056893 Gyspress 8T Push Pull Complete Pack Instruction Manual

056893 Gyspress 8T Push Pull Complete Pack

GYSPRESS 8T PUSH PULL

| EN
---|---
1| Steel arm
2| Trigger
3| Handle
4| Pressure control
5| Regulator
6| Locking pin
7| Jack axle
8| Speed control
9| Air output

This manual contains safety and operating instructions. Read it carefully before using the device for the first time and keep it in a safe place for future reference.

DESCRIPTION

Thank you for your choice In order to get the maximum benefit from your purchase, please read carefully the following instructions:
The riveting machine has been especially made for the main types of rivets used and homologated for car body repair:

• Self-piercing rivets
• Flow-form rivets

HANDLING

The correct handling procedures are explained in this user manual. It is vital that the GYS operating procedures are
followed.

COMPRESSED AIR CONNECTION

Maximum air pressure:
Make sure that the air pressure does not exceed 8 bar.

Clean compressed air:
Make sure you use only clean and dry compressed air for supply the riveting machine. Moisture and impurities can lead to system failures and/or damages on the product.

SETTING UP AN ARM

Choose an arm and prepare the locking pin (1). Put the arm with care on the riveting machine nose, making sure that the 2 points of reference are aligned.
For the implementation of large arms (eg, HR2, HR3), it is advisable to lay the arms flat on a table and bring the nose of the riveting machine in the arm’s orifice. For more details see the video:

As soon as the arm is on the riveting machine, push the locking pin in the hole.
The axle locks itself automatically and must not be allowed to become unlocked.
The locking pin must be clean with no damage. Do not use any damaged pin.

Using the screw, fasten the extension supplied with the arm.

The riveting machine is now ready to use.

CONNECTOR ASSEMBLY

Screw the required connectors kit for the riveting procedure in the arm support. Before assembling, check that the die and the punch support are correctly in place (see page 3) and screwed.

As soon as the matrix and the punch support are in place, tighten with the spanner provided. Check that the connection tips are in place after each riveting process. A release is dangerous and may damage the riveting machine.

SPEED AND PRESSURE CONTROL

The user can adjust manually the speed of the actuator as well as rivet installation pressure according to the type of material in order to avoid distortion.
See page 61 in order to adjust the pressure according to the
material and matrix.

RIVET BOX INCLUDED

The riveting machine is delivered with a box of 300 self-piercing rivets. These sample rivets are provided to allow a test of the machine. They are
specific to car body repair.

INSTALLATION OF SELF-PIERCING RIVETS

During the installation of self-piercing rivets, make sure that the rivets are well-placed. The matrix must not be damaged as problems during the riveting process may occur.

During each riveting process, make sure that the matrix – and the rivet itself – are layed out on the metal sheets to assemble. It is important to put the punch support in place in order to form a 90° angle.

RESULT OF THE INSTALLATION OF SELF-PIERCING RIVET

STAMP AND CALIBRATE HOLES FOR FLOW-FORM RIVETS

To punch the sheet to a specific diameter, it is necessary to use a specific die. This die protects the sheet from damage.

If using Flow-Form rivets, it is necessary to drill metal sheets before in order to put the rivet in place. The punch and
the die above allow for a more precise punching as well as allowing the fitting of Flow-Form rivet.

After punching the punch is pushed into the metal sheet and pierces the hole. The sheet is free from the punch and ready for riveting.

INSTALLATION OF FLOW FORM RIVETS

Before assembling metal sheets with Flow-Form rivets, it is necessary to pre- drill the metal (see the procedure above).

Once the starter hole is done, insert the Flow-Form rivet:
The end piece F1 must be on the head rivet side:

The F2 matrix has got an evacuation hole for glue resi-dues. After each use, remove all the glue residues on the tools.

RIVET EXTRACTION

For car body repairs, old or damaged rivets must be removed.
To avoid to have to take off the rivets by drilling, the extraction connection and the matrix
must be used. Indeed, they enable to extract rivets while preserving metal sheets.

Before using the riveting machine and to facilitate the extraction of self- piercing rivets, it is possible to make a mark on the rivet with the center punch tool (ref : 048379) to locate the extraction tool in the mark.

If during the extraction, the rivet stays in the die hole, remove it he blank before making another extraction. Once the hole is punched, release the pressure immediately. Failing to do so may damage the tip.

CONTROLS AND MAINTENANCE

The GYSPRESS 8T PUSH PULL does not require any special maintenance. A simple periodic visual control is recom-
mended in order to prevent any breakdown or failure during use.
Clean the GYSPRESS 8T PUSH PULL at least once a week in order to eliminate dust and dirt which could alter the function of the product in the long term. Use auto cleaning cloths. Do not use water nor flammable or corrosive liquids.

During maintenance, the compressed air supply must be disconnected.

TROUBLESHOOTING

The chart below indicates the issues that can be observed during the use of the product. If the problem observed does not appear in the table below, stop using the product and call immediately your distributor to seek support.

pressure.
Air pressure too low.| Check air pressure supply.
The air pressure is not adjusted correctly.| Adjust air pressure between 2 and 8 bar.
The potentiometer is set at the mini- mum speed.| Adjust the speed laying.
The rivet is not in place.| Mandrel or matrix faulty| Replace the mandrel or the matrix.
Presence of glue on the mandrel or inside the matrix.| Clean the glue
The pressure is not enough.| Air pressure is too low or not well- ajdusted.
Rivet length incorrect.| Follow manufacturer instructions.
Air, leak.| Faulty pipe.| Change the pipe.
Faulty coupling.| Change the coupling.
Faulty seals.| Repair by the manufacturer.

PRESSURE CONTROL CHART

• Self-piercing rivets (SPR)

• Flow-Form rivets (FFR)

AIR PRESSURE :

• 2 bar = 1.2 t = 12 kN
• 4 bar = 3.7 t = 37 kN
• 6 bar = 6.2 t = 62 kN
• 7 bar = 7.4 t = 74 kN
• 8 bar = 8.3 t = 83 kN

CONFORMITY ASSESSMENT
GYS certifies that the GYSPRESS 8T PUSH PULL conforms to the directive 206/42/EC and respects the following standards :
EN 693 / EN 792-1 / EN 792-13
Date CE : 2016.

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