Emhart Teknologies POP ProSet 1600 Series Manual de usuario

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INSTRUCTION MANUAL

ProSet® 1600 Series

Pneumatic Blind Rivet Tool

Page 2 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614

Contents

Introduction................................................................................................................................................. 2

Safety Instructions...................................................................................................................................... 3

Specifications.............................................................................................................................................. 4

Packaged Accessories............................................................................................................................ 4

Tool Requirements.................................................................................................................................. 4

ProSet®1600 Tool Dimensions .............................................................................................................. 5

Common Nosepieces ............................................................................................................................. 6

Basic Tool Operation .................................................................................................................................. 6

Front End Service ................................................................................................................................... 7

Mandrel Collection System (MCS) – ProSet®1600 MCS ...................................................................... 8

Cleaning the Collector Silencer .............................................................................................................. 8

Tool Assembly Torque Requirements ..................................................................................................... 9

ProSet®1600/1600MCS Diagram............................................................................................................ 10

Parts List................................................................................................................................................... 12

Hydraulic Oil Charging Procedure............................................................................................................ 14

Maintenance............................................................................................................................................. 15

Safety Data............................................................................................................................................... 16

Troubleshooting........................................................................................................................................ 17

EC Declaration of Conformity................................................................................................................... 18

Introduction

POP ®ProSet®1600 tools are light weight Air/Hydraulic rivet setting tools recommended for use with genuine

POP Brand Rivets per following chart:

Rivet Type Material

(Body – Mandrel)

Rivet Diameter

3/32” (*)

[2.4 mm]

1/8”

[3.0 - 3.2 mm]

5/32”

[4.0 mm]

Open End & MultiGrip

Al – Al



Al – St / SS



St – St



(†)

SS – SS; NC – St /SS



Closed End

Al – Al



Al – St / SS; Cu – St



()

St – St



SS – SS



LSR Rivets

Al – Al



HR™ Rivets

St – St



T - Rivet

Al – St



Self Plugger

St – St



Al: Aluminum, St: Steel, SS: Stainless Steel, Cu: Cooper, NC: Nickel Copper

(*) Use FAN239-176 Jaw pusher set up.

(†) Exclude MultiGrip

() Set air pressure at 90 psi (6.2 bar).

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 3

Safety Instructions

TO INSURE PROPER FUNCTIONING AND SAFE OPERATION READ THIS MANUAL

CAREFULLY BEFORE SETTING UP OR OPERATING THE POP ®ProSet™ 1600 SERIES TOOLS

1. DO NOT use this tool in a manner other than that recommended by Emhart Teknologies.

2. Always wear eye protection when using or when near a tool that is in use.

3. This tool is NOT designed for use in explosive atmospheres.

4. Inspect tool for damage before connecting to air supply including all air connections.

5. Trained personnel must perform tool repair and/or maintenance at the prescribed intervals.

6. Disconnect the air supply when adjusting, servicing or removing any part of the tool.

7. Keep fingers off the trigger when connecting the air supply or if the air supply fails.

8. Keep fingers away from the front of the tool when connecting the air supply or setting rivets.

9. DO NOT point the tool at anyone.

10. DO NOT operate tool with the nose housing removed.

11. DO NOT operate tool without the Deflector or Collector.

12. DO NOT modify the tool in any way. Modification will make void any applicable warranties

and could result in damage to the tool or physical injury to the user.

13. DO NOT look into the tool from the front or the back during use or when connected to air

supply.

14. The operating pressure must not exceed 100 psi (6.9 bar).

15. DO NOT direct tool exhaust towards anyone.

16. Wash hands if exposed to hydraulic fluid or lubricant.

17. Keep hair, fingers and loose clothing away from moving parts of the tool.

18. Emhart Teknologies recommends the use of Hearing protection when operating this tool.

Page 4 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614

Specifications

ProSet®1600 ProSet®1600MCS

Weight 2.15 lbs. (0.98 kg) 2.30 lbs. (1.05 kg)

Length

10.83” (275 mm)

10.71” (272 mm)

Height

8.94” (227 mm)

Stroke

0.71” (18 mm)

Air Consumption

0.043 cu. ft. per rivet

(1.22 lper rivet)

2.47 scfm (max.)

(70 l/min (max.))

Pulling Force

1090 lbs. @ 90 psi (4850 N @ 0.62 MPa)

Noise Level*

LAeq,T = 80.2 dB(A), LWA = 85.0 dB(A), LPeak = 110.4 dB(C)

Vibration Level

0.54 m/s

, Time to 2.5 m/s

> 24hrs (EAV)

*Note: Emhart Teknologies recommends the use of Hearing Protection when operating this tool

Packaged Accessories

Qty Item PROSET1600 PROSET1600MCS Part No.

1 ProSet®1600 Rivet Tool 

-

1 Operating Instructions P449

1 Maintenance Manual P513

1 Nosepiece for 3 size open end rivets PRN314

1 Nosepiece for 4 size open end rivets Installed Installed PRN414

1 Nosepiece for 5 size open end rivets PRN514

1 Jaw Pusher (Assy.) for 3/32” rivets FAN239-176

1 Air Line Assembly FAN239-157

1 4 mm Hex. Socket Screw Key DPN239-139

1 Warranty Card FG2184

Tool Requirements

Air supply * 6 scfm (150 l/min) Minimum

Recommended Operating Pressure 72.5-90 psi (0.5-0.62 MPa) dry, filtered

Maximum Operating Pressure 100 psi (0.69 MPa) dry, filtered

Hydraulic Oil ** POP ®p/n: PRG540-130 [1 qt. (.945 ml)]

Jaw Lubricant ** POP ®p/n: PRG510-130 [6 oz. (177 ml)]

Seal Lubricant ** POP ® p/n:PSA075508P [1 ¾ oz. (54 g)]

(*) Note: For best results and long service life, use dry, filtered air supply.

(**) Note: See lubricant safety information.

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)

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 5

ProSet®1600 Tool Dimensions

.682” (17.3 mm)

10.83” (275 mm)

8.94” (227 mm)

2.99” (76 mm)

3.27” (83 mm)

ProSet

1600

1.83” (46.5 mm)

3.3” (82 mm)

1.82” (46.3 mm)

10.71” (272 mm)

3.27” (83 mm)

2.99” (76 mm)

.682” (17.3 mm)

8.94” (227 mm)

ProSet

1600 MCS

1.83” (46.5 mm)

1.82” (46.3 mm)

3.23” (82 mm)

Page 6 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614

Common Nosepieces

* Included with the tool

Use FAN239-176 instead of DPN239-144 (installed) when using 3/32” (2.4mm) or smaller diameter

rivets.

Basic Tool Operation

Before operating the tool check the following:

Inspect tool for damage or leaking oil – do not use tool if it is damaged or leaking oil.

Check that correct nosepiece is fitted and tightened to 60 - 65 in-lbs [6.8 – 7.3 N-m] torque.

Check that the nose housing nut (8) is tight – hand tighten only.

Connect tool to air supply – see air supply requirements (page 4).

Fit Mandrel Collector (96) – (MCS tool only).

Open air supply valve by Sliding red OS Sleeve (93) on side of tool (see note below).

Insert rivet into nosepiece.

Position rivet in work piece.

Pull trigger to set rivet.

Release trigger – if equipped, MCS suction will draw mandrel into the collector.

!Note: The ProSet®1600 has an OS (Open-Shut) Valve for switching the air supply ON and OFF to

save air when the tool is not in use.

Rivet Diameter Open End

Closed End HR Rivets

Jaw Pusher

Steel Mandrel Aluminum

Mandrel

Aluminum

Body

Steel

Body

2.0 mm PRN214 - - - - FAN239-176*

(PRG402-02 - JAWS)

3/32” (2.4 mm) PRN314* - - - - FAN239-176*

1/8” (3.2 mm) or

7/64” (2.8 mm) PRN414* PRN424 PRN434 PRN414* PRN4HR

DPN239-144*

5/32” (4.0 mm) PRN514* PRN524 PRN534 PRN514* -

Air Supply ON: Open OS Valve

by sliding OS Sleeve

in the

direction shown (up).

Air Supply OFF: Close OS Valve

by sliding OS Sleev

e in the

direction shown (down).

OS Sleeve

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Front End Service

For optimum tool performance, Front-End Service should be performed regularly as per the “Preventative Maintenance

Schedule”.

!Note: UNPLUG AIR SUPPLY while servicing front-end to avoid INJURY.

1. REMOVE NOSE HOUSING:

Unscrew the Nose Housing Nut by hand and

slide Nose Housing off the tool.

2. REMOVE JAW GUIDE TO ACCESS JAWS

AND INTERNAL PARTS:

Pull back the Jaw Guide Lock to disengage the

Jaw Guide Lock Teeth and unscrew and remove

the Jaw Guide.

Remove Jaws, Jaw Pusher, and Jaw Pusher

Spring for servicing.

3. CLEAN PARTS:

Clean Jaws, Jaw Guide, Jaw Pusher, Spring

and thread area of the Pulling Head.

Apply Seal Lube to outside surface of Jaws and

inside surface of the Jaw Guide.

4. REASSEMBLY OF INTERNAL PARTS AND JAW

GUIDE:

Place the Jaws into the Jaw Guide and slide the Jaw

Pusher Spring and Jaw Pusher into the Pulling Head.

Apply a small amount of Seal lubricant to the Pulling

Head threads and Jaw Guide Lock teeth. Screw the Jaw

Guide onto the Pulling Head until the teeth on the Jaw

Guide Lock stop the Jaw Guide rotating.

Apply Jaw lubricant to the Jaw area by submerging the

assembled Jaw Guide into Jaw lube about 1 in. (25mm).

Clean off excess Jaw Lube from the outside of the Jaw

Guide.

5. REINSTALL NOSE HOUSING ASSEMBLY:

Refit the Nose Housing and Hand-tighten the Nose

Housing Nut securely against the O-Ring.If the Nut is

not tightened sufficiently against the O-Ring there may

be a loss of suction.

Nose Housing

Nose Housing Nut

Wrench Flat

Jaw Guide

Pulling Head

Jaw Guide Lock

Housing Adapter

O-Ring

Jaw Guide Lock motion

Page 8 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614

Mandrel Collection System (MCS) – ProSet®1600 MCS

For safety purposes, removing the Collector from the tool automatically turns the MCS suction OFF. Refitting

the Collector turns the MCS suction ON.

Cleaning the Collector Silencer

For optimum performance, the Collector Silencer should be cleaned at regular intervals as per the

“Preventative Maintenance Schedule”.

!Note: UNPLUG AIR SUPPLY while servicing Collector to avoid INJURY.

1. CLEAN THE COLLECTOR :

•Remove and empty the Collector (96) by turning counterclockwise.

•Remove the Collector End Nut (106) (17mm wrench) and remove the Collector End Cap (105).

•Remove the Collector Silencer (103).

•Clean and remove debris from all components.

Collector Silencer (103)

Collector End (104)

Collector End Cap (105)

Collector End Nut (106)

Collector Body (101)

MCS suction ON MCS suction OFF

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 9

2. RE-ASSEMBLE THE COLLECTOR :

•Secure Collector End (104) to Collector Body (101). Use a screwdriver or similar tool to hold the

Collector End in place during re-assembly (see picture below).

•Place the Collector Silencer (103) onto the Collector End (104).

•Place Collector End Cap (105) on Collector Body End (104).

•Install and tighten Collector End Nut (106) on Collector End (104).

Tool Assembly Torque Requirements

Item Part No. Description Torque Value

119

120

PRN414

PRN314

PRN514

Nosepiece 4 size

Nosepiece 3 size

Nosepiece 5 size

60 – 65 in-lbs (6.8 – 7.3 N-m)

51 DPN239-053 Sleeve Lower 35 - 39 ft-lbs (47 - 53 N-m)

61 DPN239-063 Sleeve Lock Nut 31 - 35 ft-lbs (42 - 48 N-m)

88 DPN907-003 Socket Head Cap Screw 46 - 51 in-lbs (5.2 – 5.8 N-m)

See exploded Tool Diagram

Screwdriver

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Page 10 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614

ProSet®1600/1600MCS Diagram

(*) These items require Loctite®242 adhesive.

(†) These items have a specific tightening torque as indicated in the “Tool Assembly Torque Requirements” table.

Use with 3 size rivets

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