Service Manual

Original Instruction

Hydro-Pneumatic
Blind Rivet Nut Tool

ProSert® XTN20 Blind Rivet Nut Tool – 74202

Hydro-Pneumatic Power Tool

ENGLISH

Fig. 1
K
20B
11 F 13
12 80

20B

46

14
19
13
15
I
C
B
12
A

75

22

31

30

15
8
739
E7
A1
Fig. 2 18
31 19
30
D6
14
5

4
13

3
C
B
2

2
ENGLISH

Fig. 3

900

3
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Fig. 4

4
 Fig. 5
16M 13
80
ENGLISH

15M
74
14M 14
13M
20A 3B
12M 15
11M
10M
9M
4
8M 38
20B
7M 17
37
6M 73
71
20C
16 58 49
2M
46 39
1
45 6
5M
4M
48
3M
12
40 10
1M 56 3C
72 78 11
47
70 68
17M 67
26
42
18M 66 3A
21E
20M 35 77
21B 57
22M 27
21A
19M 34
21M 55 3D
43
23M 28
44 54 29
21C
65
21D 30
18A 2
24 74

36
21F 18C
33 25
32
18B 1A
31
69
75A 64
9 79
41 75B 22
75H 52
62
75F 75C 63
53
61 23
75D
75G 60 8
19

50
5
76

7
75E

75F 51

59

5
6
ITEM PARNT NO DESCRIPTION QTY REC SPARES ITEM PARNT NO DESCRIPTION QTY REC SPARES
1 74202-02101 HANDLE ASSEMBLY 1 - 41 74202-02048 HEAD SPRING 1 1
2 74202-02004 AIR CYLINDER 1 42 74200-12079 BALL (RUBBER) 1 2
ENGLISH

3 74202-02106 AIR PISTON ASSEMBLY 1 43 74202-02065 SCREW M3 X 12 2 2

4 74202-02005 TIE ROD 2 44 74202-02044 AIR TUBE 2 2
5 74202-02002 RUBBER BOOT 1 45 74202-02045 OIL PLUG 1 1
6 74202-02017 AIR TUBE 1 46 74202-02012 SUSPENSION RING 1
7 74202-02007 ROD GUIDE 1 47 74202-02051 TRIGGER SPRING 1 1
8 74202-02018 VALVE SLEEVE 1 48 74202-02067 TRIGGER PIN 1
9 74202-02019 VALVE SLIDER 1 49 74202-02052 AIR SPRING 1 1
10 74202-02014 BEZEL SWITCH 1 50 74202-02071 WASHER 1
11 74202-02013 TRIGGER VALVE 1 51 74202-02072 LIP SEAL 1 1
12 74202-02020 TRIGGER 1 52 74202-02076 WASHER 2 2
13 74202-02021 NOSE CASING 1 53 74202-02077 TIE ROD NUT 2 2
14 74202-02022 CHUCK NUT 1 54 74201-12081 LIP SEAL 1 1
15 74202-02023 MANDREL ADAPTOR 1 55 74202-02086 WASHER 1
16 74202-02024 T JOINT 1 56 74202-02060 O RING 1 1
17 74202-02025 LOCKING NUT 1 57 74202-02066 O RING 2
18A 74202-02006 HYDRAULIC PISTON 1 58 07003-00029 O RING 1
18B 74202-02026 DRIVE PIN 1 59 07003-00134 O RING 1 1
18C 74202-12005 WASHER 1 60 74202-02070 O RING 1 1
19 74202-02010 STROKE ADJUSTER 1 61 74202-02074 O RING 3
20 74202-02107 END CAP ASSEMBLY 1 62 74202-02075 O RING 1 1
21 74202-02105 DISTRIBUTOR ASSEMBLY 1 63 74202-02078 O RING 1 1
22 74202-02030 MANUAL REVERSE SWITCH 1 64 74202-02079 O RING 2 2
23 74202-02031 MANUAL REVERSE SCREW 1 65 74202-02082 O RING 3 3
24 74202-02009 SPOOL VALVE 1 66 07003-00026 O RING 1 1
25 74202-02032 PRESSURE ROD 1 67 74201-12084 O RING 1 1
26 74202-02033 PRESSURE ROD SLEEVE 1 68 07003-00046 O RING 1 1
27 74201-12089 SPRING GUIDE 1 69 07003-00027 O RING 1 1
28 74202-02035 PRESSURE CATCH 1 70 74200-12121 O RING 1 1
29 74202-02036 REGULATOR 1 71 07003-00028 O RING 1 1
30 74202-02037 REGULATOR COVER 1 72 74202-02058 LIP SEAL 1 1
31 74202-02038 REGULATOR LOCK 1 1 73 74202-02039 NOSE ROD 1
32 74202-02056 SPRING 1 1 74 74202-02087 SCREW M3 X 8 3 3
33 74202-02055 LOCKING BEARING 1 1 75 74202-02103 AIR INLET ASSEMBLY 1
34 74202-02054 PRESSURE SPRING 1 76 74202-02089 BASE CAP 1
35 74201-12087 REGULATOR SPRING 1 77 74202-02090 FRONT LABEL 1
36 74202-02080 OIL ROD 1 78 74202-02091 SIDE LABEL 2
37 74202-02041 SLEEVE 1 79 73200-02022 SAFETY LABEL 1
38 74202-02047 NOSE SPRING 1 1 80 74202-02095 LOCKING PIN 1 1
39 74202-02040 CONNECTOR 1 M 1-23 74292-02104 AIR MOTOR ASSEMBLY 1
Items in bold represent sub-assemblies which can be found on page 19.
 Fig. 6
ENGLISH

All dimensions are in mm.

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Original Instruction: E-17/010

© 2018 Stanley Black & Decker, Inc.

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 applicable to the product as delivered by
STANLEY Engineered Fastening. Therefore, STANLEY Engineered Fastening cannot be held liable for any dama-
ge resulting from deviations from the original specifications 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 consequences 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
trade marks.

CONTENT
PAGE

1. Safety Definitions 9

2. Specification 11
2.1 Placing Tool Specification 11
2.3 Main Components List 12

3. Tool Setup 13

4. Operating Instructions 13
4.1 Nose Equipment 13
4.2 Air Supply 14
4.3 Setting Instructions 14

5. Operating Procedure 15

6. Servicing the Tool 16

6.1 Daily Servicing 16
6.2 Weekly Servicing 16
6.3 Priming 17
6.4 Return Spring Servicing 17

7. Maintenance 18

8. Trouble Shooting Guide 22

9. Hydraulic Oil General Safety Data 23

8
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This instruction manual must be read by any person installing or operating this tool with particular attention
to the following safety rules.

1. Safety Definitions
The definitions below describe the level of 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.
W  ARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
C AUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION: Used without the 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 THESE INSTRUCTIONS.

WARNING:

1. Do not use outside the design intent of Placing STANLEY Engineered Fastening Blind Rivet Nuts.

2. Use only parts, fasteners, and accessories recommended by the manufacturer.

3. Do not modify the tool in any way. Any modification to the tool is undertaken by the customer and will be the
customer’s entire responsibility and void any applicable warranties.

4. Prior to use, check for misalignment or binding of moving parts, breakage of parts, and any other condition
that affects the tool’s operation. If damaged, have the tool serviced before using. Remove any adjusting key or
wrench before use.

5. The 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.

6. The operating supply air must not exceed 7 bar (100 PSI).

7. Operators and others in work area must wear ANSI Z87.1 CAN/CSA Z94.3 approved safety glasses with side
shields. Always wear safety glasses and ear protection during operation.

8. Dress 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.

9. Do not operate a tool/machine that is directed towards any person(s).

9
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10. DO NOT operate tool with the nose housing removed.

11. Adopt a firm footing or a stable position before operating the tool.

12. Prior to use, inspect airlines for damage, all connections must be secure. Do not drop heavy objects on hoses. A
sharp impact may cause internal damage and lead to premature hose failure.

13. Do not lift the placing tool by the hose. Always use the placing tool handle.

14. Vent holes must not become blocked or covered.

15. Disconnect the air hose from the tool before performing any maintenance, attempting to adjust, fit or remove a
nose assembly.

16. Keep tool handles dry, clean, and free from oil and grease.

17. When carrying the tool from place to place keep hands away from the trigger to avoid inadvertent activation.

18. Never leave operating tool unattended. Disconnect air hose when tool is not in use.

19. Adequate clearance is required for the tool operators hands before proceeding.

20. Do not abuse the tool by dropping or using it as a hammer.

21. Keep dirt and foreign matter out of the hydraulic system of the tool as this will cause the tool to malfunction.

STANLEY Engineered Fastening policy

is one of continuous product development and improvement
and we reserve the right to change the specification
of any product without prior notice.

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2. Specification

The ProSert® XTN20 hydro-pneumatic tool is designed for placing STANLEY Engineered Fastening Blind Rivet
Nuts through adjustment of the force and/or the stroke.

The ProSert® XTN20 Tool is used to place Blind Rivet Nuts from a range of M3 to M10 when coupled with the
relevant nose equipment. Imperial nose equipment is also available to place UNC and UNF inch thread size
Blind Rivet Nuts

The safety instructions must be followed at all times.

2.1. Placing Tool Specification

Pull Force: Pull @ stated pull pressure 5.0 bar 17.65 kN 3968 lbf
Air Supply Pressure: Min/Max 5-7 bar 72.5-101.5 lbf/in2
Oil Pressure: Pull (max) 230 bar 3336 lbf/in2
Free Air Volume: Max @ 5.5 bar 4 ltr 244 in³
Stroke: Piston stroke 3-7 mm 0.118-0.275 in
Weight: Including nose equipment 1.59 kg 3.50 lb
Noise Level: Uncertainty noise : K=3dB(A) <75 dB(A)  <75 dB(A)
Vibration: Uncertainty vibration K=0.1 m/s² <2.5 m/s2 <8 ft/s2
Motor Speed: Forward & Reverse 2000rpm 2000rpm
Material: - Aluminium Steel Stainless Steel
Eurosert® - M3-M10 M4-M5
Thin Sheet Nutsert® M3-M10 M3-M10 M3-M10
Avdel® Product
DK/DL M4-M10 -
Range:
Euro Hexsert®/Hexsert® - M3-M8 M6
High Strength Hexsert® - M6-M8 -
Squaresert® - M5-M8 -
Standard Nut* M3-M10 M3-M8 M4-M6
Knurled Nut* M4-M8 M4-M6 -
Closed End Nut* M3-M10 M3-M8 M4-M6
POP Nut®
Hexagonal Nut* M4-M8 M4-M8 M4-M6
Product Range:
Tetra Nut* M4-M8 M4-M8 -
HB Bolt* M6-M8 M6-M8 -
Pipe Nut* M6 M6 -
Pull-to-Force operating mode Yes
Pull-to-Stroke operating mode Yes
Auto Spin On/Spin Off Yes
Additional Features:
Tool Free Mandrel fittings Yes
Manual Reverse override Yes
Hydraulic Lip Seals & O-rings Yes

Items with a * may require a mandrel adaptor kit (74202-02200 found in Accessories Manual 07900-01073). A complete ProSert®
XTN20 (74202) tool is made up of the base tool (part number 74202-02000) and the appropriate nose assembly for the insert.

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2.3. Main components list

Re-order
Part Nr. Desctription Thread QTY
Spare part numbers
M4 07555-09004 1
M5 07555-09005 1
A Mandrel
M6 07555-09006 1
M8 07555-09008 1
M4 07555-00904 1
M5 07555-00905 1
B Nose Tip
M6 07555-00906 1
M8 07555-00908 1
C Lock Nut - 07555-00901 1
13 Nose Casing - 74202-02021 1
14 Chuck Nut - 74202-02022 1
M4 07555-09104 1
M5 07555-09105 1
D Reducing Sleeve
M6 07555-09106 1
M8 07555-09108 1
M4 07555-01004 1
M5 07555-01005 1
E Drive Shaft
M6 07555-01006 1
M8 07555-01008 1
15 Mandrel Adaptor - 74202-02023 1
73 Nose Rod - 74202-02039 1
46 Suspension Ring - 74202-02012 1
20 A,B,C End Cap Assembly - 74202-02107 1
F Stroke Indication Markings - - -
80 Stroke Locking Pin - 74202-02095 1
19 Stroke Setter - 74202-02010 1
I Stroke Setter Recess - - -
75 Air Inlet Assembly - 74202-02103 1
22 Manual Reverse Trigger - 74202-02030 1
31 Regulator Lock - 74202-02038 1
30 Pressure Regulator - 74202-02037 1
12 Trigger - 74202-02020 1
K Pin Punch - 07900-00624 1

M4 07555-09884
Complete nose assembly M5 07555-09885
M6 07555-09886
M8 07555-09888

All sizes are supplied with Lock Nut (c) 07555-00901.

For additional sizes please visit www.StanleyEngineeredFastening.com

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3. Tool Setup

IMPORTANT - READ THE SAFETY RULES ON PAGE 9 & 10 CAREFULLY BEFORE PUTTING INTO
SERVICE.

Before Use

• Select relevant size nose equipment and install.

• Connect the placing tool to the air supply. Test pull and return cycles by depressing and releasing the
trigger 12.
• Set the tool for desired stroke/pressure.

CAUTION - correct supply pressure is important for proper function of the installation tool. Personal injury or
damage to equipment may occur without correct pressures. The supply pressure must not exceed that listed in the
placing tool specification.

4. Operating Instructions
IMPORTANT - READ THE SAFETY RULES ON PAGE 9 & 10 CAREFULLY BEFORE PUTTING INTO
SERVICE.

IMPORTANT - THE AIR SUPPLY MUST BE TURNED OFF OR DISCONNECTED BEFORE FITTING OR
REMOVING THE NOSE ASSEMBLY.

4.1 Nose Equipment (see Fig.2).

Fitting Instructions
Item numbers in bold refer to nose assembly components in fig 1.
• Air supply must be disconnected.
• If still fitted, remove the Nose Casing 13 and the Chuck Nut 14 while pulling back the spring loaded Nose
Rod 73.
• Insert Drive Shaft E into Mandrel Adaptor 15.
• Fit Mandrel A onto Drive Shaft E.
• Insert Reducing Sleeve D (if specified) into the Chuck Nut 14.
• Screw the Chuck Nut 14 onto the Mandrel Adaptor 15 while pulling back the spring loaded Nose Rod 73.
Tighten the Chuck Nut 14 clockwise.
• While holding the Tool, screw on the Nose Casing 13 and Nose Tip B with the nose tip Lock Nut C.
• The reverse operation is carried out for equipment removal.

With the tool still disconnected from the air supply, screw a Blind Rivet Nut onto the Mandrel manually.
• Position Nose Tip B on the Nose Casing and lock it with Lock Nut C so that the Mandrel A protrudes
slightly beyond the insert.
• Lock the Lock Nut C by turning clockwise with a spanner*. Remove the Blind Rivet Nut from Mandrel.

*Refer to items included in the Maintenance Kit 07900-09301 page 16.

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4.2 Air Supply

• All tools are operated with compressed air at an minimum pressure of 5.0 bar.
• Pressure regulators and automatic oiling/filtering systems to be used on the main air supply within 3
metres of the tool (see fig. 7).
• Air supply hoses will have a minimum working effective pressure rating of 150% of the maximum pressure
produced in the system or 10 bar, whichever is the highest.
• Air hoses must be oil resistant, have an abrasion resistant exterior and be armoured where operating
conditions may result in hoses being damaged.
• All air hoses MUST have a minimum bore diameter of 6.4 millimetres.

STOP COCK
(USED DURING MAINTENANCE
3 METRES MAXIMUM OF FILTER/REGULATOR OR
LUBRICATION UNITS)

MAIN SUPPLY

PRESSURE REGULATOR AND

FILTER (DRAIN DAILY)
LUBRICATOR

1/4" GAS
CONNECTION

Fig. 7

If above system is not available you can use the following alternative:

• Before use or when first putting the tool into service, pour a few drops of clean, light lubricating oil into
the air inlet of the tool if no lubricator is fitted on air supply. If the tool is in continuous use, the air hose
should be disconnected from the main air supply and the tool lubricated as required.
• Check for air leaks. If damaged, hoses and couplings must be replaced by new items.
• If there is no filter on the pressure regulator, bleed the air line to clear it of accumulated dirt or water
before connecting air hose to the tool.

4.3 Setting Instructions

• The stroke adjustment feature is mainly used for smaller insert sizes M3-M4.
• If you are setting the tool for optimum stroke the Stroke Setter should be wound in to minimum stroke
(3mm) and the Pressure Regulator 30 be wound in to maximum setting.
• If you are setting the tool for optimum pressure the Stroke Setter should be wound out to maximum
stroke (7mm) and the Pressure Regulator 30 be wound out to minimum setting.

When dealing with different grip thicknesses, it is always recommended that the tool is set for optimum
pressure rather than optimum stroke. Use the maximum grip condition to set optimum pressure.

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4.3.1. Stroke Adjustment (see Fig. 1A & 3).

To use this tool in stroke set operation, screw the Pressure Regulator 30 fully in to achieve full pressure then
adjust Stroke Setter to the desired stroke length:

• Open Stroke Slider 20B

• The Stroke Locking Pin 80 will be released.
• Directional arrows indicate stoke direction.
• Increase the stroke from the minimum until optimum deformation is obtained.
• The scale gives an indication of the current stroke length.
• Stroke indication markings F are shown on the End Cap fig. 1A
• Line the rear of the Stroke Setter 19 up with these marks to achieve desired stroke length.
• Each Recess I on the Stroke Setter 19 is equal to +- 0.1mm of stroke.
• Close the Stroke Slider 20B before using in the application environment.
• The Stroke Lock will activate when the Stroke Slider 20B is closed when the tool is in the upright position
• The tool is now ready to operate.

4.3.2. Pressure Adjustment (see Fig. 1B & 3).

To use this tool in pressure set operation, wind the Stroke Setter 19 to 7mm, then screw the
Pressure Regulator 30 fully out to achieve minimum pressure then adjust to the desired pressure:

• Initially the Blind Rivet Nut will not deform and the tool will spin off.
• Screw in the Pressure Regulator 30 by 1 groove on the regulator body and test.
• Repeat the operation with the Pressure Regulator 30 until optimum deformation is obtained.
• 1 notch on the Pressure Regulator 30 is equivalent to approximately 20N of pulling force.
• After a successful Blind Rivet Nut deformation, check the Blind Rivet Nut and increase the force if
necessary.
• Increase by 1-2 notches extra to allow for variation in the Blind Rivet Nuts.
• The tool is now ready to operate.

5. Operating Procedure
Installing a Blind Rivet Nut (see Fig. 3).

To install a Blind Rivet Nut.

• Check that the correct Blind Rivet Nut has been selected.
• Push Blind Rivet Nut into the application.
• Check Nose Assembly is at right angle (90°) to the work.
• Push onto the Blind Rivet Nut with the tool to spin on.
• Once fully and correctly inserted, depress tool Trigger 12 switch to start installation cycle.
• Hold the Trigger 12 until the Blind Rivet Nut is completely set and the tool has disengaged completely.

In the event a Blind Rivet Nut becomes jammed in an application press the Manual Reverse Trigger 22 to
reverse the Mandrel A and spin off the Blind Rivet Nut. Alternately disconnect from the air supply and use the
4mm Pin Punch K supplied in the Maintenance Kit to wind off the Mandrel through the Nose Casing 13 shown
in the figure 1.

CAUTION - do not attempt to force the installation of an insert as this will cause damage to the tool and/or
application.

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6. Servicing the Tool

Regular servicing must be carried out by trained personnel and a comprehensive inspection performed
annually or every 500,000 cycles, whichever is sooner.

Cleaning and Maintenance

DISCONNECT AIR SUPPLY
Nose assemblies should be serviced at weekly intervals or every 5,000 cycles
CAUTION - Blow dirt and dust out of the main housing with dry air as often as dirt is seen collecting in and
around the air vents where the Pneumatic Cylinder connects to the plastic Handle Assembly. Wear approved eye
protection and approved dust mask when performing this procedure.
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.

• Disconnect the air supply

• Remove the complete nose assembly using the reverse procedure to the Fitting Instructions page 13(4.1).
• Any worn or damaged part must be replaced by a new part.
• Particularly check wear on Mandrel.
• Assemble according to fitting instructions.

6.1 Daily Servicing

• Check for air leaks. If damaged, hoses and couplings must be replaced by new items.
• Check that the Nose Assembly is correct and fitted properly.
• Check if the stroke of the tool is adequate to place selected Blind Rivet Nut. See Stroke Adjustment page
15 (4.3.1.).
• Inspect the Mandrel A in the nose assembly for wear or damage. If any, replace.

6.2 Weekly Servicing

Maintenance Kit 07900-09301
Part Number Description Qty
07900-00624 4mm Pin Punch 1
07900-00632 17mm/19mm Spanner 1
07900-00225 5mm Hexagonal Wrench 1

• Check for oil leaks and air leaks on air supply hose, fittings and tool.
• Check oil level by laing the tool horizontally, open Oil Plug 45. If low, re-prime according to instruction
6.3 on page 17.
• Check the stroke actuation of the tool and compare with the setting of the Stroke indication markings F.
If the stroke is not achieved, grease the return spring as necessary.

For servicing the following standard tools are needed (not supplied with Service Kit).
• 2mm Hexagonal Wrench
• 2.5mm Hexagonal Wrench
• 3mm Hexagonal Wrench
• 8mm Spanner
• 22mm Spanner or Socket
• 10mm Socket
• 14mm Spanner
• Pliers
• 10mm PTFE Tape
Spanners and Wrenches are specified across flats unless otherwise stated.

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6. 3 Priming

Priming is necessary after the tool has been dismantled and prior to operating. It may also be necessary to
restore the full stroke after considerable use, if the stroke has been reduced and fasteners are not now being
fully placed by one operation of the trigger.

Oil Details

The recommended oil for priming is Hyspin® VG32 available in 0.5l (part number 07992-00002).

Priming Procedure

All operations must be carried out on a clean bench, with clean hands in a clean area.
Ensure that the oil is perfectly clean and free from air bubbles.
Care MUST be taken at all times, to ensure that no foreign matter enters the tool, or serious damage may
result.
The tool must remain on its side throughout the priming sequence

• Disconnect the air supply.

• Place tool on its side, Oil Plug 45 side up.
• With a 5mm hexagonal wrench, unscrew Oil Plug 45 and remove with Oil Seal Washer.
• Fill tool with priming oil rocking gently to expel air.
• Replace Oil Plug 45 with Oil Seal Washer and tighten.
• Reconnect the air supply.
• Depress the Trigger.
• Disconnect the air supply.
• Using a hexagonal wrench remove Oil Plug 45 and Oil Seal Washer.
• Top-up with priming oil to reset level. Replace Oil Seal Washer and Oil Plug 45 and fully tighten.

It is necessary to fit the appropriate nose equipment and adjust the tool stroke prior to operating the tool.

6.4 Return Spring Servicing

• Using a 2mm Hexagonal Wrench remove screws 74 and then the End Cap Assembly 20.
• Using a 2.5mm Hexagonal Wrench remove screws 43 and then the Distributor Assembly 21, Ball 42 and
Air Tubes 44. Note -there are several O-rings in this assembly.
• Fully unscrew the Stroke Adjuster 19 and remove Spring 41.
• Check Spring 41 and apply MolyLithium Grease liberally to the spring.
• Reassembly is reverse of this procedure.

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7. Maintenance
I M P O R TA N T
SAFETY INSTRUCTIONS APPEAR ON PAGE 9 & 10. 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.
Every 500,000 cycles the tool must be completely dismantled and inspected Components must be replaced
where worn or damaged. All ‘O’ rings and seals should be replaced with new ones and lubricated with
Molykote 55M grease before assembling.

WARNING - The airhose must be disconnected before any servicing or dismantling is attempted unless
specifically instructed otherwise.

- Dismantling operation be carried out in clean conditions.

- Before proceeding with dismantling, empty the oil from the tool. Remove oil plug 45, from
the handle assembly and drain the oil into a suitable container.

- Prior to dismantling the tool it is necessary to remove the nose assembly. For simple removal
instructions see page 13 (4.1)

For complete tool servicing we advise that you proceed with dismantling of sub-assemblies in the order
shown below. See Fig. 5 (page 5)

For complete tool strip down two additional tools a required.

Part Number Description QTY
07900-01074 Assembly Bullet 1
07900-01075 Seal Guide 1

Pneumatic Cylinder
• Remove Rubber Boot 5.
• Place tool with the base facing upwards in a vice fitted with soft jaws.
• Using a 8mm spanner remove the Tie Rod Nut 53 and Washer 52 the Air Cylinder 2 should move upward
under spring pressure.
• Remove Base Cap 76 with 3mm Hexagonal Wrench.
• Withdraw Air Piston Assembly 3 separate Assembly by holding Piston Rod in soft jaws and unscrewing the
Piston.
• Remove the spring 49

Rod Guide
• Unscrew the Rod Guide 7 using a 22mm socket and T bar.
• Withdraw the Rod Guide 7 and Washer 50. Remove the lip seal 51 and O ring 59.

Trigger
• Remove Trigger Pin 48.
• Remove Trigger 12.
• Unscrew Bezel Switch 10 using a 10mm Socket.
• Withdraw Bezel Switch 10, Trigger Valve 11 and Spring 47
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Regulator
• Unwind Pressure Switch 30 to its full extent.
Using a 2mm Hexagonal Wrench unscrew Screw 74 remove Pressure Switch 30 Regulator Lock 31, Spring
32 and Locking Bearing 33.
• Using a 14mm Spanner unscrew the Pressure Catch 28 the Regulator 29 should then be unscrewed
from the Pressure Catch 28 once withdrawn.
• Remove Spring 34 and Spring Guide 27.
• Using Pliers gently clamp onto the Pressure Rod 25 and Pull this will remove the Pressure Rod 25 and
Pressure Rod Sleeve 26 remove O Ring 66, 68.
• Remove Spool Valve 24, remove O Ring 65.
• Remove Lip Seal 54, to re-insert this seal use Seal Guide

Nose Equipment
• Using a 19mm Spanner unscrew Nose Casing 13.
• Retract the Nose Rod 73 and remove the Chuck Nut 14 by hand.
Using a 14mm Spanner and the 4mm Push Pin undo the Mandrel Adaptor 15 from the Locking Nut
17 and remove both items.

Head Assembly
• Using a 2mm Hexagonal Wrench unscrew Screws 74 and remove End Cap Assembly 20.
• Using a 2.5mm Hexagonal Wrench unscrew Screws 43 and remove Distributor Assembly 21, Ball 42 and Air
Tubes 44
• Fully unscrew Stroke Adjuster 19 and withdraw Spring 41.
• Remove Air motor assembly M, Drive pin 18B, Washer 18C, Hydraulic piston 18A. Remove Lip seal 72 and
O-ring 70.
• Some residual oil may be expelled when the Hydraulic Piston 18A is removed.
• Remove Static Lip Seal 40.
• To reassemble, use Assembly Bullet to mask Piston Rod 18B thread.

Manual Reverse Switch

• Remove Manual Reverse Screw 23.
• Withdraw Manual Reverse Switch 22, remove O-ring 64, 63.

Sub-Assemblies contained in Base Tool 74202-shown in exploded view

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AIR INLET ASSEMBLY 74202-02103

POSITION PART NUMBER DESCRIPTION QTY SPARES

74A 74202-02100 AIR FILTER 1 -

75B 07003-00026 O RING 1 -
75C 74202-02096 1/4 CONNECTION 1 -
75D 07003-00029 O RING 4 -
75E 74202-02097 MALE CONNECTION 1 -
75F 74202-02099 CIRCLIP 1 -
75G 74202-02098 FEMALE CONNECTION 1 -

DISTRIBUTOR ASSEMBLY 74202-02105

POSITION PART NUMBER DESCRIPTION QTY SPARES

21A 74202-02011 DISTRIBUTOR 1 -

21B 74202-02093 PIN 1 -
21C 74202-02066 O RING 2 -
21D 74202-02064 O RING 2 -
21E 74202-02063 O RING 1 -
21F 07001-0047 M4 GRUB SCREW 2 -

AIR PISTON ASSEMBLY 74202-02106

POSITION PART NUMBER DESCRIPTION QTY SPARES

3A 74202-02003 AIR PISTON 1 -

3B 74202-02015 PISTON ROD 1 -
3C 74202-02069 O RING 1 1
3D 07003-00029 O RING 3 3

END CAP ASSEMBLY 74202-02107

POSITION PART NUMBER DESCRIPTION QTY SPARES

20A 74202-02008 END CAP 1 -

20B 74202-02027 SLIDER 1 -
20C 74202-02092 END CAP STOPPER 1 -

20
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AIR MOTOR ASSEMBLY 74202-02104

POSITION PART NUMBER DESCRIPTION QTY SPARES

1M 74202-02028 MOTOR CASE 1 -

2M 74202-02110 HOUSING 1 -
3M 07555-09216 PIN 1 -
4M 74202-02111 HOUSING BLOCK 1 -
5M 07555-09215 BEARING 1 -
6M 74202-02112 MOTOR VANE 5 5
7M 74202-02113 MOTOR SPINDLE 1 -
8M 07555-09210 WASHER 1 -
9M 07555-09206 BEARING 1 -
19M 74202-02115 WASHER 1 -
11M 74202-02116 RING GEAR 1 3
12M 74202-02117 PLANET GEAR 3 -
13M 74202-02118 ROD 3 -
14M 74202-02119 SUN GEAR 1 -
15M 74202-02120 BEARING 1 -
16M 74202-02121 CIRCLIP 1 1
17M 74202-02043 MOTOR ROD 1 1
18M 74202-02060 O RING 1 -
19M 74202-02029 O RING 1 -
20M 07003-00315 O RING 1 -
21M 74202-02122 O RING 1 -
22M 74202-02123 PLUG 1 -
23M 07001-00479 M4 GRUB SCREW 3 -

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ENGLISH
8. Troubleshooting guide
Symptom Possible Cause Remedy Page Ref.
Air leak from motor. Check for worn seals. Replace. 18
Pneumatic motor runs Low air pressure. Increase air pressure. 14
slowly. Air way blockage. Clear restriction. 18
Motor Vanes 6M jamming Clean and lubricate. 18
Worn or damaged Drive Shaft E. Replace. 13
Mandrel turns
Worn or damaged Mandrel A. Replace. 13
independent of motor.
Chuck Nut 14 is loose. Tighten Chuck Nut 14. 13
Incorrect Blind Rivet Nut thread
Change to correct size Blind Rivet Nut. 13
size.
Insert will not place Incorrect Mandrel A fitted. Change to correct size Mandrel. 13
onto Mandrel. Worn or damaged Mandrel A. Replace. 13
Nose equipment incorrectly
Re-fit nose equipment. 13
assembled.
Excessive stroke. Reduce stroke. 3

Tool/Blind Rivet Nut is Excessive pressure. Reduce pressure. 3

jammed. Press Manual Reverse 22.
Defective Blind Rivet Nut or
Alternately use Pin Punch K to manually 15
Mandrel A.
remove the Blind Rivet Nut.
Excessive stroke. Reduce stroke. 14
Mandrel Breakage. Excessive pressure. Reduce Pressure. 14
Side load on Mandrel . Hold tool square to application. 3
Drive screw returns
Ensure trigger is held throughout full
very slow to forward Trigger is released early.
cycle to speed operation up.
position
Stroke adjustment very Use pin punch (07900-00624) to aid
Excessive pressure.
hard by hand. stroke adjustment.
Chuck Nut 14 is loose. Tighten Chuck Nut 14. 13
No air supply. Connect air supply. 14
Insufficient gap between
Tools does not spin On. Locking Nut 17 and Piston 18A. Adjust gap to 1.5mm/2mm. 4
Motor Rod 17M too short. Replace Motor Rod. 5
Lubricate tool at air inlet. If insufficient,
Air Motor jammed. 18
dismantle and clean thoroughly.
Static friction. Depress and hold Trigger 12 a few times.
Low air pressure. Increase air pressure. 14
Trigger 12 inoperative. Depress Trigger 12 several times.
Lubricate tool through air inlet.
Valve Slider 9 remains stuck. 4 & 18
If unsuccessful, dismantle, clean and
lubricate trigger components.
Chuck Nut 14 is loose. Tighten Chuck Nut 14. 13
Trigger 12 released prematurely. Press and hold for entire cycle of tool.
Tool not reaching pressure or
Reduce pressure or stroke setting. 14
Tool does not spin off. stroke.
Distributor 21A is stuck. Lubricate. 4
Lubricate tool at air inlet. If insufficient,
Air Motor jammed. 18
dismantle and clean thoroughly.

Item numbers in bold refer to assembly drawings and parts list Pages 2,4,5, and 6.
Other symptoms or failures should be reported to your local, authorised distributor or repair centre.

22
ENGLISH

9. Hydraulic Oil General Safety Data

FIRST AID
SKIN:
Unlikely to cause harm to the skin on brief or occasional contact but prolonged or exposure may lead to
dermatitis. Wash skin thoroughly with soap and water as soon as reasonably practicable. Remove heavily con-
taminated clothing and wash underlying skin.
Launder contaminated clothing.

ORAL:
Unlikely to cause harm if accidentally swallowed in small doses, though larger quantities may cause nausea
and diarrhea.
If contamination of the mouth occurs, wash out thoroughly with water. Except as a deliberate act, the ingesti-
on of large amounts of product is unlikely. If it should occur, do not induce vomiting; obtain medical advice.
Take person to nearest medical centre.

EYES:
Unlikely to cause more than transient stinging or redness if accidental eye contact occurs.
Wash eyes thoroughly with copious quantities of water, ensuring eyelids are held open. Obtain medical advice
if any pain or redness develops or persists.

DISPOSAL:
Remove all spills with inert absorbent material. Ventilate spill area. Place contaminated materials in a disposa-
ble container and dispose in a manner consistent with local regulations.

PROTECTING THE ENVIRONMENT:

Separate collection. This product must not be disposed of with normal waste. Should you find one day that
your product needs replacement, or if it is of no further use to you, do not dispose of it with regular waste.
Make this product available for separate collection. Separate collection of used products and packaging
allows materials to be recycled and used again. Re-use of recycled materials helps prevent environmental
pollution and reduces the demand for raw materials. Local regulations may provide for separate collection
of electrical products, at municipal waste sites or by the retailer when you purchase a new product. You can
check the location of your nearest authorised repair agent by contacting your local STANLEY Engineered
Fastening office at the address indicated in this manual. Alternatively, a list of authorised repair agents and full
details of our after-sales service and contacts are available on the Internet at:
www.StanleyEngineeredFastening.com

C.O.S.H.H. data for all hydraulic oils and lubricants is available on request from your tool supplier.

FIRE:
FLASH POINT: 200°C.
Extinguish with dry, chemical, foam or carbon dioxide. Do not enter confined space without self contained
breathing apparatus.

HANDLING:
Use barrier cream or oil resistant gloves.

STORAGE:
Undercover and consistent with local regulations for inflammable material.

23
 Avdel UK Limited
Stanley House, Works Road
Letchworth Garden City, Hertfordshire SG6 1JY
Tel. +44 1582 900-000 · Fax -001
enquiries2@sbdinc.com

Find your closest STANLEY Engineered Fastening location on www.StanleyEngineeredFastening.com/contact

For an authorized distributor nearby please check www.StanleyEngineeredFastening.com/econtact/distributors

Manual Number Issue C/N

07900-09302 E 17/010

© 2018 Stanley Black & Decker, Inc.

Holding your world together®, Avdel®, Eurosert®, Nutsert®, Hexsert® and Squaresert® are registered trade
marks of Avdel UK Limited. ProSert® is a trade mark of Avdel UK Limited. POP Nut® is a registered trade mark of
Newfrey LLC.
The names and logos of other companies mentioned herein may be trademarks of their respective owners.
Data shown is subject to change without prior notice as a result of continuous product development and
improvement policy.
Your local STANLEY Engineered Fastening representative is at your disposal should you need to confirm latest
information.