Avdel 74201 User manual

Threaded Insert Power Tool
74201
Instruction Manual
Original Instruction

3
Contents
LIMITED WARRANTY
Avdel makes the limited warranty that its products will be free of defects in workmanship and materials
which occur under normal operating conditions. This Limited Warranty is contingent upon: (1) the product
being installed, maintained and operated in accordance with product literature and instructions, and (2)
confirmation by Avdel of such defect, upon inspection and testing. Avdel makes the foregoing limited
warranty for a period of twelve (12) months following Avdel’s delivery of the product to the direct purchaser
from Avdel. In the event of any breach of the foregoing warranty, the sole remedy shall be to return the
defective Goods for replacement or refund for the purchase price at Avdel’s option. THE FOREGOING
EXPRESS LIMITED WARRANTY AND REMEDY ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES
AND REMEDIES. ANY IMPLIED WARRANTY AS TO QUALITY, FITNESS FOR PURPOSE, OR MERCHANTABILITY
ARE HEREBY SPECIFICALLY DISCLAIMED AND EXCLUDED BY AVDEL.
Avdel UK Limited policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice.
Safety Rules 4
Specifications
Tool Specification 5
Tool Dimensions 5
Intent of Use 6
Putting into Service
Air Supply 7
Force Adjustment 7
Operating Procedure 7
Nose Assemblies
Fitting Instructions 8
Servicing Instructions 8
Selection 9
Servicing the Tool
Daily / Weekly 10
Molykote®55m Lithium Grease Safety Data 10
Service Kit 11
Maintenance
Tool Servicing 12
Pneumatic Cylinder 12
Rod Guide 12
Trigger 12
Swivel Air Inlet 12
Differential Valve 13
Head Assembly 13
Rear Casing 13
Distributor 13
Hydraulic Piston and Air Motor Assembly 13
General Assembly of Base Tool
General Assembly of Base Tool 74201 - 12000 14
Parts List for 74201 - 12000 15
Pressure Switch Assembly 16
Pressure Switch Removal 16
Priming
Oil Details 17
Hyspin®VG 32 Oil Safety Data 17
Priming Procedure 17
Fault Diagnosis
Symptom, Possible Cause and Remedy 18-19

4
Safety Rules
1Do not use outside the design intent.
2Do not use equipment with this tool/machine other than that recommended and supplied by Avdel UK Limited.
3Any modification undertaken by the customer to the tool/machine, nose assemblies, accessories or any equipment supplied by
Avdel UK Limited or their representatives, shall be the customer’s entire responsibility. Avdel UK Limited will be pleased to advise
upon any proposed modification.
4The tool/machine must be maintained in a safe working condition at all times and examined at regular intervals for damage and
function by trained competent personnel. Any dismantling procedure shall be undertaken only by personnel trained in Avdel UK
Limited procedures. Do not dismantle this tool/machine without prior reference to the maintenance instructions. Please contact
Avdel UK Limited with your training requirements.
5The tool/machine shall at all times be operated in accordance with relevant Health and Safety legislation. In the U.K. the “Health
and Safety at Work etc. Act 1974” applies. Any question regarding the correct operation of the tool/machine and operator safety
should be directed to Avdel UK Limited.
6The precautions to be observed when using this tool/machine must be explained by the customer to all operators.
7Always disconnect the air line from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly.
8Do not operate a tool/machine that is directed towards any person(s) or the operator.
9Always adopt a firm footing or a stable position before operating the tool/machine.
10 Ensure that vent holes do not become blocked or covered.
11 The operating pressure shall not exceed 7 bar.
12 Do not operate the tool if it is not fitted with a complete nose assembly or swivel head unless specifically instructed otherwise.
13 Care shall be taken to ensure that spent stems are not allowed to create a hazard.
14 If the tool is fitted with a stem collector, it must be emptied when half full.
15 If the tool is fitted with a stem deflector, it should be rotated until the aperture is facing away from the operator and other
person(s) working in the vicinity.
16 When using the tool, the wearing of safety glasses is required both by the operator and others in the vicinity to protect against
fastener ejection, should a fastener be placed ‘in air’. We recommend wearing gloves if there are sharp edges or corners on the
application.
17 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool which should
be kept dry and clean for best possible grip.
18 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent start up.
19 Excessive contact with hydraulic fluid oil should be avoided. To minimize the possibility of rashes, care should be taken to wash
thoroughly.
20 C.O.S.H.H. data for all hydraulic oils and lubricants is available on request from your tool supplier.
This instruction manual must be read with particular attention to the following safety rules, by any person
installing, operating, or servicing this tool.

Tool Specification
Tool Dimensions
Specifications
5
Air Pressure Minimum - Maximum 5-7 bar (75-100 lbf/in2)
Free Air Volume Required @ 5 bar/75 lbf/in27.5 litres (0.26 ft3)
Stroke Maximum 7 mm (0.276 in)
Motor Speed Spin On 2000 rpm
Spin Off 2000 rpm
Pull Force @ 5 bar/75 lbf/in217.65 kN (3967.20 lbf)
Cycle Time Approximately 2.5 seconds
Noise Level Less than 75 dB(A)
Weight Without nose equipment 2.1 kg (4.63 lb)
Vibration Less than 2.5 m/s2(8 ft/s2)
Placing Features Inserts M3 - M8
100Ø
3.94Ø
1/4 GAS
295
11.61
11.81
300
45Ø
1.77Ø
25Ø
0.98Ø
Dimensions shown in bold are millimetres. Other dimensions are in inches.

6
Intent of Use
The 74201 hydro-pneumatic tool is designed for placing Avdel®threaded inserts and is ideal for batch or flow-line assembly in a wide
variety of applications throughout all industries.
The tool works on the principle of adjustment of the force rather than the stroke. The advantage lies in the fact that it is possible to
place the same insert (of the specified tightening thickness) in materials of different thicknesses, after setting the tool for the greatest
thickness.
The tool is available in the basic configuration using code 74201-12000. In addition there are nose assembly kits available to match
the type and size of the insert which is to be placed. (see selection tables on page 9). The tables also give the complete tool code
(basic tool plus nose assembly kits).
Nose assemblies must be fitted as described on page 8.

•Connect the tool to the air supply. Adjust the pull force.
•Offer up insert, lip first, to the drive screw. A slight pressure on the trigger will start the motor and automatically thread the insert
up against the nose tip and stop.
•Insert fastener squarely into application.
•Fully depress the trigger. This will both place the insert into the application and disengage it from the drive screw.
Do not connect the tool to the air supply until all the components are in place, as indicated in the drawing on page 14.
Item numbers in bold refer to the General Assembly drawing and Parts List (pages 14-15).
Air Supply
Force Adjustment
Operating Procedure
Putting into Service
7
All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and
automatic cooling/filtering systems on the main air supply. These should be mounted within 3 metres of the tool (see diagram below) to
ensure maximum tool life with minimum tool maintenance.
The flexible hoses should have a minimum effective working pressure rating of 150% of the maximum pressure produced in the system
or 10 bar, whichever is the highest. Air hoses should be oil resistant, have an abrasion resistant exterior and should be armoured
where operating conditions may result in hoses being damaged. All air hoses MUST have a minimum bore diameter of 6.4 millimetres
or 1/4inch.
Read servicing daily details page 10.
8
6
4
2
0
10
12
14
16
TAKE OFF POINT
FROM MAIN SUPPLY
STOP COCK
(USED DURING MAINTENANCE
OF FILTER/REGULATOR
OR LUBRICATION UNITS)
MAIN SUPPLY
DRAIN POINT
PRESSURE REGULATOR
AND FILTER
(DRAIN DAILY)
3
M
E
T
R
E
S
M
A
X
I
M
U
M
AIR LUBRICATION
PERMISSABLE
Allen
Key
After fitting the appropriate nose assembly for the insert to be placed,
connect the tool to the air supply hose.
Using the 3mm allen key, unscrew the Regulator 93* a few turns until
pressing the Trigger 40 produces no pull on the spindle.
To confirm this, screw an insert onto the spindle and press the trigger. The
insert will not deform and the tool will begin to spin off.
To adjust the pull force, screw in the Regulator 93*approximately half a turn
and repeat the operation with the same insert (for each trial operation, screw
in the Regulator 93* until deformation of the insert takes place without any
change in thickness). When this stage is reached, this will be the minimum
force required to deform the insert .
After a successful trial insert deformation, check the thickness and increase
the force if the insert is not sufficiently formed.
Usually, this last adjustment requires a slight increase in the tightening of
Regulator 93*.
The tool is now ready to operate.
When dealing with different thicknesses, set it for the greatest thickness.
93* See page 16 Pressure Switch Assembly.

8
Fitting Instructions
Servicing Instructions
Nose Assemblies
It is essential that the correct nose assembly is fitted prior to operating the tool. If you know the code for your complete, original tool,
or the details of the fastening systems which are to be used, you will be able to order a new complete nose assembly using the
selection tables on page 9.
IMPORTANT
The air supply must be disconnected when fitting or removing nose assemblies
unless specifically instructed otherwise.
IMPORTANT
Do not press against the drive screw when tool is connected to the air supply with no
insert in as the drive screw will start to run axially.
Nose assemblies should be serviced at weekly intervals (see page 10).
•Remove the complete nose assembly using the reverse procedure to the ‘Fitting Instructions’.
•Any worn or damaged parts should be replaced with new parts.
•Particularly check wear on the Drive Screw 3.
•Assemble according to fitting instructions (see above).
* Refers to items included in the 74200 Service Kit. For complete list see page 11.
Item numbers in bold refer to illustration below:
•If still fitted, remove the nose casing and the adaptor nut.
•Insert Drive Shaft 4into spindle.
•Fit Drive Screw 3onto Drive Shaft 4.
•Insert Reducing Sleeve 5(if specified) into the adaptor nut.
•Screw the adaptor nut onto the spindle.
•Hold the spindle with a spanner* and tighten the adaptor nut clockwise.
•While holding the adaptor nut with the spanner*, tighten the lock nut anti-clockwise.
•Screw on the nose casing and Nose Tip 1with the nose tip Lock Nut 2.
•The reverse operation is carried out for equipment removal.
1
2
3
5
SPINDLE
LOCK NUT
ADAPTOR NUT NOSE CASING
4
Items in grey are included in the base tool.
Items in black make up the nose assembly.
•With the tool still disconnected from the air supply, screw an insert onto the drive screw manually. Position Nose Tip 1on the nose
casing and lock it with Lock Nut 2so that the insert lines up with the end of Drive Screw 3.
•Lock the nose tip lock nut by turning clockwise with a spanner*.
•Remove the insert from drive screw.

9
Nose Assemblies
Nose tips vary in shape according to the insert type. Each nose assembly represents a unique assembly of components which can be
ordered individually. All nose assemblies also include a nose tip Lock Nut 2 (part number 07555-00901). Component numbers
refer to the illustration on the opposite page. We recommend holding some stock of internal components as items will need regular
replacement. Read the Nose Assemblies Servicing Instructions opposite carefully.
74201-00083
74201-00084
74201-00085
74201-00485
74201-00086
74201-00088
74201-00054
74201-00056
74201-00058
74201-00050
74201-00048
74201-00040
74201-00070
74201-00068
74201-00060
74201-00016
74201-00018
LARGE FLANGE INSERTS (9698,FS58,9408,9418,9498) + STANDARD NUTSERT®(9500) + SQUARESERT®(GK08) + EUROSERT®(GJ08)
74201-00183
74201-00184
74201-00185
74201-00186
74201-00188
74201-00154
74201-00156
74201-00158
74201-00150
74201-00148
74201-00170
74201-00168
74201-00160
74201-00116
74201-00118
74201-00130
74201-00132
74201-00134
M3
M4
M5
M6
M8
4 UNC
6 UNC
8 UNC
10 UNC
1/4UNC
10 UNF
1/4UNF
5/16 UNF
3
/ 16 BSW
1
/4BSW
0BA
2BA
4BA
THIN SHEET NUTSERT®(9468, FS38, 9650, 9488 )
74201-00283
74201-00284
74201-00285
74201-00286
74201-00288
74201-00258
74201-00250
74201-00248
74201-00278
74201-00270
74201-00268
M3
M4
M5
M6
M8
8 UNC
10 UNC
1/4UNC
8 UNF
10 UNF
1/4UNF
SUPERSERT®- OPEN AND CLOSED END ( FB )
74201-00683
74201-00684
74201-00685
74201-00686
74201-00688
M3
M4
M5
M6
M8
07555-00903
07555-00904
07555-00905
07555-00915
07555-00906
07555-00908
07555-00854
07555-00856
07555-00858
07555-00850
07555-00848
07555-00840
07555-00850
07555-00848
07555-00840
07555-00850
07555-00848
07555-00993
07555-00994
07555-00995
07555-00996
07555-00998
07555-00954
07555-00956
07555-00958
07555-00950
07555-00948
07555-00950
07555-00948
07555-00940
07555-00950
07555-00948
07555-00996
07555-00950
07555-00934
07555-07103
07555-07104
07555-07105
07555-07106
07555-07108
07555-07158
07555-07150
07555-07148
07555-07158
07555-07150
07555-07148
07555-08103
07555-08104
07555-08105
07555-08106
07555-00998
07555-09003
07555-09004
07555-09005
07555-09005
07555-09006
07555-09008
07555-09054
07555-09056
07555-09058
07555-09050
07555-09048
07555-09040
07555-09070
07555-09068
07555-09060
07555-09016
07555-09018
07555-09003
07555-09004
07555-09005
07555-09006
07555-09008
07555-09054
07555-09056
07555-09058
07555-09050
07555-09048
07555-09070
07555-09068
07555-09060
07555-09016
07555-09018
07555-09030
07555-09032
07555-09034
07555-09003
07555-09004
07555-09005
07555-09006
07555-09008
07555-09058
07555-09050
07555-09048
07555-09078
07555-09070
07555-09068
07555-09003
07555-09004
07555-09005
07555-09006
07555-09008
07555-01003
07555-01004
07555-01005
07555-01005
07555-01006
07555-01008
07555-00754
07555-00756
07555-00758
07555-00750
07555-00748
07555-00740
07555-00750
07555-00748
07555-00740
07555-00750
07555-00748
07555-01003
07555-01004
07555-01005
07555-01006
07555-01008
07555-00758
07555-00750
07555-00748
07555-00758
07555-00750
07555-00748
07555-01003
07555-01004
07555-01005
07555-01006
07555-01008
07555-09103
07555-09104
07555-09105
07555-09105
07555-09106
07555-09108
07555-09154
07555-09156
07555-09158
07555-09150
07555-09148
07555-09140
07555-09150
07555-09148
07555-09140
07555-09150
07555-09148
07555-09103
07555-09104
07555-09105
07555-09106
07555-09108
07555-09154
07555-09156
07555-09158
07555-09150
07555-09148
07555-09150
07555-09148
07555-09140
07555-09150
07555-09148
07555-09106
07555-09150
07555-09134
07555-09103
07555-09104
07555-09105
07555-09106
07555-09108
07555-09158
07555-09150
07555-09148
07555-09158
07555-09150
07555-09148
07555-09103
07555-09104
07555-09105
07555-09106
07555-09108
HEXSERT®( 9688 )
•Places all inserts listed in this section except M5 large flange Thin Sheet Nutsert®
•• Places M5 large flange Thin Sheet Nutsert® 09698-00516 ONLY
INSERT
SIZE
M3
M4
M5•
M5••
M6
M8
4 UNC
6 UNC
8 UNC
10 UNC
1/4UNC
5/16 UNC
10 UNF
1/4UNF
5/16 UNF
3
/ 16 BSW
1
/ 4 BSW
07555-09883
07555-09884
07555-09885
07555-09185
07555-09886
07555-09888
07555-09854
07555-09856
07555-09858
07555-09850
07555-09848
07555-09840
07555-09870
07555-09868
07555-09860
07555-09816
07555-09818
07555-09983
07555-09984
07555-09985
07555-09986
07555-09988
07555-09954
07555-09956
07555-09958
07555-09950
07555-09948
07555-09970
07555-09968
07555-09960
07555-09916
07555-09918
07555-09930
07555-09932
07555-09934
07555-09583
07555-09584
07555-09585
07555-09586
07555-09588
07555-09558
07555-09550
07555-09548
07555-09578
07555-09570
07555-09568
07555-09283
07555-09284
07555-09285
07555-09286
07555-09288
COMPLETE TOOL NOSE ASSEMBLY 13 45
07555-01003
07555-01004
07555-01005
07555-01006
07555-01008
07555-00754
07555-00756
07555-00758
07555-00750
07555-00748
07555-00750
07555-00748
07555-00740
07555-00750
07555-00748
07555-01006
07555-00750
07555-00756
COMPONENT NUMBERS
Selection

10
Servicing the Tool
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.
•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 Force Adjustment page 7).
•Inspect the drive screw in the nose assembly for wear or damage. Renew if necessary.
•Check for oil leaks and air leaks on air supply hose and fittings.
Grease can be ordered as a single item, the part number is shown in the Service Kit page 11.
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.
Regular servicing should be carried out and a comprehensive inspection performed annually or every 500,000 cycles, whichever is
sooner.
Daily
Weekly
Molykote®55m Lithium Grease Safety Data

11
Service Kit
Servicing the Tool
For all servicing we recommend the use of the Service Kit (part number 74200-99990) supplied in its own plastic case.
07900-00393 14mm/15mm SPANNER 1
07900-00409 12mm/13mm SPANNER 1
07900-00626 11mm SPANNER 1
07900-00632 17mm/19mm SPANNER 2
07900-00468 1.5mm ALLEN KEY 1
07900-00922 2mm ALLEN KEY 1
07900-00469 2.5mm ALLEN KEY 1
07900-00351 3mm ALLEN KEY 1
07900-00224 4mm ALLEN KEY 1
07900-00225 5mm ALLEN KEY 1
07900-00620 12mm ALLEN KEY 1
07900-00456 T BAR 1
07992-00075 MOLYKOTE 55M (100 gm TUBE) 1
07900-00627 PLASTIC CASE 1
07900-00618 PUSHER 1
07900-00619 GUIDE BUSH 1
07900-00478 Ø 3mm PIN PUNCH 1
07900-00624 Ø 4mm PIN PUNCH 1
07900-00157 INTERNAL CIRCLIP PLIERS 1
07900-00161 EXTERNAL CIRCLIP PLIERS 1
07900-00625 SOFT MALLET 1
07900-00623 25mm SOCKET 1
07900-00006 SPATULA 1
07900-00434 32mm SPANNER 1
07900-00621 28mm SPANNER 1
07900-00637 17mm SPANNER 1
07900-00643 PUSHER KNOB 1
07900-00726 BULLET 1
ITEM PART Nº DESCRIPTION Nº OFF
74200-99990 SERVICE KIT ITEM PART Nº DESCRIPTION Nº OFF
Spanners are specified in inches and across flats unless otherwise stated

12
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.
IMPORTANT
Safety Instructions appear on page 4.
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.
•Remove Rubber Base 74.
•Place tool, base uppermost in vice fitted with soft jaws.
•Using a spanner*, unscrew Base Casing 75. Pneumatic Piston 68 should move upward under Spring 65 pressure (it may be
necessary to exert hand pressure to Pneumatic Piston 68).
•Remove ‘O’ Ring 71.
•Withdraw Pneumatic Piston 68.
•Remove Lip Seal 69 and ‘O’ Rings 78 and 28.
•Hold Pneumatic Piston Rod 66 in soft vice jaws to avoid scratching rod diameter.
•Separate Pneumatic Piston Rod 66 from Pneumatic Piston 68 by unscrewing piston rod fastening Bolt 76 using a spanner*.
•Inspect Air Supply Tube 79 for damage or distortion. (Air tube is screwed internally into handle and set in position with Loctite®222)
If it is 100% necessary to remove air tube, the base of the air tube will require warming to a temperature of 100ºC to soften the
Loctite®adhesive. The Air Supply Tube 79 can then be unscrewed from the handle using an Allen key*.
•Check Spring 65 is not distorted or damaged.
•Replace any damaged seals and springs.
•Assembly is in reverse order to dismantling.
•To replace Piston Rods 67: they are screwed and locked with Loctite®222 into Base Casing 75. To remove them it may be
necessary to warm up the base of the piston rod to 100ºC to soften Loctite®222. The piston rods can be then removed with a vice.
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 35, Oil Seal Washer 36, Bleed Screw 10 and Oil
Seal Bleed Washer 9from the handle assembly and drain the oil into a suitable container.
Prior to dismantling the tool it is necessary to remove the nose assembly. For simple removal instructions see the nose assemblies
section, pages 8-9.
* Refers to items included in the 74200 Service Kit. For complete list see page 11.
Item numbers in bold refer to the General Assembly drawing and Parts List (pages 14-15).
•With tool in upside down position in vice, unscrew Rod Guide 62 using a spanner* and T-bar*.
•Withdraw Rod Guide 62.
•Unscrew Adaptor Nut 64 using an Allen key*, remove Lip Seal 63 and ‘O’ Ring 61.
•Remove ‘O’ Ring 60.
•Replace any damaged seals.
•Assembly is in reverse order to dismantling.
•With tool held in vice, remove Pivot Pin 38 using a pin punch*.
•Remove Trigger 40, Roller Pin 42, Roller 41 and Push Wedge 39.
•Gently push on the head of Trigger Rod 43 and remove together with ‘O’ Rings 48 and 44, Guide 45, Lip Seal 46 and Valve
Locking Plug 47.
•Assembly is in reverse order to dismantling. Ensure lip of Lip Seal 46 is towards head of tool.
•Remove Flexible Rubber Cover 88.
•Using flat spanner remove Air Supply Assembly 115 and Bridge Washer 95.
•Unscrew Sleeve 70.
•Using circlip pliers remove Circlip 97 and Sintered Filter 98.
•Assemble in reverse order of dismantling.
Pneumatic Cylinder
Rod Guide
Trigger
Swivel Air Inlet (74200-12700)
For total tool servicing we advise that you proceed with dismantling of sub-assemblies in the order shown below.
Tool Servicing

13
Differential Valve
Head Assembly
Rear Casing
Distributor
Hydraulic Piston and Air Motor Assembly (74200-12610)
Maintenance
•Wrap adhesive tape around Hydraulic Piston 14 thread and move assembly backwards slowly and firmly.
•Using circlip pliers* remove Circlip 11 and Front Seal 8.
•Using two spanners* separate the Hydraulic Piston 14 from Air Motor Casing 24. Shim Adjustment Ring 34, Movement Pivot 5, ‘O Ring
13 and Lip Seal 12 will come out with Hydraulic Piston 14.
•Remove ‘O’ Ring 13 and Lip Seal 12.
•Remove air motor assembly out of Air Motor Casing 24, using circlip pliers*remove Circlip 107, then tap Air Motor Casing 24 on bench to
free components.
•Parts 100 to 113 (not including Circlip 107) can be pulled out as an assembly, taking care not to drop Pin 106.
•Remove Bearing 108, Planet Gear Spindle 100, three Planets 101, Planet Gear 109 and Spacer 102.
•Using a soft mallet tap splined head of Rotor 111.
•Bearing 110 and Front End Plate 103 will come out with Stator 104 and five Rotor Blades 105. (Rotor 111 remains in place).
•Place Rear End Plate 112 in vice with soft jaws.
•Using a pin punch* tap centre of Rotor 111 to remove Bearing 113. (turn Rotor 111 upside down and Bearing 113 will come out).
•When assembling air motor, rear side of Rotor 111 must just touch Rear End Plate 112 without any axial gap, (any existing gap will
disappear when Bearing 113 is fully located).
•When inserting air motor into Air Motor Casing 24 carefully align parts so that Pin 106 locates in centre hole between spin on/off ports of
Stator 104 and Rear End Plate 112.
•When assembling Hydraulic Piston 14 onto air motor assembly, tighten parts by hand and blow air into one of the outer ports of air Motor
Casing 24, checking to see air motor rotates freely.
•When assembling front Lip Seal 12 ensure larger diameter faces rear of tool.
•Renew any damaged seals.
•Assemble in reverse order to dismantling.
* Refers to items included in the 74200 Service Kit. For complete list see page 11.
Item numbers in bold refer to the General Assembly drawing and Parts List (pages 14-15).
IMPORTANT
Check the tool against daily and weekly servicing.
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating
•Using special flat spanner* unscrew Adaptor Nut 58, withdraw and remove Spring 54 and ‘O’ Ring 55.
•Remove Threaded Pin 50 and Deflector 49.
•Using a spanner* remove Silencer 59 and nylon Washer 51.
•Push Valve Piston 57 out from its housing together with ‘O’ Rings 56, 53 and 52.
•Check ‘O’ Rings 56, 55, 53 and 52 for damage, Spring 54 for distortion and renew if required.
•Assemble in reverse order of dismantling.
•Remove Nose Casing 1, Adaptor Nut 2and ‘O’ Ring 4.
•Using spanners* remove Spindle Connector 3and Lock Nut 6.
•Using circlip pliers* remove Circlip 11 and Washer 99.
•Remove ‘O’ Ring 4.
•Renew any damaged seals.
•Assemble in reverse order of dismantling.
•Using an Allen key* remove two Screws 33 securing Rear Casing 26 and remove.
•Remove Silencer 25 from inside rear casing.
•Assembly in reverse order of dismantling.
•Using an Allen key* remove two Screws 7.
•Withdraw Distributor 27 together with Ball 18, Pushrod 17 and Spring 15, taking care not to drop Ball 18.
•Hold Distributor 27 in soft jaw vice and using circlip pliers remove Circlip 21.
•Remove Silencer 23 and Spring 22.
•Pull out Piston 29 together with three ‘O’ Rings 28.
•Using an Allen key* remove four countersunk socket head Screws 19 and withdraw Stroke Stop 16.
•Pull out two Air Supply Tubes 32 and four ‘O’ Rings 31.
•Renew any damaged seals.
•Assemble in reverse order of dismantling.
Pressure Switch Removal
•See page 16.

14
General Assembly of Base Tool 74201-12000
26
107
108
100
101
109
102
110
103
104
111
105
112
113
106
24
116 Assy
114
15
17
18
30
51
59
1
40
38
42
39
2
4
4
11
99
3
6
44
43
45
46
47
48
35
36
31 32
117 9
10
41
8
11
14
12
34
5
13
19
16 52 53 55 57
58
56
54
70
98
97
88
95
96 78
78
77
28
74
75
69
76
62
60
79
68
63
64
61
67
49
115 Assy
72
73
66
65
71
50
37
25
727
21
23
22
28 29 20
33
PRESSURE SWITCH
ASSEMBLY SEE PAGE 16

15
Parts List for 74201-12000
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
74200-12091 74200-12092 74200-12044 07003-00028 74200-12056 07555-00803 74201-12007 07265-02004 74200-12049 07001-00329 74200-12099 74200-12053 74200-12121 74201-12014 74201-12015 74201-12016 74200-12078 74200-12079 74290-03004 74201-12020 74201-12021 74201-12022 74201-12023 74201-12024 74201-12025 74290-03006 74201-12027 74290-03022 74201-12029 74290-03013 74200-12060 74290-03009 74290-03014 74200-12055 07005-01274 74290-03015 74201-12037 74200-12026 74200-12024 74200-12025
NOSE CASING ADAPTOR NUT (UP TO M8) SPINDLE CONNECTOR 'O' RING MOVEMENT PIVOT LOCK NUT M4 SCREW FRONT SEAL OIL SEAL BLEED WASHER M5 BLEED SCREW CIRCLIP LIP SEAL 'O' RING HYDRAULIC PISTON SPRING STROKE STOP PUSHROD BALL M4 SCREW 'O' RING CIRCLIP SPRING SILENCER AIR MOTOR CASING SILENCER REAR CASING DISTRIBUTOR 'O' RING PISTON PNEUMATIC CYLINDER LINER 'O' RING AIR SUPPLY TUBES SCREW SHIM ADJUSTMENT RING OIL PLUG OIL SEAL WASHER HANDLE PIVOT PIN PUSH WEDGE TRIGGER
1 1 1 2 1 1 2 1 1 1 2 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 4 1 1 4 2 2 1 1 1 1 1 1 1
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
74200-12023 74200-12022 74200-12020 07003-00315 74200-12019 74200-12018 74201-12047 07003-00027 74200-12302 74200-12301 74200-12033 07003-00046 07003-00026 74200-12104 07003-00086 07003-00040 74200-12028 74200-12027 74200-12034 07003-00100 07003-00134 74200-12015 74200-12014 74200-12013 07555-00205 74290-03018 74290-03019 74290-03020 74290-03021 07265-03221 74290-03023 74290-03024 74290-03025 74290-03026 74290-03027 74290-03028 74200-12103 07003-00029 74290-03029 74201-12080
ROLLER ROLLER PIN TRIGGER ROD 'O' RING GUIDE LIP SEAL VALVE LOCKING PLUG 'O' RING DEFLECTOR THREADED PIN 1/8 WASHER 'O' RING 'O' RING SPRING 'O' RING 'O' RING VALVE PISTON ADAPTOR NUT 1/8 SILENCER 'O' RING 'O' RING ROD GUIDE LIP SEAL ADAPTOR NUT SPRING PNEUMATIC PISTON ROD PISTON ROD PNEUMATIC PISTON LIP SEAL 1/4 SLEEVE 'O' RING WASHER NUT RUBBER BASE BASE CASING BOLT PLUG 'O' RING AIR SUPPLY TUBE 'O' RING
1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 4 2 1 1 1 1 2 1 3
81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117
74201-12081 74201-12082 74201-12083 74201-12084 74201-12085 74201-12086 74201-12087 74290-03030 74201-12089 74201-12090 74201-12091 74201-12092 74201-12093 74201-12094 07265-03021 74290-03031 74200-12097 74200-12096 74200-12099 74200-12063 07555-09208 74200-12066 07555-09210 07555-09211 07555-09213 07555-09216 74200-12061 74200-12062 74200-12065 07555-09206 74200-12070 07555-09214 07555-09215 07003-00305 74201-03002 74201-03003 07265-03021
LIP SEAL PLUG PISTON 'O' RING LINER CYLINDER SPRING FLEXIBLE RUBBER COVER SPRING RETAINER SPRING REAR CASING CASING COVER REGULATOR GRUB SCREW BRIDGE WASHER AIR INLET BLOCK CIRCLIP SINTERED FILTER WASHER PLANET GEAR SPINDLE PLANET SPACER FRONT END PLATE STATOR ROTOR BLADES PIN CIRCLIP BEARING PLANET GEAR BEARING ROTOR REAR END PLATE BEARING 'O' RING AIR SUPPLY ASSEMBLY PNEUMATIC MOTOR ASSEMBLY SUSPENSION RING
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 3 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1
ITEM PART Nº DESCRIPTION QTY ITEM PART Nº DESCRIPTION QTY ITEM PART Nº DESCRIPTION QTY
74201-12000 PARTS LIST

16
Pressure Switch Assembly
General Assembly of Base Tool 74201-12000
8182
85
80
83
87
52
84
53
89
90
93
9194
92
86
•Remove Casing Cover 92.
•Using spanner remove Rear Casing 91.
•Remove Spring 90 and Spring Retainer 89 from Regulator 93.
•Loosen Grub Screw 94 to allow Regulator 93 to be unscrewed from Rear Casing 91.
•Remove Spring 87 from Piston 83 and pull out Piston 83 which will release Cylinder 86 with three ‘O’ Rings 52, 53 and 84.
•Pull out Liner 85 with three ‘O’ Rings 80.
•Remove Plug 82 from Lip Seal 81 located in the main tool body.
•Remove Lip Seal 81 noting orientation.
•Replace seals and parts as required.
•Assemble in reverse order of dismantling.
Item numbers in bold refer to the Parts List on page 15.
Pressure Switch Removal

Oil Details
Hyspin®VG 32 Oil Safety Data
Priming Procedure
Priming
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating. It may also be necessary to restore the full
stroke after considerable use, when the stroke may have been reduced and fasteners are not now being fully placed by one operation
of the trigger.
The recommended oil for priming is Hyspin®VG32 available in 0.5l (part number 07992-00002) or one gallon containers (part number
07992-00006). Please see safety data below.
IMPORTANT
All operations should be carried out on a clean bench, with clean hands in a clean area.
Ensure that the oil is perfectly clean and free from air bubbles.
Care MUST be taken at all times, to ensure that no foreign matter enters the tool, or serious damage may result.
The tool must remain on its side throughout the priming sequence
•Place tool on its side, Oil Plug 35 side up.
•With an Allen key, unscrew Oil Plug 35 and remove with Oil Seal Washer 36.
•Fill tool with priming oil rocking gently to expel air.
•Replace Oil Seal Washer 36 and Oil Plug 35 and tighten.
•You must now bleed the tool. This operation is to ensure air bubbles are eliminated from the oil circuit.
•Ensuring oil Bleed Screw 10 is fully tightened unscrew by ONE TURN only, using an Allen key. Connect the tool to the air supply
and depress the Trigger 40.
•Wait until oil appears all around Oil Bleed Screw 10 then re-tighten. Wipe excess oil away.
•Release the Trigger 40.
•Using an Allen key remove Oil Plug 35 and Oil Seal Washer 36.
•Top-up with priming oil to reset level. Replace Oil Seal Washer 36 and Oil Plug 35 and fully tighten.
•It is necessary to fit the appropriate nose equipment and adjust the tool stroke prior to operating the tool.
Item numbers in bold refer to General Assembly drawings and Parts List (pages 14-15).
First Aid
SKIN:
Wash thoroughly with soap and water as soon as possible. Casual contact requires no immediate attention. Short term contact
requires no immediate attention.
INGESTION:
Seek medical attention immediately. DO NOT induce vomiting.
EYES:
Irrigate immediately with water for several minutes. Although NOT a primary irritant, minor irritation may occur following contact.
Fire
Flash point 232°C. Not classified as flammable.
Suitable extinguishing media: CO2, dry powder, foam or water fog. DO NOT use water jets.
Environment
WASTE DISPOSAL: Through authorised contractor to a licensed site. May be incinerated. Used product may be sent for reclamation.
SPILLAGE: Prevent entry into drains, sewers and water courses. Soak up with absorbent material.
Handling
Wear eye protection, impervious gloves (e.g. of PVC) and a plastic apron. Use in well ventilated area.
Storage
No special precautions.
17

18
Fault Diagnosis
Pneumatic motor Air leak from motor Check for worn seals. Replace 13
runs slowly Low air pressure Increase 7
Air way blockage Clear restriction in air supply
Worn drive screw Replace 8
Vanes jamming Lubricate tool through air inlet
Insert does not Force incorrectly set Adjust 7
deform properly Air pressure outside the tolerance Adjust 7
Low oil level Prime tool 17
Insert out of grip Check grip range of Insert
Drivescrew turns Worn or damaged drive shaft Replace
independent of Worn or damaged drive screw Replace 8
motor Adaptor nut loose Tighten 8
Lock Nut 6missing Fit new lock nut 13
Insert will not Incorrect Insert thread size Change to correct insert
place onto Incorrect drive screw fitted Change to correct drive screw
drivescrew Worn or damaged drive screw Replace
Nose equipment incorrectly assembled Disconnect air supply, re-fit nose 8-9
equipment carefully
Tool is jammed Excessive force/ DO NOT DEPRESS TRIGGER. Unlock
on placed insert Defective insert/ force locking device.
Worn or defective drive screw Depress trigger. Tool
should spin off. Reset force. If unable to reset,
disconnect air to tool. Insert a
4 mm Ø pin through nose casing slots
into Spindle Connector 3. Turn until drive screw
withdraws from the insert. Use new insert and
drive screw.
Drive screw Force of tool excessive Re-set force
breaks Side load on drive screw Hold tool square to application when
placing Insert
continued overleaf
Item numbers in bold refer to General Assembly drawings and Parts List (pages 14-15).
Other symptoms or failures should be reported to your local Avdel®authorised distributor or repair centre.
Symptom Possible Cause Remedy Page Ref

19
Fault Diagnosis
Tool does not Screw adaptor nut loose Tighten
spin on No air supply Connect 7
Insufficient gap between Lock Nut 6and Adjust gap to between 1.5 mm and 2mm 13
Spindle Connector 3
Pushrod 17 too short Replace 13
Air motor jammed Lubricate tool at air inlet. If insufficient
dismantle and clean air motor thoroughly
Trigger Static friction Depress trigger a few times
inoperative Low air pressure Increase air pressure
Valve piston remains stuck Depress trigger several times. Lubricate
tool through air inlet. If unsuccessful,
dismantle, clean and lubricate trigger
elements
Drive screw does Lip Seal 46 is defective Replace 12
not return and/or
keeps spinning off
Tool does not Adaptor Nut 2loose Tighten
spin off No air supply Connect
Turn Regulator 93* half turn Set tool force 7
Distributor stuck Lubricate
Air motor jammed Lubricate tool at air inlet. If insufficient
dismantle and clean air motor
thoroughly
Item numbers in bold refer to General Assembly drawings and Parts List (pages 14-15).
93* see page 16.
Other symptoms or failures should be reported to your local Avdel®authorised distributor or repair centre.
Symptom Possible Cause Remedy Page Ref

20
Notes