Pop ProSet, 1600MCS Maintenance Manual

ProSet® 1600 Series

Maintenance Manual

Rivet
Tool

Contents

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

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

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

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

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

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

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

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

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

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

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

T ool Assembly T orqu e Requirements....................................................................................................9

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

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

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

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

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

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

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

Introduction

®

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

POP

®

Brand Rivets per following chart:

POP

Rivet Type

Material

(Body – Mandrel)

Al – Al 9 9 9

Open End & MultiGrip

Closed End

LSR Rivets Al – Al 9 9 9
HR™ Rivets St – St 9 9
T - Rivet Al – St 9 9 9
Self Plugger St – St 9 9

Al: Aluminum, St: Steel, SS: Stainless Steel, Cu: Cooper, Mo: Monel

(*) Use FAN239-176 Jaw pusher set up.
(†) Exclude MultiGrip
() Set air pressure at 90 psi (6.2 bar).

Al – St / SS 9 9 9
St – St 9 9 9
SS – SS; Mo – St /SS 9 9
Al – Al 9 9 9
Al – St / SS; Cu – St 9 9 9
St – St 9 9
SS – SS 9 9

(*)

3/32”

[2.4 mm]

Rivet Diame ter

1/8”

[3.0 - 3.2 mm]

5/32”

[4.0 mm]

(†)

()

Page 2 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]

Safety Instructions

TO INSURE PROPER FUNCTIONING AND SAFE OPERATION READ THIS MANUAL

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

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

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

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

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

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

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

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

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

9. DO NOT point the tool at anyone.

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

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

12. DO NOT modify the tool in any way. Modification will make void any applicable warranties
and could result in damage to the tool or physical injury to the user.

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

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

15. DO NOT direct tool exhaust towards anyone.

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

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

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 3

Specifications

ProSet® 1600 ProSet® 1600MCS
Weight

Length
Height
Stroke

Air Consumption
Pulling Force

Noise Level
Vibration Level

Qty Item PROSET1600 PROSET1600MCS Part No.

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

10.83” (275 mm) 10.71” (272 mm)

8.94” (227 mm) 8.94” (227 mm)

0.71” (18 mm) 0.71” 18 mm)

0.043 cu. ft. per rivet
(1.22

l per rivet)

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

= 80.2 dB(A), LWA = 85.0 dB(A), L

L

Aeq,T

0.54 m/s

2

, Time to 2.5 m/s2 > 24hrs (EAV)

2.47 scfm (m ax.)
(70 l /min (max.))

= 110.4 dB(C)

Peak

Packaged Accessories

1 ProSet® 1600 Rivet Tool
1 Operating Instructions
1 Maintenance Manual
1 Nosepiece for 3 size open end rivets
1 Nosepiece for 4 size open end rivets Installed Installed PRN414
1 Nosepiece for 5 size open end rivets
1 Jaw Pusher (Assy.) for 3/32” rivets
1 Air Line Assembly
1 4 mm Hex. Socket Screw Key
1 Warranty Card

9

9 9
9 9
9 9

9 9
9 9
9 9
9 9
9 9

9

­P449
P513
PRN314

PRN514
FAN239-176
FAN239-157
DPN239-139
FG2184

Tool Requirements

Air supply *
Recommended Operating Pressure 72.5-90 psi (0.5-0.62 MPa) dry, filtered
Maximum Operating Pressure 100 psi (0.69 MPa) dry, filtered
Hydraulic Oil **
Jaw Lubricant **
Seal Lubric ant **

POP
POP

POP

®

®

®

6 scfm (150

p/n: PRG540-130 [1 qt. (.945 ml)]
p/n: PRG510-130 [6 oz. (177 ml)]
p/n: PSA075508P [1 ¾ oz. (54 g)]

l /min) Minimum

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

(**) Note: See lubricant safety information.

Page 4 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]

ProSet® 1600 Tool Dimensions

10.83” (275 mm)

3.3” (82 mm)

.682” (17.3 mm)

1.82” (46.3 mm)

1.83” (46.5 mm)

8.94” (227 mm)

2.99” (76 mm)

.682” (17.3 mm)

ProSet® 1600

3.27” (83 mm)

10.71” (272 mm)

3.23” (82 mm)

1.82” (46.3 mm)

1.83” (46.5 mm)

8.94” (227 mm)

2.99” (76 mm)

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 5

ProSet® 1600 MCS

3.27” (83 mm)

Common Nosepieces

A

Closed End HR Rivets

Rivet Diameter Open End

Steel Mandrel

Aluminum

Mandrel

Aluminum

Body

Steel
Body

2.0 mm PRN214 - - - ­3/32” (2.4 mm) PRN314* - - - - FAN239-176*

Jaw Pusher

FAN239-176*

(PRG402-02 - JAWS)

1/8” (3.2 mm) or
7/64” (2.8 mm)

PRN414* PRN424 PRN434 PRN414* PRN4K

DPN239-144*

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

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

rivets.

Basic Tool Operation

Before operating the tool check the following:

 Ins pect t ool for damage or leaking oil – do not use tool if it is damaged or leaking oil.
 Chec k that correct nosepiece is fitted and tightened to 60 - 65 in-lbs [6.8 – 7.3 N-m] torque.
 Chec k that the nose housing nut (8) is tight – hand tighten only.
 Connec t tool to air supply – see air supply requirements (page 4).
 Fit Mandrel Collector (96) – (MCS tool only).
 Open air s upply valve by Sliding red OS Sleeve (93) on side of tool (see note below).
 Insert rivet into nosepiece.
 Position rivet in work piece.

 Pull trigger to set rivet.
 Release trigger – if equipped, MCS suction will draw mandrel into the collector.

! Note: The ProSet

®

1600 has an OS (Open-Shut) Valve for switching the air supply ON and OFF to

save air when the tool is not in use.

Air Supp ly ON: Open OS Valve

by sliding OS Sleeve in the
direction shown (up).

OS Sleeve

Page 6 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]

ir Supply OFF: Close OS Valve
by sliding OS Sleeve in the
direction shown (down).