Avdel 7536 User manual

Hydro-Pneumatic Power Tool
07536
0753
TYPE
Instruction Manual

3
Contents
Safety Rules 4
Specifications
Specification for 07536 Tool 5
Specification for 07531 Intensifier 5
Intent of Use 6
Tool Dimensions 7
Putting into Service
Air Supply 8
Air Cursors 9
Loading and Re-loading the Tool 10-11
Operating Procedure 11
Servicing the Tool
Daily / Weekly 12
Moly Lithium Grease EP 3735 Safety Data 12
Service Kit 13
Maintenance
Air Cursor Tool, Intensifier & Control Box Assembly
and Parts List 15
Dismantling 07536-02200 16-17
General Assembly and Parts List 07536-02200 18-19
Intensifier 07531-02200 - Maintenance 20
Intensifier 07531-02200 - General Assembly and
Parts List 21
Priming
Oil Details 22
Hyspin®VG 32 and AWS 32 Oil Safety Data 22
Priming Procedure 22
Fault Diagnosis
Symptom, Possible Cause & Remedy 23
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.

4
Safety Rules
This instruction manual must be read with particular attention to the following safety rules, by any person
installing, operating, or servicing this tool.
1Do not use outside the design intent.
2The Hand Tool and Intensifier have been tested as separate items and combined. They must only be used together and under no
circumstances for any other purposes.
3Do not use equipment with this tool/machine other than that recommended and supplied by Avdel UK Limited.
4Any 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.
5The 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.
6The 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.
7The precautions to be observed when using this tool/machine must be explained by the customer to all operators.
8Always disconnect the airline from the tool/machine inlet before attempting to adjust, fit or remove a nose assembly.
9Do not operate a tool/machine that is directed towards any person(s) or the operator.
10 Always adopt a firm footing or a stable position before operating the tool/machine.
11 Ensure that vent holes do not become blocked or covered and that hoses are always in good condition.
12 The operating pressure shall not exceed 7 bar (100 lbf/in2).
13 The combination of fastener, mandrel, hole size and sheet thickness shall be in accordance with Avdel UK Limited. Specifications.
14 Do not operate the tool if it is not fitted with a complete nose assembly unless specifically instructed otherwise.
15 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.
16 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.
17 When carrying the tool from place to place keep hands away from the trigger/lever to avoid inadvertent startup.
18 Excessive contact with hydraulic oil should be avoided. To minimize the possibility of rashes, care should be taken to wash
thoroughly.
IMPORTANT
While a small amount of wear and marking will naturally occur through normal and correct use of mandrels, they
must be regularly examined for excessive wear and marking, with particular attention to the head diameter, the
tail jaw gripping area of the shank or heavy pitting of the shank and any mandrel distortion. Mandrels which fail
during use could forcibly exit the tool. It is the customer's responsibility to ensure that mandrels are replaced
before any excessive levels or wear and always before the maximum recommended number of placings. Contact
your Avdel. representative who will let you know what that figure is by measuring the broach load of your
application with a calibrated test tool. These tools can also be purchased under Part Number 07900-09080,
supplied with all necessary information for testing in this manual.

Specification for 07536 Tool
Specification for 07531 Intensifier
Specifications
5
Air Pressure Minimum - Maximum 5-7 bar (70-100 lbf/in2)
Free Air Volume Required @ 5.1 bar /75 lbf/in22.6 litres (0.09 ft3)
Stroke Minimum 25 mm (1 in)
Pull Force @ 5.5 bar /80 lbf/in23.89 kN (875 lbf)
Cycle time Approximately 1 second
Noise Level Less than 70 dB(A)
Weight Pistol 1.2 kg (2.64 lb)
Vibration Less than 2.5 m/s2(8 ft/s2)
Air Pressure Minimum - Maximum 5-7 bar (70-100 lbf/in2)
Intensification Ratio 32:1

6
Intent of Use
The pneumatic 07536 tool is a hand held light weight tool designed to place Avdel®speed fasteners and 1/16” Avlug®making it ideal
for batch or flow-line assembly in a wide variety of applications throughout all industries.
The Hand Tool and Intensifier have been tested as separate items and combined. They must only be used together and for no other
purposes. Refer to "Putting into Service" on page 8 & 9 for connection details.
Part numbers are shown to order a complete tool but no nose equipment.
The tool number for the 07536 model is 07536-02200.
See the general assemblies on pages 15-21.

7
Dimensions shown in bold are millimetres. Other dimensions are in inches.
Tool Dimensions - 07536 Model
Intent of Use
0753
60
2.36
28
1.10
98
3.85
130
5.12
475
18.70 338
13.30
51
2
163
6.41
140
5.51
54
2.12
201
7.91
420
16.54
333
13.10
502
19.76
Part Number 07536-02100

8
Air Supply
Putting into Service
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
0753
TYPE
All tools are operated with compressed air at an optimum pressure of 5.5 bar. We recommend the use of pressure regulators and
automatic oiling/filtering systems on the main air supply. To ensure maximum tool life and minimum tool maintenance they should be
fitted within 3 metres of the tool (see diagram below).
Air supply hoses should have a minimum working effective 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 supply hoses MUST have a minimum bore diameter of 6.4
millimetres or 1/4inch.
Follow the steps below when connecting the tool to the intensifier and main air supply:
•Push the end of the large hydraulic hose from the tool into the quick release connector on the end of the intensifier.
•On the front face of the intensifier (Refer to page 15):
•Push the blue pneumatic (4mm OD) line into the reducer fitting which is located in the left hand bulkhead connector.
•Push the black pneumatic (4mm OD) line into the plastic collet of the right hand bulkhead connector.
•On the front face of the control box (Refer to page 15):
•Push the silver pneumatic (3mm OD) line into the reducer labelled ‘Cursor’ on the front face of the control box - LH side.
•Push the green pneumatic (4mm OD) line into the reducer labelled ‘Tail Jaws’ on the front face of the control box - middle.
•Push the white pneumatic (4mm OD) line into the reducer labelled ‘Signal’ on the front face of the control box - RH side.
•Fit a pneumatic hose between the male connector at the rear of the intensifier and main air supply.

9
Air Cursors
Putting into Service
0753
TYPE
TOOL
BARREL
CURSOR
NOSE
JAWS
Air Cursor Selection
While the cursor will be fitted the correct way round when the tool is supplied, we recommend that you check its orientation before
fitting the nose equipment. The slightly concave end of the cursor should point towards the front of the tool as shown in the
illustration.
To reverse the orientation of the cursor, follow these steps:
Extreme caution must be exercised whe undertaking the following procedure. Care must be taken to avoid the barrel and protruding
mandrel.
•Remove the Nose Assembly if there is one.
•Insert an empty mandrel fully into the tool.
•Close the Tail Jaws 32, by switching on the tail jaw switch (items
18 and 19).
•The cursor will pop out of the barrel after a short delay.
•Open the Tail Jaws 32, by switching off the tail jaw switch (items
18 and 19), this will release the mandrel.
•Remove the cursor from the mandrel and insert the cursor into
the barrel.
IMPORTANT
If fitted incorrectly, the cursor will not allow the loading of the tool and feeding of the fasteners.
TOOL
BARREL
CURSOR
CONCAVE END
NOSE
JAWS
Item numbers in bold refer to the general assembly and parts list for the 07536-02200 Tool on pages 18-19.
Cursor
See separate data sheet 07900-00863 for nose assembly components.

10
Loading and Reloading the Tool
Putting into Service
When ordering a complete tool or system you will normally be supplied with all the nose equipment required for the fastener to be
placed.
If you have been supplied with a nose jaw, mandrels and mandrel follower springs proceed with loading the tool and fitting the nose
equipment as shown below.
IMPORTANT
The procedure for loading the tool and for fitting the nose equipment to the tool is integral.
Item numbers in bold refer to the general assembly and parts list for the 07536-02200 Tool on pages 18-19.
Loading the Tool
•Connect the air supply to the tool.
•Open Tail Jaws 32 which grip the mandrel, by switching off the tail jaw switch (items 18 and 19).
•Screw selected nose jaws onto Barrel 44 of the tool.
•* Insert a mandrel into the tail end of the fasteners through the paper pod.
•Slide the mandrel follower spring onto the mandrel ensuring correct orientation.
•Gripping the tail end of the mandrel, tear off the paper pod from around the fasteners.
•Open the nose jaws either by rotating the outer ring on Cam operated jaws or by pushing outwards on the jaw ends, as illustrated
below left.
•Insert the previously assembled mandrel, mandrel follower spring and fasteners into the nose jaws until the first fastener to be
placed is protruding from the nose jaw.
•Close the nose jaws and adjust so that the first fastener protrudes by 1.5mm - 3mm (1/16” to 1/8”), as shown in the illustration
below right.
•Close the Tail Jaws 32 to ensure the mandrel is gripped, by switching on the tail jaw switch (items 18 and 19).
Reloading the Tool
•Open Tail Jaws 32 of tool, by switching off the tail jaws (items 18 & 19).
•Open the nose jaws and pull the empty mandrel and mandrel follower spring out of the tool.
•Reload the tool by following the above instructions, starting at stage •*.
1.5mm - 3mm
(1/16" - 1/8")

11
Putting into Service
•Push the fastener, protruding from the nose jaws, fully into the application holes ensuring that the tool is held square.
•Operate the trigger without releasing - the mandrel head is pulled through the fastener, forming the fastener into the application.
•Remove the tool.
•Release the trigger. The next fastener will be automatically presented through the nose jaws, ready for placing.
IMPORTANT
You must check that the cursor orientation and the nose equipment are correct before attempting to operate the tool.
Item numbers in bold refer to the general assembly and parts list for the 07536-02200 on pages 18-19.
Operating Procedure
Setting the Tool - Adjustable Nose Assemblies Only
Insert the previously assembled mandrel (see Loading the Tool •*) or the disposable mandrel against the stop within the Tail Jaw Piston
Assembly 60.
While holding the mandrel, close the Tail Jaws 32, which grip the mandrel, by switching on the tail jaw switch (18 and 19).
Screw the lock nut onto the Barrel 44 of the tool.
Rotate the nose assembly onto the Barrel 44.
Adjust the nose assembly so that the first fastener protrudes by 1,5mm-3mm (1/16”-1/8”), as shown in the illustration on page 10.
Tighten the lock nut against the nose assembly to prevent the nose jaw assembly from moving.
Loading and Reloading the Tool
Reloading the Tool
Open the tail jaws of the tool, by switching off the tail jaw switch (18-19).
Open the jaws and pull the empty mandrel and follower spring out of the tool.
Insert the new mandrel against the stop within the too, and close the Tail Jaws 32 which grip the mandrel, by switching on the tail jaw
switch (18 and 19).
Close the Tail Jaws 32.

12
Daily
Pneumatic Control Box
Weekly
Moly Lithium Grease EP 3753 Safety Data
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.
IMPORTANT
Under no circumstances must the pneumatic box be opened. The box is a closed item.
The internal adjustments are preset and must not be altered or tampered with.
Only Authorised Avdel personnel may dismantle this control box.
Grease can be ordered as a single item, the part number is shown in the service kit page 13.
First Aid
SKIN:
As the grease is completely water resistant it is best removed with an approved emulsifying skin cleaner.
INGESTION:
Ensure the individual drinks 30ml Milk of Magnesia, preferably in a cup of milk.
EYES:
Irritant but not harmful. Irrigate with water and seek medical attention.
Fire
FLASH POINT: Above 220°C.
Not classified as flammable.
Suitable extinguishing media: CO2, Halon or water spray if applied by an experienced operator.
Environment
Scrape up for burning or disposal on approved site.
Handling
Use barrier cream or oil resistant gloves.
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, before use or when first putting the tool into service. Pour a few drops of clean lubricating oil into the air inlet of the
intensifier 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 and oil leaks. If damaged, hoses and couplings should be replaced.
•If there is no filter on the pressure regulator, bleed the airline to clear it of accumulated dirt or water before connecting the air
hose to the intensifier. If there is a filter, drain it.
•Check that the nose equipment is correct.
•Check mandrels regularly for signs of wear or damage monitoring the number of placings (read the safety instructions on page 4).
•Conduct the full “Daily” procedures as described above.
•Remove, inspect, clean and grease the Tail Jaws (refer to “Tail Jaw Cylinder” in the "Maintenance Section" page 16).
•Check oil level in the intensifier Unit reservoir is approximately 12mm (1/2”) below the transparent cover plate.

13
Service Kit
Servicing the Tool
For all servicing we recommend the use of the service kit (part number 07900-05300).
ITEM PART Nº DESCRIPTION Nº OFF
07900-00157 CIRCLIP PLIERS 1
07900-00006 SPATULA 1
07900-00446 EXTRACTOR 1
07900-00603 BARREL VICE JAWS 1
07900-00520 3/8" ROD 1
07900-00521 1/4" ROD 1
07900-00602 'O' RING ASSEMBLY BULLET 1
07900-00595 18mm SPANNER 1
07900-00434 32mm SPANNER 1
07900-00237 3/8" x 5/16" B.S.W. SPANNER 1
07900-00012 9/16" x 5/8" SPANNER 1
07900-00008 7/16" x 1/2" SPANNER 1
SERVICE KIT
ITEM PART Nº DESCRIPTION Nº OFF
07900-00352 SEAL REMOVAL HOOK 1
07900-00710 BARREL PLUG REMOVAL SPANNER 1
07900-00725 BULLET 1
07900-00243 SCREWDRIVER 1
07900-00717 INTENSIFIER SPANNER 1
07900-00013 1/8" ALLEN KEY 1
07900-00617 LOCTITE®MULTI-GASKET 574 50ml PACK 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
07992-00020 80g TIN MOLY LITHIUM GREASE EP 3753 1
Note: Spanner sizes are measured 'across flats' unless otherwise specified.

14
Notes

15
Air Cursor Tool, Intensifier & Control Box Assembly
07536-02100
4 5
9
2
6
3
7 8
1
BLUE PIPE
BLACK PIPE
PART SECTION 'A-A'
(PROTECTION PLATE REMOVED)
AA
CURSOR TAIL JAWS SIGNAL
SILVER
PIPE
GREEN
PIPE
WHITE
PIPE
74405-12080

16
Maintenance
Every 500,000 cycles the tool should be completely dismantled and new components should be used where worn, damaged or when
recommended. All ‘O’ rings and seals should be renewed and lubricated with Moly Lithium grease EP 3753 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.
The airline 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.
Prior to dismantling the tool, you will need to remove the nose equipment.
For total tool servicing we advise that you proceed with the dismantling of sub-assemblies in the order shown below after having
disconnected the hydraulic hose from the intensifier unit, air lines from the intensifier and control box, thus separating the pistol unit
from the intensifier unit.
TAIL JAW CYLINDER
•Manually flip the retaining Clip 53 up and remove the End Cap 59.
•Using an Allen Key*, remove one Cap Head Screw 6ensuring that any trapped air in the tail jaw cylinder is exhausted. Remove
the second Cap Head Screw 6.
•Pull out Rear Plug 50. Note: To aid extraction there is a 5mm thread on the rear face of the plug.
•Extract air tail jaw components, comprising Tail Jaw Piston Assembly 60, Stop 52, ‘O’ Ring 12 and Jaws 32.
•Extract the remaining components, comprising of Spring 36 and Jaw Housing 42.
•Free length of spring 36 should be 38.1mm (1.5”). Replace if necessary.
•Remove piston assembly seal ‘O’ Ring 11.
•Disconnect Air Cursor Concertina Tube (Green) 49 from Elbow Connector 22.
•Disconnect Air Cursor Concertina Tube (Silver) 38 from Barb Elbow 30.
•Using an Allen Key*, remove all five handle moulding securing Screws 3, 4and all four Nuts 8from the tool handle.
•Grip Barrel 44 in a vice using soft jaws* to avoid damage.
•Using a box spanner*, unscrew Barrel Plug 46, preventing Barrel 44 turning by using an open ended spanner*.
•Pull the Tail Jaw Cylinder 47 from the tool.
•Remove ‘O’ Ring 14, Rubbing Strip 41 and Barrel Return Spring 37.
•Coat the face of Tail Jaws 32 with Moly Lithium grease, in contact with Jaw Housing 42, before assembling.
•Assemble in reverse order of dismantling.
HYDRAULIC PISTON
•Remove Tail Jaw Cylinder 47 as described earlier.
•Grip Body 45 in vice using soft jaws* to avoid damage, undo Stroke Limiter 40.
•Using an Allen Key*, loosen Screw 5that is clamping the Switch Block 54 to the barrel 44.
•Hold the tool firmly and pull the Barrel 44 from the Body 45 (a small quantity of hydraulic oil may be ejected from inside the head
assembly).
•Remove Piston 39 carefully so as not to damage head bore.
•Remove Seal 16.
•Seal 17 is difficult to remove without damaging, but can remain in place during cleaning (provided it is not affected by cleaning
process). If however, Seal 17 requires renewing proceed as follows:
•Using spatula*, prise out Seal 17 from Body 45, taking care not to damage body cavity and bores. The removed Seal 17 MUST
be discarded.
•To replace Seal 17, unscrew Bleed Plug Assembly 43 until inside face is level with internal bore of the Body 45. This will provide a
smooth passage for insertion of a new Seal 17 through rear of Body 45.
•Ensure the Seal 17 is well greased and the correct way round with the open end of the seal facing the rear tail jaws.
•Complete assembly in reverse order of dismantling.
* Refers to items included in the 0753 Mkll service kit. For complete list see page 13.
Item numbers in bold refer to the general assemblies and parts lists on pages 18-19.
Dismantling 07536-02200

17
Dismantling 07536-02200
Maintenance
TRIGGER ASSEMBLY
•To dismantle/service assembly, remove covers from the tool as described earlier.
•Disconnect all air hoses from assembly, taking care not to damage them. Remove assembly.
•Using a spanner*, unscrew the Retainer 34 and remove. Take care to keep the Spring 31.
•Prise off the ‘O’ Ring 10 taking care not to damage the Spindle 35 and Retainer 34 seatings.
•Clean and re-assemble using a new ‘O’ Ring 10.
•Check length of Spring 31 which must be 12.7mm (0.5”) free length – replace if necessary.
•Assembly in reverse order of dismantling.
TAIL JAW ON/OFF VALVE
•The unit is designed so that minimum of servicing is required during the life of the tool.
•If it is necessary to dismantle the valve, proceed as follows:
•Remove Trigger Housing 56 as described in section “Hydraulic Piston”.
•Using a screwdriver*, carefully remove the Chrome Star-lock Washer 18 from Air Tail Jaw Spool 55 and discard washer.
•Extract Air Tail Jaw Spool 55 from Switch Block 54.
•Taking care not to damage the Air Tail Jaw Spool 55, remove the ‘O’ Rings 12.
•Clean spool and refit new ‘O’ Rings 12 using assembly bullet* and insert into Switch Block 54, noting its orientation.
•Fit New Chrome Star-lock Washer 18 by clamping in a soft jaw vice to prevent damage. DO NOT USE UNDUE FORCE.
•Complete assembly in reverse order of dismantling.
HANDLE & END CAP
•Clean and inspect mouldings for cracks or other damage.
CURSOR
•Clean and oil cursor assembly occasionally with a little light oil.
* Refers to items included in the 0753 Mkll service kit. For complete list see page 13.
Item numbers in bold refer to the general assemblies and parts lists on pages 18-19.
IMPORTANT
Check the tool against daily and weekly servicing.
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.

18
General Assembly of Base Tool 07536-02200
8 4
8 4
4 8
8 3
8 3
48
HANDLE COVER DETAILS
WW
14
44 25
17
54 46
37 3242
1211
11
V
V
15
16 45 47 60
39 41 33 49
36
2
(GREEN PIPE) (SILVER PIPE)
52
38
40
29
20
24
PART SECTION 'W'-'W'
PART SECTION 'V'-'V'
6
9
69
53
X
X
TRIGGER VALVE DETAIL
35
26
21
34 31
56
10
50
13
28 27
59
57 RH 58 LH
43
11
5
51
18
SECTION 'X'-'X'
55
19
12
22 (BLUE PIPE)
22 (WHITE PIPE)
(BLACK PIPE)
WW
61
30, 38
22, 49
2
2

19
Parts List for Base Tool 07536-02200
1 07007-00392 CABLE TIE (NOT SHOWN) 1 - 2 07001-00499 M3x5 LONG SOCKET SET SCREW 3 - 3 07001-00262 M4x22 LONG SOCKET HEAD CAP SCREW 1 - 4 07001-00401 M4x10 LONG SOCKET HEAD CAP SCREW 4 - 5 07001-00404 M5x6 LONG SOCKET HEAD SET SCREW 1 - 6 07001-00504 M4x6 LONG SOCKET HEAD CAP SCREW 2 2 7 8 07002-00134 M4 HEX NUT 4 - 9 07002-00153 M4 WASHER [PLASTIC] 2 -
10 07003-00022 'O' RING 1 - 11 07003-00113 'O' RING 3 3 12 07003-00121 'O' RING 3 3 13 07003-00142 1/8" BSP BONDED SEAL 1 1 14 07003-00167 'O' RING 1 1 15 07003-00386 'O' RING 2 - 16 07003-00236 SEAL [DYNAMIC] 1 1 17 07003-00237 SEAL [STATIC] 1 - 18 07004-00058 1/8" STARLOCK WASHER CHROME 1 - 19 07004-00059 1/8" STARLOCK WASHER BLACK 1 - 20 07005-10073 3MM CONNECTOR 1 - 21 07005-01357 COLLET TYPE CONNECTOR 1 - 22 07005-01571
07536-02216
ELBOW CONNECTOR LOCKNUT
3 1
- -
23 24 07005-10074 2MM CONNECTOR 1 - 25 07007-00017 DUST CAP 1 - 26 07007-00300 TRIGGER BUTTON 1 - 27 07007-01503 BOOK SYMBOL LABEL 1 - 28 07007-01504 CE MARK LABEL 1 - 29 07008-00438 FLEXIBLE HOSE ASSEMBLY 1 - 30 07005-01323 M3 BARB ELBOW 1 - 31 07125-00215 SPRING 1 - 32 07151-00403 TAIL JAWS 1 pair 2 33 07003-00016 'O' RING 1 34 07220-00803 RETAINER 1 - 35 07241-00208 SPINDLE 1 -
36 07154-00404 SPRING 1 - 37 07490-03002 BARREL RETURN SPRING 1 - 38 07536-02211 3MM AIR CURSOR CONCERTINA TUBE - SILVER 1 - 39 07536-00203
PISTON
1-
40 07530-00204 STROKE LIMITER 1 - 41 07530-00206 RUBBING STRIP 1 1 42 07536-00208 JAW HOUSING 1 - 43 07530-00500 BLEED PLUG ASSEMBLY [ITEMS 62 TO 65] ●1-
44 07536-02201 BARREL 1 - 45 07530-02202
BODY
1-
46 07530-02205 BARREL PLUG 1 - 47 07536-02207 TAIL JAW CYLINDER 1 - 48 07530-02210 LABEL 2 - 49 07536-02212 4MM AIR CURSOR CONCERTINA TUBE - GREEN 1 - 50 07536-02213 REAR PLUG 1 - 51 07530-00310 BLANKING PLUG 2 - 52 07536-02214 STOP 1 - 53 07530-02220 CLIP 1 - 54 07530-02301 SWITCH BLOCK 1 - 55 07530-02302 AIR TAIL JAW SPOOL
1
-
56 07530-02311 TRIGGER HOUSING 1 - 57 07536-02601 HANDLE MOULDING ASSEMBLY RIGHT HAND 1 - 58 07536-02602 HANDLE MOULDING ASSEMBLY LEFT HAND 1 - 59 07530-02603 END CAP 1 - 60 07536-02800 TAIL JAW PISTON ASSEMBLY 1 - 61 07536-02215 FITTING ADAPTER 1 - 62 07003-00142 ●BONDED SEAL (NOT SHOWN) 1 1 63 07003-00194 ●BONDED SEAL (NOT SHOWN) 1 1
64 07001-00442 ●SCREW (NOT SHOWN) 1 1
65 07530-00501 ●PLUG (NOT SHOWN) 1 -
ITEM PART N˚DESCRIPTION QTY SPARES ITEM PART N˚DESCRIPTION QTY SPARES
07536-02200 PARTS LISTS

20
Dismantling Instructions
Intensifier 07531-02200 - Maintenance
•When dismantling the intensifier assembly, first disconnect the air supply hose to intensifier inlet Connector 22.
•Using an Allen Key* undo four Screws 27 and remove Protection Plate 24.
•Disconnect the trigger hose 47 from the intensifier Valve 43 or 48 by depressing the outlet collet and withdrawing the hose.
•Remove Cover Plate 4and Gasket 35 by removing Screws 37 and Washers 36 using Allen Key*.
•Ensure that gasket is not damaged to ensure a proper seal on assembly.
•Invert intensifier assembly and drain oil from reservoir into a suitable container.
•Remove Quick Release Connector 32 together with Connector 31 and Seals 33 with suitable spanner*.
•Remove intensifier Valve 43 or 48 by removing the fixing screws with a suitable spanner taking care to retain ‘O’ Ring 21 located
in the Intensifier Body Casting.
•Remove Screw 19 using a suitable Allen Key* and remove Silencer Cover 16, Foam Silencer 15, Spacer 18 and Retaining Plate
20.
•Pull off the 6mm Plastic Tube 41 from Vacuum Connectors 42.
•From the base of the intensifier insert a 3mm Allen Key * through the two holes and unscrew the Vacuum Connectors 42. Note:
•Care must be taken as the vacuum connectors are locked and sealed in place using Loctite®574.
•If difficult to remove, the vacuum connectors can be drilled out using a 3/16” or 4.7mm diameter drill.
•To reassemble the Vacuum Connectors 42, the following procedure must be followed: -
•Soak the vacuum connectors in a suitable primer, i.e. Perma Bond A905
•Place a drop of Loctite®574 in the intensifier threaded hole.
•From the base of the intensifier insert the Allen Key * through the hole. Ensure that the Allen Key * is free from Loctite®574
before inserting into the vacuum connector.
•Rotate the Allen Key while applying Loctite®574 to the base of the vacuum connector.
•Screw the Vacuum connector into the intensifier, ensuring that there is sufficient Loctite®574 at the base of the fitting such
the thread is not visible.
•Using a screwdriver, carefully remove internal Retaining Ring 14. Clean and inspect groove for sign of damage.
•Using Extractor*, insert male threaded end into End Cover 12 and withdraw it along with intensifier Sleeve 28 and ‘O’ Rings 10
and 13.
•Insert Rod* through the connector orifice at the front of the intensifier body and tap out Piston Rod 9and Piston Assembly.
•Using a suitable Allen Key*, unscrew two Screws 25 and remove End Cover 12 from intensifier Sleeve 28.
•Remove Seal Plug 7with spanner*.
•Insert rod* through connector orifice at the front of the intensifier body and push out Seal Housing 5and associated ‘O’ rings and
lip seals.
•Remove Valve Housing Assembly 34 from the main body with a suitable spanner*. Clean by blowing through with a low-pressure
air jet.
•Remove Piston Rod 9from intensifier Air Piston 11 by gripping the first 20 mm (3/4”) of the rod in a vice fitted with soft jaws,
taking care not to damage or mark the working surface.
•Unscrew locking Nut 17 with a suitable spanner*.
•Assemble in the reverse order of dismantling, observing the following:
•Clean all parts and renew all ‘O’ rings.
•Lubricate all seals using Moly Lithium grease.
•Valve Housing Assembly 34 must be refitted using a thread sealing adhesive.
•Assemble the Piston Assembly using a new Nut 17.
•End Cover 12 must be fitted correctly inside Retaining Ring 14. The tool must not be operated if the end cover has been omitted.
* Refers to items included in the 0753 MkII service kit. For complete list see page 13.
Item numbers in bold refer to the illustration and parts list opposite.
IMPORTANT
Priming is ALWAYS necessary after the tool has been dismantled and prior to operating.