Operating & Service Manual

90114-IM

05/11/2011

Airetool

®

ATT-6525

Tube Tester

For additional product information visit our website at http://www.apextoolgroup.com

Safety Recommendations

FOR YOUR SAFETY AND THE SAFETY OF OTH-

ERS, READ AND UNDERSTAND THE SAFETY

RECOMMENDATIONS AND OPERATING IN-

STRUCTIONS BEFORE USING THIS TOOL.

When using this tool, basic safety practices should always be followed to reduce the risk of personal injury including the following items:

KNOW THE TOOL - Read the owners manual carefully. Learn its applications and limitations as well as the specific potential hazards peculiar to this tool.

ALWAYS DISCONNECT AIR - The air supply should be disconnected when tool is not in use and before servicing.

NEVER ACTIVATE OUTSIDE OF TUBE - The air control valv

should never be activated unless the seal is inside of-

a tube I. D. the proper size for the seal.

STAT ALERT - Be careful and watch what you are doing. Use common sense.

ALWAYS WEAR PROTECTIVE EQUIPMENT

Hearing protectors are required in high noise areas,

85 dBA or greater. The operation of tools and equipment in the area, reflective surfaces, process noises and non-resonant structures can substantially contribute to and increase the noise level in the area.

Excessive air pressure above 9o psig or worn motor components can also increase sound level emitted by tool. Proper hearing conversation measures, including annual audiograms and training in the use and fit of hearing protection devices may be necessary.

Some individuals are susceptible to disorders of the hands and arms when exposed to task which involve highly repetitive motions or vibration. Those individuals predisposed to vasculatory or circulation problems may be particularly susceptible. Cumulative trauma disorders such as Carpal Tunnel Syndrome and Tendonitis can be caused by repetitions, forceful exertions of the hands and arms. These disorders develop gradually over periods of weeks, months and years.

For additional information on eye and face protection, refer to Federal OSHA Regulations, 29 Code of federal regulations, Section 1910.133 Eye and Face

Protection, and American National Standards Institute, ANSI A87.1, Occupational and Educational Eye and Face Protection Z87.1 is available from the American National Standards Institute, 11 West 42nd Street,

New York, NY 10036.

2

Safety Recommendations

* Tasks should be performed in such a manner that the wrists are maintained in a neutral position which is not flexed, hyperextended or turned side to side.

* Stressful postures should be avoided and can be controlled through tool selection and work location.

Any user suffering from prolonged symptoms of tingling, numbness, clumsiness or weakened grip, nocturnal pain in the hand or any other disorder of the shoulders, arms, wrists or fingers is advised to consult with a physician. If it is determined that the symptoms are job related or aggravated by movements and postures dictated by the job design it may be necessary for the employer to take steps to prevent further occurrences. These steps might include, but are not limited to repositioning the work piece or redesigning the work station, reassigning workers to other jobs, rotating jobs, altering work pace and/or changing the type of tools used so as to minimize stress on the operator. Some tasks may require more than one type of tool to obtain the optimum operator/ tool/task relationship.

3

OPERATING INSTRUCTIONS

Model ATT-6525 Airetool Tube Testing Guns

8. Go to the next tube to be tested and repeat steps two (2) thru seven (7).

INSTALLING REPLACEMENT SEALS

Replacement seals for the Model ATT-6525 guns are supplied with the corresponding size washers. Always replace the seals and washers on both guns at the same time. SEE

SEAL SELECTION GUIDE ON PAGES 9 AND 10 OF THIS

MANUAL.

1. Remove the lock nut (1) from the end of the support tube

(4) and set it aside.

2. Remove the seal and washer set (2) from the support tube (4). Discard if worn or damaged. NOTE: BE SURE

TO REPLACE WITH PROPER SIZE FOR TUBES TO BE

TESTED, SEE PAGES 9 & 10 OF THIS MANUAL. Under optimum testing conditions you should be able to test between 100 and 150 tubes per set of seals and washers.

3. When replacing the seal and washer set with the same size as removed, reverse steps 1 and 2 above for reassembly. If you are replacing the seal and washer set to test a different size tube, please keep in mind that you may also have to change the support tube assembly (5) as well.

Check chart pages 9 & 10 of this manual. If the support tube does need to be replaced, see replacing the support tube to follow.

4. When replacing the lock nut (1) onto the support tube

(4), do not use a wrench. Screw the nut on finger tight only.

A small space between the lock nut , seal and back up washers is normal. The stroke of the air piston in the air cylinder will compensate for this space.

REPLACING THE SUPPORT TUBE

The Airetool Model ATT-6525 tube testing guns are shipped with three (3) sets of support tube assemblies (5). These support tube assemblies will allow you to test tube with I.

D.’s as follows: a. .280” thru .480” (7.1 thru 12.3 mm) tube I. D.

b. .490” thru .830” (12.4 thru 21.2 mm) tube I. D.

c. .840” thru 1.230” (21.3 thru 31.3 mm) tube I. D.

1. Remove the seal and washer sets (2) as previously outlined.

2. Using an open end wrench on the wrench flats provided on the piston and a small pipe wrench on the support tube

(4), gently unscrew the support tube from the piston.

3. Choose the correct size support tube for the tube I. D. to be tested. All three (3) sizes support tubes will screw directly into the piston of the test gun. Use a never seize compound product to lubricate and seal the threads. Do not over tighten the support tube.

4. Repeat steps 1 thru 3 for the remaining gun.

5. Prior to replacing the seal and washer set (2) and the tube end seal and washer set (3), inspect the support tube for scars left from the replacement procedure. File smooth if present.

5

Airetool Model ATT-6525

Injection Gun (2984876)

ITEM #

3

4

5

1

2

6

7

PART #

**

*

**

**

**

2984867

2984859

DESCRIPTION

Lock Nut

Seal & Backup Washer Set

Tube End Seal/Washer

Support Tube

Support Tube Assembly

Handle Without Bleed Valve

Pressure Gage

* See seal/washer selection guide pages 9 & 10 .

** See selection guide pages 9 & 10 .

QUAN.

1

1

1

1

1

1

1

ITEM #

8

9

10

11

12

14

PART # DESCRIPTION

2992150 Cylinder Body Complete

8010275 Pipe Nipple 1/8" NPT

2984860 Air Control Valve

8010276 Reducing Nipple 1/4" - 1/8" NPT

2984862 Bleed Valve

2900579 Regulator Assembly

QUAN.

1

1

1

1

1

1

6

Airetool Model ATT-6525

Plugging Gun (2984877)

ITEM # PART # DESCRIPTION

1

2

3

4

**

*

**

**

Lock Nut

Seal & Backup Washer Set

Tube End Seal/Washer

Support Tube

* See seal/washer selection guide pages 9 & 10 .

** See Selection guide pages 9 & 10 .

QUAN.

1

1

1

1

ITEM #

5

7

8

13

PART # DESCRIPTION

** Support Tube Assembly

2984859 Pressure Gage

2992150 Cylinder Body Complete

2984868 Dead Handle

QUAN.

1

2

1

1

7

Sales & Service Centers

Note: All locations may not service all products. Please contact the nearest Sales & Service Center for the appropriate facility to handle your service requirements.

Dallas, TX

Apex Tool Group

Sales & Service Center

1470 Post & Paddock

Grand Prairie, TX 75050

Tel: 972-641-9563

Fax: 972-641-9674

Detroit, MI

Apex Tool Group

Sales & Service Center

2630 Superior Court

Auburn Hills, MI 48326

Tel: 248-391-3700

Fax: 248-391-7824

Houston, TX

Apex Tool Group

Sales & Service Center

6550 West Sam Houston

Parkway North, Suite 200

Houston, TX 77041

Tel: 713-849-2364

Fax: 713-849-2047

Lexington, SC

Apex Tool Group

670 Industrial Drive

Lexington, SC 29072

Tel: 800-845-5629

Tel: 803-951-7544

Fax: 803-358-7681

Los Angeles, CA

Apex Tool Group

Sales & Service Center

15503 Blackburn Avenue

Norwalk, CA 90650

Tel: 562-623-4457

Fax: 562-802-1718

Germany

Cooper Power Tools

GmbH & Co. OHG a company of

Apex Tool Group, LLC

Industriestraße 1

73463 Westhausen

Germany

Tel: +49 (0) 73 63 81 0

Fax: +49 (0) 73 63 81 222

Seattle, WA

Apex Tool Group

Sales & Service Center

2865 152nd Avenue N.E.

Redmond, WA 98052

Tel: 425-497-0476

Fax: 425-497-0496

England

Cooper Power Tools

GmbH & Co. OHG a company of

Apex Tool Group, LLC

C/O Spline Gauges

Piccadilly, Tamworth

Staffordshire B78 2ER

United Kingdom

Tel: +44 1827 8741 28

Fax: +44 1827 8741 28

York, PA

Apex Tool Group

Sales & Service Center

3990 East Market Street

York, PA 17402

Tel: 717-755-2933

Fax: 717-757-5063

France

Cooper Power Tools SAS a company of

Apex Tool Group, LLC

25 rue Maurice Chevalier

77330 Ozoir-La-Ferrière

France

Tel: +33 1 6443 2200

Fax: +33 1 6443 1717

Canada

Apex Tool Group

Sales & Service Center

5925 McLaughlin Road

Mississauga, Ont. L5R 1B8

Canada

Tel: 905-501-4785

Fax: 905-501-4786

China

Cooper (China) Co., Ltd.

a company of

Apex Tool Group, LLC

955 Sheng Li Road,

Heqing Pudong, Shanghai

China 201201

Tel: +86-21-28994176

Fax: +86-21-51118446

Mexico

Cooper Tools

Brazil Hungary

Cooper Tools Industrial Ltda. Cooper Tools Hungaria Kft.

de México S.A. de C.V. a company of

Apex Tool Group, LLC

Vialidad El Pueblito #103 a company of

Apex Tool Group, LLC

Av. Liberdade, 4055

Zona Industrial - Iporanga

Parque Industrial Querétaro 18087-170 Sorocaba a company of

Apex Tool Group, LLC

Berkenyefa sor 7

Pf: 640

9027 Györ

Querétaro, QRO 76220

Mexico

Tel: +52 (442) 211-3800

Fax: +52 (442) 103-0443

SP Brazil

Tel: +55 15 2383929

Fax: +55 15 2383260

Hungary

Tel: +36 96 66 1383

Fax: +36 96 66 1135

Apex Tool Group, LLC

1000 Lufkin Road

Apex, NC 27539

Phone: 919-387-0099

Fax: 919-387-2614 www.apextoolgroup.com

90114-IM/Printed in USA 05/2011/Copyright © Apex Tool Group, LLC

Airetool

®