Pop ProSet 2500 Series Maintenance Manual

Rivet
Tool

ProSet® 2500 Series

Maintenance Manual

Contents

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

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

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

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

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

®

2500 Tool Dimensions.............................................................................................................5 ProSet

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

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

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

®

2500 MCS .....................................................................8 Mandrel Collection System (MCS) – ProSet

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

T ool Assembly Torque Requirements....................................................................................................9

®

2500/2500MCS Diagram ..........................................................................................................10 ProSet

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

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

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

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

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

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

Introduction

®

POP

®

ProSet 2500 tools are light weight Air/Hydraulic rivet setting tools recommended for use with genuine

POP

Brand Rivets per following chart:

Rivet Diameter

Material

(Body – Mandrel)

Rivet Type

1/8”

(*)

[3.2 mm]

5/32”(*)

[4.0 mm]

3/16”(**)

[4.8 mm]

Al – Al 9 9 9
Al – St / SS 9 9 9
St – St 9 9 9

Open End & MultiGrip

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 9

Closed End

SS – SS 9 9 9

LSR Rivets Al – Al 9 9 9
HR™ Rivets St – St 9 9(**) 9
T - Rivet Al – St 9 9 9
Self Plugger St – St 9 9 9
UltraGrip Al-Al , St- St, SS-SS - - 9

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

(*) Use FAN275-028 Jaw pusher set up. (**) Use DPN275-027 Jaw pusher set up.
(†) Exclude MultiGrip™

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™ 2500 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 ProSet

Packaged Accessories

Qty Item PROSET 2500 PROSET 2500MCS Part No.

1

ProSet

®

2500 Rivet Tool

9

9

-

1 Operating Instructions

9 9

P449

1 Maintenance Manual

9 9

P534

1 Nosepiece for 4 size open end rivets

9 9

PRN414

1 Nosepiece for 5 size open end rivets

9 9

PRN514

1 Nosepiece for 6 size open end rivets Installed Installed PRN614
1 Jaw Pusher (Assy.) for 1/8,5/32” rivets

9 9

FAN275-028

1 Air Line Assembly

9 9

FAN239-157

1 4 mm Hex. Socket Screw Key

9 9

DPN239-139

1 Warranty Card

9 9

FG2184

Tool Requirements

Air supply * 6 scfm (150 l/min) Minimum
Recommended Operating Pressure 72.5-90 PSI (5.0-6.2 Bar) dry, filtered
Maximum Operating Pressure 100 PSI (6.9 Bar) dry, filtered
Hydraulic Oil **

POP

®

p/n: PRG540-130 [1 qt. (.945 ml)]

Jaw Lubricant **

POP

®

p/n: PRG510-130 [6 oz. (177 ml)]

Seal Lubricant **

POP

®

p/n: PSA075508P [1 ¾ oz. (54 g)]

2500 2500MCS

2.65 lbs. (1.20 kg) 2.89 lbs. (1.31 kg)

Weight
Length 1 1.42” (290 mm) 1 1.97” (304 mm)
Height 10.20” (259 mm) 10.20” (259 mm)

0.71” (

18 mm) 0.71” (18 mm)

Tool stroke
Pulling force 21 10 lbs @ 90 PSI (9400 N @ 6.2 bar) 21 10 lbs @ 90 PSI (9400 N @ 6.2 bar)
Air consumption

0.076 cu. ft. per rivet
(2.15 liters per rivet)

2.47 scfm (MAX)
(70 ℓ/min (MAX))

(*) 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® 2500 Tool Dimensions

.81 1” (20.6 mm)

1 1.97” (304 mm)

10.20” (259 mm)

3.46” (88 mm)

1.85” (47 mm)

3.54” (90 mm)

2.15” (54.5 mm)

3.1 1” (79 mm)

ProSet® 2500 MCS

ProSet

®

2500

3.1 1” (79 mm)

1 1.42” (290 mm)

3.54” (90 mm)

.81 1” (20.6 mm)

10.20” (259 mm)

3.46” (88 mm)

2.15” (54.5 mm)

1.85” (47 mm)

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

Common Nosepieces

Closed End HR Rivets

Rivet Diameter Open End

Jaw Pusher

Steel

Mandrel

Aluminum

Mandrel

Aluminum

Body

Steel
Body

1/8” (3.2 mm) or
7/64” (2.8 mm)

PRN414* PRN424 PRN434 PRN414* PRN4K

FAN275-028*

PRN514* PRN524 PRN534 PRN514* -

5/32” (4.0 mm)

- -

- - PRN5K

DPN275-027*

3/16” (4.8 mm)

PRN614* PRN624 PRN634 PRN614* PRN6K

* Included with the tool
Use FAN275-028 instead of DPN275-027 (installed) when using 7/64” (2.8mm) - 5/32” (4.0mm).

Use N-406 nosepiece when using 3/16” (4.8mm) UltraGrip

® ®

rivets; use N-410 for Monobolt rivets.

Basic Tool Operation

Before operating the tool check the following:

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

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

! Note: The ProSet™ 2500 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 Supply ON

: Open OS Valve
by sliding OS Slider in the
direction shown (up).

A

ir Supply OFF: Close OS Valve

by sliding OS Slider in the
direction shown (down).

OS Slider

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