Bahco XT912 Series User manual

INSTRUCTION MANUAL
Documentation commissioner:
Andreas Bos
Version: 02.2017
BLIND RIVET NUT SETTING DEVICES
SERIES XT912

INSTRUCTION MANUAL
2
Safety Rules 3
7RRO$VSHFL¿$FDWLRQV 4
Working range 4
Tool dimensions 5
Start up
Air supply 6
Stroke adjustment 6
Operating procedure 6
Nose assemblies
List of sizes 7
Fitting and service instructions 8
Diagram & parts
General assembly 9
Part list 10
Tool service
Daily & weekly service 11
Safety data, grease 12
Priming
Oil details 12
Oil safety data 13
Priming procedure 14
Troubleshooting 15

INSTRUCTION MANUAL
3
This instruction manual must read by any person installing, operating, or servicing this
tool, with particular attention to the following safety rules.
1. Do not use the intended application.
2. Do not use equipment with this tool other than that recommended and supplied by
BAHCO.
! "#! $%&'()&*+*,*-.!/(0!1).!2(3*4!51-*()!6)3%0-17%)!+.!-8%!56&-(2%0!-(!-8%!-((,9!)(&%!!
assemblies, accessories or any equipment supplied by BAHCO or their representi-
ves, falls directly to the customer. BAHCO will be pleased to advice upon any
! ! '0('(&%3!2(3*4!51-*()#
4. The tool must be maintained in safe working order at all times and examined at
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this tool without prior reference to the maintenance instructions.
5. The precautions to be observed when using this tool must be explained by the
customer to all operators.
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remove a nose assembly.
7. Do not operate a tool that is directed towards any person(s) or the operator.
! B#! ?,@1.&!13('-!1!4!02!/((-*):!(0!1!&-1+,%!'(&*-*()!+%/(0%!('%01-*):!-8%!-((,#
! C#! D8%!('%01-*):!'0%&&60%!&81,,!)(-!%E5%%3!F!+10!GHII!,+J*)KL#!!
10. Do not operate the tool without full nose equipment, oil plug and oil bleed screw in
place.
11. When using the tool, safety glasses must be worn by both the operator and others
! ! *)!-8%!;*5*)*-.!-(!'0(-%5-!1:1*)&-!'*)!%A%5-*()9!&8(6,3!1!/1&-%)%0!+%!',15%3!M2*31*0N#!!
We recommend wearing gloves if the application has any sharp edges or corners.
12. Take care to avoid entangling of loose clothing, neck ties, long hair, cleaning rags
etc. in the moving parts ofthe tool, which should be kept clean and dry for the best
possible grip.
13. Excessive contact with hydraulic oil should be avoided. To minimise the possibility
of rashes, care should be taken to wash thoroughly.

INSTRUCTION MANUAL
4
Working pressure 5 - 7 bar (75 - 100 SI)
Pull force 30 kN (6 bar)
Max. Stroke 6 mm (.238 in)
Cycle hue < 2.5 Sekunden
Noise level < 75 dB (A)
Free air required 9 Liter
Weight 2.2 kgs
Vibration O!P#QJ2&K!GB!/-J&KL
Technical Data
Material M3 M4 M5 M6 M8 M10 M12
Steel XXXXXXX
Aluminium XXXXXXX
Stainless steel XXXXXXX
Working range

INSTRUCTION MANUAL
5
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8*:8!&'%%39!217*):!*-!*3%1,!/(0!+1-58!(0!V!(@S,*)%!1&&%2+,.!*)!1!@*3%!;10*%-.!(/!1'',*51S
tions throughout all industries.
Dimensions shown are in millimetres

INSTRUCTION MANUAL
6
Air supply
All tools are operated with compressed air at an optimum pressure of 6 bar (max. 7 bar).
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on the main air supply. 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 shall have a minimum bore diameter of 6.4 millimetres or 1/4
inch.
Stroke adjustment
This adjustment is required to achieve optimum deformation of the rivet nuts. The tool is
factory set to a stroke of 3 mm. Turn the Adjusting Ring (9) to the left to reduce it, to the
right to extend the stroke length. Each stroke step changes the stroke length by 0.1 mm.
To determine the correct stroke, it is recommended to place some blind rivet nuts in a
test plate with the same sheet thickness and hole diameter as the original sheet.
X/!-8%!3%/(021-*()!*&!*)&6/4!5*%)-9!-8%!+,*)3!0*;%-!)6-!51)!0(-1-%!*)!-8%!&8%%-!2%-1,#!X/!-((!
large a stroke is set, there is a risk that the mandrel tears off or the thread of the blind
rivet nut is damaged during the setting process.
For guide values for the stroke adjustment, refer to the instructions of the blind rivet nut
manufacturer.
Lubrication
Pressure regulator
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INSTRUCTION MANUAL
7
Operating Procedure
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Y![(&*-*()!-8%!+,*)3!0*;%-!)6-!()!-8%!\1)30%,!(1). A slight pressure on the upper half of the
Trigger (34) starts the clockwise rotation of the engine and the nut is spinded onto the
Mandrel as far as the stop on the mouthpiece.
Y!X)&%0-!+,*)3!0*;%-!)6-!CI!]!-(!-8%!',1-%!*)-(!-8%!&%--*):!8(,%#
Y![0%&&*):!-8%!,(@%0!81,/!(/!-8%!0%,%1&%!+6--()!@*,,!%E%56-%!-8%!&%-!&-0(7%!1)3!0*;%-!-8%!)6-#
The mandrel is automatically spinded out of the set nut.
Nose tips vary in shape according to the insert type. Each nose assembly can be orde-
red individually. Component numbers refer to the illustration. We recommend keeping
some stock as items will need regular replacement. Read the Nose Assemblies servi-
cing instructions carefully.
Mandrels and Mouthpieces XT912
'$1
mm Mandrel Mouth- piece A B C G
M 3 2111-3 2112-3 8-14 26 10 17
M 4 2111-4 2112-4 7-13 26 10 17
M 5 2111-5 2112-5 8-14 26 11 20
M 6 2111-6 2112-6 10-16 27 13 20
M 8 2111-8 2112-8 12-18 28 16 20
M10 2111-10 2112-10 14-20 28 18 20
M12 2111-12 2112-12 16-22 27 20 20
Mandrels and Mouthpieces XT912
'$1
mm Mandrel Mouth- piece A B C G
M 3 11685-3 11713-3 4-10 7 10 15
M 4 11685-4 11713-4 7-13 7 10 20
M 5 11685-5 11713-5 10-16 7 11 20
M 6 11685-6 11713-6 15-21 8 13 20
M 8 11685-8 11713-8 17-23 9 16 20
M10 11685-10 11713-10 20-26 9 18 20
M12 11685-12 11713-12 20-26 8 20 20
Mandrels and Mouthpieces XT912
'$1
mm Mandrel Mouth- piece A B C G
M 4 4331-4 4330-4 5,5-11,5 27 20 25
M 5 4331-5 4330-5 5,5-11,5 27 20 25
M 6 4331-6 4330-6 5,5-11,5 27 20 25
M 8 4331-8 4330-8 5,5-11,5 27 20 25
Dimensions are shown in millimetres

INSTRUCTION MANUAL
8
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of the fastener to be placed, will enable you to order a complete new nose assembly
using the selection tables an page 7.
Fitting instructions for Nose Assemblies
IMPORTANT!
D8%!1*0!&6'',.!26&-!+%!3*&5())%5-%3!@8%)!4!--*):!(0!0%2(;*):!)(&%!1&&%2+,*%&!6),%&&!
&'%5*4!51,,.!*)&-065-%3!(-8%0@*&%#
Item numbers in bold refer to illustration below:
Y!^((&%)!-8%!,(57)6-!(4)
Y!$%2(;%!2(6-8'*%5%!(2) with Locknut (4).
Y!^((&%)!-8%!&50%@&!(32) and screw in the adjusting sleeve (9) completely.
Y![6,,*):!-8%!'*)!(3)
Y!$%2(;1,!(/!-8%!21)30%,!(1)
Y!?&&%2+,%!*)!0%;%0&%!(03%0
Y!X)&%0-!2(6-8'*%5%!/(0!&%,%5-%3!0*;%-!)6-!1)3!-*:8-%)!,(57)6-!(4).
Servicing Instructions
Nose assemblies should be serviced at weekly intervals.
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Y!?).!@(0)!(0!3121:%3!'10-&!&8(6,3!+%!0%',15%3!@*-8!)%@!'10-&#
Y![10-*56,10,.!58%57!@%10!()!\1)30%,!(1).
Y!?&&%2+,%!155(03*):!-(!*)&-065-*()&!1+(;%#

INSTRUCTION MANUAL
9

INSTRUCTION MANUAL
10
Pos. Art.No. Description Qty
1 2111-d Mandrel 1
2 2112-d Mouthpiece 1
3 5421 Pin 1
4 2113 Locking nut 1
5 12348 Housing 1
6 12350 Mandrel holder 1
7 12349 Nut 1
8 6055 Bearing 1
9 12346 Adjust. sleeve 1
10 12347 Plate 1
11 12345 Front plate 1
12 12351 Holder 1
13 12341 Hydraulic piston 1
14 6429 O-Ring 1
15 6056 Bearing 3
16 6428 O-Ring 1
17 12352 Holder 1
18 12353 Front plate 1
19 2120 Blade 10
20 12354 Rotor 1
21 12355 Cylinder 1
22 12356 Rear plate 1
23 6481 Packing 1
24 11873 Suspension ring 1
25 6521 Packing 1
26 6568 Packing 1
27 5841A Spring 1
28 6560 Packing 1
29 5125 Screw 4
30 6322 O-Ring 1
31 2153 Nylon plug 7
32 5021 Screw 7
33 5525 Pin 1
34 11319 Trigger 1
35 5482 Pin 1
36 12365 Valve 2
37 12363 Valve guide 2
38 5896 Spring 1
39 12338 Valve seat 4
40 12366 Plate 4
41 6313 O-Ring 7
42 6317 O-Ring 5
43 1438 Inlet adapter 1
44 12339 Handle 1
45 6219 Spring 1
Pos. Art.No. Description Qty
46 6421 O-Ring 5
47 6430 O-Ring 9
48 12357 Valve housing 1
49 12359 Piston guide 1
50 6427 O-Ring 2
51 6426 O-Ring 2
52 12358 Valve rod 1
53 12360 Piston 1
54 12361 Holder 1
55 5611 Locking ring 1
56 12362 Pressure rod 1
57 12364 Cover 1
58 6422 O-Ring 1
59 6856 Valve 1
60 12468 Filter 1
61 2714-130 Tube 1
62 6509 Packing 2
63 5649 Locking ring 1
64 12372 Piston 1
65 6433 O-Ring 2
66 6352 O-Ring 1
67 12444 End piece 1
68 5523 Piston rod 1
69 12445 Air cylinder 1
70 12443 Housing 1
71 2785 Membrane 1
72 5645 Locking ring 1
73 5072 Screw 4
74 2782 Cover 1
75 12464 Filter 1
Spare Part List

INSTRUCTION MANUAL
11
Reagular servicing should be carried out and a comprehencive inspection performed
annually or every 500.000 cycles, whichever is sooner.
IMPORTANT!
The employer is responsible for ensuring that tool maintenance instructions are
given to the appropriate personnel. The operator should not be involved in main-
tenance or repair ofthe tool unless properly trained.
Daily
Y!=1*,.9!+%/(0%!6&%!(0!@8%)!4!0&-!'6--*):!-8%!-((,!*)-(!&%0;*5%9!'(60!1!/%@!30('&!(/!5,%1)9!!
! ,*:8-!,6+0*51-*):!(*,!*)-(!-8%!1*0!*),%-!(/!-8%!-((,!*/!)(!,6+0*51-(0!*&!4!--%3!()!-8%!1*0!&6'',.#!!
If the tool is in continuous use, the air hose should be disconnected from the main air
supply and the tool lubricated every two days to three hours.
Y!Z8%57!/(0!1*0!,%17&#!X/!3121:%39!8(&%&!1)3!5(6',*):&!&8(6,3!+%!0%',15%3!@*-8!)%@!!
items.
Y!X/!-8%0%!*&!)(!4!,-%0!()!-8%!'0%&&60%!0%:6,1-(09!+,%%3!-8%!1*0!,*)%!-(!5,%10!*-!(/!155626,1-%3!!
dirt or water before connecting the air hose to the tool.
Y!Z8%57!-81-!-8%!)(&%!1&&%2+,.!*&!5(00%5-#
Y!Z8%57!-81-!-8%!&-0(7%!(/!-8%!-((,!*&!13%<61-%!-(!',15%!-8%!&%,%5-%3!*)&%0-#
(See stroke adjustement page 6).
Y!X)&'%5-!-8%!\1)30%,!(1) in the nose assembly for wear or damage. If found, replace.
Weekly
Y!Z8%57!/(0!(*,!,%17&!1)31*0!,%17&!()!1*0!&6'',.!8(&%!1)3!4!--*):&#

INSTRUCTION MANUAL
12
CASTROL LMX Safety Data
First Aid
Skin: Wipe off and wash with soap and water.
Ingestion: No adverse effects are normally expected.
Eyes: Irriant but not harmful. Irrigate with water and seek medical
attention.
Environment
Scrape up for incineration or disposal at approved site.
Fire
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! ! ! ! 3*1a!Z10+()!3*(E*3%9!/(129!30.!'(@3%0!(0!4!)%!@1-%0!&'0.#
Handlin: Plastic or rubber gloves should be worn.
Storage: Away from heat and oxidising agents.
Complete Safety Data Sheet can be download from www.castrol.com.
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 consideralbe use, when the stroke
may be reduced and fasteners are not fully inserted.
Oil Details
The recommended oil for priming is Castrol Hispin AWS 32. Please see safety data next
page. Complete Safety Data Sheet can be download from www.castrol.com.

INSTRUCTION MANUAL
13
Oil Safety Data
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
unless directed to do so by medical personnel.
Eyes: Irrigate immediately with water for at least 15 minutes. Seek
medical attention if irritation occurs.
Fire
_,1&8!'(*)-! ! PPP]Z9!U(-!5,1&&*4!%3!1&!V!1221+,%#!`6*-1+,%!%E-*):6*&8*):!2%!
dia: CO2 , dry powder, foam or water fog. DO NOT use water
jets.
Environment
Water disposal: Through authorised contractor to a licensed site. May be incine-
rated. Used product may be sent for reclamation.
Spillage: Prevent entry into drains, sewers and water courses. Soak up
with absobent material.
Handling
Wear eye protection, impervious gloves (e.g. PVC) and aplastic apron. Use in well-
ventilated area.
Storage
Keep container tightly closed. Keep container in a cool and well-vnetilated area.

INSTRUCTION MANUAL
14
Priming Procedure
IMPORTANT!
All operations should be carried out on a clean bench, with clean hands in a clean
area. Ensure that the oil is perfecly clean and free from air bubbles. Care Must
be taken at all times to ensure that no foreign matter enters the tool, as serious
damage may result.
Y!b)&60%!-81-!-8%!*0!,*)%!*&!3*&5())%5-%3#
Y![,15%!-8%!-((,!*)!1)!6'0*:8-!'(&*-*()9!c*,!&50%@!(24) upwards.
Y!d)&50%@!c*,!&50%@!(24) with an allen key and remove with Seal (25).
Y!$%4!,,!e.3016*,5!c*,!*)!-8%!8(,%!1)3!&817%!-8%!-((,!-(!0%2(;%!1*0!+6++,%&#
Y!\(6)-!`6&'%)&*()!$*)c*,&50%@!(25) and Seal (26).
Y!Z())%5-!1*0!&6'',.!1)3!06)!1,,!/65-*()&!1!/%@!-*2%&#
Y!Repeat the procedure 2 - 5 times until the oil is free from air.
Y!X-!*&!)%5%&&10.!-(!4!-!-8%!1''0('0*1-%!)(&%!%<6*'2%)-!1)3!13A6&-!-8%!-((,!&-0(7%!'0*(0!-(!!
operating the tool.
Item number in bold refer to general assembly drawing and spare part list (page 9-10).

INSTRUCTION MANUAL
15
Fehlerbeseitigung
Symptom Possible cause Remedy
Tool does not term Low air pressure
Air leak from motor
Rotor blades jammed
Adjust to 5.5-7 bar / 75-100 SI
Check seals and replace
Lubricate tool through air inlet
Tool is jammed with insert Defective insert
Defective or worn Mandrel
Excessive stroke
Try to run spin off function manually
by pushing Valve (56). If not, loosen
Locking Nut (4) and turn in Nose piece
(2) and try manual spin off again. If
not, remove Plug, lock the rotation with
a pin and turn the tool until the insert
comes out.
Change Mandrel and insert.
Mandrel breaks Side load on Mandrel
Excessive stroke Place tool square to application Adjust stroke length
Tool does not pull and deform insert Low air pressure
Low oil level
Incorrect stroke
Adjust 5.5-7 bar / 75-100 SI
Prime tool
Adjust stroke length
Trigger does not work Jammed valves
Trigger is jammed Clean and grease valves, check springs
Adjust so that Trigger (34) moves
easily
Tool leaks oil Worn or defective seals
Suspension Ring loose
Replace seals, use BAHCO Seal-kit,
and prime tool
Prime tool and tighten Suspension
Ring

BAHCO GmbH & Co.KG
Martener Hellweg 60
DE- 44379 Dortmund
Phone
+49 231/91 72 11-0
Fax
+49 231/91 72 11-22
www.bahco.de
[e-mail]