OKU EP-12 User manual

English Stud Gun EP-12, EP-15
Stud Gun
Automatic Stud Gun EP-12, EP-15
Operating instructions
(ID-No. 00035103)
assembled:

00100264 EP-12 Date: _________________

00100265 EP-15 Name: _________________
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
Table of contents
Table of contents......................................................................................................................2
1 Preface and general information...........................................................................................3
1.1 General...........................................................................................................................3
1.2 Scope of supply..............................................................................................................3
1.3 Intended use...................................................................................................................3
1.4 Liability............................................................................................................................4
1.5 Warranty.........................................................................................................................4
2 Safety information .................................................................................................................5
2.1 Personnel responsible for safety ....................................................................................5
2.1.1 Operator...................................................................................................................5
2.1.2 Qualified personnel..................................................................................................5
2.2 General safety instructions.............................................................................................6
2.3 Layout of the safety instructions.....................................................................................6
3 Technical Data ......................................................................................................................8
3.1 Stud types.......................................................................................................................8
3.2 Dimensions and weight...................................................................................................8
3.3 Noise emission ...............................................................................................................8
3.4 Ambient conditions .........................................................................................................8
4 Commissioning......................................................................................................................9
4.1 Pneumatic connection ....................................................................................................9
5 Operation of the gun............................................................................................................10
5.1 Insertion of studs ..........................................................................................................10
5.2 Faults during insertion ..................................................................................................11
5.2.1 Studs inserted to deep...........................................................................................11
5.2.2 Studs jut out off the tire..........................................................................................11
6 Faults and troubleshooting..................................................................................................12
7 Lubrication and maintenance..............................................................................................13
7.1 Lubrication....................................................................................................................13
7.1.1 Lubricating oil.........................................................................................................13
7.1.2 Lubricating grease..................................................................................................13
7.2 Greasing points.............................................................................................................14
7.3 Maintenance.................................................................................................................14
8 Shutdown and dismounting.................................................................................................15
9 Spear and wear parts..........................................................................................................16
9.1 Requirements ...............................................................................................................16
9.2 Handling of order..........................................................................................................16
9.3 Explanation of spare parts list.......................................................................................16
9.4 Spare parts-set.............................................................................................................16
9.5 Exploded drawing EP-12, EP-15..................................................................................17
9.6 Spare parts list EP-12, EP-15.......................................................................................18
10 Appendix ...........................................................................................................................19
10.1 CE-Declaration of Conformity.....................................................................................19
10.2 Copyright ....................................................................................................................20
10.3 Manufacturer and contact person...............................................................................20
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
1 Preface and general information
1.1 General
The operating instructions is used for safe operation of the Stud Guns (in the
following referred to as “gun“) type Automatic Stud Gun EP-12 and EP-15 (ID-
No. 100264, 100265)). The safety instructions included hereinafter must be
observed.
The operating instructions must be available for anybody who is working with
the gun and the included instructions must be carefully attended to.
The operating instructions must always be complete and perfectly readable.
1.2 Scope of supply
The delivery normally consists of a stud gun, the operating instruction and 1
separating finger for multi-flange studs fingers (only EP-8 and EP-9). The
parts included in your delivery are stated in the accompanying papers.
These papers shall be checked for conformity, immediately after receipt of the
goods. OKU Systems GmbH & Co. KG does not provide any guarantee and/or
accept any liability for defects complained belatedly.
Therefore:
•Contact the forwarder immediately to complain visible transit dam-
ages.
•Contact OKU Systems GmbH & Co. KG immediately to complain
visible defects and/or incompleteness of delivery.
1.3 Intended use
The gun is intended to be used only for the insertion of single and multi-flange
spikes into tyres of trucks.
Any other use shall be deemed to be inappropriate!
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
1.4 Liability
The information, data and notes of this operating instruction were up-to-date
when passing for press. The specifications, illustrations and descriptions in-
cluded hereinafter do not apply for any previously supplied guns.
We do not accept liability for damages and operating troubles caused by:
•inappropriate use.
•unauthorized modification of gun.
•improper operation of the gun.
•operating errors.
•disregard of this operating instructions.
1.5 Warranty
Conditions of warranty: see Standard Terms and Conditions of OKU Systems
GmbH & Co. KG.
Assert warranty claims against OKU Systems GmbH & Co. KG immediately
after detection of the defect.
Warranty claims expire in each case in which liability claims cannot be made.
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
2 Safety information
2.1 Personnel responsible for safety
2.1.1 Operator
Operator is called any natural or legal person who is using the gun and/or on
behalf of whom the gun is used.
The operator and/or his safety officer must ensure,
•observance of the relevant regulations, instructions and laws.
•only qualified personnel is working with the gun.
•personnel having the operating instructions available at any time.
•to prohibit non-qualified personnel from working with the gun.
2.1.2 Qualified personnel
As qualified personnel are to be considered persons who were authorised by
the safety officer of the plant to perform the necessary activities and who are
able to recognise and avoid potential hazards because of their education, ex-
perience, instructions and their knowledge about corresponding standards and
rules for the prevention of accidents as well as operating conditions
(see IEC 364, definition for qualified personnel).
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
2.2 General safety instructions
These safety instructions do not claim to be exhaustive. In case of any ques-
tions, please, contact OKU.
At the time of delivery the gun is state of the art and reliable.
The gun is a source of danger for persons, for the gun itself and for other ma-
terial assets of the operator, if
•it is operated by unqualified personnel.
•it is used inappropriately.
Operate the gun only when it is in good condition.
Any upgrade, modification or redesign of the gun is basically prohibited. In this
case, please confer with OKU.
2.3 Layout of the safety instructions
The safety instructions described hereinafter are arranged consistently.
Beware of personal injury
Pictogram Meaning Signal words Notes
Warning for hazardous
electrical voltage Warns of imminent danger.Danger!
Consequences of disregarding:
Death or very severe injuries
Warns of a potential, very haz-
ardous situation.
Consequences if disregarded:
Death or very severe injuries
Warning for general dan-
ger
Warning!
Warns of a potential hazard-
ous situation.
Consequences if disregarded:
Light or minor injuries
Warning for a general dan-
ger
Caution!
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
Warning of material damage
Icons used Meaning Signal words Notes
Warns of potential material
damage.
Consequences if disregarded:
Ambient damage or damage of
the gun.
Warning of material dam-
age Stop!
Other information
Icons used Meaning Signal words Notes
Designates a general, useful
note.
Adherence hereof will ease the
use of the gun.
General note Note!
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
3 Technical Data
3.1 Stud types
The gun can be used for the insertion of single-flange and multi-flange studs
into car tires. Factory setting is for the insertion of single-flange studs.
Type ID.-No. Stud sizes
EP-12 00100264 Ø12, 15-25 mm length
EP-15 00100265 Ø15, 18-25 mm length
3.2 Dimensions and weight
The following values are valid for the gun without any accessories and can dif-
fer according to the respective extra equipment.
Length ca. 310 mm
Width ca. 70 mm
Height ca. 182 mm
Weight ca. 2,6 kg
3.3 Noise emission
The sound pressure level at the work station of the operator can reach up to
83 dB(A). Provide suitable ear protection for the operator.
3.4 Ambient conditions
Use the gun only in closed and dry rooms.
The permissible ambient temperature during operation is from 10 °C to 40 °C.
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
4 Commissioning
Precautions to be taken before start working with the gun
•Check gun for proper condition.
•Do never operate a damaged gun.
4.1 Pneumatic connection
Attention!
The pneumatic connection is to be made by qualified
personnel with extensive knowledge in handling of
pneumatic systems.
Screw provided coupling (1) onto the hand grip. Plug compressed air hose into
coupling. The gun requires compressed air with approx. 7-8 bar working pres-
sure. The maximum operating pressure amounts to 10 bar.
Coupling (1) for com-
pressed air connection
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
5 Operation of the gun
5.1 Insertion of studs
Without feeding unit: fill the feeding pipe (13) with approx. 10 studs (flange
leading).
With feeding unit: connect the gun with the feeding hose of the studs until
feeding pipe (13) is filled with studs (flange leading).
Moisten tire with low surface tension water. To get this, mix normal tap water
with some drops of usual dish liquid.
Tip!
Use only less dish liquid to avoid that the inserted
stud is pulled out again when extracting the gun.
Insert spreader fingers (34) into one of the moistened tyre holes. Operate the
trigger (17) and keep it pressed. The stud is pressed into the tire. Release trig-
ger; the gun is now loosen from the tire and the stud is inserted.
Tip!
Put some pressure onto the gun when inserting the
studs. With some practice and skill you’ll soon find
the respective pressure which shall be applied to
reach a steady result.
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
5.2 Faults during insertion
5.2.1 Studs inserted to deep
Reduce the pressure applied on the gun during insertion.
5.2.2 Studs jut out off the tire
Put more pressure onto the gun when inserting the studs.
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
6 Faults and troubleshooting
Caution!
When unscrewing the intermediate piece (21), it
must be held tight, because of the strong com-
pression spring which is in the gun. If not, it can be
ejected and pose great danger.
No. Cause Trouble shooting
Deformed or dirty stud jammed in feeding
pipe (13) or gun head. Unscrew union nut (33) and take the head (25) off the gun. Now remove the jammed
stud.
6.1
Stud in feeding pipe (13) in wrong position
(with shank leading)
6.2 Remove feeding tube and shake out stud
Remove O-Ring (19) and dowel pin (18) and
then trigger (17). Clean and lubricate trigger
slightly with oil.
Check if compression spring (3) broken, if so
replace compression spring.
6.3 Trigger (17) get caught
Unscrew union nut (33) and take the head
(25) off the gun. Remove O-Ring (31) and
replace spreader finger (34)
6.4 Worn spreader fingers (34)
Unscrew union nut (33) and take the head
(25) off the gun. Unscrew both hexagon
head cap screws (16) (Caution!), press
intermediate piece (21) against hand grip
(back-pressure of inner springs). Remove
intermediate part and circlip (15). Extract
push rod (22) together with the springs (10,
11), retaining ring (14) piston disk (6) lip seal
(7) and bushing (23). Unscrew hexagon nut
(8) and replace worn push rod. Assemble
the gun in reversed order and replace hexa-
gon nut if necessary.
6.5 Worn push rod (22)
Unscrew union nut (33) and take the head
(25) off the gun. Remove O-Ring (31) and
replace centring finger (32).
6.6 Worn centring finger (32)
Unscrew union nut (33) and take the head
(25) off the gun. Remove separating flap
(26) from dowel pin (29). The compression
spring (28) may not jump out. The separat-
ing pin (27) is riveted with the separating flap
(26). Grind off closing head and drive off
separating pin with a drift punch. Replace
and rivet separating pin. Assemble the gun
in reversed order.
6.7 Worn separating pin (27)
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
7 Lubrication and maintenance
7.1 Lubrication
Stop!
Observe the effective directions for the use and
safety of the applied lubricants!
7.1.1 Lubricating oil
Distinguishing Designation ISO-Viscosity Manufacturer
mark acc. to Index
DIN 51502 DIN 51519
Normal lubri-
cating oil AVIA (AVILUB RS 22) BP (BP Energol CS 22)
ESSO (Coray 22)
SHELL (SHELL Carnea Oel 22)
AN 22 ISO VG 22
7.1.2 Lubricating grease
Designation Designation Consistency Worked pene- Manufacturer
acc. to
DIN 51825 Index tration as per NLGI Class as per DIN ISO 2137
DIN 51818
Lubricating
grease for
bearing
KP2K-20 NLGI-2 265-295
AVIA (AVIALITH 2)
BP (Energrease L2)
ESSO (Beacon 2)
KLÜBER (CEN-
TOPLEX 2 EP)
MOBIL (Mobilux 2)
SHELL (Alvania R 2)
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
7.2 Greasing points
The following points of the gun need to be greased regularly. You will find a
maintenance-set including grease and corrosion preventive-oil-spray in the
spare parts list in chapter 9.6.
To grease the gun it must be partially dismounted (see hereto chapter 6
“Faults and trouble shooting”. We recommend taking the opportunity and
greasing the gun when replacing the wear parts.
No. Designation Service to be Consumables Frequency Notes
done Measured values
Lubricate with
oil Lubricating oil DIN 51501-L-AN 22 Oil trigger slightly
1 Trigger quarterly
Piston disk
Lip seal Lubricate with grease Lubricating grease DIN 51825-KP2K-20 Grease piston surface slightly
2 yearly
Separating
flap Lubricate with grease Lubricating grease DIN 51825-KP2K-20 Grease dowel pin and frontal
contact surface
of head gun
slightly
3 quarterly
2
3 1
7.3 Maintenance
We are working with water to insert the studs, therefore the head of the gun
shall be sprayed regularly with anticorrosive material to avoid corrosion and
extend lifetime of the gun.
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
8 Shutdown and dismounting
OKU takes back your gun. We recommend you have OKU professionally dis-
mantle the gun and dispose of it.
Tip!
Be part of the environmental protection by recy-
cling valuable materials.
What? Where?
Return to the manufacturer or for-
warder
Transport material Pallets
Packing material
Cardboard boxes to waste paper
plastic to plastic recycling or waste
material
reuse wood-wool or waste material
Dispose according to the valid regu-
lations
Lubricants Oil, grease
Used materials:
aluminium
aluminium cast
grey cast iron
steel
brass
plastic
Separate valuable substances and
dispose
Components
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
9 Spear and wear parts
9.1 Requirements
Stop!
Spare and wear parts must be in accordance with
the technical requirements stipulated by the manu-
facturer.
9.2 Handling of order
To ensure punctual handling of orders, please state always the OKU-ID.-No.
of the spare part you need when ordering. You’ll find the OKU-Id.-No. on the
drawing of the gun and the spare parts list.
9.3 Explanation of spare parts list
The numbers on the exploded drawing correspond to the item numbers of the
spare parts list.
9.4 Spare parts-set
To the gun there is available a spare parts-set including the most important
wear parts. It contains all in the spare parts list with Àmarked parts inclusive
grease and corrosion preventive-oil-spray.
OKU-Id.-No. spare parts-set EP-12: 20015508
OKU-Id.-No. spare parts-set EP-15: 20015509
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
9.5 Exploded drawing EP-12, EP-15
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
9.6 Spare parts list EP-12, EP-15
Item OKU part No. Qty Designation
1 00031539 1 Coupling
2 00003463 1 O-Ring
3 00350297 1 Compression spring
4 00350728 1 Bushing
5 00470942 1 Hand grip
6 00350664 1 Piston disk
7 00003507 1 Lip seal
8 00004082 1 Hexagon nut M8
9 00000613 1 Eyebolt
10 00000627 1 Hexagon nut M6
11 00350670 1 Compression spring,
inner
12 00350669 1 Compression spring,
outer
13 00350659 1 Feeding pipe 12
00350660 1 Feeding pipe 15
14 00350666 1 Retaining ring
15 00000796 1 Circlip
16 00004099 2 Hexagon socket head
cup screw
17 00470092 1 Trigger
Item OKU part No. Qty Designation
18 00000536 1 Dowel pin
19 00003464 1 O-Ring À
20 00003404 1 O-Ring
21 00470238 1 Intermediate piece
22 00250053 1 Push rod 12 À
00250049 1 Push rod 15 À
23 00350710 1 Sleeve
24 00000300 1 Set screw
00470221 1 Gun head EP-1225 00470222 1 Gun head EP-15
26 00350991 1 Separating flap
27 00403148 1 Separating pin
28 00350665 1 Compression spring
29 00350806 1 Dowel pin
30 00004083 1 Spring dowel pin
31 00003467 1 O-ring À
32 00353731 3 Centering finger À
33 00350923 1 Union nut
34 00470946 3
Spreader finger for
truck À
00885027 1 corrosion preventive-oil, aerosol can 100 ml (single) À
00885028 1 grease, tube 20 g (single) À
20015510 1
1 aerosol can corrosion preventive-oil (100 ml) and
1 tube grease (20 g) as maintenance-set
À= included in the spare parts-set
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
10 Appendix
10.1 CE-Declaration of Conformity
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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English Stud Gun EP-12, EP-15
10.2 Copyright
© 07/2013
This documentation is protected by copyright which covers the exclusive rights
to reproduce and distribute the documentation, as well as all translation rights.
No material published in this documentation may reproduce photographically
or stored on microfilm, in electronic data bases, video disks, etc. Technical
modifications reserved.
10.3 Manufacturer and contact person
OKU Systems GmbH & Co. KG
Assembly and Feeding Systems
Rosenstraße 15
73650 WINTERBACH
GERMANY
Postfach 11 20
73643 WINTERBACH
GERMANY
Phone: [phone]
Fax: [phone]
Internet: http://www.oku.de
Your contact person is:
Sales Department Studs Phone: [phone]
Fax: [phone]
[email protected]
E-Mail:
OKU Systems GmbH & Co. KG, 73650 Winterbach, Germany
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