Applifast AirPower Series Operating instructions

Repair Manual
AirPower4
Model Z-14026001
Hydraulic Threaded Insert Tool

- 1 -
Repair manual
-specified for riveting tools series 4 (AirPower 4, EZM4000, E-412NA, AS4)
Content:
1. Abbreviations
2. General instructions
3. Proper function of riveting tool
4. Assembly drawing of riveting tool
5. nformative list of parts of riveting tool
6. nstructions for assembling and disassembling – steps 1-19
7. nstructions for assembling and disassembling of chosen sub-assemblies – steps 20-25
8. List of defects of riveting tool
9. Description of defects and their remedies
10. Service set
11. List of special tools (assembly jigs) into the service set
1. Abbreviations:
CA - compressed air
MP - special tool (assembly jig)
D - defect
BEM - basic engine monitoring
2. General instructions:
1. Riveting tool is always deconnected from the compressed air, unless otherwise stated
2. All threads are clockwise
3. Riveting tool is gripped in a stand (see chapter 10) while assembling and disassembling, unless
otherwise stated
4. Before assembling, wash the disassembled parts in degreasing solution and insufflate with
compressed air, wipe with a cloth
5. While assembling, lubricate the sealing (O-rings, pneumatic seals) and related opposite surfaces
with oil MOGUL LV 2-3, unless stated otherwise

- 2 -
3. Proper function of riveting tool:
Operator activity Tool function
Connect the riveting tool to CA, if the tool is
equiped with main valve, turn it on. Pos. 74 is on
the front extreme position, not pressed
CA does not leak, motor does not rotate
Put a rivet on pos. 1 and press towards the
riveting tool, the rivet screws on
Motor turns right, outlet of CA through the outlets in
pos. 39
The action is ready when the rivet is completely
screwed on
Motor turns off , front of the rivet touches front of the
pos. 3. CA does not leak
Press with hand pos. 39, the rivet screws out Motor turns right , outlet CA through the outlets in
pos. 39
Release pos. 39, screwing out stops Pos. 39 gets back to the initial position, motor turns
off, air does not leak
Turn with stroke adjustement. Further
instructions are in the Operations manual
The scale moves (left +stroke, right -stroke, point of
view from pos. A23), pos. 3 springs
Put a rivet on pos. 1 and press towards the
riveting tool, the rivet screws on
Motor turns right, outlet of CA through the outlets in
pos. 39, when the rivet is completely screwed on the
motor turns off
Press pos. 74, the rivet is riveted in t the extreme stroke is not set, the rivet and pos. 1
and pos. 3 move simultaneously, the lenght of the
movement is cca 6.5mm, CA does not leak
Stop pressing pos. 74, the rivet completely
screws out
CA outles from the space pos. A47 and pos. 1 and pos.
3 get back, the motor turns, outlet of CA throuh the
outlets ins pos. 39, in the end motor stops itself, CA
does not leak

- 3 -
. Assembly drawing of riveting tool:

- 4 -
5. Informative list of spare parts of riveting tool:
Po
sition
Article Nr.
Name of part
Pcs
1
D
-
14001XX
Mandrel
s
1
3
S
-
14003XX
Anvil
s
complete
1
6
D
-
1400400
Joint s
leeve
1
7
D
-
1400500
Counternut
1
8
D
-
1401000
Joint shaft
1
9
S
-
1400600
Front nozzle compl
ete
1
0901
D
-
1400610
Front nozzle body
1
0902
D
-
1400620
Front nozzle with scale
1
0903
D
-
1400630
Front nozzle pin
2
0904
D
-
1400640
Adjusting nut
1
0905
D
-
1400650
Washer
1
0906
N
-
1500000010005
Compression spring 2x27x40x4,5
1
0907
D
-
1400670
C
overing sleeve
1
0908
D
-
1400680
Retained ring
1
0909
D
-
1400690
Spring
1
0910
N
-
3600000000005
Steel ball dia. 4,5
1
10
N
-
2103702400150
O
–
ring
24/1,5 Sh 70
1
A23
S
-
1407700
Hydraulic body
1
16
D
-
1100800
Hanger
1
A2
S
-
1400900
Hydraulic p
iston complete
1
20
D
-
1406200
Guiding band
1
A25
S
-
1407000
Motor complete
1
23
D
-
1406600
Pneumatic s
eal
35
x28x4,5
1
24
S
-
1405000
Motor
1
27
N
-
2103703000200
O
-
ring
30/2 Sh 70
1
25
N
-
2103704200150
O
-
ring
42/1,5 Sh 70
1
26
D
-
14040
00
Rear screwing
1
28
D
-
1404100
Nut
1
29
N
-
3600000000003
Steel ball 5
4
31
D
-
00220600
Spring D10
1
A35
S
-
1404300
Nut
complete
1
28
D
-
1404100
Nut
1
30
N
-
3704900208050
Permanent magnet 20x8x5
1
32
D
-
1404200
Sleeve
1
33
D
-
1404300
Sleeve of
permanent magnet
1
34
D
-
1404800
Cover of permanent magnet
1
35
S
-
1404400
Pin complete
1
36
D
-
08411500
Spring
1
37
D
-
1404500
Bush for pin
1
38
D
-
1404600
Rear body
1
39
D
-
1404700
Push button
1
A36
S
-
1407800
nsert PP complete
1
40
N
-
2
103901000200
O
-
ring
10/2 Sh 90
1
41
S
-
1401800
nsert PP
1
42
N
-
2104001800220
O
-
ring
18/2,2
1
A39
S
-
1101900
Valve piston complete
1
A 0
S
-
1102000
Valve body complete
1
7
N
-
2406696500090
Plastic ball 9
1
A 1
S
-
1102100
Valve bottom
1
50
N
-
1000798408200
Screw
M8x20 D N 7984
2
A 7
S
-
1
4
0230
5
Air supply ring complete
1
52
N
-
2103706000200
O
-
ring
60/2 Sh 70
1
53
N
-
2103706300200
O
-
ring
63/2 Sh 70
1
54
D
-
110230
5
Air supply ring
1
67
S
-
110320
3
Aircoupling
1
A43
S
-
110321
3
A
ircoupling
body
complete
1
A44
S
-
110322
1
A
ircoupling
rotary part
complete
1
6705
N
-
140
2292500012
Retaining ring
1
55
D
-
110240
3
Body bottom
1
59
D
-
1402700
P
neumatic piston
1
60
N
-
2103900400150
O
-
ring
4/1,5 Sh 90
1
61
N
-
10000912
04080
Screw
M4x8 D N 912
1
A 5
S
-
1402801
Pneumatic piston complete
1
62
D
-
1402801
Pneumatic piston
1
63
N
-
2300007140000
Pneumatic seal 14
1
64
D
-
1106400
Pneumatic seal
70x60x4,5
1
65
D
-
1103001
Pneumatic cylinder
1
66
D
-
1403100
Tube
1
68
N
-
2103700700200
O
-
ring
7/2 Sh 70
1
69
N
-
2103700400150
O
-
ring
4/1,5 Sh 70
1
A 6
S
-
1103300
Trigger body complete
1
73
D
-
1103400
Trigger piston
1
7
D
-
110350
0
Trigger
1
76
D
-
1103800
Pin
1
79
D
-
1103600
Nut of body
1
80
D
-
1103
700
Soft sleeve
1
8
1
N
-
1000091404050
Screw M4x5 imbus D N 914
1

- 5 -
6. Instructions for assembling and disassembling – steps 1-19:
Step 1
Disassembly:
Put MP14 on pos. 80, loosen and screw out pos. 65 and pos. 80.
Assembly:
Screw on pos. 65 with pos. 80, put on MP14, tighten and put coloured warranty plug. n case of
using new parts pos. 65 and pos. 80 the process is different, at first screw on pos. 65, put MP14
on, tighten and put coloured warranty plug. Then apply glue PATTEX EXPRESS F X PL600 on pos.
65, put on pos. 80 by circular motion and position it according to the picture. .

- 6 -
Step 2
Disassembly:
Release pos. A45.
Assembly:
Put on pos. A45.

- 7 -
Step 3
Disassembly:
Put MP15B on pos. 59, then press MP15B with pliers , screw out pos. 61 with imbus key nr. 3 and
take out pos. 60 and pos. 59. Then pour out the hydraulic oil from the riveting tool to the suitable
container.
Assembly:
Pour hydraulic oil KERN TE GM SO 32 in to pos. A36, oil level up to 2. sealing in pos. A36.
Lubricate the external surface of the pos. 59 with silicon paste LUKOSAN, put pos. 59 in pos A36 -
range about 68 mm, screw on MP19 tightly to the stop position, screw on MP13 (filled with
hydraulic oil) to the pos. 59. Then repeatedly press and release the piston MP13 until air bubbles
stop leaking from the hydraulic system to MP13. MP13 must be always filled with hydraulic oil, if
not fill it. After filling the hydraulic system of the riveting tool with hydraulic oil, screw out MP13
and MP19. Put pos. 60 on pos. 61 and screw it on to pos. 59 with imbus key nr. 3. Put MP15B on
pos. 59, then press MP15B with pliers and retighten pos. 61 with imbus key nr. 3. Take off MP15B.

- 8 -
Step 4
Disassembly:
Put MP11 to the locks pos. 79, divert pos. 66 from MP11 (because the surface of pos. 66 might be
damaged) and screw out pos. 79.
Assembly:
Screw pos. 79 on thread pos. A36, put MP11 on locks pos. 79, divert pos. 66 from MP 11 (because
the surface of pos. 66 might be damaged). Retighten pos. 79.

- 9 -
Step 5
Disassembly:
Screw out pos. 50 (2x) with imbus key nr. 5, put out pos. 55 with pos. 66, 68, 69 and pos. A47 with
pos. 67. Put pos. 66 with pos. 68 out., take pos. 69 out with MP32, be careful and do not damage
recess in pos. 55. Put pos. 55 out of pos. A47.
Assembly:
Put pos. 55 on pos. A47, insert pos. 66 to pos. 55. Lubricate recess in pos. 55 and insert in pos. 68
and pos. 69 and check the proper placing of pos. 68 and 69. Put pos. A47 with pos. 67, 68, 69 and
pos. 55 on pos. A23, screw on pos. 50 (2x) and tighten with imbus key nr. 5.

- 10 -
Step 6
Disassembly:
Put the blow gun on the outlet (see the detail) and release a small amount of CA, pos. A39, A40
and A41 blow out off the pos. A23, it is necessary to catch them (e.g. to the cloth).
Assembly:
nser pos. A39 into pos. A40 and insert this complet into pos. A23. nsert pos. 47 into pos. A40, put
on pos. A41 and press to the strop to pos. A23.
! Do not lubricate pos. 47 !

- 11 -
Step 7
Disassembly:
Loosen pos. A36 with MP33 key, screw out and put out from pos. A23.
Assembly.
Check the sealing of pos. 40 (see Step 22). Put pos. A36 on pos. A23, screw on and tighten with
MP33 key.
! Check the proper position of the sealing!

- 12 -
Step 8
Disassembly:
Screw out pos. 81 with imbus key nr. 2. Screw out pos. 38 with hand, put out pos. 39 and take out
pos. 31.
Assembly:
Put pos. 31 on pin pos. 39, put pos. 39 on pos. 38 and screw on this complete. Screw on pos. 81
and slightly tighten with imbus key nr. 2.
Put coloured warranty plug on pos. 38 and pos. 81.
! Be careful about proper mounting of pos. 31 to pos. 39 !

- 13 -
Step 9
Disassembly:
Take out pos. 29 (4x) with the help of MP32. Screw out pos. A35 with wrench 30.
Assembly:
Put on pos. A35 and tighten pos. A35 with wrench 30. Lubricate outlets in pos. A35 with vaseline
and press pos. 29 (4x) into outlets.

- 14 -
Step 10
Disassembly:
Screw out pos. 26 with hook spanner 30-32 and put out pos. 25
Assembly:
Put pos. 25 on pos. 26 and srew this comlete into pos. A23. Then tighten pos. 26 with hook
spanner 30-32.

- 15 -
Step 11
Disassembly:
Put out pos. A25
Assembly:
Put on pos. A25 and move around a slight amount so that hexagon pos. A25 and pos. 8 match,
then move pos. A25 to the stop. Turn pos. 1 to check if the installation was successful, rotation in
pos. A25 must be obvious and audible.

- 16 -
Step 12
Disassembly:
Screw out pos. 3 and pos. 1
Assembly:
Screw pos. 1 on pos. 6 to the stop and move back a slight amount, so that hexagon pos. 1 and pos.
6 match. Put pos. 3 on pos. 1 and pos. 6, so that hexagon socket pos. 3 match with hexagon pos. 1
and pos. 6, screw on to pos. 9. Tighten the backnut in pos. 3 to the front of pos. 9.

- 17 -
Step 13
Disassembly:
Screw out pos. 9 with wrench 24 and put out pos. 10 with MP32.
Assembly:
Put pos. 10 on pos. 9, screw on pos. 9 and tighten with wrench 24.

- 18 -
Step 14
Disassembly:
Put wrenches 12 (2x) on pos. 6 and pos. 7, loosen and screw out pos. 6, put hex key on pos. 8 and
from the side of the dart screw out pos. 7.
Assembly:
Screw pos. 7 on pos. 8 (recess in direction to pos. A24) so that the lenght between pos. 7 and pos.
A24 is 1 mm (see the detail). Put several drops of glue LOCT TE 243 on thread pos. 8, screw on pos.
6, screw wrenches 12 (2x) on pos. 6 and pos. 7 and tighten towards pos. 7.

- 19 -
Step 15
Disassembly:
Put pos. 8 out of pos. A24 in the direction of the dart.
Assembly:
Put pos 8 on to pos. A24.