Protecting The Environment - Stanley AV-15 Instruction And Service Manual

O R I G I N A L I N S T R U C T I O N
• Lubricate the surface and leading edge of the Body 2 bore into which the Rear Seal Gland 16 is to be installed with
Molykote® 111 grease. Lubricate the rear Piston 1 shaft with Molykote® 111 grease.
• Insert the *Piston Bullet - Rear into the rear Piston 1 shaft and Lubricate with Molykote® 111 grease.
• Fill the rear of the Body 2 with Enerpac® HF hydraulic oil. Oil level should be just above the rear inlet bore into the Body.
• Connect the spare *Quick Coupler - Male to the Quick Coupler - Female 11 on the Hydraulic Hose – Return 18. This will
allow air to be released from the return side of the Piston 1 when inserting the Rear Seal Gland 16.
• Place the Rear Seal Gland 16 over the *Piston Bullet - Rear. Then push the Rear Seal Gland over the Piston 1 shaft and into
the rear of the Body 2. Push the Rear Seal Gland into the Body until a few internal threads are exposed at the rear of the
Body. Take care not to damage the O-Ring 30 and Spiral Back-up Ring 36 on the threads when inserting the Rear Seal
Gland.
• Lubricate both the internal thread in the Body 2 and the external thread on End Cap 17 with MolyLithium Grease.
• Screw the End Cap 17 fully into the rear of the Body 2 using the *End Cap Assembly Tool. In doing so, the Rear Seal Gland
16 will be pressed into position within the Body and a small amount of oil will be expelled from the Hydraulic Hose -
Return 18.
• Remove the spare *Quick Coupler - Male from the Quick Coupler - Female 11 on the Hydraulic Hose - Return 18.
• Push the Deflector 3, onto the End Cap 17.
• Screw the Collet Adapter 40 on to the Piston 1 until the front face is flush with the end of the Piston. Align the hole in the
Collet Adapter with the slot in the end of the Piston and then insert Locking Pin 41.
• Prime the placing tool as described in Preparation for Use on page 10.
Hose Assembly:
• Remove the two Screws 9 from the Hose Clamp 13 using a 3.0mm Allen Key. Remove the Hose Clamp and Clamp Insert
20 from the Protective Sleeve 37 and Hydraulic Hoses - Return 18 and Pull 19.
• Using the small flat screwdriver prize the Handle Gator 8 from the handle of Body 2. Pull the Handle Gator over the
Protective Sleeve 37, Hydraulic Hoses-Return 18 and Pull 19 and remove.
• Cut the Cable Tie 35 and slide back the Protective Sleeve 37 to expose the fittings on the Hydraulic Hoses 18 and 19. The
Hydraulic Hoses can be removed form the Body 2 using 12mm and 14mm spanners.
• The Quick Couplers - Male 10 and Female 11 can be removed from the Hydraulic Hoses 18 and 19 using 18mm and
24mm spanners.
• To remove Trigger Switch 7, first loosen Cable Gland 38, so that the Control Cable 14 is free to move within the Body 2.
Then undo M4 Set Screw 12 using a 2.0mm Allen Key.
• Push the Control Cable 14 into the Body 2 and simultaneously pull the Trigger Switch 7 out of the Body to expose the
solder joints on the Trigger Switch terminals. Unsolder the terminals to remove the Trigger Switch and Trigger Insert 39.
The Trigger Insert is bonded to the Trigger Switch and cannot be removed.
• The Control Cable 14 can now be pulled from the Body 2 and removed from the Protective Sleeve 37.
Assemble in reverse order to dismantling noting the following points:
• Prior to assembly clean all threads on the Quick Couplers - Male 10 and Female 11 and the Hydraulic Hoses - Return 18
and Pull 19. Then apply two to three layers of 10mm PTFE tape to the male threads on both of the Hydraulic Hoses.
• When replacing the Trigger Switch 7 apply *Loctite® 243 to the male thread on the Trigger Switch before assembling the
Trigger Insert 39.
• Apply *Loctite® 243 to M4 Set Screw 12 prior to assembly.
• Once assembled, prime the tool as per the instructions on page 10.

5.8 PROTECTING THE ENVIRONMENT

• Assure 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 Parts List on pages 16, 17 and 18.
* Service Kit on page 12.
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