D66465 Gyspress 10 Tons Push Pull Body Punch Riveter Instruction Manual

Instruction Manual

GYSPRESS 10T PUSH-PULL

D66465 GYSPRESS 10 Tons Push Pull Body Punch Riveter

CONNECTOR KIT CONTENTS

Matrix for self-piercing rivets (RAP)
Matrix for self-piercing rivets (RAP)
Sheet flattening
Extraction mandrel
Punching mandrel
Matrix for Flow-Form rivet (RFF)
Extension
Kit of assembly keys
Spare Elastomer ring
The center punch

RIVETING ARM

WARNINGS – SAFETY REGULATIONS

GENERAL INSTRUCTIONS
This user manual includes instructions on how to operate your device and explains the precautions to be followed for your safety. Please read it carefully before first using it and keep it for future reference. This equipment should only be used by professionals and should only be installed, adjusted or operated by qualified and experienced personnel.

Do not use this machine if any parts are missing or damaged. This product must not be modified in any way.
WORKING ENVIRONMENT
Slips, trips, or falls are a major cause of serious, or even fatal, personal injury accidents. Pay attention to cables and hoses left on the floor. This device is not intended for use in potentially explosive atmospheres. This device is intended for indoor use in a well-lit environment on a flat
floor.
ENVIRONMENT
This equipment should only be used within the limits indicated on the information plate and/or the user manual. The safety guidelines must be observed. The manufacturer cannot be held responsible in the event of improper or dangerous use.
Temperature ranges:
Operate between -10 and +40°C (+14 and +104°F).
Store between -20 and +55°C (-4 and 131°F).
Air humidity:
Less than or equal to 50% at 40°C (104°F).
Less than or equal to 90% at 20°C (68°F).
Altitude:
Up to 1,000 m above sea level (3,280 feet).
PROTECTING YOURSELF AN OTHERS
Observe the following safety instructions to properly protect yourself and others:

	Always wear impact-resistant, protective eye wear when using the device.
	Wear a safety helmet when working at heights.
	Wear soundproofing headphones to protect your hearing in accordance with your employer’s instructions and as required by occupational health and safety regulations.
	Wear protective gloves to limit the risks associated with exposure to vibrations and dangerous phenomena, such as cuts or abrasions. Repeated movements and exposure to vibrations can harm your hands and arms, shoulders, neck and other parts of the body. In the event of numbness, tingling or ankylosis, stop using the machine and consult a doctor.
	Wear safety shoes in order to avoid potential accidents when assembling the device or in the event of a part falling from the equipment.

Wear a warm outfit when working in cold weather in order to keep your hands warm and dry.
Maintain a stable posture and secure footing when using this device. The operator should change posture during long tasks; this can help to avoid discomfort and fatigue.
The tool should not be operated when directed at the operator or at any other person.
Keep hands away from the compression mechanism; holding the riveter with both hands is highly recommended.
Please be aware that broken arms or consumables can generate high-velocity projectiles.
Inspect for cracks on a regular basis; injury can occur if a cracked arm is dropped during use.
USING COMPRESSED AIR
Never exceed the maximum air pressure listed on the back of the machine and in this manual.
Pressurized air can cause serious injuries. Disconnecting the machine from its compressed air supply is strongly recommended before changing the arm or consumable.
Never carry the riveter by the hose.
REPLACING ARMS AND CONSUMABLES
Use only the arms and consumables specifically recommended by GYS.
NOISE
Weighted sound power level: LWA = 78 dB.
DISPOSING OF THIS DEVICE
When disposing of the GYSPRESS 10T PUSH-PULL, it must not be dumped in the natural environment and must be taken to an authorized recycling center.

SETUP – OPERATING THE DEVICE

DESCRIPTION

This riveting machine has been developed specifically for installing the main rivet types used and approved in the automotive repair industry:

• Self-piercing rivets or ‘Punch Rivets’
• ‘Flow Form’ rivets are Ideal for all sheet metal riveting applications (up to 8.3 mm thick).

TECHNICAL CHARACTERISTICS

HANDLING
The correct handling procedures are explained in this user manual. It is vital that the GYS operating procedures are followed.

COMPRESSED AIR CONNECTION

Maximum air pressure:
Make sure that the air pressure does not exceed 10 bar.
Clean compressed air:
Make sure you use only clean and dry compressed air to supply the riveting machine. Moisture and impurities can lead to system failures and/or damage to the product.

SETTING UP AN ARM

Choose an arm and prepare the locking pin (1). Put the arm with care on the riveting machine nose, making sure that the 2 points of reference are aligned.
For the implementation of large arms (eg, HR210, HR310), it is advisable to lay the arms flat on a table and bring the nose of the riveting machine into the arm’s orifice.

As soon as the arm is on the riveting machine, push the locking pin in the hole.
The axle locks itself automatically and must not be allowed to become unlocked.
The locking pin must be clean with no damage. Do not use any damaged pins.

Using the screw, fasten the extension supplied with the arm.
The riveting machine is now ready to use.

CONNECTOR ASSEMBLY

Screw the required connectors kit for the riveting procedure in the arm support. Before assembling, check that the die and the punch support are correctly in place (see page 3) and screwed.

As soon as the matrix and the punch support are in place, tighten them with the spanner provided. Check that the connection tips are in place after each riveting process. A release is dangerous and may damage the riveting machine.

SPEED AND PRESSURE CONTROL

The user can adjust manually the speed of the actuator as well as rivet installation pressure according to the type of material in order to avoid distortion.
See page 77 in order to adjust the pressure according to the material and matrix.

RIVET BOX INCLUDED
The riveting machine is delivered with a box of 300 self-piercing rivets.
These sample rivets are provided to allow a test of the machine. They are specific to car body repair.

INSTALLATION OF SELF-PIERCING RIVETS

During the installation of self-piercing rivets, make sure that the rivets are well-placed. The matrix must not be damaged as problems during the riveting process may occur.

During each riveting process, make sure that the matrix – and the rivet itself – are played out on the metal sheets to assemble. It is important to put the punch support in place in order to form a 90° angle.

RESULT OF THE INSTALLATION OF SELF-PIERCING RIVET

STAMP AND CALIBRATE HOLES FOR FLOW-FORM RIVETS
To punch the sheet to a specific diameter, it is necessary to use a specific die. This die protects the sheet from damage.

If using Flow-Form rivets, it is necessary to drill metal sheets before in order to put the rivet in place. The punch and the die above allow for a more precise punching as well as allowing the fitting of Flow-Form rivet.

After punching the punch is pushed into the metal sheet and pierces the hole. The sheet is free from the punch and ready for riveting.

INSTALLATION OF FLOW FORM RIVETS

Before assembling metal sheets with Flow-Form rivets, it is necessary to pre-drill the metal (see the procedure above).
Once the starter hole is done, insert the Flow-Form rivet:
The end piece F1 must be on the head rivet side:

The F2 matrix has got an evacuation hole for glue residues. After each use, remove all the glue residues on the tools.
If the punch does not come out of the sheet metal, use the PULL function of the riveter. Press the PULL button and squeeze the trigger. Once the punch is out of the sheet metal, press the PUSH button.

RIVET EXTRACTION

For car body repairs, old or damaged rivets must be removed.
To avoid having to take off the rivets by drilling, the extraction connection, and the matrix must be used. Indeed, they enable to extraction of rivets while preserving metal sheets.

Before using the riveting machine and to facilitate the extraction of self-piercing rivets, it is possible to make a mark on the rivet with the center punch tool (ref: 048379) to locate the extraction tool in the mark.

If during the extraction, the rivet stays in the die hole, remove ithe blank before making another extraction. Once the hole is punched, release the pressure immediately. Failing to do so may damage the tip.

CONTROLS AND MAINTENANCE

The GYSPRESS 10T PUSH-PULL does not require any special maintenance. A simple periodic visual control is recommended in order to prevent any breakdown or failure during use. Clean the GYSPRESS 10T PUSH-PULL at least once a week in order to eliminate dust and dirt which could alter the function of the product in the long term. Use auto-cleaning clothes. Do not use water or flammable or corrosive liquids.
During maintenance, the compressed air supply must be disconnected.

TROUBLESHOOTING

The chart below indicates the issues that can be observed during the use of the product. If the problem observed does not appear in the table below, stop using the product and call immediately your distributor to seek support.

WARRANTY
The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labor).
The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping off equipment, disassembling).
• Environment-related failures (pollution, rust, dust).
  In case of failure, return the unit to your distributor together with:
  – The proof of purchase (receipt etc …)
  – A description of the fault reported

PRESSURE CONTROL CHART

– Self-piercing rivets (SPR)	– Flow-Form rivets (FFR)

AIR PRESSURE :
2 bar = 1.5 t = 15 kN
3 bar = 3.4 t = 34 kN
4 bar = 5.2 t = 52 kN
5 bar = 7.2 t = 72 kN
6 bar = 9.0 t = 90 kN
6.5 bar = 100 t = 100 kN
AIR MAX :
10 bar = 145 psi
AIR UNIT :
1 bar = 14.5 psi

SYMBOLS 

	Warning! Read the user manual before use.
	Warning! Risk of crushing fingers
	Warning! Working pressure limit.
	This hardware is subject to the waste collection according to the European directives 2012/19/EU. Do not throw it out in a domestic bin!
	Device complies with European directives, The EU declaration of conformity is available on our website (see cover page).
	Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).
	Equipment in conformity with Moroccan standards. The declaration Cم (CMIM) of conformity is available on our website (see cover page).
	This product should be recycled appropriately

SAS GYS
1, rue de la Croix des Landes
CS 54159
53941 SAINT-BERTHEVIN Cedex
France

References

• Arc Welding, Battery Chargers & Body Repair | GYS