Pop ProSet PB2500 Service Manual

Service Manual

K O N

M

1

2

©2016 STANLEY Black & Decker
All rights reserved.
The information provided may not be reproduced and/or made public in any way and through any means (electronically or
mechanically) without prior explicit and written permission from STANLEY Engineered Fastening. The information provided is based
on the data known at the moment of the introduction of this product. STANLEY Engineered Fastening pursues a policy of continuous
product improvement and therefore the products may be subject to change. The information provided is applicable to the product
as delivered by STANLEY Engineered Fastening. Therefore, STANLEY Engineered Fastening cannot be held liable for any damage
resulting from deviations from the original specifications of the product.

The information available has been composed with the utmost care. However, STANLEY Engineered Fastening will not accept any
liability with respect to any faults in the information nor for the consequences thereof. STANLEY Engineered Fastening will not
accept any liability for damage resulting from activities carried out by third parties. The working names, trade names, registered
trademarks, etc. used by STANLEY Engineered Fastening should not be considered as being free, pursuant to the legislation with
respect to the protection of trade marks.

CONTENT

1. Safety Definitions 4

1.1. GENERAL SAFETY 4

1.2. POWER TOOL USE AND CARE 4

1.3. IMPORTANT SAFETY INSTRUCTIONS FOR ALL BATTERY CHARGERS 5

1.4. IMPORTANT SAFETY INSTRUCTIONS FOR ALL BATTERY PACKS 6

1.5. SPECIFIC SAFETY INSTRUCTIONS FOR LITHIUM-ION (LI-ION) 7

1.6. RESIDUAL RISKS 7

1.7. LABELS AND ICONS 7

2. SPECIFICATIONS 8

2.1. TECHNICAL DATA 8

2.2. PLACING SPECIFICATIONS 10

2.3. PACKAGE CONTENTS 10

2.4. MAIN COMPONENTS LIST 11

2.5. OPTIONAL ACCESSORIES 11

3. Tool Use & Set up 12

4. Operating Instructions 12

4.1. NOSE EQUIPMENT 12

4.2. CHARGERS 13

4.3. BATTERY PACKS 14

5. Operating Procedure 14

5.1. Proper Hand Position 15

5.2. Tool Operation 15

6. Servicing the tool 16

6.1. Maintenance frequency 16

6.2. Cleaning 16

6.3. Spare Parts – Tools 17

6.4. Rechargeable Battery Pack 17

6.5. Protecting the Environment 17

7. Jaws, Jaw Guide, Jaw Pusher and Jaw Pusher Spring 18

8. SA Nose Housing and SA Nose Piece 22

9. Operation Test and Appearance check 24

10. Accessories 25

11. Exploded View 27

12. BOM 28

13. Troubleshooting Guide 34

3

1. Safety Definitions

The definitions below describe the level of severity for each signal word. Please read the manual and pay
attention to these symbols.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property
damage.

Denotes risk of electric shock

Denotes risk of fire

Improper operation or maintenance of this product could result in serious injury and property damage.
Read and understand all warnings and operating instructions before using this equipment. When using
power tools, basic safety precautions must always be followed to reduce the risk of personal injury.

1.1. GENERAL SAFETY

WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions

may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated
(cordless) power tool.

• Do not use outside the design intent of Placing STANLEY Engineered Fastening Blind Fasteners.

• Use only parts, fasteners, and accessories recommended by the manufacturer.

• Use Power Tool only with specifically designated battery packs.

1.2. POWER TOOL USE AND CARE

• The tool must be maintained in a safe working condition at all times and examined at regular intervals for damage and

function by trained personnel. Any dismantling procedure will be undertaken only by trained personnel. Do not dismantle
this tool without prior reference to the maintenance instructions.

4

• Do not modify the tool in any way. Any modification to the tool is undertaken by the customer and will be the customer’s

entire responsibility and void any applicable warranties.

• Disconnect the battery from the tool before performing any maintenance, attempting to adjust, fit or remove a nose

assembly.

• Prior to use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that affects the

tool’s operation. If damaged, have the tool serviced before using. Remove any adjusting key or wrench before use.

• Prior to use, inspect battery for damage. Do not drop battery. A sharp impact may cause internal damage and lead to

premature battery failure.

• Keep work area clean and well lit.

• Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose

clothes, jewelry or long hair can be caught in moving parts.

• Adopt a firm footing or a stable position before operating the tool.

• Operators and others in work area must wear ANSI Z87.1 CAN/CSA Z94.3 approved safety glasses with side shields. Always

wear safety glasses and ear protection during operation.

• Adequate clearance is required for the tool operator’s hands before proceeding.

• Do not operate a tool that is directed towards any person(s).

• DO NOT operate tool with the nose housing removed.

• Do not operate the tool or the charger in an explosive atmosphere or environment allowing exposure to combustible fluids

or gasses.

• Do not operate the tool or the charger in an environment allowing exposure to moisture or rain to avoid risk of electric

shock.

• Do not abuse the tool by dropping or using it as a hammer.

• Keep dirt and foreign matter out of the air vents of the tool as this will cause the tool to malfunction.

• Keep tool handles dry, clean, and free from oil and grease.

• When carrying the tool from place to place keep hands away from the trigger to avoid inadvertent activation.

• Never leave operating tool unattended.

• Disconnect battery when tool is not in use.

1.3. IMPORTANT SAFETY INSTRUCTIONS FOR ALL BATTERY CHARGERS

SAVE THESE INSTRUCTIONS: This manual contains important safety and operating instructions for compatible battery chargers

(refer to Technical Data).

• Before using charger, read all instructions and cautionary markings on charger, battery pack, and product using battery

pack.

WARNING: Shock hazard. Do not allow any liquid to get inside charger. Electric shock may result.

WARNING: We recommend the use of a residual current device with a residual current rating of 30mA or less.

CAUTION: Burn hazard. To reduce the risk of injury, charge only DEWALT®/POP®Avdel® rechargeable batteries. Other

types of batteries may burst causing personal injury and damage.

CAUTION: Children should be supervised to ensure that they do not play with the appliance.

5

NOTICE: Under certain conditions, with the charger plugged into the power supply, the exposed charging contacts inside the
charger can be shorted by foreign material. Foreign materials of a conductive nature such as, but not limited to, steel wool,
aluminium foil or any build-up of metallic particles should be kept away from charger cavities. Always unplug the charger from
the power supply when there is no battery pack in the cavity. Unplug charger before attempting to clean

• DO NOT attempt to charge the battery pack with any chargers other than the ones in this manual. The charger and battery

pack are specifically designed to work together.

• These chargers are not intended for any uses other than charging DEWALT®/POP®Avdel® rechargeable batteries. Any other

uses may result in risk of fire, electric shock or electrocution.

• Do not expose charger to rain or snow.

• Pull by plug rather than cord when disconnecting charger. This will reduce risk of damage to electric plug and cord.

• Make sure that cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.

• Do not use an extension cord unless it is absolutely necessary. Use of improper extension cord could result in risk of fire,

electric shock, or electrocution.

• Do not place any object on top of charger or place the charger on a soft surface that might block the ventilation slots and

result in excessive internal heat. Place the charger in a position away from any heat source. The charger is ventilated
through slots in the top and the bottom of the housing.

• Do not operate charger with damaged cord or plug—have them replaced immediately.

• Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way. Take it to an

authorised service centre.

• Do not disassemble charger; take it to an authorised service centre when service or repair is required. Incorrect reassembly

may result in a risk of electric shock, electrocution or fire.

• Disconnect the charger from the outlet before attempting any cleaning. This will reduce the risk of electric shock. Removing

the battery pack will not reduce this risk.

• NEVER attempt to connect two chargers together.

• The charger is designed to operate on standard household electrical power (refer to charger specifications). Do not attempt

to use it on any other voltage. This does not apply to the vehicular charger.

1.4. IMPORTANT SAFETY INSTRUCTIONS FOR ALL BATTERY PACKS

When ordering replacement battery packs, be sure to include catalog number and voltage.

The battery pack is not fully charged out of the carton. Before using the battery pack and charger, read the safety instructions
below. Then follow charging procedures outlined.

READ ALL INSTRUCTIONS

• Do not charge or use battery in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Inserting

or removing the battery from the charger may ignite the dust or fumes.

• Never force battery pack into charger. Do not modify battery pack in any way to fit into a non-compatible charger as battery

pack may rupture causing serious personal injury.

• Charge the battery packs only in DEWALT®/POP®Avdel® chargers.

• DO NOT splash or immerse in water or other liquids.

• Do not store or use the tool and battery pack in locations where the temperature may reach or exceed 40 ˚C (104 ˚F) (such as

outside sheds or metal buildings in summer).

• When battery pack is not in use, keep it away from other metal objects like paper clips, coins, keys, nails, screws or other

small metal objects that can make a connection from one terminal to another.

• Do not discard batteries into water.

6

WARNING: Never attempt to open the battery pack for any reason. If battery pack case is cracked or damaged, do not

Read instruction manual before use.

Charge only between 4 °C and 40 °C.

insert into charger. Do not crush, drop or damage battery pack. Do not use a battery pack or charger that has received a sharp
blow, been dropped, run over or damaged in any way (i.e., pierced with a nail, hit with a hammer, stepped on). Electric shock or
electrocution may result. Damaged battery packs should be returned to service centre for recycling.

WARNING: Fire hazard. Do not store or carry the battery pack so that metal objects can contact exposed battery
terminals. When transporting individual battery packs, make sure that the battery terminals are protected and well insulated
from materials that could contact them and cause a short circuit.

CAUTION: When not in use, place tool on its side on a stable surface where it will not cause a tripping or falling hazard.
Some tools with large battery packs will stand upright on the battery pack but may be easily knocked over.

1.5. SPECIFIC SAFETY INSTRUCTIONS FOR LITHIUM-ION (LI-ION)

1. Do not incinerate the battery pack even if it is severely damaged or is completely worn out. The battery pack can explode

in a fire. Toxic fumes and materials are created when lithium-ion battery packs are burned.

2. If battery contents come into contact with the skin, immediately wash area with mild soap and water. If battery liquid

gets into the eye, rinse water over the open eye for 15 minutes or until irritation ceases. If medical attention is needed, the
battery electrolyte is composed of a mixture of liquid organic carbonates and lithium salts.

3. Contents of opened battery cells may cause respiratory irritation. Provide fresh air. If symptoms persists, seek medical

attention.

WARNING: Burn hazard. Battery liquid may be flammable if exposed to spark or flame.

1.6. RESIDUAL RISKS

In spite of the application of the relevant safety regulations and the implementation of safety devices,
certain residual risks cannot be avoided. These are:

− Impairment of hearing

− Risk of personal injury due flying particles

− Risk of burns due to accessories becoming hot during operation.

− Risk of personal injury due to prolonged use.

1.7. LABELS AND ICONS

Markings on Tool

DATE CODE POSITION: The Date Code, which includes the year, month and location of manufacture, is printed into the

housing surface that forms the mounting joint between tool and battery.

Labels on charger and battery pack

In addition to the pictographs used in this manual, the labels on the charger and the battery pack show the following
pictographs.

7

Read instruction manual before use.

Discard the battery pack with due care for the
Battery charging.

Do not incinerate the battery pack.

Battery charged.

Only for indoor use.

Hot/cold pack delay.

Your DeWALT charger is double insulated in

Do not charge damaged battery packs.

Do not expose to water.

Charge DeWALT/POP-Avdel battery packs only

Have defective cords replaced
Risk of electric shock.

ProSet® PB2500

Voltage V 18 nom/20 max

Type

1/2

Battery Type Li-ion

Weight (without battery pack)

kg

1.35

Lpa (sound pressure)

dB(A)

74

Kpa (sound pressure uncertainty)

dB(A)

3

Lwa (sound power)

dB(A)

85

Kwa (sound power uncertainty)

dB(A)

3

Vibration total values (triax vector sum) determined according to EN 60745:

Vibration emission value ah

ah =

m/s2

< 2.5

Uncertainty K =

m/s2

1.5

environment.

accordance withEN60335; therefore no earth
wire is required.

with designated DeWALT/POP-Avdel chargers.
Charging battery packs other than the

immediately.

is one of continuous product development and improvement

2. SPECIFICATIONS

2.1. TECHNICAL DATA

2.1.1.

designated DeWALT/POP-Avdel batteries with a
DeWALT/POP-Avdel charger may make them
burst or lead to other dangerous situations.

STANLEY Engineered Fastening policy

and we reserve the right to change the specification

of any product without prior notice.

8

2.1.2.

Model

PB2500 2.0 Ah

PB2500 4.0Ah

Weight

kg [lbs]

1.7 [3.75]

2.0 [4.41]

Length

mm [in]

320 [12.6]

320 [12.6]

Height

mm [in]

240 [9,4]

260 [10,2]

Stroke

mm [in]

25 [0.984]

25 [0.984]

Pulling Force

N [lbf]

8,500 [1911]

8,500 [1911]

nom. dia.

Battery Pack*

Battery type

Li-ion

Voltage

VDC

18 nom/20 max

Capacity

Ah

2.0/4.0

Weight

Kg

0.40/0.61

Charging duration

min

30/60

Charger* NA

JP

QW/GB/XE

Battery type

Li-ion

Li-ion

Li-ion

Battery type Mains voltage

VAC

120

100

230

Input frequency

Hz

60

50/60

50

Weight

kg

0.50

0.50

0.50

Fuses

Europe

230 V tools 10 Amperes. mains

U.K. & Ireland

230 V tools 3 Amperes. in plugs

Nom. Rivet Dia.

Mm [in]

Battery 2.0Ah

Battery 4.0Ah

Ø 2,4 [3/32]

1,700

3,400

Ø 3,2 [1/8]

1,600

3,200

Ø 4,0 [5/32]

1,400

2,800

Ø 4,8 [3/16]

1,200

2,400

Rivet Range

2.1.3.

mm [in]

ø 2,4 [3/32”]) thru ø 4,8 [3/16”])

* PB Series tools are compatible with DEWALT/POP-Avdel 18V nom/20V max Li-Ion slide type batteries
** Charging duration is based on the DCB115 DEWALT Charging units

2.1.4.

Note: These values are listed as a guide only and are estimates based on a fully charged battery. Results may
vary depending on rivet material, tool/battery condition and work environment.

9

2.2. PLACING SPECIFICATIONS

2.4mm

[3/32´´]

3.2mm
[1/8´´]

4.0mm

[5/32´´]

4.8mm

[3/16´´]

OPEN END

● ● ● ● ●

CLOSED END

● ● ●

HR (except SSHR)

● ● ●

SSD SSHR

● ●

TL

● ●

Pull-Thru

●

T-Rivet (Emhart)

●

Avex®

● ● ● ●

Stavex®

● ● ●

Avinox®

● ● ●

Avibulb®

● ● ●

LSR / Bulbex®

● ● ●

T-Lok®

● ●

Avdel® SR

●

● ●

Interlock®

●

Monobolt®

●

Aveseal®(STD)

●

●

●

●

Q Rivet

●

●

Klamp-Tite BAPK®

●

Klamp-Tite BAPKTR®

●

VGrip

●

1 Cordless Installation Tool*

1 Charger

1 Lithium Ion battery pack

1 set Nose Equipment Accessories (3.2mm, 4.0mm, 4.8mm)

1 Kit Box

1 Instruction Manual

Rivet Type

3.0mm

4.3mm

5.0mm 6.0mm 7.0mm

Note: For details on the nose equipment please refer to the accessories manual.

2.3. PACKAGE CONTENTS

This package contains:

* If the Model Number purchased is a bare tool then only the Cordless Installation Tool will be supplied with a standard
set of 3.2mm [1/8“], 4.0mm [5/32“] and 4.8mm [3/16“] Open End Nose Equipment installed.

10

2.4. MAIN COMPONENTS LIST

A

Nose pieces

L

Manual

B

Nose housing

M

Charger lamp

C

Nose housing nut

N

Charger

D

Collector lock

O

Battery charger connection

E

Collector shutter

P

Jaw guide

F

Shutter guide sleeve

Q

Jaws

G

Motor housing

R

Jaw pusher

H

Exhaust vent

S

Spring

I

Handle

T

Pulling head

J

Switch

U

Front clutch

K

Battery pack 2.0 Ah

W

Collector space

K2

Battery pack 4.0 Ah

Y

Rivet

2.5. OPTIONAL ACCESSORIES

WARNING: Since accessories, other than those offered by POP-Avdel® have not been tested with this

product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only
POP- Avdel® recommended accessories should be used with this product.
Consult your dealer for further information on the appropriate accessories.

WARNING: To reduce the risk of serious personal injury, disconnect battery pack before making any

adjustments or removing/installing attachments or accessories.

For a complete list of nose equipment and other accessories available for the PB Series, please visit our
website

http://www.stanleyengineeredfastening.com/resource-center/document-library

11