Baltech RNE 181 HPP Operating Instructions Manual

BalTec Maschinenbau AG

Obermattstrasse 65 CH - 8330 Pfäffikon ZH

Phone: +41 (0)44 953 13 33 Fax: +41 (0)44 953 13 44 baltec@baltec.com http:\\www.baltec.com

803835.006/ENG

OPERATING INSTRUCTIONS

Radial riveting machine

RNE 181 HPP

reduced force max. 1.5 kN

803835.006/ENG

Machine no.

xxx.xxxx

Power supply

xxx

Introduction Radial riveting machine RNE 181 HPP

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Radial riveting machine RNE 181 HPP Introduction

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Contents

1 Introduction ............................................................................................................... 6

2 Safety regulations ..................................................................................................... 7

2.1 Term definitions ................................................................................................................................... 7

2.2 Significance of the safety regulations ................................................................................................. 7

2.3 Information and symbols ..................................................................................................................... 8

2.3.1 Warning and safety notices ............................................................................................................ 8

2.3.2 Notes and symbols on the product ................................................................................................ 9

2.4 Application limitations .......................................................................................................................... 9

2.5 Intended use ..................................................................................................................................... 10

2.5.1 Riveting machine/riveting unit ...................................................................................................... 10

2.5.2 Form tool ...................................................................................................................................... 10

2.5.3 Workpiece holders ....................................................................................................................... 11

2.6 Emissions .......................................................................................................................................... 11

2.7 Power supply ..................................................................................................................................... 11

2.8 General safety rules .......................................................................................................................... 12

2.9 Declarations ...................................................................................................................................... 12

3 Product description ................................................................................................ 13

3.1 RNE 181 reduced force HPP details ................................................................................................. 13

3.2 Dimensions drawing RNE 181 reduced force with path-measuring system HPP ............................ 14

3.3 Dimensions drawing RNE 181 reduced force with path-measuring system HPP for flange mounting

.......................................................................................................................................................... 15

3.4 Technical specifications riveting machine 181 reduced force max. 1.5 kN ...................................... 16

4 Commissioning ....................................................................................................... 17

4.1 Introduction........................................................................................................................................ 17

4.1.1 Personnel requirements ............................................................................................................... 17

4.2 Riveting unit ...................................................................................................................................... 17

5 Operation ................................................................................................................. 18

5.1 Safety regulations riveting machine .................................................................................................. 18

5.1.1 Personal safety equipment .......................................................................................................... 18

5.1.2 Workplace .................................................................................................................................... 18

5.1.3 Heating of riveting machine ......................................................................................................... 18

5.2 Basic settings .................................................................................................................................... 19

5.2.1 Riveting stroke adjustment ........................................................................................................... 19

5.2.2 Riveting spindle advance speed adjustment ............................................................................... 20

5.2.3 Riveting spindle return speed adjustment .................................................................................... 20

5.2.4 Riveting force adjustment ............................................................................................................ 21

5.3 Setting up the riveting machine for a new workpiece ....................................................................... 22

5.4 Possible machine settings................................................................................................................. 23

6 Form tools ............................................................................................................... 24

6.1 Form tool designs and closing head shapes ..................................................................................... 24

6.2 Recommended form tool materials ................................................................................................... 25

6.3 Form tool D = 10 with various lengths............................................................................................... 26

6.4 Replacing the form tool holder and pressure cup ............................................................................. 27

6.5 Standard form tool Ø10 with flat profile (081-241) ............................................................................ 29

6.6 Standard form tool Ø10 with conical profile (081-241) ..................................................................... 30

6.7 Standard form tool Ø10 with crowned profile (081-241) ................................................................... 31

7 Options .................................................................................................................... 32

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7.1 Pressure pad .................................................................................................................................... 32

7.1.1 Pressure pad dimensions drawing .............................................................................................. 33

7.1.2 Production of thrust piece and spring diagram 802297 .............................................................. 34

7.2 Automatic lubrication riveting spindle head ...................................................................................... 36

7.3 Foot switch ....................................................................................................................................... 37

7.3.1 Function ....................................................................................................................................... 37

7.3.2 Dimensions drawing .................................................................................................................... 37

7.3.3 Technical specifications .............................................................................................................. 38

7.4 Initiator upper end position ............................................................................................................... 39

7.5 Initiator lower end position (bridging initiator) ................................................................................... 39

7.6 Riveting stroke limit switch unit NHE 181-231 ................................................................................. 40

7.6.1 My-Com Switch substitution ........................................................................................................ 42

7.6.2 Magnetic field sensor adjustment ................................................................................................ 43

7.6.3 Touch probe switching point NHE-E adjustment ........................................................................ 44

7.6.4 Spring prestress adjustment riveting stroke limit switch unit NHE .............................................. 45

7.6.5 Dimensions drawing RNE 181-231 HPP with NHE .................................................................... 46

7.7 Proportional pressure regulator ........................................................................................................ 47

8 Maintenance and repair work ................................................................................ 48

8.1 Introduction ....................................................................................................................................... 48

8.1.1 Safety regulations ........................................................................................................................ 48

8.1.2 Personnel requirements .............................................................................................................. 48

8.2 Overview of maintenance work ........................................................................................................ 49

8.2.1 Riveting spindle head (form tool holder and pressure cup) ........................................................ 50

8.2.2 Riveting spindle ........................................................................................................................... 51

8.2.3 Automatic lubrication riveting spindle head (option) ................................................................... 53

8.2.4 Air maintenance unit.................................................................................................................... 54

8.2.4.1 Mist oiler adjustment ...............................................................................................................55

8.2.5 Polygon shaft ............................................................................................................................... 56

8.2.6 Two-hand operating unit ............................................................................................................. 57

8.2.7 Piston and piston rod seals ......................................................................................................... 57

8.2.8 Riveting motor terminal box ........................................................................................................ 58

8.3 Maintenance and repair log .............................................................................................................. 59

9 Decommissioning, Storage .................................................................................... 61

9.1 Decommissioning ............................................................................................................................. 61

9.2 Storage ............................................................................................................................................. 61

9.3 Re-commissioning ............................................................................................................................ 61

10 Disposal ................................................................................................................... 62

10.1 Introduction ....................................................................................................................................... 62

10.1.1 Personnel requirements .............................................................................................................. 62

10.2 Disposal ............................................................................................................................................ 62

10.2.1 Replaced parts ............................................................................................................................ 62

10.2.2 Mineral oils .................................................................................................................................. 62

10.2.3 Riveting unit ................................................................................................................................. 62

11 Appendix ................................................................................................................. 63

11.1 Schemata ......................................................................................................................................... 63

11.1.1 Pneumatic diagram with air maintenance unit 181 reduced force, 803541 ................................ 63

11.1.2 Pneumatic diagram 181 reduced force with proportional pressure regulator 803584 ................ 64

11.1.3 Pneumatic diagram for automatic lubrication 802417 ................................................................. 65

11.2 Spare parts lists ................................................................................................................................ 66

11.2.1 Machine body 181 reduced force Standard/HPP 825403-b ....................................................... 66

11.2.2 Riveting head 081-241 814310-h ................................................................................................ 70

11.2.3 Electric motor 181 825320-m ...................................................................................................... 72

11.2.4 Pneumatics 181 STF/HPP 825328-n .......................................................................................... 73

11.2.5 Automatic lubrication 814340-u ................................................................................................... 76

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11.2.6 Foot switch 813345-d ................................................................................................................... 78

11.2.7 Two-hand operating unit 814350-d .............................................................................................. 79

11.2.8 Pressure pad 081-241 814315-d ................................................................................................. 80

11.2.9 Path-measuring system HPP-181, 825408-c .............................................................................. 82

11.2.10 Riveting stroke limit switch unit NHE-U 181-231, 825290.01 ...................................................... 84

11.2.11 Riveting stroke limit switch unit NHE-H 181-231, 825290.03-a ................................................... 85

11.2.12 Riveting stroke limit switch unit NHE-E 181-231, 825290.07-a ................................................... 86

11.2.13 Riveting stroke limit switch unit NHE-Combi 181-231, 825290.09-a ........................................... 87

11.2.14 Riveting stroke limit switch unit (NHE) basic unit 181 – 431, 826098 ......................................... 88

11.2.15 Proportional pressure regulator 181/231/281 868191 ................................................................. 89

12 Index......................................................................................................................... 92

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1 Introduction

We are certain that you have made the right choice with our product and thank you for your trust.

For your personal safety

Before carrying out any activities on or with the riveting machine, please carefully read these operating instructions first, in particular the chapter on "Safety regulations".

Application area of these operating instructions

These operating instructions describe the riveting machine and provide all information required for safe operation and maintenance of functionality. Please keep these operation instructions available at all times for all persons involved with the riveting machine.

Questions or unclear points

Please contact immediately if you have any questions or unclear points:

- BalTec Maschinenbau AG, Obermattstrasse 65 CH – 8330 Pfäffikon ZH

- BalTec – distributors (see representatives list in the appendix) Please provide them with the document and page numbers located in the footer

and the machine number listed on the title page of operating instructions.

Original language of assembly instructions

These assembly instructions was originally written in German language. —— © Copyright BalTec Maschinenbau AG – Pfäffikon 2010

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2 Safety regulations

2.1 Term definitions

The following terms are used with regards to safety:

Personnel qualification

The work to be implemented with or on the product is described in the corresponding chapters in the operating instructions. The personnel qualifications listed in this chapter (in "Introduction") describes the minimum requirements for personnel regarding training and competences for implementing this work.

Personnel

Personnel are people who meet the personnel qualifications. Only such personnel are authorized to implement the work described in the applicable chapters.

User

Users are persons who cannot be identified as personnel but who still carry out activities with or on the product.

Operator

The operator is the owner of the product. This is irrespective of whether the product is:

 Operated as a stand-alone machine  Operated as part of a system or  Operated by a third party

Product life phases

The product life phases are the state or usage phases of the product. These range from leaving the assembly hall to disassembly and disposal, and are divided into correspondingly logical sections (chapters) in these operating instructions.

2.2 Significance of the safety regulations

These safety regulations contain all behavior regulations and generally applicable danger information. The safety of the user and the personnel can only be ensured when these safety regulations and the safety information listed in the individual chapters are strictly complied with and followed. The operator is responsible for the enforcement.

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2.3 Information and symbols

2.3.1 Warning and safety notices

The warning and safety notices used in these operating instructions have the following significance:

CAUTION

Indicates a hazard with low risk which, if not avoided, could result in minor or moderate injury.

WARNING

Indicates a possible hazard with medium risk which, if not avoided, could result in death or serious injury.

DANGER

Indicates an immediate hazard with high risk which, if not avoided, will result in death or serious injury.

NOTICE

Indicates practical information and tips that permit the best use of machinery, system or equipment.

CAUTION

To warn of material damage only.

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2.3.2 Notes and symbols on the product

The following information and symbols are located on the riveting machine:

Warning signs

Danger of hand injuries

Mandatory sign

Wear safety goggles

Mandatory sign

Wear gloves

2.4 Application limitations

The following technical operating instructions and ambient conditions must be complied with for the operation of the riveting machine.

Environmental conditions

Working temperature

+10 ... +50 °C

Storage temperature

- 10 ... +70 °C

Relative humidity

Max. 90%, non-condensing

Mechanical power supply

Operating pressure

See technical specifications, label

Rivet parameters

Riveting force

See technical specifications, label

Rivet diameter

See technical specifications

Electrical power supply

Rated voltage

See title page, label

Rated current

See technical specifications, label

Frequency

See title page, label

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2.5 Intended use

2.5.1 Riveting machine/riveting unit

BalTec riveting machines are intended to form positive connections by cold forming of connection elements. The connection element (rivet) can either be a separate element or a specially shaped deformation zone on the workpiece itself. The connection is created in that a riveting tool (form tool) creates a closing head on the connection element.

Following activation types are permitted to actuate the riveting process:

a) Permanent activation with two-hand switching for:

 Manual charging  Stroke H greater than 6 mm  Stroke speed greater than 30 mm/s

b) Pulse actuation with any command device (e.g. foot

switch), where one of the following conditions is met:

 Workpiece charging with handling device  Stroke H smaller than 6 mm  Stroke speed smaller than 30 mm/s

The riveting machines are laid out for use in commercial or industrial production; e.g.

a) As machining station in a production line b) As stand-alone workplace or production cell The riveting units are laid out for installation in any spatial position: e.g. a) Vertical, with direction of action from top to bottom or bottom to top b) Horizontal

2.5.2 Form tool

WARNING

Form tool breaks if an inappropriate material is used!

Eye injuries, cutting damages!

Form tool is to produce according to our specifications: material, heat treatment, geometry (see Chapter "Form tools").

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2.5.3 Workpiece holders

WARNING

Workpiece can be catapulted out!

Eye injuries, cutting damages!

Workpiece holders must be securely mounted on the machine table, e.g. with T-slots-screws, clamping shoes or other suitable and secure clamping equipment.

2.6 Emissions

Noise

The sound pressure level of noise produced by BalTec riveting machines at the operator's workplace is less than 70 dB(A) (measured according to SN EN ISO

3746).

Vibrations

Vibrations may be caused by the riveting machines dependent on the BalTec riveting process. Suitable vibration damping measures are required where other system parts may start oscillating due to resonance.

2.7 Power supply

DANGER

Electrical hazard!

Electric shock!

Before the machine or their components are connected, isolate the electrical power supply and secure against being switched on again!

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2.8 General safety rules Modifications

Modifications to the riveting machine or control unit, in the sense of attachments and conversions are only permissible after prior consultation with and written authorization from the manufacturer. This also applies to welding on load-bearing components and the attachment of control, supply and transfer systems from third party suppliers.

2.9 Declarations CE conformity declaration

A CE-compliant riveting machine is marked with a CE rating plate. The standards used to check conformity are listed in the CE conformity declaration.

The CE conformity declaration is included in the delivery documentation.

Declaration of incorporation

When being installed in other machines and/or for operation with a third party control unit, a non CE-compliant riveting machine cannot be commissioned until it is ensured that it meets the provisions of the machine directive 2006/42/EG.

The declaration of incorporation is included in the delivery documentation.

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3 Product description

3.1 RNE 181 reduced force HPP details

Item

Name

Item

Name

1

Riveting stroke adjustment

14

Water separator, sight glass

2

Clamping screw for riveting stroke adjustment

15

Water separator, drain valve

3

Lubricator nipple

16

Restrictor valve for riveting spindle advance speed

4

Supply air

17

Initiator lower end position (option)

5

Exhaust air

18

Pressure regulator valve

6

Riveting spindle head

19

Manometer

7

Form tool

27

Path-measuring system HPP

12

Air connection

28

Initiator upper end position (option)

13

Oil sight glass

32

Restrictor valve for riveting spindle return speed

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3.2 Dimensions drawing RNE 181 reduced force with path-measuring system HPP

Drawing no. 825400.42

Free height „H“ see chapter ”Form tool D=10 with various lengths“

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3.3 Dimensions drawing RNE 181 reduced force with path-measuring system HPP for flange mounting

Drawing no. 825400.45

Free height „H“ see chapter ”Form tool D=10 with various lengths“

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3.4 Technical specifications riveting machine 181 reduced force max. 1.5 kN

Maximum rivet shaft diameter (solid shaft rivet, steel 370 N/mm2)

Ø

2 Riveting unit motor, driving power at 50Hz

kW

0.25

Riveting unit motor, driving power at 60Hz

kW

0.30

Riveting unit motor, rpm at 50Hz

min-1

1330

Riveting unit motor, rpm at 60Hz

min-1

1595

Rated current at 1 x 220V

A

2.5

Rated current at 3 x 220V

A

1.8

Rated current at 3 x 400V

A

1.0

Rated current at 3 x 440V

A

0.8

Pneumatics operating pressure

bar

2 - 6

Thread size compressed air connection (air maintenance unit STF)

G ⅜“

Thread size compressed air connection (air maintenance unit)

G ¼”

Max. riveting force at 6 bar

kN

1.5

Max. permissible riveting time per cycle

sec

10

Tool stroke (stroke limiting stop-adjustment range)

mm

5 - 30

Cylinder volume at maximum stroke

cm3

78.25

Weight of riveting machine without control unit

kg

55

Weight of riveting machine with control unit

kg

65

Weight of riveting unit

kg

30

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4 Commissioning

4.1 Introduction

4.1.1 Personnel requirements

Commissioning work must be implemented by persons who have mechanical and electrical training. The connection of electrical component has to be made only by a trained authorised electrician.

4.2 Riveting unit

The necessary information for commissioning are indicated in the assembly instructions.

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5 Operation

5.1 Safety regulations riveting machine

5.1.1 Personal safety equipment

All user are obliged to wear the following personal safety equipment for all work:

 Tightly fitting working clothes  Safety goggles  Gloves

5.1.2 Workplace

The riveting machine may only be operated by one person.

CAUTION

Third party can hold fingers between form tool and workpiece!

Danger of hand injuries!

Configure workplace with rivet holder so that third parties do not have access (e.g. three-sided enclosure)

5.1.3 Heating of riveting machine

Forming procedures can lead to heating.

CAUTION

Riveting head, tool and workpiece could be hot!

Light burns!

Do not touch with unprotected hand!

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5.2 Basic settings

5.2.1 Riveting stroke adjustment

The maximum possible riveting stroke can be set with the riveting stroke adjustment.

Item

Name

1

Clamping screw (UK) / Clamping bolt (US)

2

Adjustment ring

Procedure:

1. Undo the clamping screw

2. Adjust stroke by turning the adjustment ring: Rotate to the right: Stroke is reduced

Rotate to the left: Stroke is increased

3. Value on the scale roughly represents the stroke up to the stop

4. Retighten clamping screw

NOTICE

Only tighten the clamping screw lightly to avoid damaging the clamping band!

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5.2.2 Riveting spindle advance speed adjustment

The advance speed of the riveting spindle can be adjusted with the restrictor valve.

Procedure:

Reducing the advance speed:

Rotate the level control of the restrictor valve clockwise

Increasing the advance speed:

Rotate the level control of the restrictor valve counter-clockwise

NOTICE

To have easy access to the restrictor valve, move the riveting unit up to the top position!

5.2.3 Riveting spindle return speed adjustment

The return speed of the riveting spindle can be adjusted with the restrictor valve.

Procedure

Reducing the return speed:

Rotate the level control of the restrictor valve clockwise

Increasing the return speed:

Rotate the level control of the restrictor valve counter-clockwise

NOTICE

To have easy access to the restrictor valve, move the riveting unit up to the top position!

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5.2.4 Riveting force adjustment

The riveting force (operating pressure) is adjusted at the pressure regulator of the air maintenance unit.

Procedure:

1. Pull the turning handle up out of the detent

2. Set the required operating pressure

3. The value set is displayed by the manometer

The operating pressure set determines the riveting force at the form tool (see pressure/force diagram).

Pressure/force diagram

P = operating pressure

F = riveting force

NOTICE

The operating pressure can be set between 1-6 bar. To ensure good functionality, we recommend that the minimum operating pressure of 2 bar is not undershot. The maximum operating pressure is 6 bar and must not be exceeded!

0

1

2

3

4

5

6

0 0.5 1 1.5

F [kN]

P[bar]

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5.3 Setting up the riveting machine for a new workpiece

Before setting up for a new riveting job, the following requirements must be met:

1. Suitable form tool for the rivet and closing head to be produced

2. Form tool length suitable for calotte radius of pressure cup (Rp) in the currently installed form tool holder

NOTICE

The form tool length Ls must be selected so that the form-shaping form tool profile cuts directly in the radius centerpoint (see Chapter "Form tools").

3. Rivet holder or workpiece carrier must be set up centrically to the riveting spindle axis and fixed onto the machine table

The following settings must always be made in the control unit "Setup operation" so that the procedure can be interrupted at any time:

1. Insert workpiece

2. Adjust the height of the riveting machine in the stand so that the distance of the form tool to the rivet is smaller than the maximum achievable spindle stroke. If a short cycle time is desired, this distance to the workpiece can be reduced as long as the necessary distance required to insert the workpiece is maintained.

3. Set the required dimension for the rivet path with the stroke limiting stop

NOTICE

Incrementally lower the stroke limiting ring to determine the correct setting using a test workpiece.

4. At the same time, incrementally adjust the riveting force setting (via pressure regulator) and riveting spindle advance speed (via restrictor valve) to obtain the required results

If the workpieces evidence spreading over the height, the stroke limitation may be an obstacle. In this case, the stroke limiting stop should be set slightly lower than necessary. The actual riveting path is then only limited by the termination of the specified riveting time.

NOTICE

If other system parts may start oscillating due to resonance by the riveting process, check that the tool is in perfect condition and that the workpiece holder is fastened without any play.

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5.4 Possible machine settings Riveting to stroke limiting stop

Suitable for workpieces with constant thickness.

The necessary riveting path can be finely set by adjusting the stroke limiting stop. The height of the closing head then only spreads by the workpiece height spread value. The riveting time must therefore be sufficient that the stroke limiting stop is also securely reached.

During the "riveting out" on the stroke limiting stop, stress is removed and the closing head is cleanly smoothed.

Riveting without stroke limiting stop

Suitable for parts with differing heights.

Instead of a limiting stop, the stroke is limited by the set riveting time. The closing head is then only influenced by the pressure, stroke speed (exhaust valve throttle) and the riveting time. The stroke limitation must be set so that the form tool cannot move into the workpiece carrier when a workpiece is not present.

Riveting under high pressure

Suitable for rivets where a high hole intrados pressure is required.

If a higher pressure is selected for a specific riveting, the riveting time is reduced. The permissible pressure limit is set by the workpiece itself.

The opening of the restrictor valve means both a faster advance of the riveting spindle (centre sleeve) and a steeper rise in force.

Riveting under low pressure

Suitable for joint riveting.

A longer riveting time, but lower pressure. The stress on the workpiece is reduced. Possible bending of a rivet pin can be prevented.

The partial closing of the restrictor valve also works in the same direction. Advance speed and rise in force takes place slowly. Less material is pressed into the bore, the closing head therefore has more material volume available and will tend to be larger, the intrados remains small.

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6 Form tools

6.1 Form tool designs and closing head shapes

The shape of the closing head being produced depends on the design of the form tool.

Dimensions for DS and LS, see the lists "Standard form tools".

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6.2 Recommended form tool materials Table 1

Material

DIN Name

Material no.

Max. hardness

heat treatment

Hardening

Annealing

90 Mn V8

1.2842

63-65 HRC

800-850 C

100-300 C

Analysis

C % Si % Mn %

P  % S  %

Cr % V %

0.85-0.95

0.15-0.30

1.90-2.10

0.030

0.20-0.50

0.05-0.15

Application

Preparation commercial rivet materials

Form tool designs

Normal and special designs

Table 2

Material

DIN Name

Material no.

Max. hardness

heat treatment

Hardening

Annealing

S 6-5-2

1.3343

64-66 HRC

1190-1240 C

540-560 C

Analysis

C % Si % Mn %

P  % S  %

Cr % Mon. % V % W %

0.84-

0.92

0.45

0.40

0.030

3.80-

4.50

4.70-

5.20

1.70-

2.00

6.00-

6.70

Application

Preparation tempered materials

Form tool designs

Normal and special designs

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6.3 Form tool D = 10 with various lengths

Standard form tools with shaft diameter D=10 can be replaced by hand. They are held with a permanent magnet.

CAUTION

Longer form tools require the replacement of the form tool holder and pressure cup. Form tool length must always be in combination with pressure cup and form tool holder as shown in the table below. Non-compliance can lead to the destruction of the machine!

For longer and therefore heavier form tools, the use of an O-ring (9.25x1.78mm) inserted into the groove in the form tool holder can provide a better hold.

Item

Name

1

Form tool axis

2

Pressure cup

3

Form tool holder

4

Magnet

6

Form tool

Machines

Type

Radius

Rp [mm]

Form tool

length

Ls [mm ± 0.1]

Shaft 

Ds [mm]

Angle



Free

height H

[mm]

081 170 181 220 231 241

65

39

10g6

6° 02´

18

80

54

4° 47´

33

100

74

3° 44´

53

120

94

3° 04´

73

132

106

2° 46´

85

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6.4 Replacing the form tool holder and pressure cup

Item

Name

1

Internal ring gear

2

Pressure cup

3

Form tool holder

4

Connection piece

5

Screw M4x12

6

Pressure spring

7

Cap 8 Form tool

Procedure:

1. Pull form tool out of riveting head

2. Undo the screws with which the cap is fastened

CAUTION

The cap is under spring pressure!

Cap and form tool holder fall on the fingers!

Gloves are mandatory!

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3. Once the cap is removed, pull the form tool holder and pressure spring out of the riveting head

4. Pull the pressure cup out of the centring in the connection piece using the screws M4x45 provided in the machine accessories and insert a new pressure cup

CAUTION

The screws M4x45 must not be used to push the pressure cup off the internal ring gear. Contact surface of internal ring gear will be damaged!

5. Grease the form tool holder with Klübersynt GE 46-1200 (also see Chapter "Maintenance and repair work")

6. Once the new pressure cup is inserted, hold the cap with the form tool holder and pressure spring pressed against the pressure cup. Screw cap back on

NOTICE

When installing the pressure spring in the riveting machine models 081, 170, 181, 220, 231 and 241, check that the tapering end of the pressure spring ends up positioned in the cap!

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29

6.5 Standard form tool Ø10 with flat profile (081-241)

Ls = 39 ± 0.1

Ls = 54 ± 0.1

Ls = 74 ± 0.1

Article

no.

Øds

± 0.1

α°

L2

Article

no.

Øds

± 0.1

α°

L2

Article

no.

Øds

± 0.1

α°

L2

880501*

1.0

15-45

880541

1.0

15-45

880581

1.0

15-45

880502*

1.5

15-45

880542

1.5

15-45

880582

1.5

15-45

880503*

2.0

15-45

880543

2.0

15-45

880583*

2.0

15-45

880504*

2.5

15-45

880544

2.5

15-45

880584

2.5

15-45

880505*

3.0

15-45

880545

3.0

15-45

880585*

3.0

15-45

880506*

3.5

15-45

880546

3.5

15-45

880586

3.5

15-45

880507*

4.0

15-45

880547*

4.0

15-45

880587*

4.0

15-45

880508*

4.5

15-45

880548

4.5

15-45

880588

4.5

15-45

880509*

5.0

15-45

880549

5.0

15-45

880589*

5.0

15-45

880510*

5.5

15-45

880550

5.5

15-45

880590

5.5

15-45

880511*

6.0

15-45

880551*

6.0

15-45

880591*

6.0

15-45

880512*

6.5

15-45

880552

6.5

15-45

880592

6.5

15-45

880513*

7.0

15-45

880553

7.0

15-45

880593*

7.0

15-45

880514*

7.5

15-45

880554

7.5

15-45

880594

7.5

15-45

880515*

8.0

15-45

880555*

8.0

15-45

880595*

8.0

15-45

880516*

8.5

15-45

880556

8.5

15-45

880596

8.5

15-45

880517*

9.0

15-45

880557

9.0

15-45

880597*

9.0

15-45

880518*

9.5

15-45

880558

9.5

15-45

880598

9.5

15-45

880519*

10.0 880559*

10.0 880599*

10.0 880520*

10.5 25 880560

10.5 40

880521*

11.0 25 880561

11.0 40

880522*

11.5 25 880562

11.5 40

880523*

12.0 25 880563

12.0 40

880524*

12.5 25 880525*

13.0 25 880526*

13.5 25 880527*

14.0 25

880528*

14.5 25

880529*

15.0 25

* = available from stock (α = 15°)

Form tools Radial riveting machine RNE 181 HPP

30

803835.006/ENG

6.6 Standard form tool Ø10 with conical profile (081-241)

Ls = 39 ± 0.1

Ls = 54 ± 0.1

Ls = 74 ± 0.1

Article

no.

Øds

± 0.1

α°

β°

± 30’

Rs

L2

L3

Article

no.

Øds

± 0.1

α°

β°

± 30’

Rs

L2

L3

Article

no.

Øds

± 0.1

α°

β°

± 30’

Rs

L2

L3

881501*

1.0

15-45

5

3

881541

1.0

15-45

4

881581

1.0

15-45

3

5

881502*

1.5

15-45

5

4

881542

1.5

15-45

4

5

881582

1.5

15-45

3

7

881503*

2.0

15-45

5

6

881543

2.0

15-45

4

7

881583

2.0

15-45

3

10

881504*

2.5

15-45

5

7

881544

2.5

15-45

4

9

881584

2.5

15-45

3

12

881505*

3.0

15-45

5

9

881545*

3.0

15-45

4

11

881585*

3.0

15-45

3

14

881506*

3.5

15-45

5

10

881546

3.5

15-45

4

13

881586

3.5

15-45

3

17

881507*

4.0

15-45

5

11

881547

4.0

15-45

4

14

881587

4.0

15-45

3

19

881508*

4.5

15-45

5

13

881548

4.5

15-45

4

16

881588

4.5

15-45

3

21

881509*

5.0

15-45

5

14

881549*

5.0

15-45

4

18

881589*

5.0

15-45

3

24

881510*

5.5

15-45

5

16

881550

5.5

15-45

4

20

881590

5.5

15-45

3

26

881511*

6.0

15-45

5

17

881551

6.0

15-45

4

22

881591

6.0

15-45

3

29

881512*

6.5

15-45

5

19

881552

6.5

15-45

4

23

881592

6.5

15-45

3

31

881513*

7.0

15-45

5

20

881553*

7.0

15-45

4

25

881593*

7.0

15-45

3

33

881514*

7.5

15-45

5

22

881554

7.5

15-45

4

27

881594

7.5

15-45

3

36

881515*

8.0

15-45

5

23

881555

8.0

15-45

4

29

881595

8.0

15-45

3

38

881516*

8.5

15-45

5

24

881556

8.5

15-45

4

30

881596

8.5

15-45

3

41

881517*

9.0

15-45

5

26

881557*

9.0

15-45

4

32

881597*

9.0

15-45

3

43

881518*

9.5

15-45

5

27

881558

9.5

15-45

4

34

881598

9.5

15-45

3

45

881519*

10.0 5

29

881559

10.0 4

36

881599*

10.0 3

48

881520*

10.5 5

30

22

25

881560

10.5 4

38

37

40

881521*

11.0 5

32

22

25

881561

11.0 4

39

37

40

881522*

11.5 5

33

22

25

881562

11.5 4

41

37

40

881523*

12.0 5

34

22

25

881563

12.0 4

43

37

40

881524*

12.5 5

36

22

25

881525*

13.0 5

37

22

25

881526*

13.5 5

39

22

25

881527*

14.0 5

40

22

25

881528*

14.5 5

42

22

25

881529*

15.0 5

43

22

25

881535

18 5

52

22

25

* = available from stock (α = 15°)

Radial riveting machine RNE 181 HPP Form tools

803835.006/ENG

31

6.7 Standard form tool Ø10 with crowned profile (081-241)

Ls = 39 ± 0.1

Ls = 54 ± 0.1

Ls = 74 ± 0.1

Article

no.

Øds

± 0.1

α°

Ro

± 0.1

Bt

± 0.05

L2

Article

no.

Øds

± 0.1

α°

Ro

± 0.1

Bt

± 0.05

L2

Article

no.

Øds

± 0.1

α°

Ro

± 0.1

Bt

± 0.05

L2

882501

1.0

15-45

0.8

0.05 882541

1.0

15-45

1.2

0.03 882581

1.0

15-45

1.5

0.03

882502*

1.5

15-45

1.7

0.08 882542

1.5

15-45

2.2

0.06 882582

1.5

15-45

2.8

0.05 882503*

2.0

15-45

2.6

0.12 882543

2.0

15-45

3.3

0.09 882583

2.0

15-45

4.2

0.07 882504*

2.5

15-45

3.5

0.15 882544

2.5

15-45

4.4

0.12 882584

2.5

15-45

5.6

0.10 882505*

3.0

15-45

4.4

0.19 882545

3.0

15-45

5.5

0.15 882585

3.0

15-45

7.0

0.12

882506*

3.5

15-45

5.4

0.22 882546

3.5

15-45

6.8

0.17 882586

3.5

15-45

8.5

0.14 882507*

4.0

15-45

6.4

0.25 882547

4.0

15-45

8.0

0.20 882587*

4.0

15-45

10.0

0.16

882508*

4.5

15-45

7.5

0.28 882548

4.5

15-45

9.2

0.23 882588

4.5

15-45

11.6

0.18 882509*

5.0

15-45

8.5

0.31 882549

5.0

15-45

10.5

0.25 882589*

5.0

15-45

13.2

0.20 882510*

5.5

15-45

9.5

0.34 882550

5.5

15-45

12.0

0.27 882590

5.5

15-45

15.0

0.22

882511*

6.0

15-45

10.7

0.37 882551

6.0

15-45

13.2

0.30 882591*

6.0

15-45

16.6

0.24 882512*

6.5

15-45

11.8

0.40 882552

6.5

15-45

14.6

0.32 882592

6.5

15-45

18.5

0.25

882513*

7.0

15-45

13.0

0.42 882553

7.0

15-45

16.2

0.34 882593

7.0

15-45

15.3

0.36 882514*

7.5

15-45

14.2

0.44 882554

7.5

15-45

17.4

0.36 882594

7.5

15-45

22.0

0.29 882515*

8.0

15-45

15.4

0.47 882555

8.0

15-45

19.2

0.38 882595*

8.0

15-45

24.0

0.30 882516*

8.5

15-45

16.7

0.49 882556

8.5

15-45

20.8

0.39 882596

8.5

15-45

26.0

0.32

882517*

9.0

15-45

18.0

0.52 882557

9.0

15-45

22.5

0.41 882597

9.0

15-45

28.0

0.33 882518*

9.5

15-45

19.4

0.54 882558

9.5

15-45

24.0

0.43 882598

9.5

15-45

30.2

0.34

882519*

10.0 20.5

0.56 882559

10.0 24.5

0.44 882599*

10.0 32.0

0.35 882520*

10.5 22.0

0.57

25

882560

10.5 27.2

0.46

25

882521*

11.0 23.5

0.59

25

882561

11.0 29.1

0.47

25

882522*

11.5 25.0

0.61

25

882562

11.5 31.0

0.49

25

882523*

12.0 26.7

0.62

25

882563

12.0 33.0

0.50

25

882524*

12.5 28.4

0.64

25

882525*

13.0 30.2

0.65

25

882526*

13.5 31.9

0.66

25

882527*

14.0 33.8

0.68

25

882528*

14.5 35.8

0.69

25

882529*

15.0 37.8

0.70

25

* = available from stock (α = 15°)

CAUTION

Bt and Ro dimensions must be complied with! If Ro is calculated smaller or Bt larger than the corresponding form tool diameter,

this will lead to overstressing of the form tool holder, pressure cup and riveting spindle guide!

Options Radial riveting machine RNE 181 HPP

32

803835.006/ENG

7 Options

7.1 Pressure pad Use

For parts that must be held together before the form tool touches down or parts that need to be pressed together with force for a press fit.

Pre-stress force

The necessary pre-stress force must be determined through experience or empirically.

Pressure pad components (springs, thrust piece)

The design of the pressure pad components can be seen in the diagram 802297 (series 081-241) or 802296 (series 270-381). The thrust piece must be made to match the workpiece.

The thrust piece influences the pre-stress force, the pretravel with regards to the form tool and the spring rate. In normal cases, the pressure pad is produced specifically for the customer.

NOTICE

When using a pressure pad following minimum dimensions for form tool and form tool holder are required:

Series 081-241: Form tool length Ls = 54, form tool holder radius Rp = 80 Series 270-381: Form tool length Ls = 84, form tool holder radius Rp = 116

Radial riveting machine RNE 181 HPP Options

803835.006/ENG

33

7.1.1 Pressure pad dimensions drawing

Machine type

081

170/181

220/231

241

270/281

331

381/431

A

max. 30

max. 62

B

55

90

90 C 75

75

125

D

7.5 (R80)

27.5 (R100)

7.5 (R80)

27.5 (R100)

7.5 (R80)

27.5 (R100)

7.5 (R80)

27.5 (R100)

4 (R116) 20 (R132) 36 (R148)

E

32

48

b

Application-

specific

Application-

specific

Application-

specific

Application-

specific

Application-

specific

Application-

specific

Application-

specific

G

83.5

150.5

170.5

189.5

206.5

247.5

238

Thrust piece

production

As per drawing no. 802297 "Production of thrust piece and

spring diagram”

As per drawing no. 802296 "Production of

thrust piece and spring diagram”

Options Radial riveting machine RNE 181 HPP

34

803835.006/ENG

7.1.2 Production of thrust piece and spring diagram 802297

Spring diagram

F (daN) spring force

Fmax. 1000 daN

f (mm) travel

* Travel f = 0.75h do not exceed if possible

I

7 disk springs 45x22.4x1.25 (simple)

II

10 disk springs 45x22.4x1.25 (double)

III

6 disk springs 45x22.4x2.5 (simple)

Radial riveting machine RNE 181 HPP Options

803835.006/ENG

35

Example: a and b sought for pre-stress force

Fv = 130 daN for I Fv = 220 daN for II Fv = 460 daN for III

Spring combination

Force at 0.75h

I

a=8.9 A travel of 4.5 (13.4-8.9) remains for b

-> F 190 daN

II

a=6.7 A travel of 3.85 (10.55-6.7) remains for b

-> F 380 daN

III

a=6.6 A travel of 1.95 (8.55-6.6) remains for b

-> F 770 daN

Thrust piece production

Material thrust piece: Case-hardened steel Ra = 3.2 b = depends on application Case-hardened 0.3...0.5 – 660 ± 20 HV10

Options Radial riveting machine RNE 181 HPP

36

803835.006/ENG

7.2 Automatic lubrication riveting spindle head

The automatic lubrication is recommended mainly for machines and units that are installed in automatic systems and are operated in multi-shifts. It is however also suitable for manual workplaces to ensure regular relubrication of form tool holders and pressure cups.

Two machines or units (e.g. RND) can be lubricated simultaneously with a second metering valve. The distance between both machines or units should however not exceed more than 1 meter.

A constant air pressure of 6 bar is necessary to operate the device.

Setting the grease volume

The riveting spindle head is default supplied with approx. 6mm3 grease. For extremely high loading, this volume can be increased by rotating the level control of the injection lubricator (metering valve) in the "+" direction.

One level increases the volume by approx. 1mm3.

Monitoring

The level monitoring in the grease container is implemented with an initiator whose control state is shown on the control unit display when the grease volume is too low.

Lubrication interval

The lubrication interval is specified with the setup parameter in the control unit. The default lubrication interval in the control unit is set to 5h.

The default lubrication interval of 5h can be adapted if necessary to the operating requirements. A shorter interval can be set for hard permanent operation in the upper riveting force range or a longer interval for manual insertion operation (see setup table in operating instructions “Control”).

Topping up the grease container

See Chapter "Maintenance and repair work".

Radial riveting machine RNE 181 HPP Options

803835.006/ENG

37

7.3 Foot switch

If for instance large and/or bulky parts cannot be riveted using a two-hand operating unit, a safety foot switch can be used.

7.3.1 Function

When the safety foot switch is actuated, the make contact is closed and the riveting procedure initiated. When the pedal is released, the riveting spindle automatically returns to the start position.

CAUTION

Foot switch is activated unintentionally!

Contusions, scrapes!

Set the riveting machine to the smallest possible stroke for the processing.

7.3.2 Dimensions drawing

Options Radial riveting machine RNE 181 HPP

38

803835.006/ENG

7.3.3 Technical specifications

Type F1-U1Z UN

Type F1-U2ZD UN

Part number

606.1600.006

606.1700.008

Wiring diagram Additional safety pressure point to

interrupt the operating process

No

Yes Creep switching element

Yes

Jump switching element

No

Voltage

500 VAC

Permanent current

10A

Start-up current as per IEC 947-5-1 AC 15/DC 13

Yes

Yes Switching frequency max.

50/min.

Mech. service life - number of cycles

10 x 106

Ambient temperature, min..max.

-30°C/+80°C

-22°F/+176°F

-30°C/+80°C

-22°F/+176°F

Approvals

CSA, UL

CSA, UL, BG

Cable entry

1 x M20 x 1.5

3 x M20 x 1.5

Weight

1.5kg / 3.3lb

1.6kg / 3.5lb

Radial riveting machine RNE 181 HPP Options

803835.006/ENG

39

7.4 Initiator upper end position

The upper end position of the riveting spindle is monitored by an initiator and can send the control unit the required pulse for an upstream or downstream machine (e.g. rotary indexing table, pneumatic sliding table, etc.).

For further information, such as settings and connection diagrams refer to the operating instructions of the control unit.

without path-measuring system

HPP

with path-measuring system HPP

7.5 Initiator lower end position (bridging initiator)

The lower end position initiator is used for self-holding the two-hand operating unit. For further information, such as settings and connection diagrams, refer to the

operating instructions of the control unit.

Options Radial riveting machine RNE 181 HPP

40

803835.006/ENG

7.6 Riveting stroke limit switch unit NHE 181-231

The riveting stroke limit switch unit is used for rivet projection control. As option the following riveting stroke limit switch units (view without cover) are available:

NHE-U (825290.01)

Projection measuring device with My-Com

switch

NHE-H (825290.03)

Projection measuring device with magnetic field

sensor

Application: for rivet projection measurement U

Application: for riveting modes with control variable H (driven head height)

NHE-E (825290.07)

Projection measuring device with My-Com

switch and adjustment spindle

NHE-Combi (825290.09)

Combined projection measuring device with My-

Com switch and magnetic field sensor

Application: e.g. for riveting modes with control variable E (riveting spindle path from TDC to riveting end)

Application: for rivet projection measurement U or riveting modes with control variable H (driven head height)

NOTICE

NHE-H and NHE-Combi can only be used in connection with Process-Controller HPP-25!

Radial riveting machine RNE 181 HPP Options

803835.006/ENG

41

At customer’s request the riveting stroke limit switch unit NHE can be equipped with a mechanic organ of touch.

Item

Name

Item

Name

1

Slider (carriage)

3

Touching bush

2

Touching lever

For further information, such as function and settings, refer to the operating instructions of “Process-Controller HPP-25 Autocompensation“.

Options Radial riveting machine RNE 181 HPP

42

803835.006/ENG

7.6.1 My-Com Switch substitution

Item

Name

Item

Name

1

Turning lever

4

Fitting bolt

2

My-Com-Switch

5

Mounting nut

3

Slide

6

Slider (guiding slide)

Procedure

1. Undo mounting nut and remove existent My-Com-Switch

2. Screw in so long new My-Com Switch as the lower thread edge of My-ComSwitch is mounted flush with the slide (see figure right)

3. Fix My-Com-Switch with mounting nut

After substitution effect following test: Proceed slider till My-Com-Switch switches at turning lever (opener switching point).

Maintenance

If necessary, grease between turning lever, slider and fitting bolt.

Radial riveting machine RNE 181 HPP Options

803835.006/ENG

43

7.6.2 Magnetic field sensor adjustment

Adjust magnetic field sensor with feeler gauge (nominal dimension 0.1 – 0.6mm).

NHE-H

NHE-Combi

Item

Name

Item

Name

1

Magnetic field sensor

3

Plate

2

Magnetic tape

4

Slider

Options Radial riveting machine RNE 181 HPP

44

803835.006/ENG

7.6.3 Touch probe switching point NHE-E adjustment

The riveting stroke limit switch unit NHE-E is required for operation in riveting modes N1, N2, N3, N4 and T14 of Process-Controller HPP-25.

Item

Name

Item

Name

1

Screw

3

Slide

2

Rotary knob with scale

4

Edge for reading

Procedure:

1. Undo screw item 1

2. Turn rotary knob item 2 and adjust rivet end Riveting lower: Turn rotary knob clockwise Riveting higher: Turn rotary knob counterclockwise

3. Retighten screw item 1

Radial riveting machine RNE 181 HPP Options

803835.006/ENG

45

7.6.4 Spring prestress adjustment riveting stroke limit switch unit NHE

Item

Name

1

Threaded pin

2

Spring

3

Slider (guiding slide)

The spring prestress is set from the bottom by a threaded pin in the guiding slide.

Set values

Spring rate: 1.99N/mm Spring prestress 9 – 25mm (18N – 50N)

Options Radial riveting machine RNE 181 HPP

46

803835.006/ENG

7.6.5 Dimensions drawing RNE 181-231 HPP with NHE

NHE-U/NHE-H/NHE-E

NHE-Combi

Radial riveting machine RNE 181 HPP Options

803835.006/ENG

47

7.7 Proportional pressure regulator Function and application

The Proportional pressure regulator has been designed for regulating a pressure proportional to a specified set point value. A built-in pressure sensor records the pressure at the working line and compares this value with the set point value. If the actual value differs from the set point value, the regulating valve is actuated further until the output pressure reaches the set point value.

For further information, such as settings and connection diagrams refer to the operating instructions of Process-Controller.

Maintenance and repair work Radial riveting machine RNE 181 HPP

48

803835.006/ENG

8 Maintenance and repair work

8.1 Introduction

The maintenance and repair work on the machine comprises periodic cleaning, lubrication, inspection and upkeep work.

All completed maintenance and repair work must be entered in the maintenance and repair log by the persons responsible for the work (example form see chapter “Maintenance and repair log“).

8.1.1 Safety regulations

If, during maintenance, it is noted that a machine part is defective or damaged, it must be correctly repaired or replaced.

Only use original spare and wear parts. Inform operating personnel before starting any maintenance and repair work. Implement specified adjustment, maintenance and inspection work according to

the schedule.

8.1.2 Personnel requirements

For safety reasons, maintenance and repair work may only be carried out by trained specialist personnel.

Radial riveting machine RNE 181 HPP Maintenance and repair work

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8.2 Overview of maintenance work

Assembly

Type of maintenance

Maintenance interval

(whichever is reached first)

Check

Relubrication

Removal

Cleaning

New lubrication

Topping up

Emptying

Replacement

Every 40h or weekly

Every 1000h or annually

Every 5000h or 2 years

Each time riveting unit is

dismantled

Riveting spindle head (form tool holder and pressure cup)

X X X

Riveting spindle

X X X X X

Automatic lubrication riveting spindle head (option)

X

When the corresponding

indication appears on the

control unit display

Air maintenance unit

X X X X

Polygon shaft

X X X

Two-hand operating unit

X X

Piston and piston rod seals

X

Riveting motor terminal box

X X

Maintenance and repair work Radial riveting machine RNE 181 HPP

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8.2.1 Riveting spindle head (form tool holder and pressure cup)

Item

Name

1

Form tool holder spherical plain bearing

2

Pressure cup

3

Form tool holder

4

Lubricator nipple

5

Red cap

6

Screwed connection for automatic lubrication

7

Grease gun (Article No. 459806)

Riveting spindle head (form tool holder and pressure cup) maintenance schedule

Name

Maintenance activity

Grease type

Interval

Pressure cup/form tool holder

Lubricate with one shot of the grease gun via the lubricator nipple

Klübersynth GE 46-1200 Every 40 h or weekly. Lubrication intervals should be reduced for extremely high stresses (temperature at red cap over 40° C) or during shift operation.

Clean, check for wear, relubricate

Every 1000 h or after every replacement of pressure cup/form tool holder

Form tool holder spherical plain bearing

Clean and check for wear, relubricate, replace if necessary

Every 1000 h or after every replacement of pressure cup/form tool holder

7

Radial riveting machine RNE 181 HPP Maintenance and repair work

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8.2.2 Riveting spindle

Maintenance and repair work Radial riveting machine RNE 181 HPP

52

803835.006/ENG

Riveting spindle maintenance schedule

Item

Name

Maintenance activity

Grease type

Comments

Clean and check for

wear, replace if

necessary

Dismantle

Replacement

Lubricate

Klüber-Staburags

NBU 8 EP

Mobil DTE 24

4

Guide sleeve

X X

7 Eccentric sleeve

X

16

Internal ring gear

X X X

17

Eccentric shaft

X X X

18

Washer

X

20

Buffer disc

X

33

Axial ball bearing

X X

34

Axial needle ring

X X

35

Needle bearing

X X

37

Needle ring

X X

38

I.D. seal

X

40

I.D. seal

X X

41

O.D. seal

X

42

Damping sealing ring

X

43

Compensating washer

X X

44

Compensating washer

X X

Item 44 must be centered on the damping piston item 3 during assembly (grease item 44 with Klüber-Staburags NBU 8 EP to make it easier)

45

O-Ring

X

48

O-Ring

X X

64

Counter washer

X

87

Shaft & housing locating wash.

X

The riveting unit must be completed disassembled every 2 years or 5000 operating hours for maintenance lubrication. All parts must be cleaned and the bearing surfaces must be checked for wear or burnt areas. The needle rings and axial needle bearings of the eccentric shaft must be replaced (see maintenance list). All parts must be carefully reassembled after being newly lubricated.

NOTICE

This revision interval should be shorted appropriately if high stresses are involved (higher material stressing)!

Radial riveting machine RNE 181 HPP Maintenance and repair work

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8.2.3 Automatic lubrication riveting spindle head (option)

Item

Name

Item

Name

1

Injection lubricator (metering valve)

7

Initiator

2

Lubricant line

8

Container cover

3

Solenoid valve

9

Pistons

4

Screwed connection

10

Pressure control valve

5

Plug screw

11

Compressed air hose

6

Grease container (27.6 cm3)

Topping up the grease container

ATTENTION

Container is under pressure!

Grease squirts out of container!

To topping up stop the compressed air supply!

The grease level in the grease container can be determined from the position of the piston. When the end protrudes less than 4 mm out of the container cover or when a corresponding indication appears on the control unit display, the grease container must be topped up as follows:

1. Stop compressed air supply to riveting machine

2. Disconnect compressed air hose at connection

3. Remove the lubricant line and the aperture plug screw on the grease

container

4. Push the piston through the aperture down to the stop. Slowly top up with

grease (Klübersynth GE 46-1200) until it starts to come back out of the same aperture.

5. The grease must leak through the screw connection when the plug screw is

mounted again.

6. Reconnect the lubricant line. Manually actuate the injection lubricator several

times --> there must not be any air in the lubricant line!

Maintenance and repair work Radial riveting machine RNE 181 HPP

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8.2.4 Air maintenance unit

081, 181, 231, 281

181 STF, 231 STF, 281 STF, 331, 331 STF

331, 331 STF Item

Name

Item

Name

1

Filter / water separator

4

Exhaust air filter

2

Oil tank

5

Filter element

3

Drain valve

6

Oil filler screw

Air maintenance unit maintenance schedule

Item

Maintenance activity

Oil type

Interval

1

Check water level, drain water via drain valve when necessary.

Notice: The condensate level must never exceed the maximum mark otherwise water with compressed air would be entrained to the control elements!

Every 40h or weekly

2

Check oil level, top up if necessary

Oil filler air maintenance unit 081 – 281:

 Stop compressed air supply to air maintenance

unit (oil filler under pressure not possible!)

 Unscrew oil tank  Top up oil to the mark

Oil filler air maintenance unit 331, 181 – 331 STF:

Possible during operation, system has not to be unpressurized  Undo slowly oil filler screw (pressure decrease

in oil tank)

 Top up oil to the mark  Retighten oil filler screw

See table for recommended oils

Every 40h or weekly

4

Replace filter element

Annually

Radial riveting machine RNE 181 HPP Maintenance and repair work

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55

Oils recommended for the air maintenance unit

Manufacturer

Name

BP

ENERGOL RD-E 46 (ISO)

CHEVRON (only available in USA)

ARIES ISO-VG 46

ESSO

NUTO H32

MOBIL

MOBIL DTE 24

SHELL

TORCULA Oil 32 (ISO)

TEXACO (only available in Europe)

ARIES ISO-VG 32

VALVOLINE

ATO 46 or ATO 22 SYNTH

8.2.4.1 Mist oiler adjustment

Item

Name

1

Adjustment screw

2

Mist oiler

Use the adjustment screw to set the desired oil quantity. At delivery the oiler is opened by 1½ turn clockwise.

Increasing the oil quantity = turn the adjustment screw counterclockwise Decreasing the oil quantity = turn the adjustment screw clockwise If oil escapes out of the pneumatic valve the quantity of oil could be reduced.

Maintenance and repair work Radial riveting machine RNE 181 HPP

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8.2.5 Polygon shaft

It is strongly recommended, for preventative maintenance regarding machines subject to high stresses and multiple shift work, that the polygon profile is cleaned every 1000 operating hours or at least annually and lubricated again with Interflon Grease LS1/2.

NOTICE

This point applies in particular to riveting machines that are equipped with the Process-Controller.

Radial riveting machine RNE 181 HPP Maintenance and repair work

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8.2.6 Two-hand operating unit

The two-hand operating unit must be checked regularly, at least once a year, by an expert provided by the operator. This check must cover:

1. The secure function of the two-hand operating unit

2. The condition of the two-hand operating unit components

3. The interaction of the two-hand operating unit with the riveting machine

control unit

The test results must be documented in a report to be signed by the tester. The report must be retained.

Safety inspection

After every change in working procedures, e.g tool change, change to activation type "Two-hand operating unit", additions of further safety equipment, the following must be checked:

1. That the two-hand operating unit required for safety is switched on and

functional

2. That the two-hand operating unit and exposed connection lines are visually

undamaged

3. That the necessary safety distance is complied with

Check list for two-hand operating unit check

Yes

No

Does the riveting machine start after actuation of the two-hand button at an interval of < 0.5 sec.?

X

Does the riveting machine start after actuation of the two-hand button at an interval of > 0.5 sec.?

X Two-hand button and exposed lines damaged?

X Safety distance complied with?

X

Is the start lifting movement interrupted if one button is released?

X

8.2.7 Piston and piston rod seals

NOTICE

The piston and piston rod seals must always be replaced when the riveting machine is disassembled (seals may be damaged during inappropriate removal of riveting unit).

Seals must be carefully reassembled after being newly lubricated (see riveting spindle maintenance schedule).

Maintenance and repair work Radial riveting machine RNE 181 HPP

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8.2.8 Riveting motor terminal box

The riveting motor terminal box can be opened for maintenance or fault finding.

DANGER

Touching of live parts on the open terminal box!

Electric shock!

Isolate the electrical power supply! Electrical commissioning has to be made only by a trained authorised electrician!

Radial riveting machine RNE 181 HPP Maintenance and repair work

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8.3 Maintenance and repair log

All maintenance and repair work carried out by the customer or BalTec must be entered into a maintenance and repair log. Copy the maintenance and repair log shown in these operating instructions and enter the following data:

 Effective operating hours (shown on the control unit display)  Tick in cycle column  Work carried out  Name and date

Archive the completed forms.

Example form

Maintenance log for Machine : RN 231 Machine no.: 231.9999

Work carried out

Counter display:

Operating hours

Riveting unit

dismantled

Weekly or every 40

operating hours

Half-yearly or every

500 operating hours

Yearly or every 1000

operating hours

Every 2 years or 5000

operating hours

Work

Carried out by

Date

00050

X

Lubricate riveting spindle head

S.Template

22.05.05

01025

X

Polygon shaft cleaned and lubricated

S.Template

24.06.05

01025 X Two-hand switching checked

S.Template

24.06.05

05060 X X Riveting machine checked

S.Template

24.10.05

Maintenance and repair work Radial riveting machine RNE 181 HPP

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Maintenance and repair log

Maintenance log for Machine: Machine no.:

Work carried out

Counter display:

Operating hours

Riveting unit

dismantled

Weekly or every 40

operating hours

Half-yearly or every

500 operating hours

Yearly or every 1000

operating hours

Every 2 years or 5000

operating hours

Work

Carried out by

Date

Radial riveting machine RNE 181 HPP Decommissioning, Storage

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9 Decommissioning, Storage

9.1 Decommissioning

Disconnect the riveting machine from power and pressure before shutting it down and dismantling it.

9.2 Storage

Please note the application limitations for storage.

9.3 Re-commissioning

Before recommissioning or after a long standstill, the pressure cup in the riveting spindle head must be lubricated first (see Chapter "Maintenance and repair work").

For the remaining procedures, follow the instructions in the Chapter "Commissioning" or Assembly instructions.

Disposal Radial riveting machine RNE 181 HPP

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10 Disposal

10.1 Introduction

10.1.1 Personnel requirements

For safety reasons, disposal must be carried out only by trained specialist personnel.

10.2 Disposal

10.2.1 Replaced parts

Disposal of replaced parts such as seals, filter cartridges and hydraulic oils and lubricants in particular is determined by the local disposal regularions and the environmental protection laws.

10.2.2 Mineral oils

The mineral oils recommended by us can be recycled depending on the level of contamination and decomposition. See also the manufacturer specifications.

10.2.3 Riveting unit

Once the machine has reached the end of its service life, dismantling must include safe and correct disposal of all parts, in particular those materials or parts that could be a hazard to the environment. These include:

 Lubricants  Hydraulic oils  Plastics  Batteries  Pressure accumulator (depressurize, empty)

Radial riveting machine RNE 181 HPP Appendix

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11 Appendix

11.1 Schemata

11.1.1 Pneumatic diagram with air maintenance unit 181 reduced force, 803541

Item

Name

0.1

Air maintenance unit comprising filter regulator, lubricator, manometer

0.2

Air maintenance unit comprising filter regulator, lubricator, manometer and additional outlet

1.0

Riveting unit

1.01

Restrictor valve (advance speed setting)

1.02

Restrictor valve (return speed setting)

1.1

5/2-way valve

Appendix Radial riveting machine RNE 181 HPP

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11.1.2 Pneumatic diagram 181 reduced force with proportional pressure regulator 803584

Item

Name

0.1

Air maintenance unit comprising filter regulator, lubricator, manometer

0.2

Air maintenance unit comprising filter regulator, lubricator, manometer and additional outlet

1.0

Riveting unit

1.01

Restrictor valve (advance speed setting)

1.02

Restrictor valve (return speed setting)

1.1

5/2-way valve

1.2

Proportional pressure regulator

Radial riveting machine RNE 181 HPP Appendix

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65

11.1.3 Pneumatic diagram for automatic lubrication 802417

Item

Name

0.1

Pressure control valve

1.0

Grease container

1.1

Solenoid valve

2.0

Injection lubricator (metering valve)

Appendix Radial riveting machine RNE 181 HPP

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11.2 Spare parts lists

11.2.1 Machine body 181 reduced force Standard/HPP 825403-b

Radial riveting machine RNE 181 HPP Appendix

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Appendix Radial riveting machine RNE 181 HPP

68

803835.006/ENG

Pos.

No.

Part Name

Part No.

Remarks

1 1 Cast housing

825908

Standard

2 1 Cast housing

825912

Flange mounting

3 1 Damping piston

825909

Standard

4 1 Guide sleeve

823069

6 1

Cam

823195

7 1

Eccentric sleeve

825038

9 1

Flange

825035

Standard

10 1 Connecting piece

825067

11 1 Adjustment ring

825066

12 1 Adhesive label "BalTec"

825110

13 1 Cover tube

825073

Standard

14 1 Key

825036

15 1 Scale

823023

16 1 Internal ring gear

811035

17 1 Eccentric shaft

814018

18 1 Washer

825039

19 1 Key

390108

20 2 Buffer disc

823027

21 1 Motor flange

825910

Standard

22 2 Cylinder head screw

341012

In-6kt M4x16 DIN 912-12.9

23 1 Mounting nut

522545

E-8, M10x1

24 1 Cover tube

825183

Flange mounting

25 1 Pan head screw

346071

In-6kt M4x8 ISO 7380-10.9

26 1 Cylinder head screw

341009

In-6kt M4x8 DIN 912-12.9

27 4 Cylinder head screw

341010

In-6kt M4x10 DIN 912-12.9

28 6 Cylinder head screw

341017

In-6kt M5x12 DIN 912-12.9

29 4 Cylinder head screw

341070

In-6kt M4x20 DIN 912-12.9

30 6 Cylinder head screw

341019

In-6kt M5x20 DIN 912-12.9

31 1 Flange

825182

Flange mounting

32 1 Locking screw

838094

33 2 Axial ball bearing

330056

51106

34 2 Axial needle ring

330004

AXK 1528

35 2 Needle bearing

331252

NK 30/20

36 1 Counter sunk screw

342811

In-6kt M5x12 DIN 7991-10.9

Radial riveting machine RNE 181 HPP Appendix

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69

Pos.

No.

Part Name

Part No.

Remarks

37 2 Needle ring

331024

K 14x18x13

38 1 I.D. Seal

360350

KSD – Ring

40 1 I.D. Seal

360352

KSD – Ring

41 1 O.D. Seal

360360

KSD – Ring

42 1 Damping sealing ring

361945

CYBU PEI 52x62 A01

43 1 Compensating washer

337003

44 1 Compensating washer

337005

45 1 O – Ring

362065

45 – 2.5 NBR 70 Shore

48 3 O – Ring

362125

96 – 2 NBR 70 Shore

49 1 Stop nut

348991

Nyloc M5 DIN 985

50 2 Restrictor valve

368613

AS2301F-01-06S

51 1 Clamping fixture complete

825074

54 2 Cable clamp

525305

55

2

Phillips pan head thread cutting screw

346680

Type 2 M3x8 BN 1023 56 1 Proximity switch

522517

M5 PNP/NO

57 1 Proximity switch holder

824053

58 2 Stopper

389911

3126 08 00

60 1 Proximity switch

522519

M8 PNP IFRM 08P1703/S35L

63 1 Stopper

371507

TL-4-093 for M10x1

64 1 Counter washer

330251

CP 1426

66 1 Dowel pin

356065

ø3x16 VSM 12785

67 6 Locking washer

351707

for M5

72 1 Plug with cable

522532

BKS-S 49-1-03

73 1 Motor flange

825911

HPP

76 1 Intermediate flange

826064

for USA-Motor

77 4 Cylinder head screw

341025

In-6kt M6x20 DIN 912-12.9

87 2 Shaft and housing locating washer

330702

LS 1528

98 2 Distributor

825088

99 2 Hollow-core screw

374192

G1/8" HI 118K

100 2 Screw plug

371427

R1/8" conical

104 2 Pressure transmitter

540392

0 – 10 bar

105

2

Connection cable to pressure transmitter

540393

L = 2m 1 Set of bearings

333411

1 Set of seals

363558

Appendix Radial riveting machine RNE 181 HPP

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11.2.2 Riveting head 081-241 814310-h

RNL/RNEL 231 mit NHE ohne Initiator UT

RNL/RNEL 231 with NHE without initiator BDC

Autom. Schmierung

Automatic lubrication

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

71

Pos.

No.

Part Name

Part No.

Remarks

1 1 Cap

814057

RN/RNE 081/181/231/241

2 2 Screw

341006

In-6kt M3x12 DIN 912-12.9

3 1 Pressure spring

820026

4 1

Cap

865899

RN/RNE 181/231 with NHE

5 1 Holder

865904

6 4

Screw

341083

In-6kt M4x25 DIN 912-12.9

7 2 O-Ring

362086

60-1,5

8 1 Form tool holder complete

814050

R= 65 / L= 39

9 1 Form tool holder complete

814051

R= 80 / L= 54

10 1 Form tool holder complete

814052

R=100 / L= 74

11 1 Form tool holder complete

814053

R=120 / L= 94

12 1 Form tool holder complete

814054

R=132 / L=106

13 1 Pressure cup

814001

R= 65 / L= 39

14 1 Pressure cup

814010

R= 80 / L= 54

15 1 Pressure cup

814012

R=100 / L= 74

16 1 Pressure cup

814014

R=120 / L= 94

17 1 Pressure cup

814016

R=132 / L=106

18 1 Lubricating nipple

319718

19 1 Ring fitting

366916

20 1 Hollow core screw

374179

21 2 Bonded seal

361108

USIT 5.7x9x1

22 1 Block

814151

23 2 Screw

341024

In-6kt M6x16 DIN 912-12.9

24 1 Oil hose

040034

PA Ø2.5/1.5 L = ca. 500mm

25 1 Cap

826092

RN ONLY Type 1

26 4 Screw

341011

In-6kt M4x12 DIN 912-12.9

27 4 Locking washer

351706

M4

28 2 Connection fitting

366913

29 1 Sealing ring

363681

DA M5

30 1 Cap

814164

RNL/RNEL 231/90

31 1 Cap (reworked)

814165

RNL/RNEL 231/90 with NHE

101

1

Spherical plain bearing to form tool holder

325802

GE 8 DO 102 1 Magnet to form tool holder

390001

103 1 Circlip to form tool holder

354510

SB 16

Appendix Radial riveting machine RNE 181 HPP

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803835.006/ENG

11.2.3 Electric motor 181 825320-m

Pos.

No.

Part name

Part no.

Remarks

1 1 Spring dowel sleeve

355333

"PRYM" ø4x24 DIN 7343

2 1 Polygon shaft

825053

Standard

3 1 Electric motor

542860

3x230/400V 50Hz, 3x265/460V 60Hz

4 1 Electric motor

542861

3x575V 60Hz

5 1 Electric motor

542862

1x110V 60Hz

6 1 Electric motor

542863

1x220V 50Hz

7 1 Electric motor

542889

1x120V 60Hz

8 1 Polygon shaft

825060

Bodine-Motor

9 1 Electric motor

542906

3x200V 50Hz

10 1 Feed cable motor

520169

14 1 Cable fitting

525794

M20x1.5mm 5.5-12.0mm

15 4 Cylinder head screw

341025

In-6kt M6x20 DIN 912-12.9

16 1 Cover

826012

17 3 Pan head screw

359137

M4x8 eco-fix H BN 4825 4H

18 4 Cylinder head screw

341231

In-6kt 3/8"-16 UNC x 1"

19 2 Flat plug AMP

525107

6,3x0.8 IFH 1.5

20 1 Electric motor

542918

3000rpm

21 1 Polygon shaft

826035

STF with Bodine-Motor

22 1 Feed cable motor

520169.01

USA/Canada

23 1 Cover bracket

825167

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

73

11.2.4 Pneumatics 181 STF/HPP 825328-n

Appendix Radial riveting machine RNE 181 HPP

74

803835.006/ENG

Pos.

No.

Part name

Part no.

Remarks

2 1 Bracket

814087

5 1

5/2-way valve

369345

1/4" 6 2

Silencer

379924

1/4" 7 1

Plastic hose

040038

ø12/8, L = 130mm

8 1 Direct joint

367712

1/4" ø12

9 2 Direct joint

367739

828-0406 (Standard)

9 2 Direct joint

367738

828-0404 (RNE reduced force)

10 2 Plastic hose

040021

PS 86 L=… (Standard)

10 2 Plastic hose

040026

PS 64 L=… (RNE reduced force)

11 2 Screw

341023

M6x12

12 1 Indicating label

250004

14 2 Screw

341626

M4x50

15 1 Direct joint

367713

3/8" ø12

16 1 Air maintenance unit

368300

3/8", 2-part

Single parts to Pos. 16 obtainable:

Filter-regulator

368307

C.12, 3/8"

Mist oiler

368327

L.12, G3/8"

Manometer

369812

Ø50, 0-10 bar

Gasket for manometer

363692

¼“

Tank for filter

368312

Tank for lubricator

368313

17 1 Air maintenance unit

368308

3/8", 4-part

Single parts to Pos. 17 obtainable:

Filter

368302

F.12, 3/8"

Mist oiler

368327

L.12, G3/8"

Distributor 4-part

368305

T.12, 3/8“

Pressure regulator

368303

R.12, 3/8“

Manometer

369812

Ø50, 0-10 bar

Gasket for manometer

363692

¼“

Tank for filter

368312

Tank for lubricator

368313

Radial riveting machine RNE 181 HPP Appendix

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75

Pos.

No.

Part name

Part no.

Remarks

18 2 Screw

341507

M4x30

19 1 Plug socket black

369347

22mm 230-364A

20 1 Plug socket transparent

369348

22mm 230-392A (if NHE or pathmeasuring system)

21 2 Protecting cage

368311

optional

22 1 Cable to valve

520235

L = 1300mm

23 1 Filter-regulator

368301

C.12 G, 3/8“

Single parts to Pos. 23 obtainable:

Filter-regulator

368307

C.12

Manometer

369812

Ø50, 0-10 bar

Gasket for manometer

363692

¼“

Tank for filter

368312

24 1 Air maintenance unit

368310

3/8", 3-part

Single parts to Pos. 24 obtainable:

Filter

368302

F.12, 3/8"

Distributor 4-part

368305

T.12, 3/8“

Pressure regulator

368303

R.12, 3/8“

Manometer

369812

Ø50, 0-10 bar

Gasket for manometer

363692

¼“

Tank for filter

368312

Appendix Radial riveting machine RNE 181 HPP

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11.2.5 Automatic lubrication 814340-u

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

77

Pos.

No.

Part name

Part no.

Remarks

1 1 Grease container

814112

2 1

Pressure regulating unit

368325

DR.022-L378

12 1 Plug socket

369347

black 22mm 230-364 A

14 1 Injection lubricator

378008

L11 R 1/8“ KY 2033

Single parts to Pos. 14 obtainable:

14.1

1

Clamping ring

366912

2.5x1.5 brass

14.2

1

Tube connection

366911

M8x1.00x3/32“

15 1 Connection fitting

366913

Single parts to Pos. 15 obtainable:

15.1

1

Clamping ring

366912

2.5x1.5 brass

18 1 Swivelling fitting

366150

1/8“, D=4 Art.-Nr. 0118 04 10

19 3 Screw plug

371012

B 18 23-02

21 1 Swivelling fitting

367744

1/8" 834-0204 K

23 1 Swivelling fitting

367746

1/4" 834-0404 K

25 1 Plastic hose

040026

PS 64

26 1 Plastic hose

040037

PA ø4/2.7

27 1 Oil hose

040034

PA ø2.5/1.5

28 2 Cylinder head screw

341015

In-6kt M5x8

29 1 Cylinder head screw

341027

In-6kt M6x30

30 1 Cylinder head screw

341026

In-6kt M6x25

31 1 Feeding cable valve

520235

33 1 Proximity switch

522520

M5 PNP NC BES 516-3022-E5-C-S49

34 1 Angular plug connector with cable

522532

BKS-S 49-1-03

35 1 Locking plug

371531

PE 4.5 mm

38 1 Filter

368337

¼“ F.01

39 1 Bracket assembly set

368353

40 4 Cylinder head screw

341017

In-6kt M5x12 DIN 912-12.9

Lubricating grease (1kg can)

060309

Klübersynth GE 46-1200

Appendix Radial riveting machine RNE 181 HPP

78

803835.006/ENG

11.2.6 Foot switch 813345-d

Pos.

No.

Part name

Part no.

Remarks

1 1 Foot switch

522427

F1-U1 UN

2 1 Reduction flange

525894

only for Canada

3 1 Cable fitting

525719

Pg11/6-12mm, only for Canada

4 1 Cable configured

520146

2x1.5E length = 2.5m, only for Canada

5 1 Cable fitting

525794

M20x1.5/5.5-12mm

6 1 Cable configured

520145

2x1 length = 2.5m

7 1 Case with switch

522621

F1-U1 UN

8 1 Spring

522426

F1-U1 UN

9 1 Foot switch

522429

F1-U2ZD UN

10 1 Case with switch

522430

F1-U2ZD UN

11 1 Ram incl. spring

522431

F1-U2ZD UN

12 1 Cable configured

520623

4x1.5E length = 2.5m

13 1 Cable configured

520622

4x1 length = 2.5m

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

79

11.2.7 Two-hand operating unit 814350-d

Pos.

No.

Part name

Part no.

Remarks

1 1 Housing

814109

2 1

Cover

814107

without emergency stop

3 1 Cover

814108

with emergency stop

4 2 Cylinder screw

341016

In-6kt M5x10 DIN 912-12.9

5 2 Press button

522297

green

6 1 Cable fitting

525772

Pg 11, 5-12mm

7 1 Counter nut

525204

Pg 11

8 1 Cable clamp

525304

9 1

Cylinder screw

341009

In-6kt M4x8 DIN 912-12.9

10 1 Cylinder screw

341015

In-6kt M5x8 DIN 912-12.9

11 1 Press button

522296

red, emergency stop

12 1 Supply cable

520233

RC 20 L=2000

13 1 Supply cable

520232

RC 20 L=1400

14 1 Supply cable

520660

HPP-25 L=1500

15 6 Pan head screw

346090

M3x6 ECO-FIX Form H, BN 4825 4.8

16 1 Supply cable

520661

HPP-25 L=2000 for RND, RNS, RNFS

Appendix Radial riveting machine RNE 181 HPP

80

803835.006/ENG

11.2.8 Pressure pad 081-241 814315-d

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

81

Pos.

No.

Part Name

Part No.

Remarks

1 1 Pressure piece

Client specific

2 1 Cap

814058

3 1 Pressure spring

820026

4 2

Cylinder head screw

341502

In-6kt M3x20

5 2 O-Ring

362086

60-1.5

6 1 Straight pin

355068

3x10

7 1 Snap ring

354239

46x1.75

8

1

Form tool holder complete without O-Ring

814051

R=80 / L=54

8

1

Form tool holder complete with ORing

814146

R=80 / L=54

9

1

Form tool holder complete without O-Ring

814052

R=100 / L=74

9

1

Form tool holder complete with ORing

814147

R=100 / L=74 10 1 Pressure cup

814010

R=80 / L=54

11 1 Pressure cup

814012

R=100 / L=74

12 7 Spring washer

314075

45x22.4x1.25 (60 – 170 daN)

13

10

Spring washer

314075

45x22.4x1.25 (120 – 340 daN)

14 6 Spring washer

314214

45x22.4x2.5 (400 – 650 daN)

15 1 Lubricating nipple

319718

16 1 Banjo fitting

366916

17 1 Hollow-core screw

374179

H1 M5 K

18 4 Bonded seal

361108

USIT U 5.7-9-1

19

1

Form tool holder complete without O-Ring

814053

R=120 / L=94

19

1

Form tool holder complete with ORing

814148

R=120 / L=94

20

1

Form tool holder complete without O-Ring

814054

R=132 / L=106

20

1

Form tool holder complete with ORing

814149

R=132 / L=106

21 1 Pressure cup

814014

R=120 / L=94

22 1 Pressure cup

814016

R=132 / L=106

29 1 Aluminium sealing ring

363681

DA M5

30 1 Block

814151

31 2 Cylinder head screw

341024

In-6kt M6x16 DIN 912-12.9

33 1 Oil hose

040034

PA Ø2.5/1.5 L= ca. 500mm

34 1 Connection fitting

366913

Appendix Radial riveting machine RNE 181 HPP

82

803835.006/ENG

11.2.9 Path-measuring system HPP-181, 825408-c

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

83

Pos.

No.

Part name

Part no.

Remarks

1 1 Sensor support

826133

2 1

Support

825284

3 1

Clamping ring

825285

4 1

Magnetic tape support

826104

5 1

Cover

825282

7 1

Magnetic field sensor

540421

MIL 10

8 1 Magnetic tape

540408

MLFK

9 2 Cylinder head screw

341512

In-6kt M5x30

10 2 Cylinder head screw

341100

In-6kt M3x14

12 2 Pan head screw

346080

M3x6

13 2 Cylinder head screw

341104

In-6kt M3x8

14 1 Mounting nut

522545

E-8, M10x1

18 1 Cylinder head screw

341005

In-6kt M3x10

with initiator TDC, Standard machines

15 1 Proximity switch

522519

M8 PNP

16 1 Angular plug connector with cable

522532

Cable L=3m

with initiator TDC, RNC

15 1 Proximity switch

522519

M8 PNP

19 1 Angular plug connector with cable

522546

Cable L=10m

without initiator TDC

17 1 Stopper

371504

Ø=7mm Type 6019 metrical

Appendix Radial riveting machine RNE 181 HPP

84

803835.006/ENG

11.2.10 Riveting stroke limit switch unit NHE-U 181-231, 825290.01

Pos.

No.

Part name

Part no.

Remarks

1 1 NHE basic unit

826098

181-381

2 1 Basic plate small

825292

3 1

Slide

825262

4 1

Turning lever

825265

5 1

Cover below

825289

6 1

Cover above

825299

7 1

Fitting bolt

341398

d6x20/ M5

8 1 Fitting bolt

341412

reworked

9 1 My-Com-Switch

522676

M75/S35

10 1 Cable

520644

11 1 Torsion spring

316637

12 1 Screw

341025

In-6kt M6x20

13 1 Washer large

348805

M6

14 1 Screw

341002

In-6kt M3x5

15 3 Screw

346078

In-6kt M4x6

16 2 Screw

346091

In-6kt M5x10

17 6 Screw

341018

In-6kt M5x16

18 2 Cylinder pin

355090

4-h6x16

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

85

11.2.11 Riveting stroke limit switch unit NHE-H 181-231, 825290.03-a

Pos.

No.

Part name

Part no.

Remarks

1 1 NHE basic unit

826098

181-381

2 1 Basic plate small

825292

5 1

Cover below

825289

6 1

Cover above

825299

15 3 Pan head screw

346078

In-6kt M4x6

16 2 Pan head screw

346091

In-6kt M5x10

17 8 Cylinder head screw

341018

In-6kt M5x16

18 2 Cylinder pin

355090

4-h6x16

21 1 Distance plate

825298

22 1 Magnetic field sensor

540421

MIL 10

23 1 Plate

825288

24 1 Magnetic tape

540409

MLFK L=25

25 2 Cylinder head screw

341069

In-6kt M3x16

26 2 Counter sunk screw

342801

In-6kt M3x6

Appendix Radial riveting machine RNE 181 HPP

86

803835.006/ENG

11.2.12 Riveting stroke limit switch unit NHE-E 181-231, 825290.07-a

Pos.

No.

Part name

Part no.

Remarks

1 1 NHE basic unit

826098

181-381

2 1 Basic plate small

826109

reworked

3 1 Slide

825262

4 1 Turning lever

825265

5 1 Cover below

825289

6 1

Cover above

825299

7 1 Fitting bolt

341398

d6x20/ M5

8 1 Fitting bolt

341412

reworked

9 1 My-Com-Switch

522676

RC-30 or HPP-25 control

10 1 Cable

520644

11 1 Torsion spring

316637

12 1 Screw

341025

In-6kt M6x20

13 1 Washer large

348805

M6

14 1 Screw

341002

In-6kt M3x5

15 3 Screw

346078

In-6kt M4x6

16 2 Screw

346091

In-6kt M5x10

17 6 Screw

341018

In-6kt M5x16

18 2 Cylinder pin

355090

4-h6x16

55 1 Rotary knob

310730

56 1 Adjustment spindle

825294

57 1 Heavy duty dowel pin

356060

Ø3x8

58 1 Pressure spring

316632

0.8x8.0x32

67 1 Switching amplifier with housing

826120

LC-, RX- or external control

68 1 My-Com-Switch

522678

LC-, RX- or external control

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

87

11.2.13 Riveting stroke limit switch unit NHE-Combi 181-231, 825290.09-a

Pos.

No.

Part name

Part no.

Remarks

1 1 NHE basic unit

826098

181-381

2 1 Basic plate small

825292

3 1 Slide

825262

4 1 Turning lever

825265

7 1

Fitting bolt

341398

d6x20/ M5

8 1 Fitting bolt

341412

reworked

9 1 My-Com-Switch

522676

M75/S35

10 1 Cable

520644

11 1 Torsion spring

316637

12 1 Cylinder head screw

341025

In-6kt M6x20

13 1 Washer large

348805

M6

14 1 Cylinder head screw

341002

In-6kt M3x5

15 5 Pan head screw

346078

In-6kt M4x6

17 8 Cylinder head screw

341018

In-6kt M5x16

18 2 Cylinder pin

355090

4-h6x16

22 1 Magnetic field sensor

540421

MIL 10

23 1 Plate

825288

24 1 Magnetic tape

540409

MLFK L=25

25 2 Cylinder head screw

341069

In-6kt M3x16

26 2 Counter sunk screw

342801

In-6kt M3x6

27 1 Distance plate

825286

28 1 Cover below

826101

29 1 Cover above

825273

30 1 Distance plate

825287

31 2 Cylinder head screw

341071

In-6kt M5x25

47 2 Cable clamp

525305

d=4.5

48 2 Pan head screw

346080

In-6kt M3x6

Appendix Radial riveting machine RNE 181 HPP

88

803835.006/ENG

11.2.14 Riveting stroke limit switch unit (NHE) basic unit 181 – 431, 826098

Pos.

No.

Part name

Part no.

Remarks

1 1 Guiding plate

825295

2 1

Support

825296

3 1

Slider

825293

4 1

Guiding slide

338053

MGN12H

5 1 Profile rail

338063

MGNR12 L=64

6 1 Fitting bolt

341399

d6x25/M5

7 1 Standard pressure spring

316622

1.25x10x64

8 1 Threaded pin

346980

In-6kt with flat point M14x14

9 1 Cylinder pin

355435

m6 d8x18

10 2 Cylinder pin

355087

h6 d4x10

11 4 Screw

341502

In-6kt M3x20

12 3 Screw

341006

In-6kt M3x12

13 2 Screw

341018

In-6kt M5x16

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

89

11.2.15 Proportional pressure regulator 181/231/281 868191

Pos.

No.

Part name

Part no.

Remarks

1 1 Proportional pressure regulator

529518

2 1

Feed cable with connector

529519

3 2

Swivelling screw fit

367861

G 1/8“ Ø10

4 1 Silencer

379923

1/8“ 5 1

Straight screw connection

367740

G1/4“, d10

6 1 Straight screw connection

367752

G3/8“, d10

7 2 Cylinder head screw

341629

In-6kt with shank M4x70

8 2 Plastic hose

040023

black Ø10/8

Appendix Radial riveting machine RNE 181 HPP

90

803835.006/ENG

Manufacturer

Baltec Maschinenbau AG Obermattstrasse 65 CH-8330 Pfäffikon ZH Schweiz

Tel.: 0041 (0)44 953 13 33 Fax: 0041 (0)44 953 13 44 baltec@baltec.com www.baltec.com

Representative list

Ägypten

Frankreich

Schweden

UTP Group Ltd. 5, lbn El Nabih Street Zamalek, Cairo Egypt

Tel.: 0020 2 736 05 34 Fax: 0020 2 736 33 53 Info@utp.com.eg

BalTec France 11, rue Gustave Madiot ZA les Bordes FR-91070 Bondoufle France

Tel.: 0033 1 69 47 12 00 Mobile: 0033 688 84 8862 Fax: 0033 1 69 47 13 49 sebastien.croteau@baltec.com www.baltec.fr

Colly Company AB Rasebotgsgatan 9 SE-16406 Kista Schweden

Tel.: 0046 8 703 02 57 Fax: 0046 8 703 98 41 Mobile: 0046 70 520 25 05 anders.begner@colly.se

Australien

Grossbritannien, Irland

Schweiz

Bliss & Reels Co. Pty. Ltd. 9 Kim Close P.O. Box 215 Bulleen, Victoria 3105 Australia

Tel.: 0061 39 850 6666 Fax: 0061 39 852 1345 www.blissandreels.com.au

BalTec (UK) Ltd., BalTec House 1 Heron Industrial Estate Basingstoke Road, Spencers Wood, UK-Reading, Berkshire RG7 1PJ, Great Britain

Tel.: 0044 1189 311 191 Fax: 0044 1189 311 103 sales@baltec.co.uk accounts@baltec.co.uk www.baltecuk.com

Baltec Maschinenbau AG Obermattstrasse 65 CH-8330 Pfäffikon ZH Schweiz

Tel.: 0041 (0)44 953 13 33 Fax: 0041 (0)44 953 13 44 baltec@baltec.com www.baltec.com

Baltik

Indien

Singapur

CLE Baltic Sära street 10 Peetri village Rae county 75312 Estonia

Tel.: 00372 780 35 37 Fax: 00372 780 35 39 ch.barck@clebaltic.com

Francis Klein & Co. Private Ltd. 70/1, Mission Road IN-Bangalore - 560 027 India

Tel.: 0091 80 2227 2781 0091 80 2227 2782 Fax: 0091 80 2227 6324 sales@francisklein.in

NLC Singapore Pte. Ltd 50 Bukit Batok St 23 # 04 – 11 Midview Buildings Singapore 659 578

Tel.: 0065 6268 5911 Fax: 0065 6268 2170 Mobile: 0065 9830 3017 francisgor@nakaps.com.sg

BeNeLux

Italien

Slowakei

Heesen-ICA B.V. Afrikalaan 14 A NL-5232 BD's-Hertogenbosch Nederland

Tel.: 0031 73 641 7365 Fax: 0031 73 642 5735 info@heesen-ica.nl www.heesen-ica.nl

Camar S.p.A. Via Genova, 58/A IT-10090 Cascine Vica – Rivoli (TO) Italia

Tel.: 0039 011 959 1626 0039 011 959 2970 Fax: 0039 011 959 4101 info@camarspa.it www.camarspa.it

OK Strojservis, s.r.o. Bancìkovej 1/A SK – 821 03 SVK-Bratislava Slevensko

info@ok-stroservis.sk Tel.: 0042 0563 034 505 Fax: 0042 0257 181 056

Brasilien

Japan

Slowenien, Kroatien

BalTec do Brasil Av. Marginal Direita da Anhanguera, 480 Jundiaí 13214-658 SP Brasil

Tel.: 0055 11 99657 8485 0055 11 4492 5408 Fax: 0055 11 4584 7497 rebitadeiras@baltecbrasil.com. br

Naka Seiki Co. Ltd 2-17, 1-Chome, Kinda-cho Moriguchi, JP-Osaka 570-0011 Japan

Tel.: 0081 6 6901 1875 Fax: 0081 6 6905 8241 naka-yamane@nakaseiki.co.jp www.nakaseiki.co.jp

INTERMER d.o.o. Peruzzijeva ulica 127g Sl-1000 Ljubljana Slovenija

Tel.: 00386 1 280 86 83 Mobile: 00386 41 676 583 Mobile: 00386 41 793 073 Fax: 00386 1 280 86 89 intermerkur.handels@siol.net

Bulgarien

Kolumbien

Spanien, Portugal

ALFLETH ENGINEERING AG Hardstrasse 4 CH-5600 Lenzburg Switzerland

Tel.: 0041 (062) 888 70 00 Fax: 0041 (062) 888 70 10 mail@alfleth.com www.alfleth.com

Imocom S.A. Calle 17 No. 50-24 111611 Bogotá Colombia

Tel.: 0057 1 413 7755 Fax: 0057 1 413 7755 imocom@imocom.com.co www.imocom.com.co

BalTec Espanã Avda Guadalix 26 bis ES-28702 Ciudalcampo S. Sebastian de los Reyes (Madrid) Espanã

Socio de servicio técnico:

Tojaltec-Fabrico de Máquinas Zona Industrial de Vilar de Besteiros Lote 2 PT-3465-190 Tondela Portugal

Tel.: 0034 630 442 457 carmen.perez@baltec.com

Tel.: 00351 232 848 042 Fax: 00351 232 848 050 geral@tojaltec.com

China

Korea

BalTec Machinery Shanghai Ltd Room 509, Yingjia Plaza Tower B No. 3008 Gu Dai Road 201100 Shanghai P.R. China

Tel.: 0086 21 6430 0732 Fax: 0086 21 6430 1653 laura.wu@baltec.com sam.shen@baltec.com www.baltec.cn

Dongso P.A. International 3F Dongso-Bldg. #181 Baekjegoboon-Ro, Songpa-Gu, Seoul, Korea Jamsil-Dong, 138-864

Tel.: 0082 2 338 0770 Fax: 0082 2 338 8496 Mobile: 0082 10 5663 0770 dongso@dongso.co.kr kwak@dongso.co.kr

Dänemark

Norwegen

Südafrika

Sneholt & Nilsen A/S Adalen 9 DK-4600 Koge Denmark

Tel.: 0045 4615 4600 Fax: 0045 4615 4225 sk@sneholt-nilsen.dk www.sneholt-nilsen.dk

Colly Components AS Rasebotgsgatan 9 SE-16406 Kista Schweden

Tel.: 0046 8 703 02 57 Fax: 0046 8 703 98 41 Mobile: 0046 70 520 25 05 anders.begner@colly.se

Rothco (Pty.) Ltd. P.O. Box 1756 6 Derrick Road, Spartan Kempton Park Johannesburg South Africa

Tel.: 0027 11 970 1930 /1/2/3 Fax: 0027 11 394 1132 Mobile: 0027 83 267 0857 info@rothco.co.za rob@rothco.co.za

Deutschland PLZ: 6, 7, 8 (ausser 83), 90-94

Oesterreich, Deutschland PLZ: 83

Thailand

BalTec Maschinenbau AG Home-Office Am Bahndamm 18/1 DE-73342 Bad Ditzenbach Deutschland

Tel: 0049 7335 923 412 Fax: 0049 7335 923 3069 Mobile: 0049 175 1816 132 fabian.haederle@baltec.com

HAMOTEK Montagetechnik GmbH Untersbergstrasse 1b AT-5082 Grödig Oesterreich

Tel.: 0043 6246 72788 Mobile: 0043 664 3420959 Fax: 0043 6246 72980 office@hamotek.at www.hamotek.at

Krasstec Company Ltd. 1205 Rama9 Soi55 Rama 9 Rd Suan Luang, Suan Luang THA-Bangkok 10250 Thailand

Tel.: 0066 (0) 2 732 1144 Fax: 0066 (0) 2 732 2350 Mobile: 0066 (0) 81 835 4449 kitti@krasstec.com

Deutschland PLZ: 0, 1, 39, 95-99

Polen

Tschechien

KLEINIG engineering Dechwitzer Str. 16 Gewerbepark Störmthal DE-04463 Großpösna b.Leipzig Deutschland

Tel.: 0049 34297 14 36 0 Mobile: 0049 171 673 10 70 Fax: 0049 34297 14 36 27 o.kleinig@kleinigengineering.de

OK-Strojservis Polska Sp. z o.o ul. Technologiczna 2A PL-45-839 Opole Polska

Tel.: 0048 690 368 321 info@ok-strojservis.pl www.ok-strojservis.pl

OK Strojservis, s.r.o. Na Kasárnách 152 CZ-396 01 Humpolec Czechia

Tel.: 0042 0563 034 502 Mobile: 0042 0604 311 822 Fax. 0042 0257 181 056 antonin@ok-strojservis.cz www.ok-strojservis.cz

Deutschland PLZ: 2, 3 (ausser 39), 4, 5

Rumänien

Türkei

Technisches Büro Diehl GmbH Industriestrasse 80a DE-40764 Langenfeld Deutschland

Tel.: 0049 2173 963 07 06 Fax: 0049 2173 963 07 08 info@tb-diehl.de christian.schmidt@tb-diehl.de www.tb-diehl.de

ALFLETH ENGINEERING AG N. Titulescu Str. 2 RO-500010 Brasov România

doinalica2004@gmail.com rumaenien@alfleth.com Tel.: 0040 268 510 012 Fax: 0040 268 510 011

Çağ-Kar Dış Ticaret Mümessillik Yunus Emre Mah.Veysel Karani Cad. No.143/C Yenidocan, Sancaktepe TR-34791 Istanbul Türkiye

Tel.: 0090 216 430 89 29 Mobile: 0090 542 671 36 19 Fax: 0090 216 430 90 09 c-ayhan@superonline.com cag_kar@yahoo.com www.turkticaret.net/cag-kar

Finnland

Russland

Ungarn

OY C.Lindholm Engineering Ab. Trollbergintie 10 FI-10650 Tammisaari Finnland

Tel.: 00358 207 519 600 Fax: 00358 207 519 619 svante.eklund@cle.fi www.clegroup.eu

ALFLETH ENGINEERING AG Timirayzevskaya 1 RU-127422 Moskau Russia

Tel.: 007 495 661 90 57 Fax: 007 495 661 90 58 rf@alfleth.ru

ALFLETH ENGINEERING AG Alfleth Rt. Magyarorszag Kft. Moricz Zsigmond körter 14.IV/1 HU-1117 Budapest Magyarország

Tel.: 0036 1 209 52 47 Fax: 0036 1 209 52 43 tamas.ernei@alfleth.com ungarn@alfleth.com

USA, Kanada; Mexico

BalTec Corporation 121 Hillpointe Drive Suite 900 Canonsburg, PA 1531, USA

Tel.: 001 724 873 5757 Mobile: 011 412 400 6851 Fax: 001 724 873 5858 chuck.rupprecht@baltec.com www.baltecorporation.com

Radial riveting machine RNE 181 HPP Appendix

803835.006/ENG

91

Index Radial riveting machine RNE 181 HPP

92

803835.006/ENG

12 Index

A

Air maintenance unit ................................................... 54

Application limitations ................................................... 9

Automatic lubrication riveting spindle head ........... 36, 53

B

Basic settings ............................................................. 19

C

CE conformity declaration ........................................... 12

D

Declaration of incorporation ........................................ 12

Declarations ................................................................ 12

Decommissioning ....................................................... 61

Dimensions drawing RNE 181 reduced force with path-

measuring system HPP .......................................... 14

Dimensions drawing RNE 181 reduced force with path-

measuring system HPP for flange mounting .......... 15

Dimensions drawing RNE 181-231 HPP with NHE .... 46

Disposal ...................................................................... 62

E

Electrical power supply ................................................. 9

Emissions ................................................................... 11

Environmental conditions .............................................. 9

F

Foot switch ................................................................. 37

Form tool D = 10 with various lengths ........................ 26

Form tool designs and closing head shapes ............... 24

G

General safety rules .................................................... 12

H

Heating of riveting machine ........................................ 18

I

Information and symbols ............................................... 8

Initiator lower end position (bridging initiator) ............. 39

Initiator upper end position ......................................... 39

Intended use ............................................................... 10

M

Magnetic field sensor adjustment ............................... 43

Maintenance and repair log ........................................ 59

Maintenance work....................................................... 49

Mechanical power supply ............................................. 9

Mist oiler adjustment ................................................... 55

Modifications ............................................................... 12

My-Com Switch substitution ....................................... 42

N

Noise ........................................................................... 11

Notes and symbols on the product ................................ 9

O

Oils recommended ...................................................... 55

Operator ........................................................................ 7

Original language of assembly instructions ................... 6

P

Personal safety equipment ......................................... 18

Personnel ...................................................................... 7

Personnel qualification .................................................. 7

Piston and piston rod seals ......................................... 57

Polygon shaft .............................................................. 56

Possible machine settings .......................................... 23

Power supply .............................................................. 11

Pressure pad............................................................... 32

Pressure pad dimensions drawing .............................. 33

Pressure/force diagram ............................................... 21

Product life phases ....................................................... 7

Production of thrust piece and spring diagram 802297

............................................................................... 34

Proportional pressure regulator................................... 47

Q

Questions or unclear points .......................................... 6

R

Recommended form tool materials ............................. 25

Re-commissioning ...................................................... 61

Replaced parts ............................................................ 62

Replacing the form tool holder and pressure cup........ 27

Rivet parameters ........................................................... 9

Riveting force adjustment ........................................... 21

Riveting motor terminal box ........................................ 58

Riveting spindle........................................................... 51

Riveting spindle advance speed adjustment ............... 20

Riveting spindle head (form tool holder and pressure

cup) ........................................................................ 50

Riveting spindle return speed adjustment ................... 20

Riveting stroke adjustment .......................................... 19

Riveting stroke limit switch unit NHE 181-231............. 40

Riveting to stroke limiting stop .................................... 23

Riveting under high pressure ................................ ...... 23

Riveting under low pressure ....................................... 23

Riveting without stroke limiting stop ............................ 23

RNE 181 reduced force HPP details ........................... 13

S

Schemata .................................................................... 63

Setting up the riveting machine for a new workpiece .. 22

Radial riveting machine RNE 181 HPP Index

803835.006/ENG

93

Significance of the safety regulations ........................... 7

Spare parts lists .......................................................... 66

Spring prestress adjustment riveting stroke limit switch

unit NHE ................................................................. 45

Standard form tool Ø10 with conical profile (081-241) 30 Standard form tool Ø10 with crowned profile (081-241)

............................................................................... 31

Standard form tool Ø10 with flat profile (081-241) ...... 29

Storage ....................................................................... 61

T

Technical specifications riveting machine 181 reduced

force max. 1.5 kN ................................................... 16

Topping up the grease container ................................ 53

Touch probe switching point NHE-E adjustment ......... 44

Two-hand operating unit ............................................. 57

U

User .............................................................................. 7

V

Vibrations .................................................................... 11

W

Warning and safety notices ........................................... 8

Workplace ................................................................... 18

Index Radial riveting machine RNE 181 HPP

94

803835.006/ENG

Baltech RNE 181 HPP Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual