POP 4000 SERIES RIVET TOOLS PRT4000 MCS4000 INSTRUCTION MANUAL Ver:2 05 Aug 2002 WARNING: ONLY TRAINED SERVICE PERSONNEL SHOULD PERFORM SERVICE PROCEDURES. IMPORTANT READ THE FOLLOWING SAFETY INSTRUCTIONS CAREFULLY. - 0 -
CONTENTS SECTION PAGE I DESCRIPTION AND MODEL IDENTIFICATION 2 II PREPARATION FOR OPERATION 3 III SERVICE PROCEDURES 4 IV DISASSEMBLY & ASSEMBLY INSTRUCTIONS 5 1 Handle Cap Assembly 5 2 Intensifier Assembly 6 3 Air Valve and Pressure Regulator Assembly 7 4 Handle Replacement 7 IV MAINTENANCE SCHEDULE 8 DISCONNECT TOOL FROM AIR SUPPLY BEFORE ATTEMPTING SERVICE. SERVICE SHOULD ONLY BE PERFORMED BY TRAINED PERSONNEL. SAFETY INSTRUCTIONS 1. It is recommended to wear eye protection when operating the tool. 2. To avoid injury do not point the tool at anyone. 3. Do not exceed recommended maximum air pressure (5.5 bar, 80psi). 4. Disconnect the tool from the air supply when not in use for an extended period of time or before proceeding with any maintenance procedures. Take care to control air hoses when disconnecting to prevent whipping. 5. Do not attempt to operate the tool with the Nose Housing removed. This exposes potential pinch points and could result in injury. 6. Do not tamper with Fill Screw. Loosened screws may result in malfunction or injury due to air or hydraulic pressure. 7. Do not operate the tool without either the deflector (PRT Option) or the collector (MCS Option) installed on the tool. Spent rivet mandrels may be forcefully ejected. 8. Always clear the tool of spent rivet mandrels before setting a new fastener. Failure to do so may result in tool jams or forceful ejection of spent mandrels. 9. Use caution when operating the tool, compressed air is released through the front of the Intensifier Chamber. Do not direct exhaust towards anyone. 10. Inspect the tool at regular intervals for damage and proper function. Replace damaged parts immediately. Do not connect a damaged tool to an air supply. 11. Use only genuine POP brand replacement parts. - 1 -
I DESCRIPTION AND MODEL IDENTIFICATION The 4000 Series tools are light weight air-hydraulic Rivet Tools capable of setting commercial blind rivets up to and including 3.2mm (1/8 ) diameter in aluminium. Two models are available. PRT4000 MCS4000 Setting Tool with mandrel deflector only. Setting Tool with automatic vacuum Mandrel Collector attached. PRT4000 and MCS4000 are supplied set up for 3.2mm (1/8 ) diameter rivets. A nosepiece is included for 2.4mm (3/32 ) rivets. Additionally, front end components can be ordered to set 2.0mm (5/64 ) Micro rivets. Refer to Set Up Procedures, Section II of this manual for more information. PACKED IN CARTON - MODELS PRT4000 and MCS4000 Part Number Part Name Data Model PRT4000 Rivet Tool Assembled (no airline) PRG510-56 Deflector Safety device - PRT4000 only PRT 4000-33 Spanner 8mm 19mm multi-spanner PRT4000-34 Cap Spanner 52mm cap spanner PRM 530-49 Hex Wrench 5mm hex wrench PRN314 Nosepiece 2.4mm (3/32 ) open end rivets AN500-72 Coupler Air line coupler Operator s Instructions MCS Version (additional items) MCS4000 MCS complete kit (see Parts List, page 10 for kit contents) SPECIFICATIONS PRT4000 MCS4000 Weight: 1.055kg (2.33 lbs.) 1.2kg (2.64 lbs.) Length: 155mm (6.10 in.) 236mm (9.2 in.) Height: 230mm (9 in.) 230mm (9 in.) Stroke: 16mm (.63 in.) 16mm (.63 in.) Pulling Force: 3.3kN (742 lbs.) 3.3kN (742 lbs.) Operating Pressure: 4.5-5.5bar (65-80 psi.) 4.5-5.5bar (65-80 psi.) Air Consumption: 0.9 litres/rivet 0.9 litres/rivet + 120 litres/min (MCS) I.1 THEORY OF OPERATION When connected to an air supply and the trigger operated, pressurized air pushes the Air Piston / Ram Assembly. The Ram Assembly forces hydraulic fluid from the reservoir in the handle into the main bore where it pushes the hydraulic piston and the attached pulling mechanism rearward. As the Pulling Jaws move towards the rear, they grip the rivet mandrel and set the rivet. Releasing the trigger enables the return spring to push the hydraulic piston forward to the starting position. The hydraulic fluid is forced back returning the Ram Assembly and Air Piston to the starting position. The compressed air used to set the rivet is exhausted through the front of the Intensifier Chamber. The hydraulic piston is fully returned, the broken rivet mandrel is released as the Jaws are forced open again by the Nosepiece. If the tool is equipped with a Mandrel Collection System (MCS models) the mandrel will be drawn out of the tool and deposited in the Collector Bottle, which should be emptied every 100 mandrels. - 2 -
II PREPARATION FOR OPERATION CAUTION: Do not connect to air supply until all tool parts are properly installed. It is recommended to wear eye protection when operating this tool. II.1 AIR SUPPLY REQUIREMENTS Use a dry, filtered air supply regulated to 4.5-5.5bar (65-80psi). It is not necessary to lubricate the air supply. Excess oil, water or debris in the air supply will necessitate more frequent tool service and significantly reduce the operating efficiency of the Mandrel Collection System. II.2 TOOL CAPABILITY 1. Select the appropriate Nosepiece from the chart below. The PRT4000 and MCS4000 tools are assembled with Nosepiece PRN414 (01) suitable for 3.2mm (1/8 ) rivets. 2. To set 2.4mm (3/32 ) rivets replace the installed Nosepiece PRN414 (01) with PRN314 (02) supplied in carton. 3. To set 2.0mm (5/64 ) Open or 3.2mm (1/8 ) Closed End rivets, additional components are needed. NOSEPIECE CHART II.3 CHANGING TOOL SET UP FOR DIFFERENT RIVET SIZES To prevent mandrel jams and maximise jaw life, it is important to install the correct Nosepiece, Jaws, Jaw Pusher and Mandrel Guide tube. Procedure 1. Place the tool in a soft-jawed vice, gripping the tool in the centre of the handle. 2. For Nosepieces PRN 314, PRN 414 and PRN 424, simply remove the Nosepiece fitted, replace with the required Nosepiece, and tighten. 3. For 2mm Micro rivets remove the installed Nosepiece and Nose Housing (03). 4. Remove the Jaw Guide (04), Jaws (05) and Jaw Pusher (06). 6. Install the correct Jaw Pusher (06). 7. Install the correct Jaws (05). 8. Re-install the Jaw Guide (04) and tighten. 9. Replace the Nose Housing (03) and tighten. 10. Install correct Nosepiece and tighten. - 3 -
II.4 OPERATION 1. Attach tool to suitable air supply. 2. Ensure the deflector (36) PRT4000, or collector (106) MCS4000, is in place before operating tool. 3. Insert a rivet mandrel into the Nosepiece. If the tool is equipped with a Mandrel Collection System (MCS4000) the rivet will be held in the tool by vacuum. 4. Position rivet into work piece. 5. Squeeze the trigger (27) to set the rivet. Once the rivet is set, release the trigger. If using a PRT4000 be sure to clear the mandrel from the tool by tipping the tool to let the mandrel slide either out of the front or out of the back of the tool. If using the MCS4000, the mandrel will be automatically extracted into the Mandrel Collector Bottle, which should be emptied every 100 mandrels. CAUTION: Read the Operator Instruction Leaflet before operating the tool. III III.1 SERVICE PROCEDURES SERVICING THE JAWS, JAW PUSHER AND JAW PUSHER SPRING Regular cleaning of the Jaws and front-end parts will prevent mandrels sticking in the Jaws and extend the Jaw life. Procedure 1. Disassemble the tool front end as described in Section II.3. Clean Jaws (05) using a brush and solvent. If jaw teeth show significant wear replace both jaws. 2. Check Jaw Pusher Spring (07) for fatigue. A new spring measures 54mm (2 1/8 ) in length. Replace spring if shorter than 46mm (1 7/8 ). 3. Thoroughly clean the inside of the Jaw Guide (04), Nose Housing (03), the Jaw Pusher (06) and wipe out debris from around other exposed parts. 4. Lightly oil Jaws (05) and Jaw Pusher (06) before reassembling. 5. Reassemble parts in reverse order. Ensure Jaw Guide (04), Nose Housing (03) and Nosepiece (01) are tightened. III.2 REPLENISHMENT OF HYDRAULIC FLUID A shortened stroke indicates minor hydraulic fluid loss. Hydraulic fluid can be replaced without fully disassembling the tool. CAUTION: The tool must be disconnected from the air supply before attempting to replenish hydraulic fluid. Procedure 1. Place the tool, inverted, in a soft-jaw vice, with the Chamber (52) pointing up. 2. Remove Chamber Cap (53) with the Cap Spanner (PRT4000-34) provided. 3. Remove the Air Piston Assembly (51) from the Chamber. 4. Add oil into the bore at the base of the Chamber, inside the tool handle. Fill to approximately 8mm from the top of the bore. (For oil specification see page 7). 5. Temporarily replace Air Piston Assembly (51). Pump the Air Piston 2 3 times into the bore to remove air bubbles. 6. Remove Air Piston Assembly once more. Re-check oil level. If the oil level is lower, repeat the above procedure until a satisfactory oil level is achieved. 7. When the oil level is correct, replace Air Piston Assembly (51) and push firmly into place. Replace Chamber Cap (53) and tighten. 8. Rotate tool into an upright position in the vice (chamber at bottom). - 4 -
9. Loosen Fill Screw (16) with 5mm Hex wrench (PRM530-49) provided, to remove excess oil and air bubbles. 10. After the excess oil and air has been removed, tighten Fill Screw (16) using Hex wrench provided. 11. Reconnect to Air Supply. CAUTION: Do not depress the trigger when Fill Screw (16) is loose. This will cause oil to be forced out under great pressure. If oil loss is rapid or excessive refer to Section IV of this manual for seal replacement procedures IV PRT4000 & MCS4000 DISASSEMBLY & ASSEMBLY INSTRUCTIONS IMPORTANT READ SAFETY INSTRUCTIONS ON PAGE 1 OF INSTRUCTION MANUAL DISCONNECT TOOL FROM AIR SUPPLY BEFORE ATTEMPTING SERVICE SERVICE SHOULD BE PERFORMED BY TRAINED PERSONNEL ONLY SERVICE NOTES All disassembly procedures should be performed in a clean, well-lit work area. O-rings, seals and sealing surfaces should be lightly lubricated with a white mineral oil based grease such as Lubriplate 130-AA or equivalent prior to assembly. Do not use solvents other than approved hydraulic fluid to clean O-rings or seals. FRONT END ASSEMBLY (see Changing Tool Set-Up for Different Rivet Sizes Section II.3 on page 3) IV.1.i HANDLE CAP ASSEMBLY (PRT4000) 1. Remove Deflector (36). 2. Unscrew End Cap (24) using 24mm spanner (PRT4000-34). 3. The End Cap (24), Cap Assembly (34) and Return Spring (20) can be removed. 4. Remove O-rings (21) and (33). IV.1.ii HANDLE CAP ASSEMBLY (MCS4000) 1. Remove Collector End (110), M10 nut (103) and Collector (106). 2. Unscrew End Cap (24) using 24mm spanner (PRT4000-34). 3. The End Cap (24), MCS Cap Assembly (101) and Return Spring (20) can be removed. 4. Remove O-rings (102), (107), (21), and (33). - 5 -
ASSEMBLE IN REVERSE ORDER Lubricate O-rings prior to installation. IV.1.iii CONVERSION PRT4000 TO MCS4000 Remove Handle Cap assembly as per Section III.1.i replace Cap Assembly (34) with MCS Cap Assembly (101) and Deflector (36) with Collector (106). IV.2 INTENSIFIER ASSEMBLY (PNEUMATIC PISTON) 1. Loosen the Fill Screw (16). 2. Place the tool, inverted, in a soft jawed vice with the Chamber (52) facing up. 3. Remove Chamber Cap (53) using Cap Spanner (PRT4000-34). 4. Remove Air Piston Assembly (51). 5. Ease out O-Ring (47) from Air Piston (51). 6. Place a 13mm spanner on the Lock Nut (50) and a 6mm hex wrench on the top of the Ram (43). Hold the spanner while turning the hex wrench anti-clockwise. Remove Ram from Air Piston. 7. Inspect O-Ring (47) and Rubber Cushion (45). Replace if necessary. ASSEMBLE IN REVERSE ORDER Refer to section II.2 for Hydraulic Fluid Charging Procedure. IV.3 PULLING HEAD ASSEMBLY (HYDRAULIC PISTON) 1. Secure tool upright in a soft jaw vice. 2. Remove Nose Housing (03), Jaws (05), Jaw Pusher (06), Jaw Spring (07), Jaw Guide (04). 3. Remove Handle Cap Assembly as per Section III.1.i/ii. 4. Loosen but do not remove Fill Screw (16). 5. Push the Hydraulic Piston (08) out of the rear of the tool. Take care as oil spillage will occur at this point. 6. Inspect O-Rings 2 x (18) and replace as necessary. 7. Using internal circlip pliers, remove C-Ring (10) from front of tool. Pull out Seal Sleeve (12) from front of tool. 8. Inspect all O-Rings (11), (13), (15) for damage / wear. Replace as necessary. ASSEMBLE IN REVERSE ORDER Ensure all O-Rings and the bore of the tool are lubricated. IV.4 AIR VALVE AND PRESSURE REGULATOR ASSEMBLY 1. Place tool inverted in a soft jaw vice, with Chamber (52) facing up. 2. Remove Valve Cap (56) using large flat blade screwdriver. 3. Remove Spring (61). 4. Hold tool upright and let Valve (60) drop out of tool. 5. Remove hexagonal Set Screw from Trigger Lever Cap (30) using a 2mm hex wrench. 6. Depress and hold Trigger (27), and remove Cap Assembly (30). 7. Drive out Spring Pin (31) beware of slight spring pressure. 8. Remove Valve Pusher (57), Spring (58) and Copper Washer (59), and O-Ring (37). 9. To disassemble Trigger Rod from Trigger Lever, drive out Spring Pins (28) x 2. 10. Remove Trigger (27) from Trigger Lever by driving out Spring Pin (26). - 6 -
ASSEMBLE IN REVERSE ORDER -Lubricate all O-rings and seals prior to installation. IV.5 HANDLE REPLACEMENT Note: It is normally not necessary to disassemble the Handle (09) from the Chamber (52) unless either component has been damaged. 1. Loosen and remove Fill Screw (16). Drain Hydraulic fluid from tool. 2. Remove Front End Assembly (refer to section II.3 ). 3. Remove Handle Cap Assembly (section III.1.i/ii) 4. Remove Intensifier Assembly (Pneumatic Piston) (section III.2). 5. Remove Pulling Head Assembly (section III.3) 6. Remove Air Valve / Regulator Assembly (section III.4) 7. Place tool inverted, in a soft jaw vise with Chamber (52) facing up. 8. Using a special tool number (TT 1111), undo Lock Nut (42). Separate Handle (09) from Chamber (52). ASSEMBLE IN REVERSE ORDER - Lubricate all O-rings and seals prior to installation. Take care not to wrinkle or cut O-rings during assembly. APPROVED HYDRAULIC FLUIDS MOBIL - DTE26* EXXON - NUTO H-68 SHELL - TELLUS 68 TEXACO - RANDO HD-68-7 -
V MAINTENANCE SCHEDULE DAILY 1. Inspect tool and air supply hose for damage. Replace damaged parts immediately. 2. Purge air supply filters to eliminate accumulated dirt, oil and water. 3. Ensure that air pressure is regulated at 5.5 bar (80 psi). 4. Check tightness of Fill Screw (16), Nosepiece (01) and Nose Housing (03). 5. Lubricate Jaws (05), with light oil or Jaw Lube. WEEKLY OR EVERY 15,000 CYCLES 1. Dismantle Front End Assembly, thoroughly clean all parts, check Jaws (05), Jaw Pusher (06) and Jaw Pusher Spring (07) for wear and replace as needed. 2. Lightly lubricate all parts before reassembly. ANNUALLY OR EVERY 500,000 CYCLES 1. Dismantle tool and replace all seals and O-rings. Inspect all parts for wear or damage and replace as necessary. 2. Lightly lubricate all seals, O-rings and front end parts before reassembly. - 8 -
PRT / MCS 4000 PARTS DIAGRAM MANDREL COLLECTION SYSTEM - 9 -
PARTS LIST No. Article No Description Qty No. Article No Description Qty 15800 PRT 4000 Setting Tool 1 46 15836 O-Ring P9(1A) 1 15790 MCS 4000 Setting Tool 1 47 15837 O-Ring P58(1A) 1 01 16216 PRN414 Nosepiece-3.2mmØ Rivets 1 48 15838 PRT4000-21 Ram Washer 1 02 17595 PRN314 Nosepiece-2.4mmØ Rivets 1 49 15839 PRT4000-22 Air Piston Washer 1 03 15791 PRT4000-01 Nose Housing 1 50 15840 Nut M8-T5 1 04 16212 PRH820-11A Jaw Guide 1 51 15841 PRT4000-24 Air Piston 1 05 16210 PRG402-8A Jaws 1 52 15842 PRT4000-25 Chamber 1 06 15792 PRT4000-02 Jaw Pusher 1 53 15843 PRT4000-26 Air Chamber Cap 15793 PRT4000-02-1 SUS Pipe 3.0x2.4 1 54 15844 O-Ring G65 1 15794 PRT4000-02-2 Jaw Pusher Head 1 55 15845 O-Ring AN500A-51-6 1 07 15782 PRG510-123 Jaw Pusher Spring 1 56 15846 PRT4000-27 Valve Cap 1 08 15795 PRT4000-03A Hydraulic Piston Assy 1 57 15847 PRT4000-28 Valve Pusher 1 09 15796 PRT4000-04A Handle 1 58 15848 PRT4000-29 Valve Spring 1 10 15797 C-Ring PTW22 1 59 15849 PRT4000-30 Copper Washer 1 11 15798 O-Ring P18(1B) 1 60 15850 PRT4000-31 Valve 1 12 15799 PRT4000-05 Seal Sleeve 1 61 15851 PRT4000-32 Spring 1 13 15804 O-Ring P12(1B) 1 14 15805 Backup Ring PSL600CJ-13 1 ACCESSORY PARTS 15 15806 Pentaseal PSL600CJ-14 1 Article No Description Qty 16 15807 PRT4000-06 Fill Screw 1 15852 PRN530-49 Hex Wrench 1 17 15808 PRT4000-07 Fill Washer 1 15853 PRT4000-33 Spanner 1 18 15809 O-Ring P22(1B) 2 15854 PRT4000-34 Cap Spanner 1 19 15810 Backup Ring T2P22 1 15855 AN500-72 Coupler 1 20 15811 PRT4000-08 Return Spring 1 21 15812 O-Ring S26(1A) 1 OPTIONAL PARTS 22 15813 PRT4000-09 Tool Hanger 1 Article No Description Qty 23 15814 E-Ring 10 1 16213 PRN424 Nosepiece-3.2mm Ø Closed End 1 24 15815 PRT4000-10 End Cap 1 15801 PRN214 Nosepiece-2.0mm Ø Rivets 1 25 15816 Set Screw SS-M6*5 1 15802 PRT4000-50 Jaw Pusher 2.0mm Ø Rivets 1 26 15817 PRM530-40 Spring Pin 1 15803 PRG402-02 Jaws-2.0mm Ø Rivets 1 27 15818 PRT4000-11 Trigger 1 28 15819 Spring Pin SPIN-3*8AW 2 MCS PARTS LIST 29 15820 PRT4000-12 Trigger Rod 1 No. Article No Description Qty 30 15821 PRT4000-13 Trigger Lever Cap 1 100 15856 Complete MCS Kit 1 31 15822 Spring Pin SPIN-3*14AW 1 101 15857 MCS4000-01 MCS Cap Assembly 1 32 15823 PRT4000-14 Trigger Lever 1 102 15858 O-Ring P7A(1A) 1 33 15824 O-Ring P16(1A) 1 103 15859 Hexagon Thin Nut M10 T5 1 34 15825 PRT4000-15 Cap Assembly 1 104 15789 MCS4000A-09 MCS Nozzle 1 35 15826 Set Screw SS-M4*5 1 105 15788 MCS4000A-06 Collector Lock Nut 1 36 16309 PRG510-56 Deflector 1 106 15787 MCS4000A-07 Collector 1 37 15827 O-Ring PRL600-10 3 107 15786 O-Ring 1033(1A) 1 38 15828 O-Ring P4(1A) 1 108 15785 MCS4000A-07-1 Collector Body 1 39 15829 Pentaseal PS15 1 109 15784 MCS4000A-07-2 Collector Cover 1 40 15830 Backup Ring T2P15 1 110 15783 MCS4000A-07-3 Collector End 1 41 15831 O-Ring P15(1B) 1 33 15824 O-Ring P16(1A) 1 42 15832 PRT4000-17 Lock Nut 1 37 15827 O-Ring PRL600-10 1 43 15833 PRT4000-18A Ram 1 23 15814 E-Ring 10 1 44 15834 Toothed Lock Washer TLW-A8 1 45 15835 PRT4000-20A Rubber Cushion 1 Emhart Fastening Teknologies Walsall Road, Birmingham B41 1BP, UK Tel: +44 (0)121 356 4811 Fax: +44 (0)121 356 1598-10 -