CLAS OM 9203 Fiat Injector Extractor Box Instruction Manual

CLAS OM 9203 Fiat Injector Extractor Box Instruction Manual

WARNING

Before returning this product for any reason (installation problem, instructions for use, breakdown, manufacturing problem…), please contact us.

Contact :
You can reach us by mail sav@clas.com or by phone +33(0)4 79 72 69 18 or go directly to our website clas.com

If you have changed your mind regarding your purchase, please return this product before you attempt to install it.

COFFRET EXTRACTEUR INJECTEURS FIAT

Components

311083005: MAIN EXTRACTOR’S BODY

311083001: SUPPORT FOOT

311070017:  SCREW M18X1.5 FOR BOSCH INJECTOR REMOVAL

311083004: WASHER COMPLETE WITH BEARING

311070016: FIXINGS PLATES 6 mm – Ø8.5

311070018: RING NUT M27X1

311070006:  NUT M18X1.5 30 mm WRENCH

270027019. AB: SUPER COMPACT GO-THROUGH MECHADRAULIC CYLINDER 12 TONS

270027009:  SCREWDRIVER FOR BUSHING

270027010: M18X1.5 BUSHING

270027014: M10 BUSHING

270027014: M10 BUSHING

270027013: M12 BUSHING

270027011: M16 BUSHING

270027020: PIN FOR SCREW

APPLICATION

FIAT| 500, Punto, Grande Punto , Panda, Idea, Doblò, Stilo, Qubo| 1.3 Multijet 16v| 169A1.000, 188A8.000, 188A9.000, 199A2.000, 199A3.000, 223A9.000
---|---|---|---
LANCIA| Ypsilon, Musa| 1.3 multijet 16v| 188A9.000
ALFA ROMEO| MiTO| 1.3 multijet 16v|
OPEL| Corsa, Agila, Meriva, Astra, Astra GTC, Tigra Twin Top, Combo Tour| 1.3 CDTI| Z13DTH, Z13DTJ, Z13DT
SUZUKI| Ignis, Splash, Swift, Wagon R+| 1.3 DDiS 16v| Z13DT

INTRODUCTION

It is compulsory to read this instruction manual before starting any kind of action.

The proper operation and full compliance of this product’s performance is guaranteed only if all the instructions provided in this manual are closely adhered to.

We guarantee that this product complies with the technical specifications described in this manual.

The manufacturer shall not be held responsible for any improper uses other than those described herein.

Use protective work gloves, protective footwear, hard hat and safety goggles

Misuse:

• This product should only be used as described in this documentation; any other use is considered improper.
• The manufacturer accepts no responsibility for any damage caused by the incorrect or unreasonable use of the equipment.
• Moreover, misuse shall also void the warranty.

Take care of your tools:

• Be sure to store your tools in a clean state.
• Place the tools inside their original package.

CAUTION – is used to indicate correct operating or maintenance procedures to prevent damages to the equipment or the surrounding environment:

• Always check the integrity of the cylinder;
• Keep the cylinder away from flames, heat and sparks;
• Do not use the cylinder outside the temperature range indicated in table A;
• In case of topping up or replacement of grease, use a lubricant compatible with the gaskets assembled on the cylinder, see use temperatures and viscosity table A;

WARNING – indicates a potential danger that requires correct procedures or practices to avoid personal injury:

• lways wear personal protective devices when operating, handling and maintaining the equipment  protective gloves against mechanical risks and goggles with lateral protection);
• Do not use pneumatic or electric screwers to screw the pusher (CH. 19) that is on the handle or use extensions to increase the torque;
• Select steel or wood blocks that are capable of supporting the maximum load of the cylinder and place them under or on it;
• Do not use the cylinder as thickness element or wedge;
• Cylinders should be placed on a flat surface before their use. The configuration of the components under strain should be stable;
• Distribute the load evenly across the entire saddle surface (piston) in order to avoid misalignments or situations which could lead to slipping of the parts under strain;
• Immediately replace worn or damaged parts by genuine Clas parts

DANGER: is used when your action or lack of action may cause serious injury or even death:

• To avoid personal injury keep hands and feet away from cylinder and components under strain;
• An unexpected grease leakage could tear skin, causing serious injury; in that case, seek medical advice immediately. If oil penetrates the skin, see a doctor immediately.
• Always wear the personal protective devices indicated

APPLICATION FIELD

The mechanical characteristics, shape and dimensioning of Clas mechadraulic cylinders make their use limited to car industry, such as:

• Disassembly of injectors;
• Assembly of bearings;
• Coaxial release of very tight mechanical components;

TECHNICAL DATA

Extraction bushes supplied ATTENTION: Use the Max. torque indicated in the chart in the first part of the manual (page 4).| M18x1.5 M16 M14 M12 M10
Grease temperature range of use| from -25°C to 80°C
Recommended viscosity of the fluid| 15÷100 mm²/s
Center distance of the 4 holes for fastening the cylinder| 68 x 36,5 mm (rif. A)
Size of fixing holes| Ø7 mm (rif. A)

OPERATION

**** Use the cylinder only with the bushes supplied. Do not use improperly.

• Cylinder should be placed so as to have a stable and firm base, which is perpendicular to the direction of the piston thrust.
• Lubricate the screw with grease or lubricating oil.
• Move forward the piston screwing clockwise the screw pusher, which is on the handle. Use a normal CH. 19 wrench and keep fix the hexagonal end part with a CH.30 wrench. Do not use electrical or pneumatic screwers or other power-assisted systems to increase the torque on the pusher. The piston maximum stroke is of 8 mm. The screw cannot be screwed beyond this travel.
• For piston return, unscrew anti-clockwise the pusher up to complete withdrawal of the former.

Remove the mechadraulic cylinder from its position only after verifying that each component is not stressed by its thrust.

Notes: Do not allow piston rotation during its thrust. Piston rotation could damage internal seals above all the return spring.

DANGER

• Never release the internal hydraulic pressure by loosening the handle!
• Never release the internal hydraulic pressure by loosening the air release screw!
• Never screw clockwise the pusher in case of grease leakage from the handle.

MAINTENANCE

Mechadraulic cylinders do not require any particular maintenance; however, users should consider the following aspects to increase their service life:

• In case of replacement or topping up, always use grease compliant with the characteristics indicated in table A;
  

• Cylinders should be kept in dry and not dusty places to increase their service life in case they are not used;

• Store cylinders with the rod completely set back to avoid external chemical agent attacks which might damage smoothness and seal;

• Before and after any use, always check if grease leakage occurs;

• If internal rings are replaced, the cylinder should be repaired only by qualified and experienced personnel.

Cylinder bleeding (rif. B)

• Place the cylinder so that the piston goes downwards and the handle is lower than the air release screw.
• Screw the screw pusher and slightly loosen the air release; screw tight the air release screw as soon as grease starts coming out.
• Always keep clean the pusher screw to avoid traces of metal particles.
• Operation should be flowing and fluid, therefore verify that the screw thread has not been damaged.

STORAGE

Protect cylinders from water if storage is in the open air.

HOW TO USE

• Remove the electrical connection from the injector’s head (fig. 1);
  

• Remove from the injector the internal solenoid connector: also in this case it is recommended the usage of the wrench (fig. 2);
  

• Screw the M18x1.5 screw inside the whole length of the injector’s thread (fig. 3), then, screw completely the M27x1 ring nut on to the screw, the ring nut must touch the head of the screw (fig. 4);
  
  

• Insert into the 3 holes the feet to support the bar (fig. 5);
  

• Now put the bar on the 3 feet already mounted (fig. 6);
  

• Fix the bar to the feet, using the 3 plates supplied (fig. 7);
  

• Insert on the M18x1.5 screw the ring nut with the internal bearing and fix it with the M18 x1.5 nut (fig. 8);
  

• Now remove the injector, using a 30 mm wrench for the M18 nut and a 10 mm wrench for the M18 screw (fig. 9);
  

• After the injector’s removal, remove the screw and the ring nut and keep on dismounting all the other injectors (fig. 10) following the same procedure.

CLAS Equipements
ZA de la CROUZA
73800 CHIGNIN
FRANCE
Tél. +33 (0)4 79 72 62 22
Fax. +33 (0)4 79 72 52 86
OM 9203
COFFRET EXTRACTEUR INJECTEURS FIAT
INJECTOR EXTRACTOR SET FIAT
Si vous avez besoin de composants ou de pièces, contactez le revendeur
En cas de problème veuillez contacter le technicien de votre distributeur agréé
If you need components or parts, please contact the reseller.
In case of problems, please contact your authorized technician.

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