Bollhoff 4080 Tool User Manual

4080 Tool

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1

ENGLISH

TABLE OF CONTENTS

1.PNOITPIRCSED LOOTI

3.PSEIROSSECCA II

3.PNOITAREPO LOOT III

5.PECNANETNIAM VI

8.PSNOITULOS DNA GNITOOHSELBUORT V

I - TOOL DESCRIPTION

Tool function

The 4080 tool is intended to crimp RIVKLE

®

blind rivet nuts into previously drilled supports

or punched holes in the parent material.

Stroke installation

This tool allows crimping RIVKLE

®

items according to the stroke installation method

Features

- Installation capacity: RIVKLE

®

M3 to M12, steel (max. load: 21 kN at 6 bar)

mm 7:ekorts .xaM -

- Operating pressure 5.5 bar min. to 7 bar max.

- Weight, equipped as M6: 2.6 kg

- Air consumption: 8 L
)A( Bd 07 <:level esioN -

Dimensions

M3 M4 M5 M6 M8 M10 M12

Standard A 68 68 68 68 68 68 68

rod L 32 31 41 42 42 52 56

Commercial A 59 59 59 59 59

screw L 33 34 40 42 47

SAFETY: BEFORE ANY INTERVENTION ON THE 4068 TOOL, DISCONNECT THE COMPRESSED
AIR FITTING

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N°1 N°2 N°1 N°2

M3 236 113 03 020 236 113 03 030 376 113 03 020 376 113 03 030

M4 236 113 04 020 236 113 04 030 376 113 04 020 376 113 04 030

M5 236 113 05 020 236 113 05 030 376 113 05 020 376 113 05 030

M6 236 113 06 020 236 113 06 030 376 113 06 020 376 113 06 030

M8 236 113 08 020 236 113 08 030 376 113 08 020 376 113 08 030

M10 236 113 10 020 236 113 10 030 376 113 10 020 376 113 10 030

M12 236 153 10 020 236 113 12 030

2

1+2+3+4 1* 2 3 4

M3 236 803 03 000

CHC ISO4762

236 113 03 030 236 803 03 040 236 803 03 010

DIN912 : M3 x 60

M4 236 803 04 000

CHC ISO4762

236 113 04 030 236 803 04 040 236 803 04 010

DIN912 : M4 x 60

M5 236 803 05 000

CHC ISO4762

236 113 05 030 236 803 05 040 236 803 05 010

DIN912 : M5 x 70

M6 236 803 06 000

CHC ISO4762

236 113 06 030 236 803 06 040 236 803 06 010

DIN912 : M6 x70

M8 236 803 08 000

CHC ISO4762

236 113 08 030 236 803 08 010

DIN912 : M8 x70

ENGLISH

T)swercs 01( 020X0308632 :* ab. 1

340 00 351 632 = 5 .oN612 00 308 632 = 6 + 831 + 541 .oN

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II - ACCESSORIES

Tooling for RIVKLE

®

item installation with socket head cap screw mandrel (p. 12)

SOCKET HEAD CAP SCREW CHC DIN912

Screw replacement

- Loosen anvil locknut and unscrew anvil (2)

- Unscrew nose-piece (5)

- Fit screw (1) through washer (3), suitable for the required diameter (no washer for M8)

- Fit drive end piece (4) into screw (1) recess

- Slide the assembly into pull-out bush (7)

- Re-install nose-piece (5)

- Re-install anvil and locknut (2)

STANDARDS TOOLS

Setting tooling for RIVKLE

®

or RIVKLE®stud (with special female mandrel) (p. 12)

If you already use an OPEN tool, the existing female mandrel can be re-used.

Tooling replacement (with special female mandrel)

- Keep nose-piece (5) in place; loosen anvil locknut, then remove anvil (2) and locknut.

- Drive out pin (9) by means of a drift without damaging retaining ring (8)
and release mandrel entirely (1).

- Re-install new mandrel (1) and t pin (9) again, ensuring that it is retained by retaining ring (8).

- Screw in nose-piece (5) again and torque to 15 Nm.

- Screw in new anvil (2) again inside nose piece and lock by means of locknut.

III - TOOL OPERATION

Anvil position adjustment versus mandrel

- Anvil position depends on RIVKLE®length before crimping.

- Adjust anvil position as indicated in gure 3.

- After adjustment, lock anvil locknut (2) to 10 Nm torque..

OPEN RIVKLE

®

BLIND RIVKLE

®

Flush-mounted mandrel at RIVKLE®end

Mandrel at 1 turn from thread bottom

3

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4

Connection to compressed air system

All tools are air-driven, at an optimum pressure of 6 bar. We recommend the use of air treatment
units including lubrication, ltering and pressure control on the compressed air supply system.

These devices must be installed at maximum 3 metres from the tool in order to ensure optimum
tool service life and minimum maintenance.

All air hoses MUST MANDATORILY FEATURE AN INNER DIAMETER OF AT LEAST 6.4 mm

Operating method

The tool can be operated in all positions, either carried in hand or suspended.

Operating procedure

- Connect the air supply to the tool.

- Oer up the RIVKLE

®

onto the mandrel. A slight pressure will start the motor

and automatically initiate RIVKLE

®

screwing in onto the nose-piece, then motor shutdown

(Push-Pull system).

- Introduce the RIVKLE

®

into the hole in intended application.

- Press the trigger and keep depressed until the device is fully released.
This action both crimps the RIVKLE

®

into the intended application

and releases it from the mandrel (by unscrewing).

- Check that air system pressure is set between 5,5

and 7 bar.

- Before crimping, adjust stroke to 0 by turning the adjustment ring
to minimum position in (-) direction.

- Gradually increase crimping stroke by turning the adjustment ring

towards (+). This adjustment ring features
3 index marks. 1/3 turn corresponds to 0.5 mm
(1 complete turn = 1.5 mm).

- At each step, test RIVKLE

®

crimping quality,

until obtaining optimum crimping.

- Optimum crimping (dimension s) is indicated

in your RIVKLE

®

catalogue

Crimping pressure adjustment

 Unscrewing button

In case of unscrewing problem, the 4080 tool is
equipped with an unscrewing control button on
top of the crimping trigger. To start unscrewing,
press unscrewing button (1), then press crimping
trigger 2 at the same time.

CAUTION: THE TRIGGER MUST BE KEPT DEPRESSED FOR THE ENTIRE CYCLE. RELEASING THE
TRIGGER WOULD RESULT IN FAULTY CRIMPING.

CAUTION: WHEN DELIVERED, THE TOOL IS DELIBERATELY SET TO 0 MM STROKE. THEREFORE, IT
IS MANDATORY TO ADJUST THE DEVICE WHEN PUTTING INTO SERVICE.
EXCESSIVE STROKE CAN DAMAGE RIVKLE

®

TAPPED THREADS, AS WELL AS THE MANDREL, OR
PREVENT MANDREL UNSCREWING.
WHEN CORRECT CRIMPING IS OBTAINED, RECORD THE POSITION OF THE INDEX MARK ON THE
ADJUSTMENT RING, FOR REFERENCE.

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2

1

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5

IV - MAINTENANCE

General maintenance

YCNEUQERFNOITAREPO

Check that the installed tool corresponds to your RIVKLE

®

At each adjustment

Check that tool crimping stroke is suitable for the selected RIVKLE

®

yliad ecnO.)tnemtsujda erusserp ees(

yliad ecnO.deriuqer sa ecalper ;noitidnoc lerdnam kcehC

Check that “ screwing - crimping - unscrewing ” operations are
controlled by pressure exercised on the mandrel and the trigger, Once daily
without RIVKLE®loaded.

Check that rst RIVKLE®is screwed in down to the anvil.
Always keep mandrel perpendicular to parent material. /
Lightly oil mandrel. Every 50 RIVKLE®crimped
After use, protect mandrel with a RIVKLE

®

/

Occasionnal maintenance

The compressed air supply must be disconnected before any maintenance or removal operation.

Every 500,000 cycles, the tool must be entirely dismantled and all worn or damaged items
replaced.
It is also recommended to replace all items contained in the repair kits.

Any removal operation should be performed in good cleanliness conditions.

Maintenance kit

In order to facilitate maintenance, we recommend the use of special maintenance tools in order not
to damage your tool.

IMPORTANT NOTE: TOOL MAINTENANCE MUST BE ENSURED BY COMPETENT TECHNICIANS. THE
OPERATOR MUST NOT CARRY OUT TOOL MAINTENANCE OR REPAIR, UNLESS SUITABLY TRAINED
FOR THIS PURPOSE.

Oil level lling

- Disconnect compressed air supply.

- Remove upper oil lling threaded plug, It. 9, and screw It. 54.

- Using a mandrel, push back pneumatic piston It. 37
down to tank bottom, It. 36.

- Check oil level through port (It. 9), and ll as required,
to reach the lower section of the tapped port.

- Re-install threaded plug It. 9 with seal It. 10 & screw It. 54.

- Reconnect the compressed air supply and check the crimping

pressure after several cycles of the trigger.

- In case of insucient stroke, repeat the operations.

EXCLUSIVELY USE HYDROLUB H68 CONDAT OIL OR SIMILAR.

Repair kit N ° 236 155 00 220

Special maintenance tools Upon request

It. 9

It. 54

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/

5

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ENGLISH

DESCRIPTION P/N

030 56 351 6321* gnirpS2

3 Receiver piston 1 236 153 65 002
4 Guide bush * 1 236 153 00 390

410 00 308 6321gniR5

6 Anti-extrusion ring * 1 236 153 65 112

701 56 351 6321* laeS7

611 56 351 6321wercs 6M9
10 BS ring, 8 DIA. * 1 236 153 65 113
11 Thrust washer 1 236 153 65 104

430 56 351 6321* laeS21
13 Anti-extrusion ring * 1 236 153 65 111
14 Stroke stop 1 236 155 00 014
15 Pin, Ø 510 00 551 63214

610 00 551 6321gniR61

210 56 351 6321evirD71
18 M10 screw 1 C95 101 51 010
19 Pull-out pin 1 C25 110 10 100
20 Retaining ring 1 C25 110 10 410
21 Pull-out bush 1 236 155 00 021
22 Nose-piece 1 236 155 00 022
23 Rear cover seal 1 236 155 00 023
24 Circlips ring, 44 mm DIA. 1 236 153 65 101
27 Spring washer 1 236 153 65 026

820 00 551 6322esoH82

920 00 551 6322wercs 4M92

030 00 551 6322gulP03

501 56 351 6322* laeS13

301 56 351 6321* laeS23
33 Anti-extrusion ring * 1 236 153 65 110
34 Transmitter piston bearing 1 236 153 65 021

630 00 551 6321knaT63

801 56 351 6321* laeS83

901 56 351 6321* laeS93
40 Tank protection 1 236 803 00 064

220 56 351 6321gulp knaT14

911 56 351 6321retliF35

511 56 351 6321wercs 8M36
73 Push-pull rod * 1 236 153 65 011
74 Plastic grip 1 236 155 00 074

570 00 551 6321* laeS57

670 00 551 6321* laeS67

770 00 551 6321* laeS77
78 Indexing bush 1 236 155 00 078

102 00 551 6321ydoB1E
E2 Cycle start trigger 1 236 155 00 202
E3 Unscrewing button 1 236 155 00 203

402 00 551 6321noinu riA4E
E5 Distributor valve 1 236 153 65 806
E6 Push-pull * 1 236 153 65 807

008 56 351 6321rotoM8E
E9 Cycle distributor valve 1 236 155 00 209

012 00 551 6321notsip riA01E

E11 Stroke adjustment ring 1 236 155 00 211
E12 Rear cover 1 236 155 00 212

022 00 551 6321tik riapeR02E

7

* items included

in repair kit
23615500220

ENGLISH

Qt.

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PROBLEM

Damaged mandrel threads.
Dicult screwing/unscrewing
actions.

RIVKLE

®

threads

defective after installation.

RIVKLE

®

turns in the hole.

Device does not unscrew
at end of crimping stroke.

Screwing function inoperative.

No crimping stroke.

Tool mandrel spins continuously.

Unscrewing function inoperative
(device blocked on the part).
Tool stuck in the RIVKLE

®

.

PROBABLE CAUSE

1 - Thickness to be crimped

incompatible with RIVKLE

®

.

2 - Excessive crimping stroke.
3 - Device positioning incorrect

during crimping.

4 - Damaged pull-out rod threads.

1 - Damaged mandrel threads.
2 - RIVKLE

®

incompletely screwed

on mandrel.
3 - Excessive crimping stroke.
4 - Thickness to be crimped

incompatible with RIVKLE

®

.

1 - Thickness to be crimped

incompatible with RIVKLE

®

.

2 - RIVKLE

®

head not bearing

on anvil at the time of crimping.
3 - Insucient crimping stroke.

1 - Low compressed air pressure.
2 - Low oil level.
3 - Motor problem.

1 - No air supply to device.
2 - Push-Pull valve out of adjustment.

1 - Adjustment ring at minimum

position.
2 - Low oil level in tool.

1 - Push-Pull valve out of adjustment.

1 - RIVKLE

®

tapped threads

or

mandrel threads damaged.
2 - Low oil level.
3 - Insucient air pressure.

SOLUTION

1 - Check crimping stroke range

in RIVKLE

®

catalogue.

2 - Repeat crimping test according

to instructions.

3 - Keep mandrel/tool perpendicular

to parent material.

4 - Replace mandrel as per instructions.

1 - Replace mandrel as per instructions.
2 - Adjust anvil position as per

instructions.

3 - Repeat crimping tests as per

instructions.

4 - Check crimping stroke according

to RIVKLE

®

catalogue.

1 - Check crimping stroke according

to RIVKLE

®

catalogue.

2 - Ensure that head is correctly

bearing, when screwing.

3 - Repeat crimping test as per

instructions.

1 - Check air supply pressure.
2 - Fill oil level as per instructions

in § 5.

3 - Check motor rotation at no load.

1 - Check that compressed air

supply to device is ensured.

2 - Adjust Push-Pull valve per

instruction item.

1 - Adjust crimping stroke.
2 - Fill oil level.

1 - Adjust Push-Pull valve per

instruction item.

1 - To release the tool:

- position pin (9) to match an
aperture in nose-piece (5) and
drive pin out,

- unscrew anvil (2),

- release the tool.

2 - Fill oil level as per instructions

in § 5.

3 - Check air pressure.

V - TROUBLESHOOTING AND SOLUTIONS

Before any intervention, check oil level and air supply pressure (between 5.5 and 7 bar)

ENGLISH

8

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