Avdel T40 User manual

Hydro-Electric Power Tool
T40 Installation Tool
Instruction Manual
Original Instruction

3
Contents
Safety 4
Specifications
Intent of Use 5
Tool Specification 5
Tool Dimensions 5
Putting into Service
Principle of Operation 6
Preparation for Use 6
Hydraulic Hose Kits 6
Operating Instructions 7
Maintenance
Dismantling Instructions 8
Assembling the Tool 8
To Bleed the Tool 9
General Assembly for T40 Installation Tool
73414-02000 10
Parts List for T40 Installation Tool
73414-02000 11
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.
Warranty
The ninety day warranty herein expressed shall be the exclusive warranty on items
manufactured by seller and shall be in the place and stead of any other warranty, expressed or
implied, including but not limited to the implied warranties of merchantability and fitness for a
particular purpose.
Seller shall not be liable for any loss or damage resulting from delays or non-fulfilment or
orders owing to strikes, fires, accidents, transportation companies or for any reason or
reasons beyond the control of seller or its suppliers.
All warranty claims must be submitted to the seller in writing, within 90 days from date of
shipment, and no returns will be accepted without written permission.
Other provisions hereof notwithstanding, seller shall not be liable for any loss of business
profits or any incidental or consequential damages incurred by Buyer or any third person in
connection with the items or use thereof, however caused.
Tool Warranty
Seller expressly disclaims any warranty express or implied, as to the condition, design,
operation, merchantability or fitness for use of any tool, or part(s) thereof not manufactured by
seller. The only warranties made with respect to such tool or part(s) thereof are those made
by the manufacturer thereof and seller agrees to cooperate with buyer in enforcing such
warranties when such action is necessary. Seller agrees to repair or replace F.O.B. seller's
plant, any tool or part(s) thereof manufactured by it and proved to seller to be defective due to
faulty workmanship or material.
Servicing the Tool
Daily 12
Weekly 12
Every 1200 Working Hours (at least once a year) 12
Service Tools 12
Hydraulic Oil General Safety Data 12
Fault Diagnosis
Symptom, Possible Cause and Remedy 13-14

4
Safety
1Do not use outside the design intent.
2Do not use equipment with this tool/machine other than that recommended by Avdel UK Limited.
3Any modification undertaken by the customer to the tool/machine shall be the customer’s entire responsibility.
4Always disconnect the tool from the HydraPac before attempting to adjust, remove or fit the nose assembly.
5Do not operate a tool/machine that is directed towards any person(s).
6Always adopt a firm footing or a stable position before operating the tool/machine.
7If cycling the tool without the nose assembly, care must be taken to avoid contact with the moving piston.
8Ear protection must be worn by the operator and others in the vicinity as noise levels exceed the permitted maximum. For values
see Tool Specification on page 5.
9Do not fit flexible hoses rated at less than 10,000 psi (69 mPa) working pressure.
10 The operating pressure shall not exceed 8,000 psi (55.2 mPa).
11 Care shall be taken to ensure that spent pintails are not allowed to create a hazard.
12 When using the tool, the operator and others in the vicinity are recommended to wear safety glasses.
13 Take care to avoid entanglement of loose clothes, ties, long hair, cleaning rags etc. in the moving parts of the tool.
14 The tool should be kept clean and dry for the best possible grip.
15 When carrying the tool from place to place keep hands away from the trigger to avoid inadvertent start up.
16 The 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®procedures.
Do not dismantle the machine without prior reference to the maintenance instructions. Contact Avdel®with your training
requirements.
17 The machine shall at all times be operated in accordance with relevant Health and Safety legislation. In the UK the "Health & Safety
at Work Act 1974" applies. Any question regarding the correct operation of the machine must be directed to Avdel®.
This instruction manual must be read with particular attention to the following safety rules, by any person
installing, operating, or servicing this tool.
CAUTIONS
AVDEL RECOMMENDS THAT ONLY HYDRAPAC UNITS BE USED TO DRIVE INSTALLATION TOOLS, AS OTHER MAKES OF
HYDRAULIC POWER UNITS MAY NOT OPERATE AT THE SAFE DESIGNED WORKING PRESSURES.
ENSURE THAT THERE IS ADEQUATE CLEARANCE FOR THE TOOL OPERATOR'S HANDS BEFORE PROCEEDING.
DO NOT ABUSE THE TOOL BY DROPPING OR USING IT AS A HAMMER.
KEEP DIRT AND FOREIGN MATTER OUT OF THE HYDRAULIC SYSTEMS OF THE TOOLS AS THIS WILL CAUSE THE TOOL AND
HYDRAPAC TO MALFUNCTION

5
Intent of Use
Tool Specification
Tool Dimensions
Specifications
The T40 Installation Tool is basically a Piston and Cylinder Assembly. When coupled Hydraulically and Electrically to a compatible
Hydraulic Power Source and the relevant Nose Assembly is attached, it is then used to install 1/2’’ to 3/4” Avdelok®and 5/8” Avbolt®
in industrial environments.
Refer to the table below for the list of applicable fasteners and associated nose equipment.
Refer to the datasheets listed in the table for the relevant nose assembly instructions.
FASTENER
TYPE SIZE
NOSE ASSEMBLY
PART Nº H AT REF. DIM. ‘A’
NOSE ASSEMBLY
DATASHEET
PART Nº
®
07900-00919
07900-00919
07900-00919
07900-00905
73412-03100
73412-03200
73412-03300
73412-03400
N31
N37
N30
Avbolt
LD Avdelok
1/2”
3/4”
5/8”
5/8”
110mm
113mm
131mm
113mm
N32
®
Length 250 mm 9.8 in
Body Diameter 76 mm 2.9 in
Height 190 mm 7.50 in
Weight 7 kg 15.5 lbs
Stroke 41 mm 1.6 in
Pull Force 175kN 39340lbf
Pull pressure 55.2 mPa 8000 PSI
Return Pressure 20.7 mPa 3000 PSI
Hydraulic Oil ISO VG 46 OR EQUIVALENT
Fastener Range 1/2’’ to 3/4” Avdelok®and 5/8” Avbolt®
Noise Level 126.2 dB(A)
Sound Power 100.9 dB(A)
Vibration 8.6 m/sec3
A
250 mm 76 mm
190 mm

6
Putting into Service
When both hoses and control cord are connected to the HydraPac, the pull and return cycles of the tool are controlled by depressing
and releasing the trigger switch located in the handle respectively.
When the switch is depressed the solenoid valve located in the HydraPac is energised and directs the pressurised oil flow to the pull
side of the piston in the tool. This also allows the oil in the return side of the tool to return to the tank. The piston/collet assembly now
moves towards the rear of the tool allowing the cushion to push the follower and jaws forward. If a Avdelok®pin has been inserted in
the nose for assembly, the jaw set will clamp onto the pintail and assembly will commence.
The cycle of installation will first clamp the joint to be fastened and then as the anvil continues to move forward the collar will be
swaged into the locking grooves of the pin. At the end of the swaging cycle the anvil will come hard up against the joint and as
movement continues the pintail will be broken off.
The trigger switch must be released immediately after pin break occurs. Releasing the trigger switch will cause the solenoid to de-
energise and reverse the flow of pressurised oil.
Pressurised oil will now flow into the return side of the installation tool with the oil in the pull side returning to the tank.
The forward movement of the piston/collet assembly firstly ejects the installed fastener from the anvil and as the forward movement
continues, the jaw release mechanism will cause the jaws to open and release the broken off pintail, which will then be ejected.
When the piston returns to the fully forward position the pressure build up in the system will cause the Hydrapac to go into idle mode.
This keeps the installation tool in the forward position. Once the pintail has been ejected from the nose, the tool is ready for the next
installation.
Please note that with all electric HydraPacs there is a built in "Sleep Mode" which in effect means that the electric motor will
automatically switch off if the trigger switch is not operated for approximately 25 seconds. The HydraPac will automatically start up on
depression of the tool trigger switch. However the diesel HydraPac does not have a "Sleep Mode" and the diesel engine needs to be
switched off manually.
•Attach the correct nose assembly to the tool as per instructions in the relevant nose assembly data sheet.
•Ensure the HydraPac is not running.
•Connect hoses and the control cord to the HydraPac, the tool is supplied with a 0.7m hose length.
Additional hydraulic hose lengths are available to order separately as required. Refer to the table below for the available lengths and
associated part numbers.
•Start the HydraPac. Depress and release the trigger switch a few times to almost the full stroke of the tool to circulate hydraulic
fluid. Observe action of tool. Check for fluid leaks and ensure that in the idler mode the piston is in the fully forward position.
IMPORTANT
Read the safety rules on page 4 carefully
Principle of Operation
Preparation for Use
PART NUMBER HOSE LENGTH
HYDRAULIC HOSE KITS
07005-10014
07005-10034
07005-10035
6 METRE
10 METRE
15 METRE

7
Putting into Service
To install a Avdelok®Fastener
•Check work and remove excessive gap. (Gap is the space between components of the Joint. Gap is excessive if not enough pintail
sticks through the collar for the nose assembly jaws to grab onto.)
•Put Avdelok®pin into hole.
•Slide Avdelok®collar over pin. (The bevelled end of the collar must be towards the nose assembly and tool.)
•Push nose assembly onto pin until the nose assembly anvil stops against the collar. Tool and nose assembly must be held at right
angles (90°) to the work.
•Depress tool trigger switch to start installation cycle.
•When the forward motion of the nose assembly anvil stops and the pintail breaks off, release the switch. The tool will go into its
return stroke and push off the installed fastener. At the end of the return stroke the jaws will release the expended pintail which can
be removed by tilting the tool down.
•Once the expended pintail has been ejected, the tool and nose assembly is ready for the next installation cycle.
CAUTION
DO NOT ATTEMPT TO BREAK OFF A PINTAIL WITHOUT THE INSTALLATION OF A COLLAR AS THIS WILL CAUSE THE
UNSECURED PORTION OF THE AVDELOK®PIN TO EJECT FROM THE NOSE AT A HIGH SPEED AND FORCE.
Operating Instructions

8
•Uncouple the two Hydraulic Hoses 23 and disconnect Control Cord 26.
•Unscrew and remove the anvil by hand.
•Unscrew the collet and remove the inner assembly by hand.
•Loosen Grub Screw 7 on Anvil Retainer 1using a 4 mm Allen Key.
•Unscrew Anvil Retainer 1.
•Loosen Grub Screw 7on End Cap 19 using a 4 mm Allen Key.
•Unscrew End Cap 19.
•Place a tray under the tool to catch the oil.
•If a hand pump (73010-00001) is available, connect to female coupling and slowly pump Piston 10 out of Cylinder 13.
•Otherwise clamp Piston 10 in a soft jawed vice and tap Cylinder 13 backwards with a soft mallet.
•Remove Rear Gland 17 followed by removing Securing Ring 16.
•When Securing Ring 16 is removed, tap Piston 10 forward until the piston is out.
•Remove the Front Gland 4 from Piston 10.
•Remove Rear Piston 15 from Cylinder 13.
•Inspect and replace seals if necessary with Service Kit SK40.
IMPORTANT
Be sure the HydraPac is turned off before removing tool or nose.
Examine and replace all worn parts. Fit new 'O' Rings and Back-up Rings (Service Kit SK40).
•Apply hydraulic oil to all 'O' rings, back-up rings and contact surfaces before fitting.
•Fit externally new ‘O' Ring 3and Back-up Ring 2, fit internally new Back-up Ring 5and ‘O’ Ring 6 to Front Gland 4.
•Fit internally new'O' Ring 18 to Rear Gland 17.
•Fit 'O' Ring 8 and Back-up Ring 9to Piston 10.
•Fit externally new ‘O' Ring 8and Back-up Ring 9, fit internally new Back-up Ring 5and ‘O’ Ring 6 to Rear Piston 15.
•Fit internally new Back-up Rings 11 and ‘O’ Ring 12 into Cylinder 13.
•Install Piston 10 into Cylinder 13.
•Install Front Gland 4.
•Install Anvil Retainer 1.
•Re-clamp Grubscrew 7using a 4 mm Allen Key.
•Insert Spring 14 onto rear of Piston 10.
•Install Rear Piston 15 followed by Securing Ring 16.
•Install Rear Gland 17.
•Refit End Cap 19.
•Re-clamp the Grubscrew 7using a 4 mm Allen Key.
•Bleed the Tool.
Item numbers in bold refer to the general assembly drawing and parts list on pages 10-11.
Dismantling Instructions
Assembling the Tool
Maintenance

9
To Bleed the Tool
Maintenance
To Bleed the Tool:
•Couple the short tool hoses directly onto a HydraPac or compatible hydraulic power source.
Note: Do not use long extension hoses as these will prevent the air from escaping into the HydraPac.
•Plug in a HydraPac Test Trigger.
•Position the tool so that the piston rod side faces vertically up.
•Cycle a few times.
•Reverse the vertical position and cycle again.

10
General Assembly for T40 Installation Tool
73414-02000
12
7
13
14
3
8* 9*
12*11*
10
11*
4
56
7
8* 9*
5* 6*
15
16
17 18*
19
20
21
22 23
24
25
26

11
Parts List for T40 Installation Tool
73414-02000
ITEM PART Nº DESCRIPTION QTY SERVICE KIT
T40 INSTALLATION TOOL PARTS LIST
*
'O' Rings and Back-up Rings only supplied in Service Kit SK40.
1 T404 ANVIL RETAINER 1
2 E222 BACK-UP RING 1 *
3 R222 'O'RING 1 *
4 T403 FRONT GLAND 1
5 E123 BACK-UP RING 2
*
6 R123 ëO ’RING 2 *
7 GS11 GRUB SCREW 2
8 R226 'O'RING 2 *
9 I226 BACK-UP RING 2 *
10 T402 PISTON 1
11 E219 BACK-UP RING 2 *
12 R219 'O'RING 1 *
13 T401 CYLINDER 1
1 14 T409
T405
SPRING
REAR PISTON 115
T406 SECURING RING 116
T407 REAR GLAND 117
R217 'O'RING 1
*
18
T408 END CAP 1 19
NG059 90 HOSE ADAPTOR 1 20
MS19 TRIGGER SWITCH 121
CO84 HANDLE 122
HS02 HYDRAULIC HOSE 223
HS01 QUICK COUPLER SET 24
C325 MALE PLUG
1
25
26 C106 CONTROL CORD
1
1

12
•Check for oil leaks.
•Check the stroke of tool.
•Check for worn anvil indicated by score marks on the installed collar. This can also be confirmed by referring to the installed data
in the fastener catalogue. Excessive wear can cause the anvil to rupture.
•Check function of pull pressure safety valve.
•Dismantle and clean the nose assembly especially the jaws.
•Check for oil leaks.
The tool should be completely dismantled and worn components replaced including 'O' rings and back-up rings.
•Open Ended Flat Spanners - 17, 19, 24 mm
•Allen Keys - 4 mm, 6 mm
First Aid
SKIN:
Under normal conditions skin irritation will not occur, contaminated skin should however be washed thoroughly with soap and water.
Launder contaminated clothing.
ORAL:
If swallowed and person is conscious give water or milk. Do not induce vomiting unless on advice of medical personnel. Take person
to nearest medical centre.
EYES:
Flush immediately with water for several minutes
DISPOSAL:
Remove all spills with inert absorbent material. Ventilate spill area. Place contaminated materials in a disposable container and
dispose in a manner consistent with local regulations.
Fire
FLASH POINT: 200°C.
Extinguish with either dry chemical, foam or carbon dioxide. Do not enter confined space without self contained breathing apparatus.
Handling
Use barrier cream or oil resistant gloves.
Storage
Undercover and consistent with local regulations for inflammable material.
Daily
Weekly
Service Tools
Hydraulic Oil General Safety Data
Every 1200 working hours (at least once a year)
Servicing the Tool

13
Tool fails to operate Inoperative HydraPac Check power supply to HydraPac
Loose or disconnected control cord Check for loose or broken wires
Defective switch assembly Replace switch assembly
Faulty hydraulic hose couplings Replace faulty couplings
Tool leaks hydraulic Depending on what leaks occur, Check and replace 'O' rings
oil defective or worn 'O' rings, loose and back-up rings, or
hydraulic hose connections at tool tighten hydraulic hose
Hydraulic oil Restriction in hydraulic line Check couplings and replace
overheats if necessary
Tool operates Low or erratic hydraulic See HydraPac instruction
erratically and fails pressure supply manual
to install fastener Defective or excessively worn Replace 'O' ring and back-up
properly piston, 'O' ring and back-up rings rings
and back-up rings in tool
Excessive wear or scoring of Check and replace defective
sliding surface of tool parts parts
Pull grooves on Operator not pushing nose Instruct operator in proper
fastener pintail completely onto fastener pintail installation methods
stripped during pull before operating tool
stroke Incorrect fastener length Use correct length fastener
Worn or damaged jaw segments Check and replace jaw set
Metal chips accumulated in pull Clean jaw segments
grooves of jaw segments
Excessive sheet gap Eliminate excessive gap
Collar of Hydraloc Improper tool operation See
fastener not Worn anvil in nose Check and replace anvil
completely swaged
Tool "hang up" on Improper tool operation See
swaged collar Hydrapac in idler mode Switch HydraPac off and
on and restart by
depressing trigger switch
Pintail of fastener Pull grooves on fastener stripped See
fails to break Improper tool operation Instruct operator in correct
tool operation
continued overleaf
2
1
2
2
1
Fault Diagnosis
Symptom Possible Cause Remedy Page Ref

14
Jaw segments do not Improper operation of jaw Check internal parts of the
maintain proper follower collet for wear i.e. jaws,
position in collet follower, cushion and end cap.
Clean before reassembling
Hydraulic couplers Defective or worn 'O' ring in Replace 'O' ring and back-up ring
leak oil coupler body
Pintail fails to release Incorrect assembly of Nose Refer to nose assembly table on page 5
Fault Diagnosis
Symptom Possible Cause Remedy Page Ref

15
This box contains a power tool which is in
conformity with Machines Directive
2006/42/EC. The ‘Declaration of Conformity’
is contained within.
Declaration of Conformity
We, Avdel UK Limited, Watchmead Industrial Estate, Welwyn Garden City, Herts, AL7 1LY
declare under our sole responsibility that the product:
Model: 73414-02000
Serial No. ................................................
to which this declaration relates is in conformity with the following standards:
EN ISO 12100 - parts 1 & 2
BS EN ISO 8662 - part 6 BS EN ISO 11202
BS EN ISO 3744 BS EN 982
ISO EN 792 part 13 - 2000 BS EN 983
following the provisions of the Machine Directive 2006/42/EC
Date of issue
A. Seewraj - Product Engineering Manager - Automation Tools

Since 1 936 2010Since 1922
www.avdel-global.com
www.infastech.com
02.2011 • © 2010 Infastech
Autosert®(equipment), Avbolt ®, Avdel®, Avdelmate®, Avdel TX2000®, Avdelok®, Avex®, Avibulb®, Avinox®, Avinut™, Avlug
®, Avmatic®, Avplas®,
Avseal®, Avsert®, Avtainer®, Avtronic®, Briv®, Bulbex®, Chobert®, Eurosert®, Fastriv®, Finsert®, Genesis®, Grovit®, Hemlok®, Hexsert®, Holding
your world together®, Hydra®, Interlock®, Klamp-Tite®, Klamptite KTR ®, Kvex®, Maxlok®, Monobolt®, Monobulb®, Neobolt®, Nutsert®, Nutsert
SQ®, Portariv®, Rivmatic®, Rivscrew®, Speed Fastening®, Squaresert®, Stavex®, Supersert®, Thin Sheet Nutsert®, Titan®, T-Lok®, TLR®, TSN
®,
TX2000®, Versa-Nut®, Viking®and Viking360 ®are trademarks of Avdel UK Limited. Infastech™ and Our Technology, Your Success™ are
trademarks of Infastech Intellectual Properties Pte Ltd. The names and logos of other companies mentioned herein may be trademarks
of their respective owners. This document is for informational purposes only. Infastech makes no warranties, expressed or implied, in this
document. Data shown is subject to change without prior notice as a result of continuous product development and improvement policy.
Your local Avdel representative is at your disposal should you need to confirm latest information.
AUSTRALIA
Infastech (Australia) Pty Ltd.
891 Wellington Road
Rowville
Victoria 3178
Tel: [phone]
Fax: [phone]
[e-mail]
CANADA
Avdel Canada Limited
1030 Lorimar Drive
Mississauga
Ontario L5S 1R8
Tel: [phone]
Fax: [phone]
infoA[email protected]
CHINA
Infastech (China) Ltd.
RM1708, 17/F., NanyangPlaza,
57 HungTo Rd., Kwun Tong
HongKong
Tel: [phone]
Fax: [phone]
[e-mail]
FRANCE
Avdel France S.A.S.
33 bis, rue des Ardennes
BP4
75921 Paris Cedex 19
Tel: [phone]
Fax: [phone]
AvdelF[email protected]
GERMANY
Avdel Deutschland GmbH
Klusriede 24
30851 Langenhagen
Tel: [phone]
Fax: [phone]
[e-mail]
INDIA
Infastech Fastening Technologies
India Private Limited
Plot No OZ-14, Hi Tech SEZ,
SIPCOT Industrial Growth Center,
Oragadam, Sriperumbudur Taluk,
Kanchipuram District,
602105 Tamilnadu
Tel: [phone]
Fax: [phone]
[e-mail]
ITALY
Avdel Italia S.r.l.
Viale Lombardia 51/53
20047 Brugherio (MI)
Tel: [phone]
Fax: [phone]
[e-mail]
JAPAN
Infastech Kabushiki Kaisha
Center Minami SKY,
3-1 Chigasaki-Chuo, Tsuzuki-ku,
Yokohama-city,
Kanagawa Prefecture
Japan 224-0032
Tel: [phone]
Fax: [phone]
[e-mail]
MALAYSIA
Infastech (Malaysia) Sdn Bhd
Lot 63, Persiaran Bunga Tanjung1,
SenawangIndustrial Park
70400 Seremban
Negeri Sembilan
Tel:
[phone]
Fax: [phone]
info-m[email protected]
SINGAPORE
Infastech (Singapore) Pte Ltd.
31 Kaki Bukit Road 3
#05-03/06 Techlink
Singapore, 417818
Tel: [phone]
Fax: [phone]
[e-mail]
SOUTH KOREA
Infastech (Korea) Ltd.
212-4, Suyang-Ri,
Silchon-Eup, Kwangju-City,
Kyunggi-Do, Korea, 464-874
Tel: [phone]
Fax: [phone]
[e-mail]
SPAIN
Avdel Spain S.A.
C/ Puerto de la Morcuera, 14
Poligono Industrial Prado Overa
Ctra. de Toledo, km 7,8
28919 Leganés (Madrid)
Tel: [phone]
Fax: [phone]
[e-mail]
TAIWAN
Infastech/Tri-Star Limited
No 269-7, BaodongRd,
Guanmiao Township,
71841 Tainan County,
Taiwan, R.O.C
Tel:
[phone] (ext 201)
Fax: [phone]
[e-mail]
UNITED KINGDOM
Avdel UK Limited
Pacific House
2 Swiftfields
Watchmead Industrial Estate
Welwyn Garden City
Hertfordshire AL7 1LY
Tel: [phone]
Fax: [phone]
[email protected]
USA
Avdel USA LLC
614 NC Highway 200 South
Stanfield, North Carolina 28163
Tel: [phone]
Fax: [phone]
infoA[email protected]
Manual No. Issue Change Note No. Date
A 08/083 05/08
B 08/131 06/08
B2 11/061 03/11
07900-00909