Sherex FLEX?5S Instruction manual

Quick Start Manual
FLEX‐5S
Threaded Insert Power Tool
Pull to Stroke Set Up

PartoftheFLEXfamilyofmodular‐basedtooling.
FLEXtoolinghasthecapabilitytobeupgradedfromtheoriginalbasetool.
Upgradesincludeprocess‐monitoring,conversiontoin‐linetool,
conversiontoasplittoolwitharemotebooster,
andconversiontoapulltopressuretool.


cONTENTS
SAFETY........................................................................................................................................................................2
TOOL OVERVIEW........................................................................................................................................................3
TOOL SPECIFICATIONS.............................................................................................................................................4
AIR SERVICE................................................................................................................................................................5
NOSE KIT ASSEMBLY................................................................................................................................................ 5
NOSE ASSEMBLY COMPONENTS............................................................................................................................6
PULL FORCE REGULATION......................................................................................................................................7
OPERATION.................................................................................................................................................................7
MAINTENANCE...........................................................................................................................................................8
TROUBLESHOOTING.................................................................................................................................................9
SHEREX SHOWCASE.................................................................................................................................................10
Sherex Warranty
Sherex Fastening Solutions FLEX-5S carries a 6 month warranty against defects that are
caused by faulty materials or workmanship. Sherex warranty period commences from the
date of delivery which is confirmed either by the invoice or delivery note. The warranty
becomes invalidated if the installation tool is misused or not serviced, maintained, and
operated according to the instructions in the Quick Start and Repair Manuals.
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1

SAFETY
DO NOT USE THIS TOOL FOR ANY PURPOSE OTHER THAN THOSE SPECIFIED.
DO NOT USE ANY EQUIPMENT ALONG WITH THE TOOL THAT HAS NOT BEEN
RECOMMENDED OR PROVIDED BY SHEREX FASTENING SOLUTIONS.
▪Failure to do so could result in voided warranty and/or personal injury
THIS TOOL MUST BE KEPT IN EXCELLENT CONDITION AND SHOULD BE CHECKED
BY SPECIALIZED PERSONNEL ON A REGULAR BASIS TO DETECT DAMAGES AND
EVALUATE ITS OPERATING CONDITION.
ALWAYS DISCONNECT THE AIR SUPPLY BEFORE SET UP, ADJUSTMENT, OR
REMOVAL OF THE NOSE ASSEMBLY.
AIR INLET SHALL NOT EXCEED 7 BAR (102 PSI).
DO NOT USE THE TOOL WITHOUT OIL PLUG IN PLACE.
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2

TOOL OVERVIEW
The FLEX-5S tool is designed for installing Sherex threaded insert/rivet nuts. The tool utilizes a pull to
stroke installation method. The advantage with this method is that the pulling distance of the tool can
be set to a specified distance ensuring the rivet nut insert is pulled to the same position (distance)
with each actuation of the tool (contact Sherex for the conversion instructions for changing this tool to
a pull to pressure installation method).
The tool is designed to install rivet nuts from M3 to M10, # 6-32 to 3/8-24. The recommended
operating air pressure is between 5 - 7 bar (72.5 - 101.5 PSI).
Sherex
Rivet Nut Series

Thread
Sizes
CAL
CAK
CAH
CAO
CPB
CPN
CA
CFH
CFT
CFW
TU
CLM
CKM
#6 & M3 X
#8 & M4 X
#10 & M5 X
1/4 & M6 X
5/16 & M8 X X
3/8 & M10 X X X
FLEX Tool Recommended
X FLEX Tool Not Recommended
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3

SPECIFICATIONS
FLEX-5S Tool Specifications
AIR PRESSURE Minimum - Maximum 5 – 7 bar 72-101 psi
STROKE Maximum 7 mm .280 in
MOTOR SPEED SPIN ON 1500 rpm
SPIN OFF 2000 rpm
PULL FORCE @ 6.2 bar 22.25 kN 5,000 lbf
CYCLE TIME Approximately 2.5 sec
NOISE LEVEL Less than 70 dB(A)
WEIGHT Without kit 1.9 kg 4.2 lbs
VIBRATION Less than 2.5 m/s2
PLACING FEATURES Inserts M3 – M10 # 6-32 – 3/8-24
Contact Sherex should you require a pull to
stroke setup for this tool (FLEX 5P)
FLEX TOOL DIMENSIONS
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4
10.24
260.1
10.45
265.43
2.0
50.3
Dimensions shown in bold are in inches. The other
dimenions are in millimeters.
4.32
109.73

SERVICE
AIR SUPPLY
We suggest you use a pressure regulator and automatic oiling / filtering system on the main air
supply, to ensure its maximum life cycle with reliable trouble free use.
NOSE KIT ASSEMBLY
ASSEMBLY INSTRUCTIONS
IMPORTANT
DISCONNECT THE AIR SUPPLY WHEN SETTING UP
OR REMOVING A NOSE ASSEMBLY.
•Choose the proper nose assembly.
•Remove the nose case, if still mounted.
•Unscrew the adaptor nut while moving away the stop pins.
•Insert hex driver 4into spindle, place socket head cap screw (mandrel) 3on to hex driver 4
and reducing sleeve 5on 3.
•Hold the adaptor nut, ensure the stop pins are seated in the last possible notch on the adapter
nut (may require you to turn forward 1 notch).
•Screw on the nose casing and the nose tip 1with the lock nut 2on it.
•To remove the equipment, do the reverse operation.
Nose Casing
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PLACING RIVET NUT ONTO MANDREL- LENGTH CHECK
•Keeping the tool disconnected from air supply, place an insert on mandrel 3 adjust item 1in
order to match the insert and mandrel end. It is ideal to have 1-2 threads of the mandrel
protruding from the back of the rivet nut. This will ensure full thread engagement during the
installation process, lock position by threading 2 against nose casing.
Nose assemblies should be serviced weekly. Any damaged or worn out parts should be replaced.
Check for mandrel wear and replace when necessary. Sherex recommends using high quality socket
head cap screws such as Unbrako® and Holo-Krome®.

NOSE ASSEMBLY COMPONENTS
Nose pieces vary in shape according to the insert thread size. Each nose assembly represents a
unique group of components that can be ordered individually and are unique to the size of the
fastener. We suggest you keep the components listed below in stock to be used as replacements.
(Numbers refer to sketch on previous page).
THREAD SIZE COMPLETE NOSE
ASSEMBLY 1+2 NOSEANDLOCK NUT 3 MANDREL 4 HEXDRIVER 5 REDUCINGSLEEVE
STANDARD RIVET NUTS
M3 FL5-HS-M3 FL5-HS-00903
M-M3-45 FL5-HS-01003 FL5-HS-09103
M4 FL5-HS-M4 FL5-HS-00904
M-M4-45 FL5-HS-01004 FL5-HS-09104
M5 FL5-HS-M5 FL5-HS-00905
M-M5-65 FL5-HS-01005 FL5-HS-09105
M6 FL5-HS-M6 FL5-HS-00906
M-M6-65 FL5-HS-01006 FL5-HS-09106
M8 FL5-HS-M8 FL5-HS-00908
M-M8-65 FL5-HS-01008 FL5-HS-09108
M10 FL5-HS-M10 FL5-HS-00910
M-M10-65 FL5-HS-01010 XXXX
# 4-40 UNC FL5-HS-0440 FL5-HS-00854 M-0440-175 FL5-HS-00754 FL5-HS-09154
# 6-32 UNC FL5-HS-0632 FL5-HS-00856
M-0632-175 FL5-HS-00756 FL5-HS-09156
# 8-32 UNC FL5-HS-0832 FL5-HS-00858
M-0832-175 FL5-HS-00758 FL5-HS-09158
# 10-24 UNC FL5-HS-1024 FL5-HS-00850
M-1024-250 FL5-HS-00750 FL5-HS-09150
# 10-32 UNF FL5-HS-1032 FL5-HS-00850
M-1032-250 FL5-HS-00750 FL5-HS-09150
1/4-20 UNC FL5-HS-2520 FL5-HS-00848
M-2520-250 FL5-HS-00748 FL5-HS-09148
1/4-28 UNF FL5-HS-2528 FL5-HS-00848
M-2528-250 FL5-HS-00748 FL5-HS-09148
5/16-18 UNC FL5-HS-3118 FL5-HS-00840
M-3118-250 FL5-HS-00740 FL5-HS-09140
5/16-24 UNF FL5-HS-3124 FL5-HS-00840
M-3124-250 FL5-HS-00740 FL5-HS-09140
3/8-16 UNC FL5-HS-3716 FL5-HS-00842
M-3716-250 FL5-HS-00742 XXXX
3/8-24 UNF FL5-HS-3724 FL5-HS-00842
M-3724-250 FL5-HS-00742 XXXX
RIV-FLOAT® Riv-float is covered under U.S. Patent No. 7,713,011
M3 FL5-HS-2528R FL5-HS-00848 M-2528-225 FL5-HS-00748 FL5-HS-09148
M4 FL5-HS-2528R FL5-HS-00848 M-2528-225 FL5-HS-00748 FL5-HS-09148
M5 FL5-HS-M5R FL5-HS-R0995 M-M5-65 FL5-HS-01005 FL5-HS-09105
M6 FL5-HS-M6R FL5-HS-R0996 M-M6-65 FL5-HS-01006 FL5-HS-09106
# 4-40 UNC FL5-HS-2528R FL5-HS-00848 M-2528-225 FL5-HS-00748 FL5-HS-09148
# 6-32 UNC FL5-HS-2528R FL5-HS-00848 M-2528-225 FL5-HS-00748 FL5-HS-09148
# 8-32 UNC FL5-HS-2528R FL5-HS-00848 M-2528-225 FL5-HS-00748 FL5-HS-09148
# 10-24 UNC FL5-HS-1024R FL5-HS-R0950 M-1024-250 FL5-HS-00750 FL5-HS-09150
# 10-32 UNF FL5-HS-1032R FL5-HS-R0950 M-1032-250 FL5-HS-00750 FL5-HS-09150
1/4-20 UNC FL5-HS-2520R FL5-HS-R0948 M-2520-250 FL5-HS-00748 FL5-HS-09148
1/4-28 UNF FL5-HS-2528R1 FL5-HS-R0948 M-2528-250 FL5-HS-00748 FL5-HS-09148
RIVET NUT STUDS
M5 Stud FL5-HS-M5S FL5-HS-S0905 FL5-HS-0S005 FL5-HS-01010 XXXX
M6 Stud FL5-HS-M6S FL5-HS-S0906 FL5-HS-0S006 FL5-HS-01010 XXXX
M8 Stud FL5-HS-M8S FL5-HS-S0908 FL5-HS-0S008 FL5-HS-01010 XXXX
# 10-24 UNC Stud FL5-HS-1024S FL5-HS-S0850 FL5-HS-S1024 FL5-HS-01010 XXXX
# 10-32 UNF Stud FL5-HS-1032S FL5-HS-S0850 FL5-HS-S1032 FL5-HS-01010 XXXX
¼-20 UNC Stud FL5-HS-2520S FL5-HS-S0848 FL5-HS-S2520 FL5-HS-01010 XXXX
¼-28 UNF Stud FL5-HS-2528S FL5-HS-S0848 FL5-HS-S2528 FL5-HS-01010 XXXX
5/16-18 UNC Stud FL5-HS-3118S FL5-HS-S0840 FL5-HS-S3118 FL5-HS-01010 XXXX
5/16-24 UNF Stud FL5-HS-3124S FL5-HS-S0840 FL5-HS-S3124 FL5-HS-01010 XXXX
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STROKE ADJUSTMENT PROCEDURE
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Socket Head Cap
Screw Mandrel (2)
Determine the proper stroke distance of the tool based on the size
and style of rivet nut insert you are using for your application material
thickness. Contact Sherex should you require assistance determining
the appropriate stroke. Warning** A stroke setting that is too large
for the application may cause an over installed installation condition
which may damage the mandrel, the base material, and/or the rivet
nut insert.
Stroke Adjustment (3)
Install the proper nose assembly for the rivet nut thread size that you
will be using. Attach an air supply to the Air Inlet (1) per the
recommendations in this manual.
To adjust the stroke distance of the tool, use the key provided with
the tool and place it in the stroke adjustment ring (3) located in the cut
out of the back cover. The ring, when threaded fully in, will pull to 1
mm (0.040”) of stroke. Turning the key counter-clockwise from one side of the window to the other
will increase the stroke approximately .12 mm (.005). Continue to adjust the ring out until you have
approximated the stroke distance required. Test by installing a rivet nut and measuring the collapsed
distance of the part. Adjust the ring as required to achieve the desired installation distance.
Note**Threading the adjustment ring beyond the 6 mm stroke may cause the auto-reverse to not
function. If this occurs, turn the adjustment ring in the opposite direction reducing the stroke distance
to 6 mm.
Manual Reverse
Button (4)
Air Inlet (1)
Thread an insert/rivet nut on to the tool 1 or 2 turns. Apply pressure to the insert and the auto-spin on
feature will engage thereby spinning the rivet nut up the mandrel until it comes in contact with the
nose piece.
If during the set up process the tool does not automatically reverse out of the rivet nut press the
manual reverse button (4).
operation
Operating procedure
•Nose kit assembled, tool connected to air supply, force adjustment complete.
•Screw the rivet nut onto the mandrel a couple turns, then a light pressure on it will start the
spinning of the mandrel (push to spin) and automatically stop when the rivet nut comes in
contact with the nose piece.
•Insert fastener into the application.
•Depress the trigger fully. This will place the insert and automatically reverse the tool out of the
installed rivet nut. (Depress the trigger and hold until auto-reverse engages). If auto-reverse
does not engage and insert has not collapsed, apply a manual pushing force to engage the
auto spin-on, and then depress the trigger. (Ensure the air pressure is within the specified
range).
•If, at any time, manual-reverse (4) needs to be engaged, depress the button at the base of the
handle, to the right of the air inlet.
IMPORTANT
Do not push the mandrel without a rivet nut as this will cause the
mandrel to s
p
in automaticall
y
. Ensure
p
ressure settin
g
s are correct.

MAINTENANCE
Servicing should be performed on a regular basis and a complete inspection will be needed once a
year or every 500,000 cycles, whichever comes first.
IMPORTANT
The employer is the sole responsible party for ensuring the training of staff on proper
tool use and maintenance. The operator should not perform any servicing or repairs,
unless properly trained.
DAILY SERVICING
•Every day, before use, pour a few drops of light lubricating oil on tool air inlet,
if the air supply is not equipped with lubricator.
•Check for air leaks. If damaged, hoses and coupling should be replaced.
•Make sure you are using the proper nose assembly.
•Make sure the pull force is correct for the selected rivet nut.
•Check the mandrel for wear or damage and replace if needed.
WEEKLY SERVICING
•Check for oil and air leaks.
MAINTENANCE
Every 500,000 cycles the tool should be completely checked and parts that are worn or damaged
should be replaced. O rings should be replaced and lubricated with Molykote®55M grease before
assembly.
Only a trained technician should service the Flex 5S tool. Should the Flex 5S tool require repair, the
tool can be sent to the Sherex authorized repair center:
Alcorn Industrial, Inc
5412 Rock Hampton Court
Indianapolis, IN 46268
[e-mail]
1800-317-4775
P R I M I NG P R O C E D U R E
•Place the tool on its side with the oil plug facing up.
•With a 5mm Allen key, unscrew the oil plug
•Fill tool with DEA Astron HLP 32 hydraulic fluid, or equivalent
•Gently rock tool back and forth to express any trapped air
•Return oil plug and tighten
•Connect air supply and cycle the tool multiple times
•Disconnect air supply and unscrew oil plug a few turns
•Re-tighten oil plug
•If, at any time, oil is leaking from the reservoir, replace the oil seal washer
located at the top of the threaded section.
www.sherex.com 866-4SHEREX 400 Riverwalk Pkwy, Suite 600 ~ Tonawanda, NY, 14150
8

TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE SOLUTION
⇒ Motor air leaks ⇒
Check for worn out seals. Replace
⇒ Low air pressure ⇒
Increase it
Pneumatic motor
runs slowly
⇒ Air vanes jammed ⇒
Lubricate tool through air inlet
⇒ Pull stroke not set properly ⇒
Adjust
⇒ Air pressure outside limits ⇒
Adjust
⇒ Low oil level ⇒
Add oil and prime
Insert does not
deform properly
⇒ Insert out of the grip ⇒
Check the insert grip range
⇒ Mandrel worn/damaged ⇒
Replace Mandrel
⇒ Hex Driver worn/damaged ⇒
Replace Hex Driver
Mandrel does not
spin
⇒ Loose locking ring ⇒
Tighten Locking Ring
⇒ Incorrect insert thread ⇒
Replace with proper insert
⇒ Incorrect mandrel ⇒
Replace with proper mandrel
Insert does not
spin on the
mandrel ⇒ Mandrel out or damaged ⇒
Replace
⇒ Excessive pull stroke ⇒
⇒
⇒
Defective insert
Defective or worn out or
damaged mandrel
⇒
⇒
Tool is locked in
installed insert
Depress manual spin off
If this does not work, disconnect
air, insert a pin through nose
casing slots and unscrew.
Contact Sherex
Replace Mandrel
⇒ Excessive pull stroke ⇒
Re-set pull strokeMandrel breaks
prematurely ⇒ Side load on mandrel ⇒
Keep the tool square to the application
when placing insert
⇒
⇒
No air supply
Insufficient distance between
locknut and spindle
⇒
⇒
Connect
Set distance between 1.5 and 2 mm
Tool does not spin
on insert
⇒ Air motor jammed ⇒
Lubricate through air inlet or if required
contact Sherex authorized repair center
www.sherex.com 866-4SHEREX 400 Riverwalk Pkwy, Suite 600 ~ Tonawanda, NY, 14150
9

Sherex Showcase
The FLEX line of tooling is just one of many Product lines that
Sherex offers to help meet your application requirements
BLIND RIVET NUT
S
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10
Blind rivet nuts are suitable for providing load-bearing threads in thin
materials & blind applications. Sherex Fastening Solutions offers the
most comprehensive line of blind rivet nuts from thin wall parts to heavy
duty. Available in American & European style rivet nuts. Special designs
are available to meet customer specific needs.
BRASS INSERT
S
Brass inserts from Sherex Fastening Solutions are designed to provide a
threaded hole in plastics that are not strong enough to support a thread.
Brass inserts are available in many options such as ultrasonic, press-in,
flanged and molded-in. These inserts have a self aligning lead for accurate
installation and can be easily mounted. Suitable industy applications
include automotive, communication and computer equipment, or almost
anywhere strong durable threads are required in plastics.
RIV-FLOA
T
®
RIV-FLOAT® is the next generation of fastening technology that has
internally floating threads that allow for component attachment in off center
applications. was designed for installation post finish in applications where
cage nuts, clinch nuts, floating nut plates or weld nuts are typically used. By
aligning to the drive angle of the screw, RIV-FLOAT® accounts for tolerance
stack up, saving rework of components and downtime associated with
stripped or cross threaded fasteners.
Internally Floating
Thr
eads
CLINCH NUT
S
Sherex offers three different kinds of clinch nuts to meet the specific
requirements of the customer’s application. Sherex clinch nuts can be
used in various high strength steels such as dual phase alloy, HSLA, and
TRIPS to meet class 10 nut strength requirements. Sherex clinch nuts can
be used in any material that offers access from both sides of the base
material.
Sherex combines world class fastener manufacturing and design
capability with industry leading automation equipment to offer the best
solution for your application. This “One Source” service ensures that
you are receiving the best support before and after the start of
production. Whether you are using 10,000 pieces or 10 million pieces,
Sherex offers different levels of automation capability to meet your
budget requirements and also the proper fastener to meet your
performance requirements.
FASTENER
AUTOMATION

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SHEREX FASTENING SOLUTIONS
400 Riverwalk Pkwy., Suite 600
Tonawanda, NY 14150
Phone: [phone]
Fax: [phone]
Email: [email protected]
www.sherex.com
SHEREX TAIWAN
No. 201, Sandong Road, Chungli City
Tao-Tuan Hsien, Taiwan, R.O.C.
Phone: [phone]
Fax: [phone]
Email: [email protected]
www.sherex.com.tw
SHEREX MEXICO S. de R. L. de C.V.
Av. Constituyentes 47, Desp 104
Col. El Pocito
Corregidora, Queretaro
C.P. 76910
Mexico
Phone: [phone]
Email: [email protected]
www.sherex.com