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24952 Broken stud M8 remover kit with press function, version Nr.1- y.2016
Security precautions
To understand the activities of the instrument is required in advance to read these instructions!
- Carefully and in the right order, please read this manual before setting - up the device
- At work, always follow the data in the instructions / maintenance manual manufacturer for
current information and steps in the right order
- The instructions for use and recommended tools in this set are as a guideline and it is no
guarantee for success
- This set contains special products, which was several times successfully tested and used
successfully. It is necessary to pay attention to the accuracy of compliance with the order of
the steps
- The device must only be used professionally
Set 24952 contains instruction manual + detailing photo documents.
Set is packed in EVA foam in plastic case.
All part are available separately.
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Summary of Contents for Triumf 24952
- Page 1 24952 Broken stud M8 remover kit with press function, version Nr.1- y.2016 Security precautions To understand the activities of the instrument is required in advance to read these instructions! - Carefully and in the right order, please read this manual before setting - up the device...
- Page 2 Spring washer 8,2 Zn, DIN 7980 35221 Washer 8 DIN125 Zn 8.4 31096 Nut hex M8 Zn DIN 934 32018 Main drilling unit with press function 35259 Tap wrench 23953 Plastic case 35290 EVA foam 35281 Picture1. Set 24952 – Part list...
- Page 3 Problem localization: Set of special tools is suitable for light commercial vehicle with engine 3,0l: Engine code F1CE-3,0l in: Fiat Ducato Iveco Daily, Massif Peugeot Boxer Citroën Jumper (Euro 3, 4 & 5) Mitsubishi Fuso Canter Picture 2. Dismantled cylinder head of engine Fiat Ducato HPi 3.0l Diesel injectors of the engines mentioned above are fixed by bolt M8.
- Page 4 But it is wrong. Solution The solution to this issue is The drill out device - manufactured by Triumf with order number 24952. Picture 5. Body of drilling out mechanism from set 24952...
- Page 5 Despite the time consumption associated with dismantling workspace is time saving as well as a guaranteed result of the work. The working comfort is unparalleled advantage with the time required for removal of the above-mentioned parts. Before installation of drilling mechanism is necessary to dismantle the injector in order to properly drilling block centering with respect to the exact positioning or centering and drilling tip for broken stud M8.
- Page 6 Picture 9. On the left is dismantled cylinder head of Fiat Hpi 3.0l, right dismantled engine parts needed for installation drilling out mechanism from set 24952...
- Page 7 Installation procedure of drilling mechanism 1 Support rails installation for drilling mechanism TIP: Rails are selfcentering. Rail centering is not necessary, since the holes are precision pre- driller. To make faster and easy to install drilling mechanism are all screws with inbus head 5mm. Rails contain also predrilled holes M8.
- Page 8 For fixing rail No.2 use screws that are part of this bar and are therefore part of the set 24952. set screws are screwed firmly by T Allen key 5mm (No. 14).
- Page 9 installation drilling out mechanism. All rails must fit properly in their recesses and outer corners of the support frame of the drilling mechanism. It must be withheld roundly. Fit the last rail using two screws (also part of this rail). Picture 13.
- Page 10 Picture 14. Injector retaining broken stud Fiat Hpi 3,0l Broken stud is neccesary resurface, straighten the edges in the case stud is bent so to pass a neck centering tip 8mm - tip # 4 or # 6, due to possibility of variant broken stud. Picture 15.
- Page 11 3 Drilling mechanism installation 3.1 Install drilling mechanism over the before fitted support frame in order to ensure centering axis of drilling mechanism and broken stud. For broken stud centering with drilling mechanism use a centering tip No. 4 or No. 5 (in case of deep broken stud). 3.2 Before installation of drilling mechanism just release 3 screws of stops (see red marked round –...
- Page 12 Picture 18. Handle removing from centre part of drilling mechanism and separate centre part from base plate of drilling mechanism by using T handle hex key 5mm. 3.3 Insert base plate of drilling mechanism to supporting the frame. Position base plate of drilling block around the center of the broken stud M8.
- Page 13 3.5 When base unit was installed, tight the 4 screws of base plate (Fig. 19). which hold the longitudinal rails. Final centering carried out by setting of stop blocks (Fig. 20) on the sides, to facilitate remove and insert drilling mechanism without resetting the base plate and centered position.
- Page 14 4 Drilling out of broken stud M8 When drilling mechanism is right centered, replace centering tip (8mm) for 9 mm drilling tip. The tip is made of high quality hardened material, where there is no way to scuff interior walls of tip. Tip will serve as a long time as a solid guide for drilling out broken stud M8. The cylinder walls drilling mechanism are perfectly cut and polished, therefore greasing in every use is very important.
- Page 15 4.3 Drilling process The set order no 24952, you have purchased contains cobalt drills with respect to screw material the injector. Drill material is the most proven in compare with other types of drills. The set contains drill bits of the same diameter but different lengths. Short drill No. 10 is used for the initial drilling out the stud, which stick out over the camshaft cover and the other length drill (4 drills with exact length), guarantees 100% stud drilling out with no water canals damaging.
- Page 16 milled surface on drill shank for accurate installation of the drill Picture 24. Drill bit installation into the estended drilling spindle for drilling mechanism. Picture 25. Installing appropriately selected drill and tighten the three screws of center part of drilling mechanism 4.6 Now connect drill machine (electric or battery) and set speeds ranging from 500 to 800.
- Page 17 I. Knurled presser handle ensures a firm grip even with greasy hands of the operator – non slip effect. The sliding mechanism includes a bearing, thanks to lever movement is smooth and easy II. Dual lines lever of sliding mechanism ensures increased rigidity and high resistance.
- Page 18 Picture 27. Drill machine connect Picture 28. Vŕtanie s miernym prítlakom. Možnosť obojsmerného natočenia odvŕtavacieho mechanizmu. 4.8 Drill intermittently with proportional downforce. Pull the handle over while drilling for breakage of the chips. The drilling out process is performed intermittently, cold it by air and oil.
- Page 19 Picture 29. Joints cleaning and oiling and blowing metal chips by compressed air Picture 30. Greasing of drill spiral flute After drilling out of broken stud clean hole off metal chips any other residues. Remove center part of drilling out mechanism.
- Page 20 Picture 32. Detail fully drilled out broken stud M8 Fiat Hpi 3. Picturec32. Cross view of cylinder Fiat Ducato HPi 3.0l...
- Page 21 5 Thread tapping M10x1 Note: thread cutting done by hand not electrically. Picture 33. Tapping process M10x1 Extra long tap M10x1 can be used directly in the drilled hole without additional activities. Slide guide sleeve over the long tap, ensuring tap alignment and hole where we need to cut thread.
- Page 22 Picture 34. Stud installation. Picture 35. New stud installing by hand or by rathet spanner. Opposite side of stud has a thread M8x1,25, what is a standard thread using by original manufacturer (stay original thread) 7 Drilling out mechanism moving for other cylinder positions For moving of drilling mechanism to drilling out other broken studs for other cylinder position there is no need to re-adjust all mechanism, just slide right or left on longitudinal rails and fixed it by 4 screws placed in re-drilled holes M8 in these rails.
- Page 23 Dismantle drilling mechanism in the back order of its assembly. Check the cleaness of the injector stud hole. After detaching drilling mechanism and before stud installing can be thread more cutted if necessary. In case of any question please contact Triumf company: Triumf professional tools s.r.o. Kollárova 88...
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