Stanley ProSert XTN20 74202 Instruction Manual

ProSertTM XTN20 Blind Rivet Nut Tool – 74202

Hydro-Pneumatic Power Tool

Instruction Manual

Hydro-Pneumatic Blind Rivet Nut Tool

Rebitadeira Hidropneumática de Porca Rebite Cega

Remachadora hidroneumática para tuercas remachables

Sertisseuse Oléopneumatique pour écrous aveugles

11 12 13

Fig. 2

Fig. 1

18 19

1918

Fig. 3

CONTENT

PA GE

1. Safety Denitions 6

2. Specication 8

2.1 Placing Tool Specication 8

2.2 The Package Contains 8

2.3 Main Components List 9

3. Tool Setup 10

4. Operating Instructions 10

4.1 Nose Equipment 10

4.2 Air Supply 11

4.3 Setting Instructions 11

5. Operating Procedure 12

6. Servicing the Tool 13

6.1 Daily Servicing 13

6.2 Weekly Servicing 13

7. Declaration of Conformity 14

8. Protect your investment . Warranty registration 15

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 speci cations 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 trade marks.

Original Instruction

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This instruction manual must be read by any person installing or operating this tool with particular attention to the following safety rules.

1. Safety De nitions

The de nitions 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. v 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 THESE INSTRUCTIONS. WARNING:

1. Do not use outside the design intent of Placing STANLEY Engineered Fastening Blind Rivet Nuts.

2. Use only parts, fasteners, and accessories recommended by the manufacturer.

3. Do not modify the tool in any way. Any modi cation to the tool is undertaken by the customer and will be the customer’s entire responsibility and void any applicable warranties.

4. Prior to use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that a ects the tool’s operation. If damaged, have the tool serviced before using. Remove any adjusting key or wrench before use.

5. 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.

6. The operating supply air must not exceed 7 bar (100 PSI).

7. Operators and others in work area must wear ANSI Z87.1 CAN/CSA Z94.3 approved safety glasses with side shields. Always wear safety glasses and ear protection during operation.

8. 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.

9. Do not operate a tool that is directed towards any person(s).

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10. DO NOT operate tool with the nose housing removed.

11. Adopt a  rm footing or a stable position before operating the tool.

12. 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.

13. Do not lift the placing tool by the hose. Always use the placing tool handle.

14. Vent holes must not become blocked or covered.

15. Disconnect the air hose from the tool before performing any maintenance, attempting to adjust,  t or remove a nose assembly.

16. Keep tool handles dry, clean, and free from oil and grease.

17. When carrying the tool from place to place keep hands away from the trigger to avoid inadvertent activation.

18. Never leave operating tool unattended. Disconnect air hose when tool is not in use.

19. Adequate clearance is required for the tool operators hands before proceeding.

20. Do not abuse the tool by dropping or using it as a hammer.

21. Keep dirt and foreign matter out of the hydraulic system of the tool as this will cause the tool to malfunction.

STANLEY Engineered Fastening policy

is one of continuous product development and improvement

and we reserve the right to change the speci cation

of any product without prior notice.

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Items with a * may require a mandrel adaptor kit (74202-02200 found in the Accessories Manual 07900-01073). A complete ProSert XTN20 (74202) tool is made up of the base tool (part number 74202-02000) and the appropriate nose assembly for the insert.

2. Speci cation

UNDER NO CIRCUMSTANCES SHOULD ANY MAINTENANCE OR SERVICING BE CONDUCTED APART FROM NOSE EQUIPMENT CHANGE.

The ProSert XTN20 hydro-pneumatic tool is designed for placing STANLEY Engineered Fastening Blind Rivet Nuts through adjustment of the force and/or the stroke.

The ProSert XTN20 Tool is used to place Blind Rivet Nuts from a range of M3 to M10 when coupled with the relevant nose equipment. Imperial nose equipment is also available to place UNC and UNF inch thread size Blind Rivet Nuts.

The safety instructions must be followed at all times.

2.1. Placing Tool Speci cation

2.2. The package contains:

• 1 XTN20 Blind Rivet Nut Tool

• 1 set M4, M5, M6, M8 Nose Equipment & Mandrels

• 1 Printed Instruction Manual

• 1 Maintenance Kit

Pull Force: Pull @ stated pull pressure 5.0 bar 17.65 kN 3968 lbf

Air Supply Pressure: Min/Max 5-7 bar 72.5-101.5 lbf/in

Oil Pressure: Pull (max) 230 bar 3336 lbf/in

Stroke: Piston stroke 3-7 mm 0.118-0.275 in

Weight: Including nose equipment 1.59 kg 3.50 lb

Noise Level: Uncertainty noise: K=3dB(A) <75 dB(A) <75 dB(A)

Vibration: Uncertainty vibration: K=0.1 m/s² <2.5 m/s

<8 ft/s

Motor Speed: Forward & Reverse 2000rpm 2000rpm

Additional Features:

Pull-to-Force operating mode Yes Pull-to-Stroke operating mode Yes Auto Spin On/Spin O Yes Tool Free Mandrel  ttings Yes Manual Reverse override Yes Hydraulic Lip Seals & O-rings Yes

Material: - Aluminium Steel Stainless Steel

Avdel® Product

Range:

Eurosert® - M3-M10 M4-M5 Thin Sheet Nutsert® M3-M10 M3-M10 M3-M10 DK/DL M4-M10 Euro Hexsert®/Hexsert® - M3-M8 M6 High Strength Hexsert® - M6-M8 Squaresert® - M5-M8 -

POP Nut®

Product Range:

Standard Nut* M3-M10 M3-M8 M4-M6 Knurled Nut* M4-M8 M4-M6 Closed End Nut* M3-M10 M3-M8 M4-M6 Hexagonal Nut* M4-M8 M4-M8 M4-M6 Tetra Nut* M4-M8 M4-M8 HB Bolt* M6-M8 M6-M8 Pipe Nut* M6 M6 -

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2.3. Main components list

ref  g. 1 & 2 Re-order Spare part numbers Qty

1 Mandrel

M4 07555-09004 1 M5 07555-09005 1 M6 07555-09006 1 M8 07555-09008 1

2 Nose Tip

M4 07555-00904 1 M5 07555-00905 1 M6 07555-00906 1

M8 07555-00908 1 3 Lock Nut - 07555-00901 1 4 Nose Casing - 74202-02021 1 5 Chuck Nut - 74202-02022 1

6 Reducing Sleeve

M4 07555-09104 1

M5 07555-09105 1

M6 07555-09106 1

M8 07555-09108 1

7 Drive Shaft

M4 07555-01004 1

M5 07555-01005 1

M6 07555-01006 1

M8 07555-01008 1 8 Mandrel Adaptor - 74202-02023 1 9 Nose Rod - 74202-02039 10 Suspension Ring - 74202-02012 1 11 Stroke Slider - 74202-02092 1 12 Stroke Indication Markings - - 13 Stroke Locking Pin - 74202-02095 1 14 Stroke Setter - 74202-02010 1 15 Stroke Setter Recess - - 16 Air Inlet Assembly - 74202-02103 1 17 Manual Reverse Trigger - 74202-02030 1 18 Regulator Lock - 74202-02038 1 19 Pressure Regulator - 74202-02037 1 20 Trigger - 74202-02020 1 21 Pin Punch - 07900-00624 1

Complete nose assembly

M4 07555-09884

M5 07555-09885

M6 07555-09886

M8 07555-09888

* All sizes are supplied with Lock Nut (3) 07555-00901.

For additional sizes please visit www.StanleyEngineeredFastening.com

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3. Tool Setup

IMPORTANT - READ THE SAFETY RULES ON PAGE 6 & 7 CAREFULLY BEFORE PUTTING INTO SERVICE.

Before Use

• Select relevant size nose equipment and install.

• Connect the placing tool to the air supply. Test pull and return cycles by depressing and releasing the

trigger 20.

• Set the tool for desired stroke/pressure.

CAUTION - correct supply pressure is important for proper function of the installation tool. Personal injury or damage to equipment may occur without correct pressures. The supply pressure must not exceed that listed in the placing tool speci cation.

4. Operating Instructions

IMPORTANT - READ THE SAFETY RULES ON PAGE 6 & 7 CAREFULLY BEFORE PUTTING INTO SERVICE.

IMPORTANT - THE AIR SUPPLY MUST BE TURNED OFF OR DISCONNECTED BEFORE FITTING OR

REMOVING THE NOSE ASSEMBLY.

4.1 Nose Equipment (see Fig.2).

Fitting Instructions

Item numbers in bold refer to nose assembly components in  g 1.

• Air supply must be disconnected.

• If still  tted, remove the Nose Casing 4 and the Chuck Nut 5,while pulling back the spring loaded Nose Rod 9. •

• Insert Drive Shaft 7 into Mandrel Adaptor 8.

• Fit Mandrel 1 onto Drive Shaft 7.

• Insert Reducing Sleeve 6 (if speci ed) into the Chuck Nut 5.

• Screw the Chuck Nut 5 onto the Mandrel Adaptor 8 while pulling back the spring loaded Nose Rod 9. Tighten the Chuck Nut 5 clockwise.

• While holding the Tool, screw on the Nose Casing 4 and Nose Tip 2 with the nose tip Lock Nut 3.

• The reverse operation is carried out for equipment removal.

With the tool still disconnected from the air supply, screw a Blind Rivet Nut onto the Mandrel manually.

• Position Nose Tip 2 on the Nose Casing 4 and lock it with Lock Nut 3 so that the Mandrel 1 protrudes slightly beyond the insert.

• Lock the Lock Nut 3 by turning clockwise with a spanner*. Remove the Blind Rivet Nut from Mandrel.

*Refer to items included in the Maintenance Kit 07900-09301 page 13.

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4.2 Air Supply

• All tools are operated with compressed air at an minimum pressure of 5.0 bar.

• Pressure regulators and automatic oiling/ ltering systems to be used on the main air supply within 3 metres of the tool (see  g. 4).

• Air supply hoses will have a minimum working e ective pressure rating of 150% of the maximum pressure produced in the system or 10 bar, whichever is the highest.

• Air hoses must be oil resistant, have an abrasion resistant exterior and be armoured where operating conditions may result in hoses being damaged.

• All air hoses MUST have a minimum bore diameter of 6.4 millimetres.

LUBRICATOR

PRESSURE REGULATOR AND

FILTER DRAIN DAILY

STOP COCK

USED DURING MAINTENANCE

OF FILTER/REGULATOR OR

LUBRICATION UNITS

MAIN SUPPLY

3 METRES MAXIMUM

If above system is not available you can use the following alternative:

• Before use or when  rst 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  tted 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 must be replaced by new items.

• If there is no  lter on the pressure regulator, bleed the air line to clear it of accumulated dirt or water before connecting air hose to the tool.

4.3 Setting Instructions

• The stroke adjustment feature is mainly used for smaller insert sizes M3-M4.

• If you are setting the tool for optimum stroke the Stroke Setter should be wound in to minimum stroke (3mm) and the Pressure Regulator 19 be wound in to maximum setting.

• If you are setting the tool for optimum pressure the Stroke Setter should be wound out to maximum stroke (7mm) and the Pressure Regulator 19 be wound out to minimum setting.

When dealing with di erent grip thicknesses, it is always recommended that the tool is set for optimum pressure rather than optimum stroke. Use the maximum grip condition to set optimum pressure.

Fig. 4

1/4" GAS

CONNECTION

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4.3.1. Stroke Adjustment (see Fig. 1A & 3).

To use this tool in stroke set operation, screw the Pressure Regulator 19 fully in to achieve full pressure then adjust Stroke Setter to the desired stroke length:

• Open Stroke Slider 11.

• The Stroke Locking Pin 13 will be released.

• Directional arrows indicate stoke direction.

• Increase the stroke from the minimum until optimum deformation is obtained.

• The scale gives an indication of the current stroke length.

• Increments 12 shown are 3, 5 and 7mm on one side and 4 and 6mm on the opposite.

• Line the rear of the Stroke Setter 14 up with these marks to achieve desired stroke length.

• Each Recess 15 on the Stroke Setter 14 is equal to +- 0.1mm of stroke.

• Close the Stroke Slider 11 before using in the application environment.

• The Stroke Lock will activate when the Stroke Slider 11 is closed when the tool is in the upright position

• The tool is now ready to operate.

4.3.2. Pressure Adjustment (see Fig. 1B & 3).

To use this tool in pressure set operation, wind the Stroke Setter 14 to 7mm, then screw the Pressure Regulator 19 fully out to achieve minimum pressure then adjust to the desired pressure:

• Initially the Blind Rivet Nut will not deform and the tool will spin o .

• Screw in the Pressure Regulator 19 by 1 groove on the regulator body and test.

• Repeat the operation with the Pressure Regulator 19 until optimum deformation is obtained.

• 1 notch on the Pressure Regulator 19 is equivalent to approximately 20N of pulling force.

• After a successful Blind Rivet Nut deformation, check the Blind Rivet Nut and increase the force if necessary.

• Increase by 1-2 notches extra to allow for variation in the Blind Rivet Nuts.

• The tool is now ready to operate.

5. Operating Procedure

Installing a Blind Rivet Nut (see Fig. 3).

To install a Blind Rivet Nut.

• Check that the correct Blind Rivet Nut has been selected.

• Push Blind Rivet Nut into the application.

• Check Nose Assembly is at right angle (90°) to the work.

• Push onto the Blind Rivet Nut with the tool to spin on.

• Once fully and correctly inserted, depress tool Trigger 20 switch to start installation cycle.

• Hold the Trigger 20 until the Blind Rivet Nut is completely set and the tool has disengaged completely.

In the event a Blind Rivet Nut becomes jammed in an application press the Manual Reverse Trigger 17 to reverse the Mandrel 1 and spin o the Blind Rivet Nut. Alternately disconnect from the air supply and use the 4mm Pin Punch 21 supplied in the Maintenance Kit to wind o the Mandrel through the Nose Casing 4 shown in the  gure 1.

CAUTION - do not attempt to force the installation of an insert as this will cause damage to the tool and/or application.

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6. Servicing the Tool

Regular servicing must be carried out by trained personnel and a comprehensive inspection performed annually or every 500,000 cycles, whichever is sooner.

Cleaning and Maintenance

DISCONNECT AIR SUPPLY

Nose assemblies should be serviced at weekly intervals or every 5,000 cycles

CAUTION - Blow dirt and dust out of the main housing with dry air as often as dirt is seen collecting in and around the air vents where the Pneumatic Cylinder connects to the plastic Handle Assembly. Wear approved eye protection and approved dust mask when performing this procedure. 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.

• Disconnect the air supply

• Remove the complete nose assembly using the reverse procedure to the Fitting Instructions page 10(4.1).

• Any worn or damaged part must be replaced by a new part.

• Particularly check wear on Mandrel.

• Assemble according to  tting instructions.

6.1 Daily Servicing

• Check for air leaks. If damaged, hoses and couplings must be replaced by new items.

• Check that the Nose Assembly is correct and  tted properly.

• Check if the stroke of the tool is adequate to place selected Blind Rivet Nut. See Stroke Adjustment page 12 (4.3.1.).

• Inspect the Mandrel 1 in the nose assembly for wear or damage. If any, replace.

6.2 Weekly Servicing

• Check for oil leaks and air leaks on air supply hose and  ttings and tool.

• With the tool laid horizontally, open “Oil Plug” and check oil level, if low re-prime, refer to “Service manual, Section 6”.

For full servicing, troubleshooting and maintenance instructions please refer to Service Manual 07900-09302.

Maintenance Kit 07900-09301

Part Number Description Qty 07900-00624 4mm Pin Punch 1 07900-00632 17mm/19mm Spanner 1 07900-00225 5mm Hexagonal Wrench 1

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7. Declaration of Conformity

We, Avdel UK Limited, Stanley House, Works Road, Letchworth Garden City, Hertfordshire,

SG6 1JY UNITED KINGDOM, declare under our sole responsibility that the product:

Description ProSertTM XTN20 Hydro-Pneumatic Blind Rivet Nut Tool Brand/Model POP-Avdel 74202 Serial No.

to which this declaration relates is in conformity with the following standards:

ISO 12100:2010 EN ISO 28927-5:2009 EN ISO 11202:2010 EN ISO 3744:2010 EN ISO 4413:2010 EN ISO 11148-1:2011 EN ISO 4414:2010 EN 28662-1: 1993

Technical documentation is compiled in accordance with Annex 1, section 1.7.4.1,

in accordance with the following Directive:

2006/42/EC The Machinery Directive

UK Statutory Instruments 2008 No 1597 - The Supply of Machinery (Safety) Regulations refers.

A. K. Seewraj

Technology Manager – EU Blind Fastening

Avdel UK Limited, Stanley House, Works Road, Letchworth Garden City,

Hertfordshire, SG6 1JY UNITED KINGDOM

Place of issue: Letchworth Garden City

Date of issue: 01-04-2015

This machinery is in conformity with

Machinery Directive 2006/42/EC

Original Instruction

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8. Protect your Investment!

POP®Avdel® BLIND RIVET NUT 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  rst 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 Modi cation.

Defects or damages resulting from service, testing adjustment, installation, maintenance, alteration or modi cation 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  tness 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 POP®Avdel®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.

To register your warranty online, visit us

http://www.stanleyengineeredfastening.com/popavdel-powertools/warranty-card

Thank you for choosing an STANLEY Engineered Fastening’s POP®Avdel® Brand tool.

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Stanley ProSert XTN20 74202 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual