JARVIS
TABLE OF
CONTENTS Page.........................
Stunner Tester, AST--100 115V, 4016003
Stunner Tester, AST--100 220V, 4016006
• Notice to Employer and Safety
Director 2.........................
• Notice to Operators, Maintenance
and Cleanup Personnel 3............
• Parts Diagram and List 4............
• Operation Diagram 7................
• Installation Instructions 8............
• Operation Instructions 8.............
• Maintenance Instructions 8..........
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA
TEL. 860-347-7271 FAX. 860-347-6978
6216002
Model AST--100
STUNNER TESTER
EQUIPMENT
SELECTION Ordering No..............
®
Preliminary
noticetoemployer
and safety director
Model AST--100
page 2 of 8
JARVIS
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA
TEL. 860-347-7271 FAX. 860-347-6978
6216002
®
NOTICE TO EMPLOYER AND SAFETY DIRECTOR
AVOID INJURY
1. Remove and repair any tool that malfunctions. All personnel must be instructed to remove any mal-
functioning equipment.
2. Ensure that all employees who use this tester are trained in the proper use of the AN--10K1 Stunner
and are aware of the dangers that may arise if they do not follow procedures outlined in this brochure.
3. Ensure that all employees are instructed to stand clear of the tester during its use, and to never put fin-
gers, hands or other parts of the body directly in front of the AN--10K1.
4. Enclosed are four (4) copies of “NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PER-
SONNEL.” Post one copy on the employees’ bulletin board; give one copy to the operator(s); give one
copy to the maintenance foreman; and give one copy to the sub--contract cleanup / internal cleanup fore-
man. Additional copies will be provided upon request.
5. The AN--10K1 Stunner is designed and intended to be powerful. This fact should be obvious to your
employees, but you must emphasize it to them.
6. Ensure eye and ear protection i s worn at all times when operating the AN--10K1 Stunner.
7. Never make modifications or alterations to the tester. Replace any missing or illegible labels.
8. Ensure that proper procedures are established in accordance with OSHA’s lockout/tagout procedures
(29 CFR 1910.147) to prevent accidental startup or release of stored energy.
9. Follow our installation and maintenance instructions for proper installation and care of the tester.
10. Avoid injury. Do not permit the tester to be misused.
11. If you resell or distribute a Jarvis product, you must provide the purchaser with the appropriate safety
sheets and tool brochure. Additional copies of safety sheets and tool brochures will be provided upon
request.
Keep body parts clear
notice to operators, maintenance
and cleanup personnel
Model AST--100
page 3 of 8
6
JARVIS
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA
TEL. 860-347-7271 FAX. 860-347-6978
6216002
®
NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PERSONNEL
ANY MALFUNCTIONING TOOL MUST BE REMOVED FROM SERVICE
REPORT ANY PROBLEMS TO YOUR SUPERVISOR
1. Disconnect the power in accordance with OSHA’s lockout/tagout procedures (29 CFR 1910.147) be-
fore performing any repair or maintenance.
2. Disconnect the power -- or have the air hose disconnected -- in accordance with OSHA’s lockout/tagout
procedures (29 CFR 1910.147) before performing any cleanup.
3. Never put fingers, hands or other parts of the body directly in front of the AN--10K1 Stunner.
4. Always wear eye and ear protection when operating the tester.
5. Always keep operator’s head a safe distance away and off to one side of the stunner when using the
tester to avoid injury from the stunner’s recoil.
6. Always keep all body parts away from t he stunning rod guide when triggers are activated.
7. Never squeeze the triggers while inserting t he AN--10K1 Stunner into the tester. The stunner could
fire if the stunning rod guide is displaced by contact with the tester while both triggers are depressed.
8. Never make modifications or alterations to the tool. Replace any missing or illegible labels.
Keep body parts clear
parts diagram and list
Model AST--100
page 4 of 8
JARVIS
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA
TEL. 860-347-7271 FAX. 860-347-6978
6216002
®
ITEM PART NO. PART NAME QTY
1 1055746 Socket Head Cap Screw 6
2 1058186 Guide 1
3 1016650 Housing 1
4 1017390 Nameplate Label 1
5 1055274 Drive Screw 6
6 1032646 Wear Plate 1
7 1017400 Name and Info Label 1
8 1005156 Proximity Switch 2
9 1032702 Safety Plate 1
AST--100
Stunner Tester
Figure A
parts diagram and list
Model AST--100
page 5 of 8
6
JARVIS
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA
TEL. 860-347-7271 FAX. 860-347-6978
6216002
®
10 1001198 Wire with Molded Plug 2
11 1012113 Cable Tie with Marker 2
12 1011364 Strain Relief Connector 2
13 1007385 Locking Nut 2
14 1032691 Mounting Plate 1
15 1017392 Wiring Diagram (120V) 1
1017393 Wiring Diagram (220V)
16 1016692 Electrical Enclosure 1
17 1042471 Terminal Rail 1
18 1063496 Terminal Block, Yel/Gr 2
19 1055010 Pan Head Screw 2
20 1004022 Internal Lock Washer 2
21 1060100 Threaded Insert 2
22 1063494 Terminal Block, Grey 5/4*
23 1063363 Terminal Marker 14
ITEM PART NO. PART NAME QTY
Electric Control Box
Current Configuration
Figure B
ITEM PART NO. PART NAME QTY
24 1072070 Timer 1
25 1061512 Wire Ferrules 5/2*
26 1017384 On/Off Label 1
27 1005174 Electric Switch 1
28 1063456 Terminal Marker 2
29 1063352 Time Delay Fuse (120V) 1
1063826 Time Delay Fuse (220V)
30 1063455 Fuse Term. Block (120V) 1
1063390 Fuse Term. Block (220V)
31 1007249 Locking Nut 1
32 1011248 Cord Connector 1
33 1001194 Power Cord (120V) 1
3001078 Power Cord (220V)
3063350 Control Box Assy (120V)
3063351 Control Box Assy (220V)
* QTY = 120V/220V
parts diagram and list
Model AST--100
page 6 of 8
JARVIS
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA
TEL. 860-347-7271 FAX. 860-347-6978
6216002
®
10 1001198 Cable with Molded Plug 2
11 1012113 Cable Tie with Marker 2
12 1011364 Strain Relief Connector 2
13 1007385 Locking Nut 2
18 1063496 Green/Yellow Terminal Block 2
19 1055010 Pan Head Screw 2
20 1004022 Internal Lock Washer 2
22 1063494 Grey Terminal Block *4/3
23 1063363 Terminal Marker 27
25 1061512 Ferrule *4/1
26 1017384 Off/On Label 1
27 1005174 Selector Switch 1
28 1063456 Terminal Marker 2
31 1007249 Locking Nut 1
32 1011248 Cord Connector 1
33 3001078 Line Cord (220V) 1
1001194 Line Cord (120V) 1
34 1063967 Electrical Connector, 6 ckt 1
35 1063968 Crimp Terminal 5
36 1063969 Power Supply 1
37 1055482 Pan Head Screw 4
38 1004006 Internal Lock Washer 8
39 1061475 Hex Spacer 4
ITEM PART NO. PART NAME QTY
ITEM PART NO. PART NAME QTY
40 1063970 Electrical Connector, 3 ckt 1
41 1063971 Female Terminal Disconnect 1
42 1063822 Terminal Block Base 5
43 1063490 Diode 2
44 1063972 Terminal Bridge 5
45 1063823 Terminal Block Plug 5
46 1063973 Resistor 2
47 1063974 Resistor 1
48 1063495 Blue Terminal Block *0/1
49 1042313 Terminal Rail 1
50 1032644 Mounting Plate 1
51 1016652 Electrical Enclosure 1
52 1063455 Fuse Block Terminal 1
53 1063975 Fuse 1
54 1005175 Push Button Switch 1
55 1017385 Clear Label 1
56 1063976 Timer 1
57 1071016 Ferrule 5
58 1063728 Terminal Strip 4
59 1017388 Wiring Diagram (220V) 1
1017383 Wiring Diagram (120V) 1
3063314 Control Box Assy (120V)
3063333 Control Box Assy (220V)
* QTY = 120V/ 220V
Electric Control Box
Original Configuration
Figure C
operation diagram
Model AST--100
page 7 of 8
6
JARVIS
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA
TEL. 860-347-7271 FAX. 860-347-6978
6216002
®
installation, operation and
maintenance instructions
Model AST--100
page 8 of 8
JARVIS
PRODUCTS CORPORATION
33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457-4926
UNITED STATES OF AMERICA
TEL. 860-347-7271 FAX. 860-347-6978
6216002
®
INSTALLATION INSTRUCTIONS
IMPORTANT: ALWAYS TURN THE POWER OFF IN ACCOR-
DANCE WITH OSHA’S LOCKOUT/TAGOUT PROCEDURES
(29 CFR 1910.147) BEFORE PERFORMING ANY MAINTE-
NANCE OR REPAIRS.
1 Mount the Model AST--100 tester securely on a bench
or table top in the vicinity of where the Model
AN--10K1 Stunner is being used and/or maintained.
Be sure to mount the safety plate (item 9) between the
Model AST- 100 and the bench.
1.1 Use the four (5/16) clearance holes to secure the
housing and safety plate.
1.2 Make sure that the top of the housing is at a conve-
nient height to facilitate insertion and extraction
of the AN--10K1 Stunner.
2 Mount the control box in the vicinity of the tester
housing. Two cords, two meters long with connectors
are provided.
3 The power requirement for the tester is 10 Watts at
120VAC, 60 Hz or 220VAC, 50 Hz.
4 Connect the control box to the proximity switches
(item 8) using the two cables (item 10) provided with
the control box.
4.1 The top and bottom cables are clearly identified
(top or bottom) with cable ties (item 11) and must
be connected to the appropriate (top or bottom)
connector.
OPERATION INSTRUCTIONS
Note: Operator’s head must be a safe distance away
and on one side of the AN-10K1 Stunner when the
stunner is in use to avoid injury from the tool’s recoil.
Note: It is not necessary to test the AN--10K1 Stunner be-
fore every use, but the tool should be checked at least
once per shift to ensure effectiveness of the stunner.
1 Turn power switch (item 27) on.
2 Verify that the pressure regulator for the air supply to
the AN--10K1 Stunner is set for 150--175 psi.
3 Place the AN--10K1 Stunner into the tester.
3.1 Be careful to align the slot in the top of the tester
housing with the ear on the trigger contact bushing
of the AN--10K1 Stunner.
4 After the AN--10K1 Stunner is resting in the tester
housing, hold the tool firmly to reduce and contain the
recoil.
5 For Current Comtrol Box (Figure B): squeeze the trig-
ger once to obtain reading.
For Original Comtrol Box (Figure C): squeeze the
trigger once to prime the timer, and then squeeze the
trigger a second time to obtain a reading.
6 The display will read directly in microseconds the
time it takes for the stunning rod to pass by both p rox-
imity switches. A reading of 2250 equals 0.00225 sec-
onds.
6.1 A reading below 2250 indicates an acceptable
stunning speed. A reading above 2500 indicates
a repair is necessary.
MAINTENANCE INSTRUCTIONS
ALWAYS TURN THE POWER OFF IN ACCORDANCE WITH
OSHA’S LOCKOUT/TAGOUT PROCEDURES (29 CFR
1910.147) BEFORE PERFORMING ANY MAINTENANCE OR
REPAIRS.
1 DAILY:
1.1 Check that the proximity switches (item 8) are se-
curely attached to the tester housing.
1.2 Check that the two cables from the control box are
securely attached to the proximity switches in the
tester housing.
2 REPLACING THE PROXIMITY SWITCHES:
2.1 Remove the cable from the control box.
2.2 Loosen the locking nut on the proximity switch
(item 8) and unthread the switch from the tester
housing.
2.3 Thread the new switch into the tester housing.
2.4 Locate the front end of the switch 1/16th inch re-
cessed from the inside diameter of the guide (item
2). The end of the switch must not protrude into
the guide bore.
2.5 Tighten the locking nut after the switch has been
properly located.
3 REPLACING THE GUIDE:
3.1 Remove the p roximity switches (item 8) as de-
scribed in section 2.
3.2 Remove three socket head cap screws (item 1).
3.3 Push guide out from top of tester housing.
3.4 To reassemble, reverse steps 3.1 to 3.3.
3.4.1 Use Loctite 262 on the three socket head cap
screws (item 1).
/
