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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