Periodic maintenance, repair and replacement parts due to normal wear and tear are excluded from coverage.
Abuse & Misuse.
Defect or damage that results from improper operation, storage, misuse or abuse, accident or neglect, such as physical damage are excluded from coverage.
Unauthorized Service or Modification.
Defects or damages resulting from service, testing adjustment, installation, maintenance, alteration or modification in any way by anyone other than STANLEY® Engineered Fastening, or its authorized service centres, are excluded from coverage.
All other warranties, whether expressed or implied, including any warranties of merchantability or fitness for purpose are hereby excluded.
Should this tool fail to meet the warranty, promptly return the tool to our factory authorized service centre location nearest you. For a list of STANLEY® Engineered Fastening Authorized Service Centres in the US or Canada, contact us at our toll free number (877)364 2781.
Outside the US and Canada, visit our website www.StanleyEngineeredFastening.com to find your nearest STANLEY Engineered Fastening location.
STANLEY Engineered Fastening will then replace, free of charge, any part or parts found by us to be defective due to faulty material or workmanship, and return the tool prepaid. This represents our sole obligation under this warranty.
In no event shall STANLEY Engineered Fastening be liable for any consequential or special damages arising out of the purchase or use of this tool.
Register Your Blind Rivet Tool online.
To register your warranty online, visit us at: https://www.stanleyengineeredfastening.com/support/warranty-registration- form
Thank you for choosing a STANLEY® Engineered Fastening’s Stanley Assembly Technologies Brand tool.

References

• Global Leader in Fastening Technology | STANLEY® Engineered Fastening
• 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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