Bostitch Staple Gun SW9040 5 8 SW9040 3 4 SW9040 7 8 User Manual

D16-2AD  
BOXLOK STAPLER  
STAPLE SIZES:  
SW7437 7/16  
SW9040 5/8  
SW7437 5/8  
SW9040 3/4  
SW7437 3/4  
SW9040 7/8  
OPERATION and MAINTENANCE MANUAL  
BEFORE OPERATING THIS TOOL, ALL OPERATORS SHOULD STUDY THIS MANUAL TO UNDERSTAND  
AND FOLLOW THE SAFETY WARNINGS AND INSTRUCTIONS. KEEP THESE INSTRUCTIONS WITH  
THE TOOL FOR FUTURE REFERENCE. IF YOU HAVE ANY QUESTIONS, CONTACT YOUR BOSTITCH  
REPRESENTATIVE OR DISTRIBUTOR.  
DO NOT USE SUPPLY SOURCES WHICH CAN POTENTIALLY EXCEED 80 PSIG (5.7 KG/CM2) AS TOOL  
MAY BURST, POSSIBLY CAUSING INJURY.  
WHEN AIR SUPPLY .IS CONNECTED KEEP HANDS AND BODY AWAY FROM STAPLE DISCHARGE AREA  
AT ALL TIMES. DO NOT FIRE THE TOOL WITHOUT STAPLING INTO MATERIAL.  
THE CONNECTOR ON THE TOOL MUST NOT HOLD PRESSURE WHEN AIR SUPPLY IS  
DISCONNECTED. IF A WRONG FITTING IS USED, THE TOOL CAN REMAIN CHARGED WITH AIR  
AFTER DISCONNECTING AND THUS WILL BE ABLE TO DRIVE A STAPLE EVEN AFTER THE AIR LINE  
IS DISCONNECTED POSSIBLY CAUSING INJURY.  
DO NOT PULL TRIGGER OR DEPRESS CONTACT ARM WHILE CONNECTED TO THE AIR SUPPLY AS  
THE TOOL MAY CYCLE, POSSIBLY CAUSING INJURY.  
DO NOT USE OXYGEN, COMBUSTIBLE GASES, OR BOTTLED GASES AS A POWER SOURCE FOR THIS  
TOOL AS TOOL MAY EXPLODE, POSSIBLY CAUSING INJURY.  
FAILURE TO OBSERVE ANY OF THESE WARNINGS MAY RESULT IN INJURY.  
BSA981SREVE 9/03  
Stanley Fastening Systems  
 
TO PREVENT ACCIDENTAL INJURIES:  
• Never place a hand or any other part of the body in staple discharge area of  
tool while the air supply is connected.  
• Never point the tool at anyone else.  
• Never engage in horseplay.  
• Never pull the trigger unless nose is directed at the work.  
• Always handle the tool with care.  
• Do not pull the trigger while loading the tool.  
TO OPERATE  
SHUT OFF AIR SUPPLY BEFORE MAKING ADJUSTMENT, REMOVING CLOGGED STAPLES OR SERVICING.  
To operate machine, grasp handle. Position machine on box placing directly over the seam between flaps and  
in line with desired staple location. Squeeze trigger and release completely before moving machine. Move  
machine to each staple position and repeat. Strongest closure requires end staples close to end of box,  
approximately 1” (25.4mm). Be sure staples penetrate inner flaps. Check staple clinching in sample of box  
board, such as that being used. Adjustment for depth of penetration is easy and full advantage should be taken.  
Clincher adjusting clamp settings as listed in chart are offered only as a guide and may have to be slightly  
modified.  
MAINTENANCE  
Always disconnect air supply: 1.) Before making adjustments; 2.) When servicing the tool;  
3.) When clearing a jam; 4.) When tool is not in use; 5.) When moving to a different work  
area, as accidental actuation may occur, possibly causing injury.  
When working on air tools note the warnings in this manual and use extra care when  
evaluating problem tools.  
Specify the part number when ordering replacement parts. Do not order by description. Do not wrench, twist or  
force parts during servicing, as damage may result.  
Check screws periodically for tightness. Observe caution against stripping threads when tightening. When the  
tool is disassembled, clean thoroughly. Lubricate all moving parts after cleaning. Apply “Magnalube-G” to O-  
rings. Examine all parts for wear during servicing so that replacement parts can be ordered in advance of  
trouble.  
LUBRICATION  
Frequent, but not excessive, lubrication is required for best performance. Oil added through the air line  
connection will lubricate the internal parts. Use BOSTITCH Air Tool Lubricant, Mobil Velocite #10, or  
equivalent. Do not use detergent oil or additives as these lubricants will cause accelerated wear to the seals  
and bumpers in the tool, resulting in poor tool performance and frequent tool maintenance.  
If no airline lubricator is used, add oil during use into the air fitting on the tool once or twice a day. Only a few  
drops of oil at a time is necessary. Too much oil will only collect inside the tool and will be noticeable in the  
exhaust cycle.  
CAUTION: Do not store tools in a cold weather environment to prevent frost or ice formation on the tools  
operating valves and mechanisms that could cause tool failure.  
NOTE:  
Some commercial air line drying liquids are harmful to “O”-rings and seals – do not use these low  
temperature air dryers without checking compatibility.  
FILTER:  
Dirt and water in the air supply are major causes of wear in pneumatic tools. A filter will help to get the best  
performance and minimum wear from the tool. The filter must have adequate flow capacity for the specific  
installation. The filter has to be kept clean to be effective in providing clean compressed air to the tool.  
Consult the manufacturer’s instructions on proper maintenance of your filter. A dirty and clogged filter will  
cause a pressure drop which will reduce the tool’s performance.  
REGULATOR:  
A pressure regulator with an operating pressure of 0 - 125 p.s.i. (0 - 8.79 KG/CM2) is required to control the  
operating pressure for safe operation of this tool. Do not connect this tool to air pressure which can potentially  
exceed 200 p.s.i. (14 KG/CM2)as tool may fracture or burst, possibly causing injury.  
 
1. Apply LOCTITE 242 to screw thread before  
assembling hanger to tool.  
2. Use a swivel type hook on the counterbalance  
used to suspend this tool.  
VALVE  
54  
ASSEMBLY  
D60064A  
SEE VIEW “A”  
55  
56  
57  
VIEW “A”  
ITEM  
NO.  
PART NO.  
DESCRIPTION  
ITEM  
NO.  
PART NO.  
DESCRIPTION  
1.  
2.  
121830  
D16243  
T20111  
T20018  
T20049  
D16163A  
85014  
Cylinder  
26.  
27.  
28.  
32.  
34.  
D16111A  
D16112  
Clincher Adj. Plate  
Clincher Adj. Clamp  
Front Plate  
Cylinder Gasket  
Trigger  
3.  
D16114  
4.  
Trigger Pivot Pin  
Trigger Pin Retaining Ring  
Frame  
D16149A  
UA4814.1  
Pusher Assembly  
1/4-20 x 7/8 Soc. Hd.  
Cap Screw  
5.  
6.  
7.  
“O” Ring  
35.  
36.  
37.  
LW14.2  
1/4 Lock Washer  
1/4 Pipe Plug  
8.  
D16168  
D16167  
D16179  
UA4006.2  
D16327  
D16180  
85012  
Driver Guide L.H.  
Driver Guide R.H.  
Driver Block  
UA9607  
9.  
UA4816.12  
1/4-20 x 1” Cone Pt.  
Set Screw  
10.  
13.  
14.  
15.  
16.  
17.  
18.  
19.  
20.  
21.  
22.  
23.  
24.  
25.  
Driver Retaining Screw  
Retaining Screw Spacer  
Piston Rod  
38.  
39.  
HN1420.2  
UA2810  
1/4-20 Hex Jam Nut  
#8-32 x 5/8” Soc. Hd.  
Cap Screw  
“O” Ring  
40.  
41.  
42.  
LW8  
#8 Lock Washer  
3/8-24 Elastic Stop Nut  
#8-32 x 1/2” Soc. Hd.  
Cap Screw  
D16185  
D14227B  
D16146  
85016  
Driver Block Pin  
Piston  
HN3824.4  
UA2808.1  
Piston Washer  
“O” Ring  
43.  
44.  
45.  
LW8  
#8 Lock Washer  
Washer  
D16183  
D16184A  
D14130  
D14132A  
D14133A  
Escapement Roller  
Clincher Link Plate  
Clincher Link  
PW516.4  
UA5812.3  
5/16-18 x 3/4” Soc. Hd.  
Cap Screw  
Clincher Lever L.H.  
Clincher Lever R.H.  
46.  
UA 3808.8  
#10-24 x 1/2” Soc. Hd.  
Cap Screw  
 
ITEM  
NO.  
PART NO.  
DESCRIPTION  
ITEM  
NO.  
PART NO.  
DESCRIPTION  
47.  
48.  
49.  
50.  
51.  
LW10  
#10 Lock Washer  
3/32 x 3/4” Cotter Pin  
Pusher Spring  
52.  
53.  
54.  
55.  
56.  
57.  
D60009  
851201  
D60008  
86458  
Valve Stem  
UP2912.3  
D14164  
UB2814.2  
D60054  
O-Ring .301 x .070  
Valve Body  
Pin, Spring .094 x .88  
Spring, Valve  
O-Ring 1/16”x 1/2” ID  
O-Ring 1/16”x 9/16” ID  
O-Ring 1/16”x 5/8” ID  
86998  
86459  
VARIABLE PARTS  
ITEM NO.  
DESCRIPTION  
Driver  
STANDARD PARTS  
D16170 (long)  
OPTIONAL PARTS  
D16178 (short)  
11.  
30.  
Clincher  
D16124 (deep)  
D16124B (deep pointed)  
D14135 (shallow)  
33.  
29.  
C’ Balance Hanger  
Magazine Assembly  
D16106A  
D16169A  
D16164A  
[5/8” (15.9mm)  
3/4” (19.1mm)  
and 7/8” (22.2mm)  
staples]  
[7/16” (11.1mm)  
5/8” (15.9mm)  
and 3/4” (19.1mm)  
staples]  
D14135 CLINCHERS  
Approx. Clincher Adjusting  
To obtain maximum efficiency from the staple  
closure, it is important that the staple be clinched properly.  
Proper clinching for any thickness board may be obtained by  
adjusting the clincher setting with staples of proper leg length.  
Clamp Setting  
(2) A Board-Blind  
6
5
4
3
2
1
5/8”  
(15.9mm)  
Leg  
Use the proper length staples for the thickness of work to be  
stapled, otherwise unnecessary pressure is exerted and  
staple crowns and legs will be distorted, or the clinch will be  
too loose.  
3/4”  
(19.1mm)  
Leg  
(2) A Board-Through  
(2) B Board-Blind  
7/16”  
(11.1mm)  
Leg  
5/8”  
(15.9mm)  
Leg  
Staple driven completely through two  
thicknesses of corrugated board and clinched on  
underside.  
(2) B Board-Through  
(2) C Board-Blind  
7/16”  
(11.1mm)  
Leg  
5/8”  
(15.9mm)  
Leg  
(2) C Board-Through  
Staple clinched “blind” when desired, in two  
thicknesses of corrugated board.  
D16124 DEEP CLINCHERS  
Approx. Clincher Adjusting  
CLINCHER ADJUSTMENT:  
Always disconnect air supply: 1.)  
Before making adjustments; 2.)  
When servicing the tool; 3.) When  
clearing a jam; 4.) When tool is not  
in use; 5.) When moving to a  
different work area, as accidental  
actuation may occur, possibly  
causing injury.  
Clamp Setting  
6
5
4
3
2
1
3/4”  
(19.1mm)  
Leg  
(2) A Board-Through  
3/4”  
(19.1mm)  
Leg  
(2) AB Board-Blind  
7/8”  
(2) AB Board-Through  
(22.2mm)  
Leg  
When working on air tools note the  
warnings in this manual and use  
extra care when evaluating problem tools.  
D14135 clinchers are for shallow penetration as in single  
wall board and will clinch inside board without damage to  
contents. D16124 clinchers are for deep penetration as in  
double wall board.  
Clincher adjustment for depth of penetration is obtained by  
loosening the clincher adjusting clamp screw on front of  
machine and moving it up or down. When in its highest  
position, the clinchers are set for the shallowest staple  
penetration. Lowering the clinchers increases the  
penetration. After establishing the setting, tighten  
adjustment screw.  
CAUTION: WHEN USING DEEP PENETRATION  
CLINCHERS, IT MAY BE NECESSARY TO USE A  
FILLER  
TO  
PREVENT  
DAMAGE  
TO  
MERCHANDISE. D16124 CLINCHERS MAY ALSO  
BE USED FOR STAPLING THROUGH SINGLE  
WALL BOARD PROVIDED A FILLER IS USED TO  
PREVENT DAMAGE TO CONTENTS OR  
CLINCHERS.  
NOTE: The D16-2AD is equipped with a driver to  
countersink the crown of the staple below the surface of  
the box. The shorter driver, available on order, will allow the  
crown of the staple to rest on the top of the box.  
 
CLINCHER REPLACEMENT:  
Always disconnect air supply: 1.) Before making adjustments; 2.) When  
servicing the tool; 3.) When clearing a jam; 4.) When tool is not in use; 5.)  
When moving to a different work area, as accidental actuation may occur,  
possibly causing injury.  
When working on air tools note the warnings in this manual and use extra  
care when evaluating problem tools.  
1. Loosen the clincher adjusting clamp screw.  
2. Slide the clincher adjusting clamp to the highest position. Retighten clamp screw. The clincher screws will be  
aligned with and visible through the 2 round holes in the back of the machine frame. Insert a socket screw  
wrench to loosen and remove screw holding clincher.  
3. Grasp the clinchers by hand or with pliers and lift off the anchor dowels.  
4. To assemble new clincher and screw, clean parts thoroughly. Degrease threads with Loctite Safety Solvent  
#75559; apply Loctite Grade 222 to screw threads and assemble. Refer to Loctite’s instructions. Tighten  
screw firmly.  
5. Re-adjust the clincher adjusting clamp to the desired setting and tighten.  
DRIVER REPLACEMENT:  
Always disconnect air supply: 1.) Before making adjustments; 2.) When servicing the  
tool; 3.) When clearing a jam; 4.) When tool is not in use; 5.) When moving to a  
different work area, as accidental actuation may occur, possibly causing injury.  
When working on air tools note the warnings in this manual and use extra care  
when evaluating problem tools.  
1. Remove the magazine.  
2. Remove the driver retaining screw, Item 13. Driver may now be removed from the housing.  
MAGAZINE REPLACEMENT:  
Always disconnect air supply: 1.) Before making adjustments; 2.) When servicing the  
tool; 3.) When clearing a jam; 4.) When tool is not in use; 5.) When moving to a  
different work area, as accidental actuation may occur, possibly causing injury.  
When working on air tools note the warnings in this manual and use extra care  
when evaluating problem tools.  
1. Remove staples from magazine.  
2. Loosen the two magazine binding screws and nuts.  
3. Pull magazine out of engagement with the frame.  
4. Insert new magazine making sure the front edge contacts the rear of driver guides. Centralize magazine in  
driver guides with binding screws. Tighten the magazine binding screw and nut so that magazine is securely  
held.  
CAUTION: DO NOT TIGHTEN THE MAGAZINE BINDING SCREW EXCESSIVELY AS TOO  
MUCH PRESSURE WILL DAMAGE THE MAGAZINE.  
DRIVER BLOCK PIN REPLACEMENT:  
Always disconnect air supply: 1.) Before making adjustments; 2.) When servicing the  
tool; 3.) When clearing a jam; 4.) When tool is not in use; 5.) When moving to a  
different work area, as accidental actuation may occur, possibly causing injury.  
When working on air tools note the warnings in this manual and use extra care when  
evaluating problem tools.  
1. Remove piston rod and driver block assembly from machine.  
2. Remove as much flare on end of driver block pin as possible.  
3. Use a rod smaller than pin diameter as a punch and drive pin free.  
4. To reassemble, insert new driver block pin thru driver block and piston rod. Support driver block pin on head  
and flare opposite end. Only a slight flare of approx. .020 greater than pin diameter is required to retain pin  
and provide proper linear movement of pin in assembly.  
 

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