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Novitool Aero 625 Instructions Manual

Retrofit kit
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Aero
Stand
®
Retrofit Kit Instructions
To Accommodate Aero
625-925-1225 along with 900-1200-1500
®
WARNING
IMPROPER OR UNSAFE use of this tool can result in serious bodily injury! This manual contains important information
about product function and safety. Please read and understand this manual BEFORE operating the tool. Please keep this
manual available for other users and owners before they use the tool. This manual should be stored in a safe place.
www.flexco.com

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Summary of Contents for Novitool Aero 625

  • Page 1 Aero Stand ® Retrofit Kit Instructions To Accommodate Aero 625-925-1225 along with 900-1200-1500 ® WARNING IMPROPER OR UNSAFE use of this tool can result in serious bodily injury! This manual contains important information about product function and safety. Please read and understand this manual BEFORE operating the tool. Please keep this manual available for other users and owners before they use the tool.

  • Page 2: Table Of Contents

    Table of Contents Aero® Stand Retrofit Assembly ..............3 Gear Pawl Offloading System ..............4 Description ..................... 5 Specifications....................5 Tools Required for Assembly ............... 5 General Safety Rules ..................6 Retrofit Installations Instructons ..............8 Operation .....................23 www.flexco.com —2—...

  • Page 3: Aero® Stand Retrofit Assembly

    Aero Stand Retrofit Assembly ® to Additionally Accommodate 625-925-1225 Item No. Part Number Description Qty. GQ863 COUNTERWEIGHT AERO 1225 ® GQ860 CHANNEL LB INTERFACE GQ865 LIFT BAR G2-G3 GQ862 PIN WEIGHT ALIGNMENT GQ861 ADAPTER ELEV BRACKET GQ915 CHAIN WIRE ASSY 625-1225 GQ909 GUARD CHAIN STAND 625-1225 G9968...

  • Page 4: Gear Pawl Offloading System

    Gear Pawl Offloading System 5 Assemble Spring Pin into Guard Assemble Spring Pin into Guard No Spring Pin Needed No Spring Pin Needed Item No. Part Number Description Qty. GQ868 GUARD PAWL GEAR LIFT SYSTEM GQ912 PIN SPRING M5X14 SS GQ867 PAWL LIFT SYSTEM GQ910...

  • Page 5: Description

    Description This is the Aero® retrofit kit for your current stand that is required in order to accommodate the Aero 625, 925, and 1225. The stand will continue to provide convenience and time savings for your belt fabrication. The design allows for the Aero presses to be loaded quickly and conveniently. The lower beam of the Aero is fixed into the stationary cradle of the press stand.

  • Page 6: General Safety Rules

    General Safety Rules –Save These Instructions– Signal words: 1. WORK AREA CAUTION “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in Keep your work area clean and well lit. death or serious injury. This signal word is limited to the most extreme situations.
  • Page 7 General Safety Rules –Save These Instructions– 4. SERVICE AND MAINTENANCE 5. AERO STAND SAFETY ® CAUTION DANGER When servicing a tool, use only original Read and understand the Aero® Press operations replacement parts. Use of unauthorized parts or manual before using the press in the Aero Stand. failure to follow Maintenance Instructions, may create a risk of injury.

  • Page 8: Retrofit Installations Instructons

    Retrofit Installation Instructions 1. Ensure “AERO® 900” weight is secure with the latch (1a and 1b). Further lock-out of weight is recommended via clamping or blocking. 2, Unscrew 2-hole alignment pins (2a and 2b) and replace with 3-hole alignment pins (2c) (part GQ862). Thread in fully, then back out to ensure holes face in pin direction (2d).
  • Page 9 Retrofit Installation Instructions 3. Move 625/1200 & 925/1500 weight plates to upper position shown. Insert pins (3a). Further lock-out of weight is recommended via clamping or blocking. 4. Remove guide rod nuts located below bottom weight plate (4a). On upper weight plate hold down black grommets in place while turning rods and moving rods upward approximately 2"...
  • Page 10 Retrofit Installation Instructions 5. Remove the two pins from lifting bar (not required further). (5a) Remove the two sets of fasteners at both ends of the lifting arm to remove the power cable (save fasteners). (5b) Remove the three bolts that connect the three cables to lifting arm (save fasteners). (5c) Remove the lifting bar (not required further).
  • Page 11 Retrofit Installation Instructions 7. Remove cable retention bolt on the rear 3-cable roller (7a). 8. Remove cable retention bolt on the center roller (save fasteners) (8a). Remove center cable (8b and 8c). —11—...
  • Page 12 Retrofit Installation Instructions 9. Disengage links of the two remaining cables from the weight compartment (9a). Pull cables and hang over each respective roller and shaft (9b). 10. Remove the shaft bolt (10a) and the roller that engaged the three cables positioned directly above the weight compartment (10b).
  • Page 13 Retrofit Installation Instructions 11. Loop the chain-cable assembly (part GQ915) over the center groove of the center roller from the kit (11a and 11b). Re-install the original cable retention bolt and nut (11c). Re-install the other two cables verifying the cables engage in the three different roller slot positions –...
  • Page 14 Retrofit Installation Instructions 13. While holding the shaft bolt, manually thread the sprocket onto the shaft (13a). Ensure the shaft bolt draws through the opposite top beam hole, and confirm the sprocket is fully threaded on the shaft (13b). 14. Position the (GQ877) nut, (GQ866) gear, and (GQ868) inner gear guard oriented as shown (14a). NOTE: direction of gear as shown is critical.
  • Page 15 Retrofit Installation Instructions 15. On shaft hex side, install inner gear guard (GQ868) (15a) and gear (GQ8666) (15b). NOTE: direction of gear as shown is critical. 15a 15b 16. Route cables and chain over the roller/sprocket assembly (16a). Ensure cables do not cross and chain is not twisted.
  • Page 16 Retrofit Installation Instructions 17. Install pawl (GQ867) (17a) then install outer gear guard (17b) (with pin) and original nylok nut on the cable retention bolt (17c). Tighten nut sufficiently to provide smooth operation for both pawls (GQ867). 18. Drive spring pins into inner gear guard (GQ868), both sides.
  • Page 17 Retrofit Installation Instructions 20. Install wheel (GQ875) using washer (GR145) and socket head screw (GQ919). NOTE: during screw torque, use wheel as wrenching device to avoid rotation of the left hand threaded shaft nut (GQ877). Both sides (20a and 20b). 20a 20b 21.
  • Page 18 Retrofit Installation Instructions 22. Re-engage cable loops with lift eye connecting links (22a). 23. Apply weight decals as shown (23a, 23b, 23c and 23d). 23a 23b 23c 23d www.flexco.com —18—...
  • Page 19 Retrofit Installation Instructions 24. Install chain guard (GQ909). Remove adhesive 25. Remove original strips from chain guard. Position inside top hold down post beam as shown, with adhesive strips down. from stand Engage adhesive strips with top beam inner cradle (25a). flanges (24a).
  • Page 20 Retrofit Installation Instructions 28. Place adapter brackets (GQ861) on Aero® Stand cradle. One at the front of the cradle and the other at approximate position of end of press (28a). Install M8 x 100 detent pins (G2034) through holes in adapter bracket tabs on underside of cradle (28b).
  • Page 21 Retrofit Installation Instructions 30. Place Aero® Press bottom beam on cradle within the adapter brackets (30a). Place the Aero Press top beam in place and pin to lifting bar using new pins. (GR102) (30b) In weight cabinet, pin the appropriate counterweight for the press placed in the stand. Elevate Aero top beam to determine the ‘suspended’...
  • Page 22 Retrofit Installation Instructions 32. With Aero® Press top beam suspended, check tension of each cable (32a). If a cable has significantly less tension than the others, unload weight from top press beam, lock out weight in compartment (32b), adjust the counterweight lifting eye thread engagement to better distribute the cable tension (32c and 32d).

  • Page 23: Operation

    Approximately 2-3 ‘clicks’ of the pawl lever are typically sufficient to completely off-load the counterweight. Follow operating instructions from Novitool® Aero® Splice Press Safety and Operation Manual to complete the splice. —23—...
  • Page 24 Once the splice process is complete, unfasten the press connector bolts. To off-load the top press beam: Grasp the off-load wheel, (c) Rotate the off-load wheel in the counterweight ‘lift’ direction until the pawl lever is released, (d) Rotate the pawl lever to the ‘up/disengaged’ position (both pawl levers up), (e) Lift top press beam with lifting arm attached (f) WARNING...

This manual is also suitable for:

Aero 1225Aero 900Aero 1500Aero 1200Aero 925