SERVICING THE TOOL
8 9
Regular servicing should be carried out and a comprehensive inspection performed annually or every
500,000 cycles, whichever is sooner.
Daily
• Daily, before use or when first putting the tool into service, pour a few drops of clean, light lubricating oil
into the air inlet of the tool 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 leaks. If damaged, hoses and couplings should be replaced by new items.
• If there is no filter on the pressure regulator, bleed the air line to clear it of accumulated dirt or water
before connecting air hose to tool.
• Check that the nose assembly is correct.
• Check the stroke of the tool is adequate to place selected insert. (See stroke adjustment page 6).
• Inspect the drive screw in the nose assembly for wear or damage. Renew if necessary.
Weekly
• Check for oil leaks and air leaks on air supply hose and fittings.
Molykote® 55m Lithium Grease Safety Data
Grease can be ordered as a single item, the part number is shown in the Service Kit page 14.
First Aid
SKIN: Wipe off and wash with soap and water.
INGESTION: No adverse effects are normally expected. Treat symptomatically.
EYES: Irritant but not harmful. Irrigate with water and seek medical attention.
Environment
Scrape up for incineration or disposal on approved site.
Fire
FLASH POINT: 101 °C
Not classified as flammable.
Suitable extinguishing media: Carbon dioxide, foam, dry powder or fine water spray.
Handling
Plastic or rubber gloves should be worn.
Storage
Away from heat and oxidising agent.
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.
MAINTENANCE
Every 500,000 cycles the tool should be completely dismantled and components replaced where worn,
damaged or when recommended. All 'O' rings and seals should be replaced with new ones and lubricated
with Molykote® 55M grease before assembling.
The air line 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.
Before proceeding with dismantling, empty the oil from the tool. Remove Oil Plug 42 and
Oil Seal Washer 43.
Prior to dismantling the tool it is necessary to remove the nose assembly. For simple removal instructions
see the nose assemblies section, page 7.
For total tool servicing we advise that you proceed with dismantling of sub-assemblies in the order shown
below.
Pneumatic Cylinder
• Remove Rubber Base 2.
• Place tool, base uppermost in vice fitted with soft jaws.
• Using a spanner*, unscrew end plug 3. Pneumatic Piston 9 should move upward under Spring 11 pres-
sure (it may be necessary to exert hand pressure to Pneumatic Piston 9).
• Remove 'O' Ring 4.
• Withdraw Pneumatic Piston 9.
• Remove Lip Seal 8 and 'O' Ring 36.
• Hold Piston Rod 10 in soft vice jaws to avoid scratching rod diameter.
• Separate Piston Rod 10 from Pneumatic Piston 9 by unscrewing piston rod fastening
Bolt 5 using a spanner*.
• Inspect Air Supply Tube 12 for damage or distortion. (Air tube is screwed internally into handle and set
in position with Loctite® 222) If it is necessary to remove air tube, the base of the air tube will require
warming to a temperature of 100°c to soften the Loctite® adhesive. The Air Supply Tube 12 can then be
unscrewed from the handle using an Allen key*.
• Check Spring 11 is not distorted or damaged. Replace any damaged seals and springs.
• Assembly is in reverse order to dismantling.
Rod Guide
• With tool in upside down position in vice, unscrew Rod Guide 15 using a spanner* and T-bar*.
• Withdraw Rod Guide 15.
• Unscrew locknut 13 using an Allen key*, remove Seal 14 and 'O' Ring 98.
• Remove 'O' Ring 16.
• Replace any damaged seals.
• Assembly is in reverse order to dismantling.
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
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