Stanley 734 AV Series Troubleshooting guide

INSTRUCTION AND
SERVICE MANUAL
AV®5 Installation Tool – 73425-02000
Hydro-Electric Power Tool
EN
Hydro-Electric Power Tool
FR
Outil électrique hydropneumatique
DE
Hydroelektrisches Setzgerät
IT
Utensile elettroidraulico
PL
Narzędzie hydrauliczno-elektryczne
ES
Herramienta hidroneumática
NL
Hydro-elektrisch gereedschap
DA
Hydroelektrisk elværktøj
FI
Hydrosähköinen työkalu
NO
Hydroelektrisk verktøy
SV
Hydroelektriskt kraftverktyg
PT
Ferramenta hidroeléctrica

ENGLISH ORIGINAL INSTRUCTION
1
©2021 by STANLEY Black & Decker brand
All rights reserved.
The information provided may not be reproduced and/or made public in any way and through any
means (electronically or mechanically) without prior explicit and written permission from STANLEY
Engineered Fastening. The information provided is based on the data known at the moment of the
introduction of this product. STANLEY Engineered Fastening pursues a policy of continuous product
improvement and therefore the products may be subject to change. The information provided is appli-
cable to the product as delivered by STANLEY Engineered Fastening. Therefore, STANLEY Engineered
Fastening cannot be held liable for any damage resulting from deviations from the original specicati-
ons of the product.
The information available has been composed with the utmost care. However, STANLEY Engineered
Fastening will not accept any liability with respect to any faults in the information nor for the conse-
quences thereof. STANLEY Engineered Fastening will not accept any liability for damage resulting from
activities carried out by third parties. The working names, trade names, registered trademarks, etc. used
by STANLEY Engineered Fastening should not be considered as being free, pursuant to the legislation
with respect to the protection of Trademarks.
CONTENT
1. SAFETY DEFINITIONS............................................................................................................................3
1.1 GENERAL SAFETY RULE................................................................................................................................................... 3
1.2 PROJECTILE HARZARDS ................................................................................................................................................. 3
1.3 OPERATING HAZARDS .................................................................................................................................................... 4
1.4 REPETITIVE MOTIONS HAZARDS .................................................................................................................................. 4
1.5 ACCESSORY HAZARDS.................................................................................................................................................... 4
1.6 WORKPLACE HAZARDS .................................................................................................................................................. 4
1.7 NOISE HAZARDS............................................................................................................................................................... 5
1.8 VIBRATION HAZARDS...................................................................................................................................................... 5
1.9 ADDITIONAL SAFETY INSTRUCTIONS FOR HYDRAULIC POWER TOOLS............................................................. 5
2. SPECIFICATION ......................................................................................................................................6
2.1 INTENT OF USE.................................................................................................................................................................. 6
2.2 TOOL SPECIFICATION...................................................................................................................................................... 6
2.3 TOOL DIMENSIONS ......................................................................................................................................................... 7
3. PUTTING IN SERVICE.............................................................................................................................8
3.1 PRINCIPAL OF OPERATION ............................................................................................................................................ 8
3.2 PREPARATION FOR USE .................................................................................................................................................. 9
4. OPERATING INSTRUCTIONS ...............................................................................................................10
4.1 TO INSTALL AN AVBOLT® FASTNER............................................................................................................................10
4.2 TO INSTALL AN AVDELOK®FASTNER.........................................................................................................................10
4.3 TO INSTALL A NEOBOLT® FASTENER ..........................................................................................................................11

ENGLISH ORIGINAL INSTRUCTION
2
5. SERVICING THE TOOL..........................................................................................................................12
5.1 DAILY SERVICING............................................................................................................................................................12
5.2 WEEKLY SERVICING........................................................................................................................................................12
5.3 ANNUAL SERVICING / EVERY 250K OPERATIONS....................................................................................................12
5.4 SERVICE KIT .....................................................................................................................................................................12
5.5 SERVICING TOOLS..........................................................................................................................................................12
5.6 HYDRAULIC OIL ..............................................................................................................................................................13
5.7 DISMANTLING INSTRUCTIONS....................................................................................................................................13
5.8 PROTECTING THE ENVIRONMENT..............................................................................................................................16
6. GENERAL ASSEMBLYAND PART LIST..................................................................................................17
6.1 GENERAL ASSEMBLY......................................................................................................................................................17
6.2 PARTS LIST........................................................................................................................................................................19
7. SAFETY DATA ......................................................................................................................................20
7.1 Enerpac® HF HYDRAULIC OIL - SAFETY DATA..........................................................................................................20
7.2 MOLYLITHIUM GREASE EP 3753 - SAFETY DATA .....................................................................................................20
7.3 Molykote® 111 GREASE - SAFTEY DATA.....................................................................................................................21
8. FAULT DIAGNOSIS ...............................................................................................................................22
9. EC DECLARATION OF CONFORMITY...................................................................................................24
10. UK DECLARATION OF CONFORMITY..................................................................................................25
11. PROTECT YOUR INVESTMENT!............................................................................................................26

ENGLISH ORIGINAL INSTRUCTION
3
This instruction manual must be read by any person installing or operating this tool with particular atten-
tion to the following safety warnings and instructions.
Always wear impact-resistant eye protection during operation of the tool. The grade of protection requi-
red should be assessed for each use.
Use of the tool can expose the operator’s hands to hazards, including crushing, impacts, cuts and abrasi-
ons and heat. Wear suitable gloves to protect hands.
Use hearing protection in accordance with employer’s instructions and as required by occupational
health and safety regulations.
1. SAFETY DEFINITIONS
The denitions below describe the severity for each signal word. Please read the manual and pay attention to these
symbols.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
CAUTION: Used without safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
Improper operation or maintenance of this product could result in serious injury and property damage.
Read and understand all warnings and operating instructions before using this equipment. When using
power tools, basic safety precautions must always be followed to reduce the risk of personal injury.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE.
1.1 GENERAL SAFETY RULE
yFor multiple hazards, read and understand the safety instructions before installing, operating, repairing, maintai-
ning, changing accessories on, or working near the tool. Failure to do so can result in serious bodily injury.
yOnly qualied and trained operators must install, adjust or use the tool.
yDO NOT use outside the design intent of placing STANLEY Engineered Fastening Blind Rivets.
yUse only parts, fasteners, and accessories recommended by the manufacturer.
yDO NOT modify the tool. Modications can reduce the eectiveness of safety measures and increase the risks to the
operator. Any modication to the tool undertaken by the customer will be the customer’s entire responsibility and
void any applicable warranties.
yDo not discard the safety instructions; give them to the operator.
yDo not use the tool if it has been damaged.
yPrior to use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that
aects the tool’s operation. If damaged, have the tool serviced before using. Remove any adjusting key or wrench
before use.
yTools shall be inspected periodically to verify that the ratings and markings required by this part of ISO 11148 are
legibly marked on the tool. The employer/user shall contact the manufacturer to obtain replacement marking labels
when necessary.
yThe tool must be maintained in a safe working condition at all times and examined at regular intervals for damage
and function by trained personnel. Any dismantling procedure will be undertaken only by trained personnel. Do
not dismantle this tool without prior reference to the maintenance instructions.
1.2 PROJECTILE HARZARDS
yDisconnect the tool from the hydraulic pump unit before performing any maintenance, attempting to adjust,  t or
remove a nose assembly or accessories.
yBe aware that failure of the workpiece or accessories, or even of the inserted tool itself can generate high-velocity
projectiles.

ENGLISH ORIGINAL INSTRUCTION
4
yAlways wear impact-resistant eye protection during operation of the tool. The grade of protection required should
be assessed for each use.
yThe risks to others should also be assessed at this time.
yEnsure that the workpiece is securely xed.
yCheck that the means of protection from ejection of fastener and/or mandrel is in place and is operative.
yWarn against the possible forcible ejection of mandrels from the front of the tool.
yDO NOT operate a tool that is directed towards any person(s).
1.3 OPERATING HAZARDS
yUse of the tool can expose the operator’s hands to hazards, including crushing, impacts, cuts and abrasions and
heat. Wear suitable gloves to protect hands.
yOperators and maintenance personnel shall be physically able to handle the bulk, weight, and power of the tool.
yHold the tool correctly; be ready to counteract normal or sudden movements and have both hands available.
yKeep tool handles dry, clean, and free from oil and grease.
yMaintain a balanced body position and secure footing when operating the tool.
yRelease the start-and-stop device in the case of an interruption of the hydraulic supply.
yUse only lubricants recommended by the manufacturer.
yContact with hydraulic uid should be avoided. To minimise the possibility of rashes, care should be taken to wash
thoroughly if contact occurs.
yMaterial Safety Data Sheets for all hydraulic oils and lubricants is available on request from your tool supplier.
yAvoid unsuitable postures as it is likely for these positions not to allow counteracting of normal or unexpected
movement of the tool.
yIf the tool is xed to a suspension device, make sure that the xation is secure.
yBeware of the risk of crushing or pinching if nose equipment is not tted.
yDO NOT operate tool with the nose casing removed.
yAdequate clearance is required for the tool operator’s hands before proceeding.
yWhen carrying the tool from place to place keep hands away from the trigger to avoid inadvertent activation.
yDO NOT abuse the tool by dropping or using it as a hammer.
yCare should be taken to ensure that spent mandrels do not create a hazard.
1.4 REPETITIVE MOTIONS HAZARDS
yWhen using the tool, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of
the body.
yWhile using the tool, the operator should adopt a comfortable posture whilst maintaining a secure footing and avo-
iding awkward or o -balance postures. The operator should change posture during extended tasks; this can help
avoid discomfort and fatigue.
yIf the operator experiences symptoms such as persistent or recurring discomfort, pain, throbbing, aching, tingling,
numbness, burning sensations or sti ness, these warning signs should not be ignored. The operator should tell the
employer and consult a qualied health professional.
1.5 ACCESSORY HAZARDS
yDisconnect the tool from the hydraulic and electrical supply before tting or removing the nose assembly or acces-
sory.
yUse only sizes and types of accessories and consumables that are recommended by the manufacturer of the tool;
do not use other types or sizes of accessories or consumables.
1.6 WORKPLACE HAZARDS
ySlips, trips and falls are major causes of workplace injury. Be aware of slippery surfaces caused by use of the tool and
also of trip hazards caused by the air line or hydraulic hose.
yProceed with care in unfamiliar surroundings. There can be hidden hazards, such as electricity or other utility lines.
yThe tool is not intended for use in potentially explosive atmospheres and is not insulated against contact with
electric power.
yEnsure that there are no electrical cables, gas pipes, etc., which can cause a hazard if damaged by use of the tool.
yDress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving
parts. Loose clothes, jewellery or long hair can be caught in moving parts.
yCare should be taken to ensure that spent mandrels do not create a hazard.

ENGLISH ORIGINAL INSTRUCTION
5
1.7 NOISE HAZARDS
yExposure to high noise levels can cause permanent, disabling hearing loss and other problems, such as tinnitus
(ringing, buzzing, whistling or humming in the ears). Therefore, risk assessment and the implementation of appro-
priate controls for these hazards are essential.
yAppropriate controls to reduce the risk may include actions such as damping materials to prevent workpieces from
“ringing”.
yUse hearing protection in accordance with employer’s instructions and as required by occupational health and
safety regulations.
yOperate and maintain the tool as recommended in the instruction manual, to prevent an unnecessary increase in
the noise level.
1.8 VIBRATION HAZARDS
yExposure to vibration can cause disabling damage to the nerves and blood supply of the hands and arms.
yWear warm clothing when working in cold conditions and keep your hands warm and dry.
yIf you experience numbness, tingling, pain or whitening of the skin in your ngers or hands, stop using the tool, tell
your employer and consult a physician.
yWhere possible Support the weight of the tool in a stand, tensioner or balancer, because a lighter grip can then be
used to support the tool.
1.9 ADDITIONAL SAFETY INSTRUCTIONS FOR HYDRAULIC POWER TOOLS
yThe operating hydraulic supply must not exceed 550 bar (8000 PSI).
yOil under pressure can cause severe injury.
yDo not t exible hydraulic hoses rated at less than 700 bar (10,000 PSI) working pressure at a ow rate of 2.73 l/min
(200 in 3/min).
yNever leave operating tool unattended. Disconnect hydraulic hose and electrical cable from the pump unit when
tool is not in use, before changing accessories or when making repairs.
yWhipping hoses can cause severe injury. Always check for damaged or loose hoses and ttings.
yPrior to use, inspect hydraulic hoses for damage, all hydraulic connections must be clean, fully engaged and tight
before operation. Do not drop heavy objects on hoses. A sharp impact may cause internal damage and lead to
premature hose failure.
yWhenever universal twist couplings (claw couplings) are used, lock pins shall be installed and whipcheck safety
cables shall be used to safeguard against possible hose-to-tool or hose-to-hose connection failure.
yDO NOT lift the placing tool by the hose or electrical cable. Always use the placing tool handle.
yDO NOT pull or move the hydraulic pump unit using the hoses. Always use the pump unit handle or roll cage.
yKeep dirt and foreign matter out of the hydraulic system of the tool as this will cause the tool to malfunction.
yUse only clean oil and lling equipment.
yOnly recommended hydraulic uids may be used.
yPower units require a free ow of air for cooling purposes and should therefore be positioned in a well ventilated
area free from hazardous fumes.
yMaximum temperature of the hydraulic uid at the inlet is 110°C (230°F).
STANLEY Engineered Fastening policy is one of continuous product development and improvement and
we reserve the right to change the specication of any product without prior notice.

ENGLISH ORIGINAL INSTRUCTION
6
2. SPECIFICATION
2.1 INTENT OF USE
The AV®5 Installation Tool is principally 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 fasteners inclu-
ding 3/8”Avdelok®, 3/8”NeoBolt®, 5/16”Avbolt® and Ø16mm Avseal® in Industrial Environments.
The placing tool and hydraulic pump unit may only be used in accordance with the operating instructions for placing
Stanley Engineered Fastening structural rivets.
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.
DO NOT use under wet conditions or in the presence of flammable liquids or gases.
FASTENER NOSE ASSEMBLY NOSE ASSEMBLY
DATASHEET
TYPE SIZE PART NUMBER DIM. ‘A’ DIM. ‘B’ PART NUMBER
AVBOLT® 1/4” 07220-07500 70 mm 19 mm 07900-00905
5/16” 07220-07700 100 mm 27mm 07900-00905
AVDELOK® 5/16” 07220-05600 130 mm 27 mm
3/8” 07220-02000 100 mm 27 mm
AVSEAL® II 16 mm 07220-06800 100 mm 27 mm 07900-00840
AVTAINER® 3/8” * 71230-15600 130 mm 23 mm
MONOBOLT® 1/4” * 71230-15800 130 mm 27 mm
3/8” 07220-07200 110 mm 27 mm
NEOBOLT® 5/16” 73200-05000 100 mm 27 mm 07900-01071
3/8” 73200-05100 100 mm 27 mm 07900-01071
Notes:
Length dimensions rounded.
* It is a requirement to fit adaptor part number 07267-00800 to fit this nose assembly.
*Nose assembly with jaw release.
Refer to the illustration on page 8 for the identification of the nose assembly dimensions ‘A’ and ‘B’.
The safety instructions must be followed at all times.
2.2 TOOL SPECIFICATION
SPECIFICATION METRIC IMPERIAL
Force: Pull @ stated pull pressure 36.0 kN 8992.4 lbf
Push Off @ stated return pressure 17.5 kN 3934.1 lbf
Pressure: Pull 510 bar 7396.9 lbf/in²
Return 200 bar 2900.7 lbf/in²
Stroke: Minimum piston stroke 30.0 mm 1.18 in
Weight: With nose equipment and hose 2.9 kg 6.4 lb
Hydraulic Oil: Enerpac Hydraulic Oil - HF-95X - -
Stem Ejection Rear
Seal Arrangement Twin Lip & Wiper seals
Additional Features: Hydraulic Bearing Rings Yes – Front & Rear
Protective Handle / Hose Gator Yes
Protective Hose Guard Yes
Hose / Cable Retention Clamps Yes

ENGLISH ORIGINAL INSTRUCTION
7
Noise values determined according to noise test code ISO 15744 and ISO 3744. AV5
A-weighted sound power level dB(A), LWA Uncertainty noise: kWA = 3.0 dB(A) 86.9 dB(A)
A-weighted emission sound pressure level at the work station
dB(A), LpA Uncertainty noise: kpA = 3.0 dB(A) 75.9 dB(A)
C-weighted peak emission sound pressure level dB(C), LpC, peak Uncertainty noise: kpC = 3.0 dB(C) 81.1 dB(C)
Noise values determined according to noise test code ISO 20643 and ISO 5349 AV5
Vibration emission level, ahd: Uncertainty vibration: k = 1.34 m/s22.69 m/s2
Declared vibration emission values in accordance with EN 12096
2.3 TOOL DIMENSIONS
All dimensions are shown in millimetres. Illustration shown with 3/8”NeoBolt® nose assembly tted. Tool appearance
will vary with dierent nose assemblies tted.
Refer to the table on page 7 for the nose assembly dimensions‘A’and‘B’.
The tool is tted with two Hydraulic Hoses and an electrical Control Cable, 0.6m in length. Additional hydraulic hose
and cable extension lengths are available to order separately as required. Refer to the table below for the available hose
assembly lengths and associated part numbers.
HYDRAULIC HOSE ASSEMBLY
PART NUMBER HOSE LENGTH
07008-00448 5 Metre
07008-00449 10 Metre
07008-00450 15 Metre

ENGLISH ORIGINAL INSTRUCTION
8
3. PUTTING IN SERVICE
3.1 PRINCIPAL OF OPERATION
IMPORTANT - READ THE SAFETY RULES ON PAGES 4 - 6 AND THE PUMP UNIT INSTRUCTION MANUAL CAREFULLY
BEFORE PUTTING INTO SERVICE.
When both hoses and control cable are connected to the Avdel® / Enerpac®hydraulic pump unit, the pull
and return cycles of the tool are controlled by depressing and releasing the trigger located in the handle.
When the switch is depressed the solenoid valve, located in the hydraulic pump unit, is energised and
directs the pressurised oil flow to the pull side of the piston in the placing tool. This also allows the oil in
the return side of the placing tool to return to the reservoir.
During the pull cycles the piston/collet assembly moves towards the rear of the tool allowing the O-ring
type cushion to push the follower and jaws forward. If a fastener pin has been inserted in the nose assem-
bly, the jaw set will clamp onto the pintail and assembly will commence.
For Avbolt®and Avdelok®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 up against the joint and as movement continues the pintail will
be broken off.
The trigger switch should 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.
If the trigger is not released, the placing tool piston will continue to move towards the rear of the tool until it reaches
the end of its stroke. The pressure in the pull side will then increase until a preset‘High Pressure’value is achieved at
the pump. At this point the solenoid valve will automatically de-energise and reverse the ow of pressurised oil to the
return side of the placing tool.
In either case, pressurised oil will now ow into the return side of the placing tool, with the oil in the pull side returning
to the reservoir.
The forward movement of the piston/collet assembly will eject the installed fastener from the anvil.
At the point of releasing the trigger or when the‘High Pressure’value is achieved, the solenoid valve will de-energise
and activate a preset‘Return Timer’. This controls the time that the pump motor will continue run before switching to
the idle mode. The timer can be manually set between 5 and 20 seconds to ensure that the placing tool piston always
fully returns to the forward position (refer to pump manual 07900-01030, pages 10 and 13).
When the piston returns to the fully forward position, the pressure will increase to preset low pressure value - c200bar.
The pump motor will continue to run until the Return Timer has expired. After this time period the motor will stop auto-
matically and valve will switch to the idle position. The solenoid valve will then automatically cycle to release pressuris-
ed oil to the reservoir from both the pull and return side of the placing tool.
This keeps the installation tool in the forward position. No pressure will be present in the hydraulic system at this point.
The hydraulic pump unit will automatically start up on depression of the tool trigger switch.

ENGLISH ORIGINAL INSTRUCTION
9
3.2 PREPARATION FOR USE
CAUTION - CORRECT PULL AND RETURN PRESSURES ARE IMPORTANT FOR PROPER FUNCTION OF THE ISTALLA-
TION TOOL. PERSONAL INJURY OR DAMAGE TO EQUIPMENT MAY OCCUR WITHOUT CORRECT PRESSURES. THE
PULL AND RETURN PRESSURES SUPPLIED BY THE HYDRAULIC PUMP UNIT MUST NOT EXCEED THOSE PRESSURES
LISTED IN THE PLACING TOOL SPECIFICATION.
IMPORTANT – BEFORE PUTTING THE PLACING TOOL AND HYDRAULIC HOSE SET INTO SERVICE:
ENSURE THAT THE PUMP PRESSURE RELIEF VALVES HAVE BEEN SET IN ACCORDANCE WITH THE PUMP INSTRUC-
TIONS AND THE MAXIMUM PRESSURES SPECIFIED FOR THE PLACING TOOL AND HOSES.
ENSURE THAT THE HOSE KIT IS PRIMED WITH HYDRAULIC FLUID IN ACCORDANCE WITH THE PROCEDURE IN THE
PUMP INSTRUCTION MANUAL 07900-01030.
yEnsure the mains power supply to the hydraulic pump unit is switched o.
yConnect the placing tool hydraulic hose quick couplers directly to the pump unit before connecting the electri-
cal control cable. Hoses and control cable must be connected in this order and disconnected in reverse order.
ySwitch on the mains supply to the hydraulic pump unit. Wait 5 seconds for the pump unit to complete the boot
sequence, before pressing the trigger switch. When all set the LCD screen on the pump unit will display‘AVDEL’.
yDuring the boot sequence the pump control system identies any trigger operation as a potential malfunction
and prevents the motor from starting. The LCD screen will display‘BUTTON FAULT’in this instance. Reset by
switching o the power supply for 10 seconds.
yEnsure that the placing tool is positioned below the pump reservoir tanks. Depress and release the placing tool
trigger switch a few times to almost the full stroke of the tool to circulate hydraulic uid and expel any air from
the tool.
yObserve action of tool. Check for uid leaks and ensure that in the idler mode the piston is in the fully forward
position. The placing tool will now be primed.
ySwitch o the mains power supply to the hydraulic pump unit and then disconnect the placing tool from the
pump unit in reverse order to that described above.
yNow connect the placing tool to the primed hydraulic hose kit and electrical control cable. Then connect hy-
draulic hose kit quick couplers and the electrical control cable to the pump unit.
yAttach the nose assembly to the tool as per the instructions in the relevant nose assembly datasheet.
ySwitch on the mains supply to the hydraulic pump unit as described above.
yDepress and release the placing tool trigger switch a few times to almost the full stroke of the tool to circulate
hydraulic uid.
yThe placing tool is now ready for use.

ENGLISH ORIGINAL INSTRUCTION
10
4. OPERATING INSTRUCTIONS
4.1 TO INSTALL AN AVBOLT® FASTNER
Forfurtherinformationregardingthisfastener,refertothenoseassemblydatasheetaslistedinthetableon page no 7.The
information below is for guide use.
yCheck 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).
yPut Avbolt®fastener into hole.
yPush nose assembly onto the pin until the nose assembly anvil stops against the collar. Tool and nose assembly
must be held at right angles (90°) to the work.
yDepress tool trigger switch to start installation cycle.
yWhen the forward motion of the nose assembly anvil stops and the pintail breaks o, release the trigger. The
tool will go into its return stroke and push o the installed fastener. At the end of the return stroke the jaws will
partially release the expended pintail which can then be pushed through the jaws with the next installation and
then ejected through the rear of the tool.
yOnce the installed fastener has been ejected, the tool and nose assembly is ready for the next installation.
4.2 TO INSTALL AN AVDELOK®FASTNER
Forfurtherinformationregardingthisfastener,refertothenoseassemblydatasheetaslistedinthetableon page no 7.The
information below is for guide use.
yCheck 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).
yPut Avdelok®fastener into hole.
ySlide Avdelok®collar over the pin. (The beveled end of the collar must be towards the nose assembly and tool.)
yPush nose assembly onto the pin until the nose assembly anvil stops against the collar. Tool and nose assembly
must be held at right angles (90°) to the work.
yDepress tool trigger switch to start installation cycle.
yWhen the forward motion of the nose assembly anvil stops and the pintail breaks o, release the trigger. The
tool will go into its return stroke and push o the installed fastener. At the end of the return stroke the jaws will
partially release the expended pintail which can then be pushed through the jaws with the next installation and
then ejected through the rear of the tool.
yOnce the installed fastener been ejected, the tool and nose assembly is ready for the next installation.
CAUTION - DO NOT ATTEMPT TO BREAK OFF A PINTAIL WITHOUT THE INSTALLATION OF A COLLAR AS THIS WILL
CAUSETHE UNSECURED PORTION OF THE AVDELOK®OR AVBOLT®PINTAIL TO EJECT FROM THE NOSE AT A HIGH
SPEED AND FORCE.

ENGLISH ORIGINAL INSTRUCTION
11
4.3 TO INSTALL A NEOBOLT® FASTENER
Forfurtherinformationregardingthisfastener,refertothenoseassemblydatasheetaslistedinthetableon page no 7.The
information below is for guide use.
yPut NeoBolt®pin tail into hole and push fully through the joint layers.
yFitNeoBolt®collaroverthepintail(theangedendofthecollarmustbeclosesttotheworkpiece)and rotateclockwise
toengagethecollar onto thepint-up threadby atleasthalfaturn.
yPushthecolletfullyoverthepinpullingtailuntilcolletfullycoversthepullinggrooveontheNeoBolt® pinandthepulling
tailmakescontactwiththecolletstop.Theplacingtoolmustbeheldperpendicular (90°) to the work piecesurface.
yDepressandholdthetooltriggerswitchtostarttheinstallationcycle.ThecolletwillgriptheNeoBolt® pin tail and pull
the anvil up against the collar.
yContinuetoholdthetriggerdownuntilthecollarisfullyswagedandtheforwardmotionoftheanvil stopsagainstthe
collarange.Theplacingtoolpistonandcolletwillthenautomaticallyreturntopush the anvil o theinstalled collar
and release the pintailfrom the collet.
yRelease thetrigger.
yOncetheinstalledfastenerhasbeenejectedfromtheanvil,theplacingtool,noseassemblyandpump unit are ready for
the next installation.
CAUTION – Do not release the trigger until the placing tool pull cycle is complete and the pump unit and tool
have switched automatically to the return cycle. Releasing the trigger before this point will result in an inco-
rrectly placed and partially installed NeoBolt® fastener.

ENGLISH ORIGINAL INSTRUCTION
12
5. SERVICING THE TOOL
IMPORTANT - READ SAFETY INSTRUCTIONS ON PAGES 4 - 6. 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 TOOL
SHALL BE EXAMINED REGULARLY FOR DAMAGE AND MALFUNCTION.
5.1 DAILY SERVICING
yCheck placing tool, hoses and quick couplers for oil leaks.
yWorn or damaged hoses and couplings should be replaced.
yCheck that the stroke of tool meets the specication.
yCheck the end cap is properly and tightly tted to the AV®5 body.
yCheck that the stem deector is tted.
yCheck that the pump pull / advance pressure relief valve is functioning correctly.
yCheck nose equipment is correct for the rivet to be placed and that it is tted properly.
yCheck for worn anvil indicated by score marks on the installed collar. This can also be conrmed by referring to
the installed data in the fastener catalogue. Excessive wear can cause the anvil to rupture.
5.2 WEEKLY SERVICING
yDismantle and clean the nose assembly especially the jaws as described in the relevant nose assembly data-
sheet.
yCheck for oil leaks in placing tool, hoses and quick couplers.
CAUTION – Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These
chemicals may weaken the materials used in these parts.
5.3 ANNUAL SERVICING / EVERY 250K OPERATIONS
yAnnually or every 250,000 cycles (which is sooner) the tool should be completely dismantled and new compo-
nents should be used where worn, damaged or as recommended. All O-rings, back-up rings and seals should be
renewed and lubricated with MolyKote®111 grease before assembling.
5.4 SERVICE KIT
For a complete service the following Service Kit is available:
SERVICE KIT: 73425-99990
PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION
07005-10118 Quick Coupler – Male 07900-01103 AV®5 Piston Guide Sleeve
07005-10120
Quick Couple – Female 07900-01104 AV®5 End Cap Assembly Tool
07900-00043
AV ® 5 PistonBullet – Front AV ® 5 07992-00020 Grease – MolyLithium EP3753
07900-01101
PistonBullet – Rear 07900-00755 Grease – MolyKote 111
07900-01102 AV®5 Front Gland Guide Rod 07900-00756 Loctite 243 Thread Locker
07002-00478 M4 X 20 Socket HD cap screw
5.5 SERVICING TOOLS
The following standard tools are also required:
yAllen Key: 2.0 / 3.0 mm
yOpen End Flat Spanner: 12 / 14 / 18 / 24 / 45 mm A/F
yPTFE Tape: 10 mm
yEngineers Vice with Jaw Guards – 150 mm

ENGLISH ORIGINAL INSTRUCTION
13
5.6 HYDRAULIC OIL
CAUTION – Use only Enerpac®HF hydraulic oil – the use of any other oil may cause the placing tool and pump to
malfunction and will render the placing tool warranty null and void.
Hydraulic oil is available to order under the following part numbers.
HYDRAULIC OIL
PART NUMBER 07992-00081 07992-00082 07992-00083
Enerpac® Part Number HF-95X HF-95Y HF-95T
Volume 1 Litre 5 Litres 20 Litres
Viscosity 32 mm2/s 32 mm2/s 32 mm2/s
5.7 DISMANTLING INSTRUCTIONS
IMPORTANT – ENSURE THE MAINS POWER SUPPLY TO THE HYDRAULIC PUMP UNIT IS SWITCHED OFF BEFORE
REMOVING THE NOSE ASSEMBLY OR DISMANTLING THE PLACING TOOL.
Before Dismantling:
yUncouple the Quick Couplers 9and 10 and the electrical Control Cable 14 between the placing tool and the Hy-
draulic Hose Assembly.
yRemove the nose assembly from the placing tool as per the instructions in the relevant nose assembly datasheet.
yThe potentially dangerous substances that could have deposited on the machine as a result of work processes
must be removed before maintenance.
For a complete service of the tool, we advise that you proceed with dismantling the tool in the order shown on pages
14 to 17. After dismantling the tool we recommend that you replace all seals.
Head Piston Assembly:
yRemove the Deector 3, from the End Cap 15.
yClamp the tool handle in a vice with soft jaws so that the tool is pointing nose down. Insert the dowel pins on
the *End Cap Assembly Tool into the three holes in the End Cap 15.
yUsing a 45 mm A/F spanner, unscrew and remove the End Cap 15, from the Body 1.
yUsing a small at screwdriver, remove O-Ring 28 from the End Cap 15 and discard.
yConnect the spare *Quick Coupler – Male to the Quick Coupler – Female 10 on the Hydraulic Hose - Return 24.
This will release any pressure from the return side of the Piston 18 and ease the removal of the Rear Seal Gland
16. Note: Hydraulic oil will be expelled from the spare quick coupler – male
yInsert three M4 screws into the Rear Seal Gland 16 and use them to pull the part o the rear shaft of the Piston
18 and out of the Body 1.
yUsing a small at screwdriver or similar tool, remove O-Ring 31 and Spiral Back-up Ring 30, from the external
groove on the Rear Seal Gland 16, and discard. When removing the seals, take care not to damage the surface of
the Rear Seal Gland with the screwdriver.
yRemove Rod Seal 29 and Wiper Seal 33, from the internal grooves on the Rear Seal Gland 16, and discard. When
removing the seals, take care not to damage the surface of the Rear Seal Gland with the screwdriver.
yRemove Rear Bearing Ring 32 and check the part for wear or damage. Discard if necessary.
yRemove the placing tool from the vice and empty the hydraulic oil from the rear of the tool. Remove the spare
*Quick Coupler – Male from the Quick Coupler – Female 10 on Hydraulic Hose - Return 24.
All numbers in bold refer to the General Assembly and Parts List on pages 18, 19 and 20.
y* Service Kit on page 13
yConnect the spare *Quick Coupler - Female to the Quick Coupler – Male 9on the Hydraulic Hose - Pull 25. This

ENGLISH ORIGINAL INSTRUCTION
14
will release any pressure from the pull side of the Piston 18 and ease the removal of the Piston. Note: Hydraulic
oil will be expelled from the spare quick coupler – female.
yScrew the *Piston Bullet - Front on to the front of the Piston 18.
yPlace the Body 1nose up on a bench. Then using a soft mallet, tap the Piston 18 towards the rear of the Body
and out the back end, taking care not to damage the bore within the Body.
yNote that when removing the Piston 18, oil on the pull side of the Piston 18 will leak from the front and rear of
the Body 1.
yWhen removing the Piston 18, the Front Seal Gland 17 may be retained on the Piston shaft. If this is the case,
unscrew the *Piston Bullet - Front and pull the Front Seal Gland o of the Piston.
yUsing a small at screwdriver remove Piston Seal 35 and the two Anti-Extrusion Rings 34, from the external
groove on the Piston 18, and discard. When removing the seals, take care not to damage the surface of the
Piston with the screwdriver.
yIf the Front Seal Gland 17 is still retained in the Body 1. Place the Body nose up on a bench and then push the
Front Seal Gland from the front until it is free from the recess within Body. The Front Seal Gland can then be
removed from the back end of the Body. Take care not to damage the bore within the Body when doing so.
yUsing a small at screwdriver remove O-Ring 38 and Spiral Back-up Ring 39, from the external groove on the
Front Seal Gland 17, and discard. When removing the seals, take care not to damage the surface of the Front
Seal Gland with the screwdriver.
yRemove Rod Seal 36 and Wiper Seal 40, from the internal grooves on the Front Seal Gland 17, and discard. When
removing the seals, take care not to damage the surface of the Front Seal Gland with the screwdriver.
yRemove the Front Bearing Ring 37 and check the part for wear or damage. Discard if necessary.
yRemove the spare *Quick Coupler - Female from the Quick Coupler - Male 9on the Hydraulic Hose - Pull 25.
Assemble in reverse order to dismantling noting the following points:
yClean all components before assembling.
yTo aid assembly of seals apply a light coating of Molykote® 111 grease to all seals, seal grooves, back-up rings
and the assembly tools.
ySlide O-Ring 38 over the Front Seal Gland 17 and into the external groove. Insert the Spiral Back-up Ring 39 in
the same groove, in front of the installed O-Ring. Refer to the General Assembly and Parts List for the correct
orientation of the O-Ring and Spiral Back-up Ring.
yPress the Front Bearing Ring 36 into the internal recess within the Front Seal Gland 17 and then install Rod Seal
36 behind the Front Bearing Ring. Install the Wiper Seal 40 in the front recess of the Front Seal Gland. Refer to
the General Assembly to ensure the correct orientation of the Rod Seal and Wiper Seal.
yLubricate the surface and leading edge of the Body 2bore into which the Front Seal Gland 17 is to be installed
with Molykote® 111 grease.
yLubricate the spigot on the *Front Gland Guide Rod tool and then place the Front Seal Gland 17, Rod Seal 36
end rst, fully over spigot. Insert *Front Gland Guide Rod into the rear of the Body 1and then push the Front
Seal Gland fully into the bore within the Body. Reasonable force is required to insert Front Seal Gland into the
Body, so the use of a press or vice may be necessary. Remove the *Front Gland Guide Rod while ensuring that
the Front Seal Gland stays in place.
yLubricate the seal groove and major external diameter of the Piston 18 with Molykote® 111 grease. Slide the
Piston Seal 35 over the front of the major Piston diameter and into the seal groove. Install two Anti-Extrusion
Rings 34 into the Piston seal groove, one either side of the Piston Seal.
yScrew the *Piston Bullet - Front onto the front of the Piston 18. Lubricate the *Piston Bullet - Front, Piston shaft
and Piston Seal 35 with Molykote® 111 grease.
All numbers in bold refer to the General Assembly and Parts List on pages 18, 19 and 20.
* Service Kit on page 13

ENGLISH ORIGINAL INSTRUCTION
15
yScrew the *Piston Guide Sleeve fully into the rear of the Body 1. Lubricate the bores in both the Body and the
*Piston Guide Sleeve with Molykote® 111 grease.
yConnect the spare *Quick Coupler - Female to the Quick Coupler - Male 9on the Hydraulic Hose - Pull 25. This
will allow air to be released from the pull side of the Piston 18 when inserting the Piston.
yInsert the assembled Piston 18 into the rear of the Body 1and through the assembled Front Seal Gland 17. Push
the Piston into the fully forward position until it stops against the Front Seal Gland. Hydraulic oil will be expelled
from the Hydraulic Hose - Pull 25.
yRemove the spare *Quick Coupler - Female from the Quick Coupler - Male 9on the Hydraulic Hose - Pull 25.
Remove the *Piston Guide Sleeve from the rear of the Body 1.
ySlide O-Ring 31 over the Rear Seal Gland 16 and into the external groove. Insert the Spiral Back-up Ring 30 in
the same groove, behind the installed O-Ring. Refer to the General Assembly and Parts List for the correct orien-
tation of the O-Ring and Spiral Back-up Ring.
yPress the Rear Bearing Ring 32 into the internal recess within the Rear Seal Gland 16 and then install Rod Seal
29 behind the Rear Bearing Ring. Install the Wiper Seal 33 in the rear recess of the Rear Seal Gland. Refer to the
General Assembly to ensure the correct orientation of the Rod Seal and Wiper Seal.
yClamp the tool handle in a vice with soft jaws so that the tool is pointing nose down.
yLubricate the surface and leading edge of the Body 1bore into which the Rear Seal Gland 16 is to be installed
with Molykote® 111 grease. Lubricate the rear Piston 18 shaft with Molykote® 111 grease.
yInsert the *Piston Bullet - Rear into the rear Piston 18 shaft and Lubricate with Molykote® 111 grease.
yFill the rear of the Body 1with Enerpac® HF hydraulic oil. Oil level should be just above the rear inlet bore into
the Body.
yConnect the spare *Quick Coupler - Male to the Quick Coupler - Female 10 on the Hydraulic Hose – Return 24.
This will allow air to be released from the return side of the Piston 18 when inserting the Rear Seal Gland 16.
Note: Hydraulic oil may be expelled from the spare quick coupler – female.
yPlace the Rear Seal Gland 16 over the *Piston Bullet - Rear. Then push the Rear Seal Gland over the Piston 18
shaft and into the rear of the Body 1. Push the Rear Seal Gland into the Body until a few internal threads are ex-
posed at the rear of the Body. Take care not to damage the O-Ring 31 and Spiral Back-up Ring 30 on the threads
when inserting the Rear Seal Gland.
yLubricate both the internal thread in the Body 1and the external thread on End Cap 15 with MolyLithium Gre-
ase.
yScrew the End Cap 15 fully into the rear of the Body 1using the *End Cap Assembly Tool. In doing so, the Rear
Seal Gland 16 will be pressed into position within the Body 1and a small amount of oil will be expelled from the
Hydraulic Hose - Return 24.
yRemove the spare *Quick Coupler - Male from the Quick Coupler - Female 11 on the Hydraulic Hose - Return 24.
yPush the Deector 3, onto the End Cap 15.
yPrime the placing tool as described in Preparation for Use on page 10.
Hose Assembly:
yRemove the two Screws 8from the Hose Clamp 13 using a 3.0 mm Allen Key. Remove the Hose Clamp and
Clamp Insert 26 from the Protective Sleeve 27 and Hydraulic Hoses - Return 24 and Pull 25.
yUsing the small at screwdriver prize the Handle Gator 7from the handle of moulding 11 and 12. Pull the
Handle Gator over the Protective Sleeve 27, Hydraulic Hoses-Return 24 and Pull 25 and remove.
yUsing a 3.0 mm Allen Key (and 7.0 mm spanner on bottom nut) unscrew the four screws 20 holding handle
mouldings 11 and 12 together and remove.
All numbers in bold refer to the General Assembly and Parts List on pages 18, 19 and 20.
* Service Kit on page 13

ENGLISH ORIGINAL INSTRUCTION
16
yThe trigger 6is soldered to control cable. Remove this assembly from the handles 11 and 12. The cable gland 22
is part of this assembly.
yCut the Cable Tie 43 and slide back the Protective Sleeve 27 to expose the ttings on the Hydraulic Hoses 24
and 25. The Hydraulic Hoses can be removed from the Body 1using 12mm and 14mm spanners.
yThe Quick Couplers - Male 9and Female 10 can be removed from the Hydraulic Hoses 24 and 25 using 18mm
and 24mm spanners.
Assemble in reverse order to dismantling noting the following points:
yPrior to assembly clean all threads on the Quick Couplers - Male 9and Female 10 and the Hydraulic Hoses -
Return 24 and Pull 25. Then apply two to three layers of 10mm PTFE tape to the male threads on both of the
Hydraulic Hoses.
yOnce assembled, prime the tool as per the instructions on page 10.
5.8 PROTECTING THE ENVIRONMENT
yAssure conformity with applicable disposal regulations. Dispose all waste products at an approved waste facility
or site so as not to expose personnel and the environment to hazards.
All numbers in bold refer to the General Assembly and Part List on pages 18, 19 and 20.
* Service Kit on page 13.

ENGLISH ORIGINAL INSTRUCTION
17
6. GENERAL ASSEMBLYAND PART LIST
6.1 GENERAL ASSEMBLY
ITEMS MARKED * SCALED FOR EASE OF VIEW

ENGLISH ORIGINAL INSTRUCTION
18

ENGLISH ORIGINAL INSTRUCTION
19
6.2 PARTS LIST
73425-02000 PARTS LIST
ITEM
No.
PART NUMBER DESCRIPTION QTY.
1 73425-02003 AV®5 Head 1
2 73425-02014 AV®5 Label 1
3 73200-02030 Deector 1
4 73200-02041 Adaptor 1
5 73200-02042 Retaining Nut 1
6 73425-02013 Trigger Assembly 1
7 73430-02020 Handle Gator 1
8 07001-00686 M4 Socket Cap Screw 2
9 07005-10118 Quick Coupler - Male 1
10 07005-10120 Quick Coupler - Female 1
11 73425-02009 Handle Molding - Left 1
12 73425-02015 Handle Molding - Right 1
13 73430-02023 Hose Clamp 1
14 07007-02105 Control Cable 1
15 73425-02007 End Cap 1
16 73425-02006 Rear Seal Gland 1
17 73425-02005 Front Seal Gland 1
18 73425-02011 Head Piston 1
19 73200-02043 Adaptor Ring 1
20 07001-00688 M4 Socket Cap Screw 4
22 07007-02140 Rubber Grommet 1
23 07002-00134 M4 Nut 1
24 07005-10119 Hydraulic Hose - Return 1
25 07005-10117 Hydraulic Hose - Pull 1
26 73430-02024 Clamp Insert 1
27 07005-10121 Protective Sleeve 0.4m
28 07003-00308 O-Ring 1
29 07003-00442 Wiper Seal 1
30 07003-00527 Spiral Back-up Ring 1
31 07003-00526 O-Ring 1
32 73430-02010 Rear Bearing Ring 1
33 07003-00441 Rod Seal 1
34 07003-00521 Anti-Extrusion Ring 2
35 07003-00520 Piston Seal 1
36 07003-00523 Rod Seal 1
37 73200-03104 Bearing Ring 1
38 07003-00524 O-Ring 1
39 07003-00525 Spiral Back-up Ring 1
40 07003-00522 Wiper Seal 1
41 73425-02016 Safety Label 1
42 07007-01504 CE Label 1
43 07007-02032 Cable Tie 1