Gyspress Premium 10T Push Pull US - Riveting machine GYS - Free user manual and instructions

USER MANUAL Gyspress Premium 10T Push Pull US GYS

Matrix for self-piercing rivets (RAP)

Matrix for self-piercing rivets (RAP)

Matrix for Flow-Form rivet (RFF)

Kit of assembly keys

INSTALLATION – FONCTIONNEMENT PRODUIT

POSE DE RIVETS FLOW-FORM

ANOMALIES, CAUSES, REMÈDES

Translation of the original instructions

WARNINGS - SAFETY INSTRUCTIONS

GENERAL INSTRUCTIONS This user’s manual includes operating instructions for your device and safety warnings for your protection. Please read it carefully before rst use and keep it for future reference. This equipment should only be used by profes- sionals and only qualied and experienced personnel should install, adjust, or operate it. Do not use this tool if any parts are missing or damaged. This product must not be modied in any way. WORKING ENVIRONMENT Slips, trips or falls are a major cause of serious injury or death. Look out for loose cables on the oor. This appliance is not intended for use in poten- tially explosive atmospheres. This appliance is intended for use indoors in a well-lit environment on level ground. ENVIRONMENT This product must only be used within the limits indicated on the indicator plate and/or in the manual. These safety guidelines must be observed. The manufacturer cannot be held responsible in the event of improper or dangerous use. Temperature range: Use between -10 and +40°C (+14 and +104°F). Store between -20 and +55°C (-4 and 131°F). Air humidity: Lower than or equal to 50% at 40°C (104°F). Lower than or equal to 90% at 20°C (68°F). Altitude: Up to 1,000 m above sea level (3280 feet).

PROTECTING YOURSELF AND OTHERS

To protect yourself and others, please observe the following safety instructions: Always wear impact-resistant eye protection when using the device. Always wear a safety helmet when working at height. Wear hearing protection in accordance with your employer’s instructions, and as required by occupational health and safety regu- lations. Exposure to high sound levels can cause permanent hearing loss and other associated conditions, such as tinnitus. A risk assessment is crucial. Check that the mu󰀪ers are present and in good condition. Wear protective gloves to reduce the exposure to vibration and other hazards such as cuts and abrasions. Repetitive movements and severe vibration exposure can be harmful to arms and hands, shoulders, neck and other parts of the body. If numbness, tingling, or sti󰀨ness occurs, stop using the product and consult a qualied health care professional. Wear safety shoes in order to avoid an injury if a part is dropped during operation or assembly. Wear warm clothing when working in cold weather to keep hands warm and dry. Maintain a stable posture and secure footing when using the machine. It is advisable for the user to change posture during long tasks, which can help to relieve discomfort and fatigue. The tool must not be used facing towards the operator or any other person. Keep your hands away from the compression mechanism; it is strongly recommended to hold the riveting machine with both hands. Be aware that broken parts of the machine can act as high-speed projectiles. Regularly inspect for cracks; injuries may occur if the device’s arm cracks and is dropped during use.

USE OF COMPRESSED AIR

Never exceed the maximum air pressure stated on the back of the machine and in this manual Pressurised air can cause serious injury. It is recommended that the machine be disconnected from the compressed air supply before changing arms or attachments. Empty the hose before use. Disconnect the air supply when the tool is not in use. Never carry the riveter by the hose16 User manual

GYSPRESS PREMIUM 10T PUSH-PULL US

Translation of the original instructions

REPLACEMENT OF ARMS AND ACCESSORIES

Only use arms and accessories recommended by the manufacturer. NOISE Weighted sound power level: LWA = 78 dB VIBRATION Vibration emissions are below the imposed threshold of 2.5 m/s².

If the machine is to be disposed of, it must not be left in the open and should be taken to an authorised recycling centre.

INSTALLATION - USING THE PRODUCT

DESCRIPTION This riveting machine has been specially designed for the installation of all the main types of rivets used and approved in the automotive repair in- dustry:

• Self-piercing rivets «Punch Rivets»

• «Flow Form» rivets Suitable for all riveting tasks on sheet metal (up to 8.3 mm thick). TECHNICAL FEATURES Riveter weight 4.1 kg Max air system pressure 110 psi Maximum clamping force 100 kN HANDLING All the necessary steps for correct use are outlined in this manual. Operating procedures that are not explicitly approved by the manufacturer, GYS, are not permitted. DESCRIPTION OF THE EQUIPMENT (I)

Translation of the original instructions ARM INSTALLATION a a Carefully place the arm on the nose of the riveter, making sure to align the 2 markings (a). When tting large arms, it is recommended that the arms are laid at on a table, and the nose of the riveter is brought into the arm opening. Once the arm is placed on the riveter, insert the locking pin (I-8) into the slot. The pin locks automatically after insertion, and should not spon- taneously escape from the slot. The locking pin must be clean with no damage. Do not use a damaged pin. Screw on the extension supplied with the arm. The riveting machine is now ready to use.18 User manual

GYSPRESS PREMIUM 10T PUSH-PULL US

Translation of the original instructions

MOUNTING THE FITTINGS

Screw the end-cap kit required for the riveting procedure into the arm support. Before each assembly, check that the die and rivet holder are correctly paired (see page 4) and tightened securely. As soon as the die and the punch support are in place, nish tightening with the delivered spanner. Check that the connection tips are in place after each riveting process. Any loosening is dangerous and may cause damage to the riveter.

AIR PRESSURE CONNECTION

Maximum air pressure: Make sure that the air pressure does not exceed 110 psi. Clean compressed air: Ensure that only clean, dry compressed air is used to feed the riveter. Moisture and dirt can lead to performance issues and/or damage to the unit.

SPEED AND PRESSURE CONTROL

The user can manually adjust the speed of the ram and the rivet setting force, according to the type of material to be joined, in order to avoid any deformation of the workpiece. To set the pressure according to the dies and materials, see table at the end of the manual. Speed PressureEN

Translation of the original instructions

Translation of the original instructions

The riveter is supplied with a box of 300 self-piercing steel rivets (RAP) (ref. 048706). These test rivets are provided for the purpose of testing the riveter and should not be used for automotive repair under any circumstances.

INSTALLATION OF SELF-PIERCING RIVETS

Ø 3.3 mm Ø 5.3 mm During the installation of self-piercing rivets, make sure that the rivets are well-placed. The dies must not be damaged as this could cause problems with the riveting process. During each riveting procedure, it is imperative to ensure that the die - and not the rivet itself - is placed on the sheets being joined. It is also important to position the punch support on the sheets that being joined so that it forms a 90° angle. 90° Self-piercing rivets PUNCHING AND SIZING HOLES FOR FLOW-FORM RIVETS Ø 6 mm Ø 6 mm Ø 6 mm ST1 T5 T7EN

Translation of the original instructions To punch the sheet metal to a specic diameter, it is necessary to use a specic die. This die protects the sheet from damage. After punching, the punch is pushed into the metal sheet and pierces the hole. The sheet is released from the punch, and is ready for riveting. If the punch does not come out of the sheet, use the PULL function of the riveter. Select PULL mode and press the trigger. Once the punch is withdrawn from the sheet, select the PUSH mode.22 User manual

GYSPRESS PREMIUM 10T PUSH-PULL US

Translation of the original instructions

INSTALLATION OF FLOW FORM RIVETS

Before you can consider joining sheets with Flow-Form rivets, it is necessary to make a pilot hole (see above). Once the pilot hole has been created, insert the Flow-Form rivet into it. The F1 tip should be positioned on the head side of the rivet. The F2 die has a drain hole for adhesive residues. After each rive- ting process, remove adhesive residues from all a󰀨ected tools. Flow-form rivetEN

Translation of the original instructions RIVET EXTRACTION For car body repairs, old or damaged rivets must be removed from the metal sheets. To avoid the necessity of removing these rivets by drilling, the extraction tip and its die should be used. They allow the rivets to be removed without damaging the sheet metal. Before using the riveter, and to facilitate the extraction of self-piercing rivets, an indentation can be made on the rivet with a Centre Punch Tool (048379) so that the extraction punch can subsequently be wedged into the recess. If the rivet remains in the die hole during extraction, remove it before performing another extraction. Once the hole is punched, release the pressure immediately. Bringing the point to the end of its travel can generate additional stresses on the point, which may cause it to break.

CONTROLS AND MAINTENANCE

The riveter does not require any special maintenance. A basic periodic visual check is recommended to prevent any breakdown or failure during use. Clean the riveter at least once a week to remove all dust and dirt that could a󰀨ect the long-term performance of the product. Use self-cleaning clo- ths. Do not use any water, nor ammable or corrosive liquids. During maintenance, the compressed air supply must be disconnected from the unit.24 User manual

GYSPRESS PREMIUM 10T PUSH-PULL US

Translation of the original instructions

DEFECTS, CAUSES, AND SOLUTIONS

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 your distributor in order to nd out the procedure you need to follow.

TROUBLESHOOTING CAUSES SOLUTIONS

The riveting machine does not work. Air supply is not attached. Connect the compressed air. Air pressure too low. Check air pressure supply. The air pressure is not adjusted properly. Set the compressed air to between 40 and 90 psi. The potentiometer is set to the minimum setting. Adjust the driving speed. The rivet is not in place. Defective chuck or die. Replace the chuck or the die. Presence of glue on the chuck or inside the die. Clean o󰀨 the adhesive The pressing pressure is not enough. Air pressure is too low or not well-ajdusted. Rivet length wrong. Follow manufacturer instructions. Air, leakage. Faulty pipe. Change the pipe. Faulty coupling. Change the coupling. Faulty seals. Repair required by the manufacturer. OPTIONS (NON-EXHAUSTIVE LIST) Riveter support for changing accessories 054158 Workstation trolley 054233 Workstation trolley + support 055391 Pressure sensor 062115 Adapter 24 kN for blind rivets Standard 063822 Compact 077164 Adapter 50 kN for blind rivets 064867 Find all riveting accessories and dies on www.gys.fr

WARRANTY CONDITIONS FRANCE

The warranty covers any defects or manufacturing faults for two years from the date of purchase (parts and labour). The warranty does not cover:

• Any other damage caused during transport.

• The general wear and tear of parts (i.e. : cables, clamps, etc.).

• Incidents caused by misuse (incorrect power supply, dropping or dismantling).

• Environment-related faults (such as pollution, ru󰀬 and du󰀬). In the event of a breakdown, please return the item to your di󰀬ributor, along with: - a dated proof of purchase (receipt or invoice etc.). a note explaining the malfunction.25

GYSPRESS PREMIUM 10T PUSH-PULL US

Pressure control chart

Self-piercing rivets (SPR)

Dimensions DIMENSIONS

Warning ! Read the user manual before use.

Warning! Risk of crushing ngers.

This hardware is subject to waste collection according to the European directives 2012/19/EU. Do not throw out in a domestic bin !

Device complies with euro- peans 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).

This product should be recycled appropriately.