henrob maintenance

Preventive Maintenance Guide for Henrob™ Electric SPR Gun Assemblies

Manual Part Number: 30-00088

Henrob™ Corporation

Michigan Office 30000 South Hill Road New Hudson, MI 48165 Phone: (248) 493-3800

Fax: (248) 493-3800

North Carolina Office 9805 NorthCross Center Ct. Suite A,

Huntersville, NC 28078. Phone: (704) 987-8005

Fax: (704) 987-8006

Henrob Limited Henrob GmbH Henrob™ Pty Flintshire

United Kingdom Herford

Germany Queensland

Australia

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Safety Precautions

Safety Precautions

It is the responsibility of the buyer/user to insure that the rivet gun is used and operated within a SAFE system of work. It is important that only trained personnel use this equipment. In the interest of operator safety, HENROB recommends the installation of safety curtains and/or guards, etc. to prevent inadvertent operator injury. Please contact Henrob Corporation for more details.

Do Not cycle the gun without a rivet, material, and upsetting die in position.

Do Not attempt to set a rivet on top of a previously inserted rivet.

Do Not switch on the Electric Setter Controller or operate the rivet gun with the cover of the electrical enclosure open (except qualified maintenance personnel carrying out fault finding).

Do Not operate the equipment without suitable eye protection.

Do Not operate the equipment without ALL machine guards in place.

The Henrob Servo Self-Pierce Riveting system operates using lethal voltage, stored energy, compressed air and crushing forces. All of these can pose serious hazards to health and safety if appropriate procedures and levels of care are not applied.

Preventive Maintenance

Henrob Corporation © 2015 Page: 2

Preventive Maintenance The primary objective of preventive maintenance is for trends leading to potential failure, including deterioration and wear of components, are identified and corrected before they become serious. The following schedule includes items that can be covered by this approach.

Please note that all frequencies are recommended as a baseline. A predictive maintenance program is recommended as it can extend the life of spare parts and find issues that need extra attention.

The Henrob self-piercing riveting system has been designed to offer very high reliability together with low maintenance requirements. It is strongly recommended that preventive maintenance be carried out in accordance with the following schedule:


4.2: Schedule for the Rivet Setter Assembly FREQUENCY TASK DESCRIPTION

Every 100,000 cycles GB/SD Cleaning Procedure Remove the GB/SD from the setter. Blow loose debris using an approved blow gun. Inspect all features and openings for excessive wear and foreign matter. Inspect punch for damage. Clean and lubricate as necessary using General Purpose Grease (Henrob Part Number P900).

Every 100,000 cycles Replace Punch Remove the drive belt cover. Remove the screw from the guide bush and discard it. Remove the GB/SD assembly. Install the punch change tool, part number 27-00052, Advance the rivet setter toward the die by hand cranking the pulley in the counter clockwise direction until the clamp tube has bottomed against the punch change tool. Grasp the exposed end of the punch and rotate it so that the retaining screw is aligned with the hole located in the side of the clamping cylinder. Loosen the set screw and remove the punch. Inspect the end of the plunger for wear and/or damage. Insert a new set screw through the access hole in the clamping tube. Install the new punch, and tighten the screw. Manually crank the actuator pulley in a clockwise direction to retract the rivet setter until the clamping tube clears the punch removal fixture. Unscrew and remove the punch change tool. Reinstall the M1945 lock nut.

Every 100,000 cycles Stud Nose Feeder Maintenance Clean and lubricate the Stud Nose Feeder components with General Purpose Grease (Henrob Part Number P900) as necessary - Stud Probe, Cylinder, Stud Feeder housing, Anti rotate extension bracket. Inspect components excessive wear and damage. Replace bearings and jaw spring.

Every 500,000 cycles Replace Nose Switch/APB Spring Nose Switch Spring - Remove the GB/SD assembly. Remove the trigger switch from the GB/SD. Remove the switch cover. Replace the trigger, switch spring. APB Spring - Remove the GB/SD assembly. Remove the tape guide from the GB/SD. Replace the APB spring.

Every 1,000,000 cycles

Note: Depending on the force of the rivet setter, the Million Cycle Maintenance may need to be performed every 500,000 cycles.

Rivet Setter Million Cycle Maintenance Remove the actuator from the setter and clamp the actuator in a vise. Remove the Extension tube. Remove the keys. Remove the four M4 socket head cap screws that hold the shaft coupling to the actuator shaft. Remove the shear pin. Remove the front end. Remove bush coupler. Remove the spacer. Compress and remove the spring, shaft coupler and plunger. Discard the spring. Inspect and clean the components. Reassemble in the opposite order. Clean and lubricate as necessary using General Purpose Grease (Henrob Part Number P900) except for the internal actuator which uses special grease ( (Henrob Part Number 27-00091).

Every 1,000,000 cycles Clean and Inspect Rivet Nose Feeder components

Rivet Nose Feeder Maintenance - Clean, inspect and lubricate the River Nose feeder components with General Purpose Grease (Henrob Part Number P900) as necessary. Disconnect the air hoses and remove the screws from the feeder halves and clean using a clean dry cloth. Do not use cleaning fluids or lubricants on the feeder. Replacing the cylinder - Remove the cylinder retaining screws and remove the cylinder. Inspect the pivot bearings, feeder halves, and rivet pusher for wear or damage. Replace the cylinder and fit to tool.



Every 1,000,000 cycles Clean and Inspect Standside dock components

Standside Dock Maintenance - Clean and lubricate the Standside Dock components with General Purpose Grease (Henrob Part Number P900) as necessary. Inspect components excessive wear and damage. Replace the escapement cylinders - Remove the cylinder from the stand. Remove the pneumatic hoses and switches. Remove the gate cylinder bolts. Remove the slider gate drive pin from the gate cylinder rod. Install the new slider gate drive pin on the new escapement cylinder and install. Replace the pneumatic hoses and switches. Adjust switches per drawing.

Every 1,000,000 cycles Clean and Inspect the Magazine. Replace the three position cylinder, gate locking pin and rivet full probes.

Magazine Million Cycle Maintenance - Clean and lubricate the Magazine components as necessary - Gate assembly, Escapement. Inspect components excessive wear and damage. Replace three position cylinder - Disconnect the air supply lines. Remove the cylinder bolts. Install the new cylinder. Replace the gate locking pin - Remove the two bolts from the docking face. Pull the docking face away from the gate. Set the docking face on the top of the magazine. Use a flat-blade screwdriver to remove the detent pin. Replace the detent pin. Replace the rivet full probes - Remove the 2mm screws. Remove the cylinder. Remove the probe from the cylinder rod. Remove the hoses and switches. Install new probe. Reconnect the pneumatic hoses and switches on the new cylinder. Adjust switches per drawing.

Every 1,000,000 cycles Clean and Inspect the Bulk Feed Cube components

Bulk Feed Cube Million Cycle Maintenance - Clean and lubricate the Bulk Feed Cube components with General Purpose Grease (Henrob Part Number P900) as necessary - Vibratory Control Module, Bowl Vibratory Unit, Bowl, Hopper and Rivet Exit Track. Inspect components excessive wear and damage. Replace the escapement cylinder - Remove the sensor and pneumatic hoses. Remove the escapement bolts from the cylinder. Remove the track cover. Remove and replace the escapement cylinder.

Every 1,000,000 cycles Clean and Inspect the Stud Feed Cube components

Stud Feed Cube Million Cycle Maintenance - Clean and lubricate the Stud Feed Cube components with General Purpose Grease (Henrob Part Number P900) as necessary - Vibratory Control Module, Bowl Vibratory Unit, Bowl, Hopper and Rivet Exit Track. Inspect components excessive wear and damage. Replace the escapement cylinder - Remove the sensor and pneumatic hoses. Remove the escapement bolts from the cylinder. Remove the track cover. Remove and replace the escapement cylinder.

Every 1,000,000 cycles Clean and Inspect Stud Nose Feeder components

Stud Nose Feeder Million Cycle Maintenance - Clean and lubricate the Stud Nose Feeder components with General Purpose Grease (Henrob Part Number P900) as necessary - Stud Probe, Cylinder, Stud Feeder housing, Anti rotate extension bracket. Inspect components excessive wear and damage. Replace cylinder - Remove the air lines. Remove the mounting bolts. Remove the sensor connectors. Unscrew the cylinder from the clevis. Replace the cylinder. Replace bearings - Remove the Stud feed head from the rivet setter. Remove the bolts and separate the feed heads. Remove the circlip from the link arm end. Remove the link arm from the feed head. Remove and replace the bearings.


Every 1,000,000 cycles Replace the Dynamic Feed Tube Remove the sensor clamp and the track cover from the stand side magazine. Remove the feed tube from the stand side magazine. Remove the plate assembly cover from the tool side magazine. Remove the tool side magazine track cover. Remove the feed tube from the tool side magazine.

Every 2,000,000 cycles Replace Tape Cutter Blade Remove the Tape Cutter bolt. Replace Tape Cutter Blade.

Every 2,000,000 cycles Replace the Stud Static Feed Tube Loosen the securing screw from the top of the GS/BD. Pull the feed tube to remove the feed tube from the nose feeder. Remove the tube retaining set screw from the bowl feeder. Remove the feed tube from the bowl feeder. Pull the tube from the conduit. Feed the new tube into the conduit, Cut the tube to length. Prepare the tube ends and install.

Every 4,000,000 cycles Replace the Static Feed Tube Remove the clamp sensor and track cover from the bowl feeder. Remove the sensor clamp and the track cover from the stand side magazine. Pull the feed tube out from the bottom of the bowl feeder. Pull the tube from the conduit. Feed the new tube into the conduit, Cut the tube to length. Prepare the tube ends and install.

Every 4,000,000 cycles

Note: Depending on the force of the rivet setter, the Actuator Rebuild Procedure may need to be performed every 2,000,000 cycles.

Actuator Rebuild Procedure Send the actuator to Henrob to perform the actuator rebuild procedure. Exchange late clamp module.

Record of Amendments


Record of Amendments The information in this manual will be subject to revisions in accordance with alterations made to the equipment described. Users of this manual should check that they are in possession of the latest issue relevant to the equipment purchased.

Issue Amendment Date of revision Text affected

A Released R01563

July 2010

B E06333 November 2013 Revised all frequencies

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HENROB Corporation

30000 South Hill Road, New Hudson, Michigan 48165

Telephone: (248) 493-3800, (800-4-HENROB)

www.henrob.com

henrob maintenance

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