5
TOOL SERVICE
For item and part numbers, refer to the component list and exploded views on page 8.
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Place the riveter over an oil pan to avoid and contain fluid spills; clean up and dispose of used fluid properly.
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Use care handling the internal components and valve cavities; nicks or scratches may make components unusable.
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Make sure that you have all the tools necessary before proceeding to service the tool.
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Apply an O-ring lubricant to all seals and mating surfaces.
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When installing Back-up Rings, make sure the curved surface faces the O-ring.
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Use Loctite® only where indicated; use of Teflon tape is prohibited.
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Handle with care and clean components thoroughly; avoid contamination as it causes internal valve malfunction.
Tools needed:
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F800KS maintenance kit , Loctite® 545 (or comparable)
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1/16”, 1/8” and 5/32” hex wrenches,
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2” deep socket hex wrench, 9/16” size
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Adjustable wrench, a pair of pliers
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Bent hook for O-ring removal
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Oil Pan large enough to contain fluid spills
BEFORE TAKING THE TOOL APART
Remove the foam handle by twisting and pulling it off; if removal is not possible, it may need to be cut off and replaced.
With the 5/32” hex wrench remove the side screw, spring and ball (45, 46, 15 & 16); place them in a clean area.
HYDRAULIC PUMP SERVICE
Unthread and remove the front Adaptor (2). Unthread the
hydraulic pump with a 9/16” deep socket wrench and pull
it out carefully; you may need to extract it with the help of
a pair of pliers (grab on the smaller diameter towards the
front). Place pump assembly in a vise and unthread item
16 (use the socket wrench). Push the stage piston (20)
out so the O-rings are accessible for replacement.
Unthread set-screw 14 with the help [of the 1/8 hex
wrench and remove the spring and ball (15 & 16); clean
the ball and cavity carefully with a soft, lint free piece of
cloth. Replace spring (15), re-assemble with ball (16)
and thread-in the set-screw (14) flush with the front
surface of item 17. Replace O-ring 18.
Place stage piston (20) in a vise, unthread the cap (21)
and clean it. Inspect the edge of the hole facing the ball to
make sure it is clean and in good condition, free of nicks
and scratches; reassemble the stage piston (20).
Replace the larger O-ring and back-up ring (11 & 12).
Remove O-rings and back-up ring (9, 30, and 31) from the
power cylinder (29) and replace them.
Apply O-ring lubricant to all the seal surfaces and push the
stage piston (20) back into the power cylinder (29). Re-
assemble the rest of the components (17 &18, 19); use
Loctite® on the threads and tighten securely.
The hydraulic pump is now completed.
PRESSURE RELIEF VALVE SERVICE
With the help of the 1/16 hex wrench, unthread the flat
head screw (47) while holding the button (48). Pull button
(48) out carefully. Unthread the pressure relief valve (32)
with a 9/16” deep socket wrench. Unthread the
adjustment plug (33) and remove the spring and poppet
(25 & 34). Replace the spring with a new one. The seals
can now be removed using a bent hook; make sure to
remove the seals 38 & 39 from inside the cavity. Clean
and inspect the inside of the valve body and the poppet
(34 & 36); replace the seals. Place the poppet and spring
(34, 25) back into the body (36) and thread in the
adjustment plug (33 - no Loctite® on these threads).
Place a new O-ring and back-up ring (38 & 39) onto the
poppet stem protruding out of the pressure relief valve.
The valve is now completed.
PISTON AND ADAPTOR
Unthread adaptor (49) and push piston rod (10) out of the
adaptor (2). Remove and replace seals (1, 3, 4, 6 & 7).
Remove the retaining ring (5) and push piston (8) and rod
(10) apart (light tapping with a mallet is OK). Replace O-
ring (9) and reassemble piston and rod (8 & 10) by
pressing them into each other and secure with the
retaining ring (5). Remove the internal O-ring and back-up
ring (11, 12) with a bent hook and replace them. Apply
O-ring lubricant to all seal surfaces; push piston rod (10)
through the adaptor (2).
Re-assemble and tighten piston rod adaptor (49); use
Loctite to secure in place.
FINAL ASSEMBLY
Place the hydraulic pump inside the riveter body and thread it in with the help of the 9/16” deep socket wrench.
Make sure it there that the lever is pushed forward and there is no play after fully threading the hydraulic pump in.
Place spring (13) inside the riveter body, over the hydraulic pump and thread in the piston and adaptor completed
above (use Loctite® on the threads). Tighten the adaptor securely. Prime, fill and bleed the riveter (see next page).
