Table of Contents

Operation of 6000 Series Wire Wrap Tool
Tools Required for Repairing 6000 Series Pneumatic Tools
Lubrication for 6000 Series Pneumatic Wire Wrap Tools
Lubrication Instructions for Repair and Maintenance
Troubleshooting Guide
Disassembly
Assembly


Operation of 6000 Series Pneumatic Wire Wrap Tool

The following guidelines are provided to insure safe operation of Standard Pneumatic's 6000 Series Pneumatic tools.

* For safety, top performance, and maximum durability of parts, operate these tools at 90 psig (6.2bar/620kPa) maximum air pressure at the inlet with 1/4" (6mm) ID air hose.

* Standard Pneumatic is not responsible for damage caused by any customer modifications of tools.

* Do not disassemble if the tool is still in the warranty period. Disassembly by anyone who is not an authorized Standard Pneumatic service technician will void the warranty.

* Always use clean, dry air. Dust, corrosive fumes, or excessive moisture can damage the motor of an air tool. An air line filter and lubricator are required.

* Low or fluctuating air pressure causes variations in tool speed and performance.

* The wrapping bit and sleeve should be installed by loosening the sleeve nut and inserting the bit into the sleeve holder, with the flat on the shank end of the bit turned upward, a slight rotation of the bit maybe required to properly engage the bit driver. Next, place the sleeve over the bit and slide it into sleeve holder, aligning the key slot of sleeve with the key in the sleeve holder. Tighten sleeve nut to retain both the bit and sleeve.

* Operating the tool while tightening the sleeve nut will insure proper positioning of the bit and sleeve.

* The wire to be wrapped is inserted in the small off-center hole of the bit, while the center hole slips over the terminal pin. There are sleeves available with a funnel for easier insertion of the wire.


Tools Required for Repairing 6000 Series Pneumatic Tools

* Adjustable wrench - Jaw opening to 3/4"
* Vise - bench model or portable
* Small arbor press
* Small slotted screwdriver
* 1" micrometer
* 1/16 and 1/4 hex wrench
* Flat Plate (glass or other)
* Emery Cloth
* Tachometer
* Container (at least 6" diameter with low walls)


Lubrication for 6000 Series Pneumatic Wire Wrap Tools

When other manufactures of lubricators are used, it is recommended that the customer check with that particular manufacturer for the proper procedure for setting the lubricator to deliver 1/10 of a drop per minute to the tool. Many lubricators, especially larger units, require high airflow rates for the lubricator to operate properly. Therefore, the manufacture should also be asked to verify the operation of the lubricator at a 3.6 cfm flow rate for the 6000 series.

Multiple tools on one air system present another problem. When several tools are connected to the same lubricator, it is not possible for the correct amount of lubrication to go to each tool. Since it is highly unlikely that the same number of tools would also be in operation at the same time, the airflow through the lubricator would be a variable; thus the amount of lubrication put into the airflow would also vary, however, with the micro fog type of lubricator, such as our model 280, the oil particle size is such that the oil stays suspended in the air through several take-offs better than with other types of lubricators without wetting out, which results in multiple tools on the same line being better lubricated.

The position of the various tools in the system in relation to the distance away from the lubricator would also cause a variance in the amount of lubrication to each tool. If several tools must be connected to the same lubricator, the same procedure for setting the amount of the lubrication on the unit should be used with only one of the tools running. It is assumed that the increased airflow of several tools operating at the same time will pull more oil into the system. The maximum number of tools that we recommend connected to one Model 280 is two.


Lubrication Instructions for Repair and Maintenance

1. JDV recommends using lubricating oil: Rock Drill Oil, ISO 32
2. Generously lubricate rotor and rotor blades prior to reassembly of the motor.
3. Apply a film of Dow Corning 55 O-ring lubricant to all o-rings before final assembly.
4. Coat all idler gears and spindle gears with Darina AX multifuse grease or equivalent.


Trouble Shooting Guide

Symptom

Possible Cause

Tool will not run or stalls

*Air pressure must be at 90psig (6.2bar/620kPa)
*Missing or broken rotor blades
*Rotor or rotor blades too long
*Burrs on gears
*Incorrect positioning of trigger on trigger rod
*Worn end plates or rotor
*Lack of lubrication

Loss of power

*Lack of lubrication
*Muffler clogged
*Badly worn rotor blades
*Air pressure must be at 90 psig (6.2bar/620kPa)
*Rotor blades installed backwards
*Rust and rotor blade debris in cylinder

Will not index properly

*Trigger adjusted incorrectly
*Worn clutch slide or index dog
*Spindle/bit driver positioned wrong in clutch slide
*Trigger not fully released
*Damaged o-rings on valve stems



Disassembly

1. Grasping the front nut (40) turn clockwise (left hand threads) to remove. The index dog (36), driver/spindle (38,34), bushing (39), sleeve holder (41) and sleeve nut (42) will pull away from housing (1) in a unit or assembly.

2. Place a 1/4 hex wrench into the hex opening in the end cap (31), turn clockwise (left hand threads) to remove. While grasping the tool housing in one hand, lightly tap on the back of motor housing so the motor assembly (21 - 30) will slide out from the motor housing (20).

3. It may require using a punch and hammer or arbor press to drive/press the spindle (21) from the bearing (22) in the upper bearing ring (30). Support the gear end (21) of the motor, leaving an opening for the spindle. The spindle should move only far enough to remove the bearing. After the bearing is free of spindle the upper end plate (29), cylinder (26), rotor with blades (27,28) and lower end plate (25) can be removed.

4. Clean the component parts of motor thoroughly. Inspect the end plates (29,25), rotor (27), and cylinder (26) for any scoring or excessive wear. The teeth of the spindle gear (21) should be checked for burrs or excessive wear.

5. If the end plates have slight scoring they can be refurbished by lightly sliding them cross ways on a piece of emery cloth placed on a flat surface. This process should be done until a good finish has been achieved. Note: Always make sure that each item is flat against the emery cloth when doing this process.

6. Using a 1/16 hex wrench loosen the set screw (12) located on the under side of the trigger button (11). Place a straightened paper clip or rod, approximately .046 diameter into the small hole on front of the trigger. While holding the trigger outward (the off position) push the paper clip or rod into the trigger, this releases the trigger button (11) and clutch slide (32) so they can be removed from the housing.

7. A tool for removing the valve bushing (10) can be made by taking another bushing and pressing a 1/16 dowel pin into each hole, the two pins are to be place into the holes of the bushing in the housing. The modified bushing allows a clearance hole for the valve stem. Place a rod through the hole at the back of the bushing for a T-handle. Turn clockwise to remove. Check valve bushing and valve stem for excessive wear. O-rings (6,7) should be replaced whenever maintenance is being performed on tool.

8. Using a thin blade screwdriver remove the two slotted screws on the index dog (36), and then remove the sleeve holder (41). Place the index dog on a flat surface with the spindle up, using a hammer gently tap spindle to remove bit driver (38) and bushing (39). To remove the drive dog (14), idler gears (18) and motor housing (20); place the spindle (34) (as shown in parts diagram) into the drive dog (14). Holding the spindle in place, turn housing so the spindle rests against a flat surface, then grasp the housing assembly and apply forward pressure to slide items (13-20) from the housing assembly.

9. Check the bearing (15) that is attached to the drive dog, for excessive wear and smooth rotation. Inspect the idler gears for burrs or excessive wear. Inspect o-rings (16,19) for cracks or cuts and replace if necessary. Check the tangs on the drive dog and the teeth of the internal gear in the motor housing (20) for excessive wear.

10. Lightly grasp the handle of the housing (1) in leather covered vise jaws so the muffler (5) and air inlet(2) are upward. Using an adjustable wrench remove the muffler assembly for cleaning or replacement. Grasp muffler element (66350) with a pair of needle nose pliers then withdraw from housing, it can cleaned in a suitable cleaning solution. If the muffler element cannot be cleaned then replace with new one.

11. Clean all parts thoroughly, using cleaning solvent, acentone or ultrasonic cleaner with specified soap.


Assembly

Note: Always clean every part and apply a thin film of pneumatic tool oil to every motor component. Sealed or shielded bearings should never be cleaned. Open or single row radial ball bearing can be cleaned and then work new grease into the bearing prior to installation. Apply o-ring lubricant to all o-rings.

1. Place the housing in a padded vise with the handle end pointing upward. Insert muffler element (5), and muffler adapter (5), into the air port, then using a 5/8" open end wrench or an adjustable wrench turn the adapter clockwise until securely tightened.

2. Rotate the housing in vise so the handle lies horizontally and the trigger port is accessible.

3. Apply o-ring lubricant to the two small o-rings (7), then slide one over the solid end of the valve stem until it is seated in the groove next to the relived portion of the valve stem.

4. Insert the grooved end of the valve stem (8) into the threaded end of the valve bushing (10) until the groove is exposed at the opposite end. Care must be taken so that the valve stem is not inserted too far causing the installed o-ring to pass into the side hole resulting in a portion of the o-ring being sliced off due the sharp edge of the cross hole. If this occurs, remove the valve stem to inspect the o-ring (7) and if it has been damaged replace it with a new one, then re-insert the valve stem through the valve bushing (10). Install a new o-ring in the groove located at the end of the valve stem.

5. Thread the valve bushing with valve stem into the valve port located just below the motor housing in the relief of the handle. It can be tightened using a modified bushing as described in paragraph 7 of the disassembly instructions.

6. Assemble the motor by holding the spindle gear (21), then slide the bearing (22) onto the shaft until it is seated against the recess prior to the gear. Check to be sure the press fit of the bearing and spindle gear is solid, (tight). If the bearing will not slide by hand then use an arbor press to push the spindle gear onto the bearing. Care must be taken not to damage the bearing or pressing it too far so that the teeth rub against the bearing shield.

7. Place the lower bearing ring (24) on the bearing and then slide the lower end plate (25) onto the spindle gear (21), making sure that the counter bore faces the bearing. Insert the alignment pin into the small hole opposite the 3 air inlet holes of the bearing ring (24) and the small hole next to the slot in the end plate (25).

8. The rotor has 3 internal lobes in the I.D. located on one end, slide the opposite end onto the spindle gear until the end of the shaft contacts the lobes, turn the rotor slightly to align the lobes with the grooves in the spindle, then slide both together. Place the cylinder (26), with end that has the alignment hole facing down, over the rotor onto the dowel pin. Wipe each rotor blade (28) with a film of pneumatic tool oil, and then insert a blade into each slot of the rotor with the 30-degree angles facing the center of the rotor. Place the upper end plate (29), bearing (22), and bearing ring (30) onto the end of the spindle gear. Note: the counter bore in the end plate should face the bearing.

9. Apply a thin film of o-ring lubricant to each o-ring prior to their installation. Install an o-ring (19) into each groove, located on the outside diameter of the motor housing (20). Install an o-ring (16) into the groove located in the end of the motor housing that has the larger I.D. opening.

10. Place each idler gear (18) on one of the three pins of the gear carrier assembly (17), making sure each one turns smoothly. If the bearing (15) requires replacement then place the drive dog in a vise and tighten the jaws just enough to prevent it from turning. Place a screwdriver between the idler gear pins then turn clockwise to loosen the carrier from the drive dog. The bearing should be oriented with the open side facing the gear carrier assembly and the shielded side should face the drive dog. Replace the two o-rings (33) and lightly coat with Darina AX multifuse grease or equivalent.

11. Place the drive dog-bearing-gear assembly (18,17,15,14) with the idler gears first, into the end of the motor housing that contains the o-ring (16) and has the larger I.D. opening. Turn the drive dog to insure that the teeth of the idler gears mesh properly with the teeth of the internal gear in the motor housing.

12. Install the motor housing washer (13) and o-ring (19) into the right side opening of the housing assembly (1). Install the motor assembly with the spindle gear first into the motor housing; rotate the drive dog so the idler gears will properly mesh with the spindle gear and the motor will fully seat. Then install the motor housing with the drive dog first into the right side opening of the housing assembly.

13. Place the last o-ring (19) onto the shoulder of the motor housing (20), then place the cap on the threaded end, using a 1/2" allen wrench placed in the back of the cap tighten by turning counter clockwise (left hand threads).

14. Insert the clutch slide (32) into the top of the housing assembly and then install the trigger (11) onto the valve stem making sure that the stud at the top of the trigger seats into the large groove of the clutch slide and the small flat on end of the valve stem faces the set screw at the bottom of the trigger.

15. Items (36-39, 41 & 42) should be together as an assembly, unless they were disassembled for replacing the bushing (39), if so reassemble as shown in the parts diagram. This assembly is placed into the opening that has the clutch slide (32). Insert the small diameter end of the hex spindle (34) into the clutch slide until it is fully seated in the o-rings located in the drive dog. Place the front nut (40) over the sleeve holder (41) and index dog (36), until contact is made with the threads on the housing. Turn the front nut counter clockwise until tight.

Note: To properly set the indexing install a wire wrap bit into the sleeve holder (41) until it engages the bit driver (38). As the assembly (items 35 through 42) is placed into the housing assembly, rotate the bit until the wire slot faces straight up. The bit will rotate the hex spindle for the correct alignment with the clutch slide.

16. To properly adjust the trigger attach the tool to an airline and once the air is turned on, the trigger rod will extend outward. The trigger rod will properly seat in the trigger button when the tool is actuated. Using a 1/16 allen wrench tighten the set screw (12) under the trigger. The tool should have a free speed of 4500 RPM.

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