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POP 4000 SERIES RIVET TOOLS ®

PRT4000 MCS4000 _______________________ INSTRUCTION MANUAL

Ver:2 – 05 Aug 2002

WARNING:

ONLY TRAINED SERVICE PERSONNEL SHOULD PERFORM SERVICE PROCEDURES.

IMPORTANT READ THE FOLLOWING SAFETY INSTRUCTIONS CAREFULLY.

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CONTENTS SECTION I

DESCRIPTION AND MODEL IDENTIFICATION

PAGE 2

PREPARATION FOR OPERATION

III

SERVICE PROCEDURES

DISASSEMBLY & ASSEMBLY INSTRUCTIONS 1 Handle Cap Assembly 2 Intensifier Assembly 3 Air Valve and Pressure Regulator Assembly 4 Handle Replacement

5 5 6 7 7

MAINTENANCE SCHEDULE

DISCONNECT TOOL FROM AIR SUPPLY BEFORE ATTEMPTING SERVICE. SERVICE SHOULD ONLY BE PERFORMED BY TRAINED PERSONNEL.

SAFETY INSTRUCTIONS 1.

It is recommended to wear eye protection when operating the tool.

To avoid injury do not point the tool at anyone.

Do not exceed recommended maximum air pressure (5.5 bar, 80psi).

Disconnect the tool from the air supply when not in use for an extended period of time or before proceeding with any maintenance procedures. Take care to control air hoses when disconnecting to prevent whipping.

Do not attempt to operate the tool with the Nose Housing removed. This exposes potential pinch points and could result in injury.

Do not tamper with Fill Screw. Loosened screws may result in malfunction or injury due to air or hydraulic pressure.

Do not operate the tool without either the deflector (PRT Option) or the collector (MCS Option) installed on the tool. Spent rivet mandrels may be forcefully ejected.

Always clear the tool of spent rivet mandrels before setting a new fastener. Failure to do so may result in tool jams or forceful ejection of spent mandrels.

Use caution when operating the tool, compressed air is released through the front of the Intensifier Chamber. Do not direct exhaust towards anyone.

10.

Inspect the tool at regular intervals for damage and proper function. Replace damaged parts immediately. Do not connect a damaged tool to an air supply.

11.

Use only genuine POP® brand replacement parts.

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DESCRIPTION AND MODEL IDENTIFICATION

The 4000 Series tools are light weight air-hydraulic Rivet Tools capable of setting commercial blind rivets up to and including 3.2mm (1/8”) diameter in aluminium . Two models are available. PRT4000 MCS4000

Setting Tool with mandrel deflector only. Setting Tool with automatic vacuum Mandrel Collector attached.

PRT4000 and MCS4000 are supplied set up for 3.2mm (1/8”) diameter rivets. A nosepiece is included for 2.4mm (3/32”) rivets. Additionally, front end components can be ordered to set 2.0mm (5/64”) ‘Micro’ rivets. Refer to Set Up Procedures, Section II of this manual for more information.

PACKED IN CARTON - MODELS PRT4000 and MCS4000 Part Number

Part Name

Data

Model PRT4000 PRG510-56 PRT 4000-33 PRT4000-34 PRM 530-49 PRN314 AN500-72

Rivet Tool Deflector Spanner Cap Spanner Hex Wrench Nosepiece Coupler Operator’s Instructions

Assembled (no airline) Safety device - PRT4000 only 8mm – 19mm multi-spanner 52mm cap spanner 5mm hex wrench 2.4mm (3/32”) open end rivets Air line coupler

MCS Version (additional items) MCS4000

MCS complete kit

(see Parts List, page 10 for kit contents)

SPECIFICATIONS Weight: Length: Height: Stroke: Pulling Force: Operating Pressure: Air Consumption:

I.1

PRT4000

MCS4000

1.055kg (2.33 lbs.) 155mm (6.10 in.) 230mm (9 in.) 16mm (.63 in.) 3.3kN (742 lbs.) 4.5-5.5bar (65-80 psi.) 0.9 litres/rivet

1.2kg (2.64 lbs.) 236mm (9.2 in.) 230mm (9 in.) 16mm (.63 in.) 3.3kN (742 lbs.) 4.5-5.5bar (65-80 psi.) 0.9 litres/rivet + 120 litres/min (MCS)

THEORY OF OPERATION

When connected to an air supply and the trigger operated, pressurized air pushes the Air Piston / Ram Assembly. The Ram Assembly forces hydraulic fluid from the reservoir in the handle into the main bore where it pushes the hydraulic piston and the attached pulling mechanism rearward. As the Pulling Jaws move towards the rear, they grip the rivet mandrel and set the rivet. Releasing the trigger enables the return spring to push the hydraulic piston forward to the starting position. The hydraulic fluid is forced back returning the Ram Assembly and Air Piston to the starting position. The compressed air used to set the rivet is exhausted through the front of the Intensifier Chamber. The hydraulic piston is fully returned, the broken rivet mandrel is released as the Jaws are forced open again by the Nosepiece. If the tool is equipped with a Mandrel Collection System (MCS models) the mandrel will be drawn out of the tool and deposited in the Collector Bottle, which should be emptied every 100 mandrels.

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PREPARATION FOR OPERATION CAUTION: Do not connect to air supply until all tool parts are properly installed. It is recommended to wear eye protection when operating this tool.

II.1

AIR SUPPLY REQUIREMENTS Use a dry, filtered air supply regulated to 4.5-5.5bar (65-80psi). It is not necessary to lubricate the air supply. Excess oil, water or debris in the air supply will necessitate more frequent tool service and significantly reduce the operating efficiency of the Mandrel Collection System.

II.2

TOOL CAPABILITY

Select the appropriate Nosepiece from the chart below. The PRT4000 and MCS4000 tools are assembled with Nosepiece PRN414 (01) suitable for 3.2mm (1/8”) rivets. To set 2.4mm (3/32”) rivets replace the installed Nosepiece PRN414 (01) with PRN314 (02) supplied in carton. To set 2.0mm (5/64”) Open or 3.2mm (1/8”) Closed End rivets, additional components are needed.

2. 3.

NOSEPIECE CHART

II.3

CHANGING TOOL SET UP FOR DIFFERENT RIVET SIZES To prevent mandrel jams and maximise jaw life, it is important to install the correct Nosepiece, Jaws, Jaw Pusher and Mandrel Guide tube.

Procedure 1. 2. 3. 4. 6. 7. 8. 9. 10.

Place the tool in a soft-jawed vice, gripping the tool in the centre of the handle. For Nosepieces PRN 314, PRN 414 and PRN 424, simply remove the Nosepiece fitted, replace with the required Nosepiece, and tighten. For 2mm ‘Micro’ rivets remove the installed Nosepiece and Nose Housing (03). Remove the Jaw Guide (04), Jaws (05) and Jaw Pusher (06). Install the correct Jaw Pusher (06). Install the correct Jaws (05). Re-install the Jaw Guide (04) and tighten. Replace the Nose Housing (03) and tighten. Install correct Nosepiece and tighten.

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II.4

OPERATION

1. 2. 3.

Attach tool to suitable air supply. Ensure the deflector (36) – PRT4000, or collector (106) – MCS4000, is in place before operating tool. Insert a rivet mandrel into the Nosepiece. If the tool is equipped with a Mandrel Collection System (MCS4000) the rivet will be held in the tool by vacuum. Position rivet into work piece. Squeeze the trigger (27) to set the rivet. Once the rivet is set, release the trigger. If using a PRT4000 be sure to clear the mandrel from the tool by tipping the tool to let the mandrel slide either out of the front or out of the back of the tool. If using the MCS4000, the mandrel will be automatically extracted into the Mandrel Collector Bottle, which should be emptied every 100 mandrels.

4. 5.

CAUTION:

Read the Operator Instruction Leaflet before operating the tool.

III

SERVICE PROCEDURES

III.1

SERVICING THE JAWS, JAW PUSHER AND JAW PUSHER SPRING Regular cleaning of the Jaws and front-end parts will prevent mandrels sticking in the Jaws and extend the Jaw life.

Procedure 1. 2. 3. 4. 5.

III.2

Disassemble the tool front end as described in Section II.3. Clean Jaws (05) using a brush and solvent. If jaw teeth show significant wear replace both jaws. Check Jaw Pusher Spring (07) for fatigue. A new spring measures 54mm (2 1/8” ) in length. Replace spring if shorter than 46mm (1 7/8”). Thoroughly clean the inside of the Jaw Guide (04), Nose Housing (03), the Jaw Pusher (06) and wipe out debris from around other exposed parts. Lightly oil Jaws (05) and Jaw Pusher (06) before reassembling. Reassemble parts in reverse order. Ensure Jaw Guide (04), Nose Housing (03) and Nosepiece (01) are tightened.

REPLENISHMENT OF HYDRAULIC FLUID A shortened stroke indicates minor hydraulic fluid loss. Hydraulic fluid can be replaced without fully disassembling the tool.

CAUTION:

The tool must be disconnected from the air supply before attempting to replenish hydraulic fluid.

Procedure 1. 2. 3. 4. 5. 6. 7. 8.

Place the tool, inverted, in a soft-jaw vice, with the Chamber (52) pointing up. Remove Chamber Cap (53) with the Cap Spanner (PRT4000-34) provided. Remove the Air Piston Assembly (51) from the Chamber. Add oil into the bore at the base of the Chamber, inside the tool handle. Fill to approximately 8mm from the top of the bore. (For oil specification see page 7). Temporarily replace Air Piston Assembly (51). Pump the Air Piston 2 – 3 times into the bore to remove air bubbles. Remove Air Piston Assembly once more. Re-check oil level. If the oil level is lower, repeat the above procedure until a satisfactory oil level is achieved. When the oil level is correct, replace Air Piston Assembly (51) and push firmly into place. Replace Chamber Cap (53) and tighten. Rotate tool into an upright position in the vice (chamber at bottom). -4-

9. 10. 11.

Loosen Fill Screw (16) with 5mm Hex wrench (PRM530-49) provided, to remove excess oil and air bubbles. After the excess oil and air has been removed, tighten Fill Screw (16) using Hex wrench provided. Reconnect to Air Supply. CAUTION:

Do not depress the trigger when Fill Screw (16) is loose. This will cause oil to be forced out under great pressure.

If oil loss is rapid or excessive refer to Section IV of this manual for seal replacement procedures

PRT4000 & MCS4000 DISASSEMBLY & ASSEMBLY INSTRUCTIONS IMPORTANT READ SAFETY INSTRUCTIONS ON PAGE 1 OF INSTRUCTION MANUAL DISCONNECT TOOL FROM AIR SUPPLY BEFORE ATTEMPTING SERVICE SERVICE SHOULD BE PERFORMED BY TRAINED PERSONNEL ONLY _____________

SERVICE NOTES All disassembly procedures should be performed in a clean, well-lit work area. O-rings, seals and sealing surfaces should be lightly lubricated with a white mineral oil based grease such as Lubriplate 130-AA or equivalent prior to assembly. Do not use solvents other than approved hydraulic fluid to clean O-rings or seals.

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FRONT END ASSEMBLY (see ‘Changing Tool Set-Up for Different Rivet Sizes’ Section II.3 on page 3)

IV.1.i HANDLE CAP ASSEMBLY (PRT4000) 1. Remove Deflector (36). 2. Unscrew End Cap (24) using 24mm spanner (PRT4000-34). 3. The End Cap (24), Cap Assembly (34) and Return Spring (20) can be removed. 4.

Remove O-rings (21) and (33).

IV.1.ii HANDLE CAP ASSEMBLY (MCS4000) 1.

Remove Collector End (110), M10 nut (103) and Collector (106).

Unscrew End Cap (24) using 24mm spanner (PRT4000-34).

The End Cap (24), MCS Cap Assembly (101) and Return Spring (20) can be removed.

Remove O-rings (102), (107), (21), and (33). -5-

ASSEMBLE IN REVERSE ORDER – Lubricate O-rings prior to installation.

IV.1.iii CONVERSION PRT4000 TO MCS4000 Remove Handle Cap assembly as per Section III .1.i – replace Cap Assembly (34) with MCS Cap Assembly (101) and Deflector (36) with Collector (106).

IV.2

INTENSIFIER ASSEMBLY (PNEUMATIC PISTON)

1. Loosen the Fill Screw (16). 2. Place the tool, inverted, in a soft jawed vice with the Chamber (52) facing up. 3. Remove Chamber Cap (53) using Cap Spanner (PRT4000-34). 4. Remove Air Piston Assembly (51). 5. Ease out O-Ring (47) from Air Piston (51). 6. Place a 13mm spanner on the Lock Nut (50) and a 6mm hex wrench on the top of the Ram (43). Hold the spanner while turning the hex wrench anti-clockwise. Remove Ram from Air Piston. 7. Inspect O-Ring (47) and Rubber Cushion (45). Replace if necessary. ASSEMBLE IN REVERSE ORDER –Refer to section II.2 for Hydraulic Fluid Charging Procedure.

IV.3

PULLING HEAD ASSEMBLY (HYDRAULIC PISTON)

1. Secure tool upright in a soft jaw vice. 2. Remove Nose Housing (03), Jaws (05), Jaw Pusher (06), Jaw Spring (07), Jaw Guide (04). 3. Remove Handle Cap Assembly as per Section III.1.i/ii. 4. Loosen but do not remove Fill Screw (16). 5. Push the Hydraulic Piston (08) out of the rear of the tool. Take care as oil spillage will occur at this point. 6. Inspect O-Rings 2 x (18) and replace as necessary. 7. Using internal circlip pliers, remove C-Ring (10) from front of tool. Pull out Seal Sleeve (12) from front of tool. 8. Inspect all O-Rings (11), (13), (15) for damage / wear. Replace as necessary. ASSEMBLE IN REVERSE ORDER – Ensure all O-Rings and the bore of the tool are lubricated.

IV.4

AIR VALVE AND PRESSURE REGULATOR ASSEMBLY

Place tool inverted in a soft jaw vice, with Chamber (52) facing up.

Remove Valve Cap (56) using large flat blade screwdriver.

Remove Spring (61).

Hold tool upright and let Valve (60) drop out of tool.

Remove hexagonal Set Screw from Trigger Lever Cap (30) using a 2mm hex wrench.

Depress and hold Trigger (27), and remove Cap Assembly (30).

Drive out Spring Pin (31) – beware of slight spring pressure.

Remove Valve Pusher (57), Spring (58) and Copper Washer (59), and O-Ring (37).

To disassemble Trigger Rod from Trigger Lever, drive out Spring Pins (28) x 2.

10. Remove Trigger (27) from Trigger Lever by driving out Spring Pin (26).

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ASSEMBLE IN REVERSE ORDER -Lubricate all O-rings and seals prior to installation.

IV.5

HANDLE REPLACEMENT

Note: It is normally not necessary to disassemble the Handle (09) from the Chamber (52) unless either component has been damaged. 1.

Loosen and remove Fill Screw (16). Drain Hydraulic fluid from tool.

Remove Front End Assembly (refer to section II.3 ).

Remove Handle Cap Assembly (section III.1.i/ii)

Remove Intensifier Assembly (Pneumatic Piston) – (section III.2).

Remove Pulling Head Assembly (section III.3)

Remove Air Valve / Regulator Assembly (section III.4)

Place tool inverted, in a soft jaw vise with Chamber (52) facing up.

Using a special tool number (TT 1111), undo Lock Nut (42). Separate Handle (09) from Chamber (52).

ASSEMBLE IN REVERSE ORDER - Lubricate all O-rings and seals prior to installation. Take care not to wrinkle or cut O-rings during assembly.

____________________________________________________

APPROVED HYDRAULIC FLUIDS MOBIL - DTE26* EXXON - NUTO H-68 SHELL - TELLUS 68 TEXACO - RANDO HD-68 ______________________________________________

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MAINTENANCE SCHEDULE

DAILY 1. Inspect tool and air supply hose for damage. Replace damaged parts immediately. 2. Purge air supply filters to eliminate accumulated dirt, oil and water. 3. Ensure that air pressure is regulated at 5.5 bar (80 psi). 4. Check tightness of Fill Screw (16), Nosepiece (01) and Nose Housing (03). 5. Lubricate Jaws (05), with light oil or Jaw Lube.

WEEKLY OR EVERY 15,000 CYCLES 1. Dismantle Front End Assembly, thoroughly clean all parts, check Jaws (05), Jaw Pusher (06) and Jaw Pusher Spring (07) for wear and replace as needed. 2. Lightly lubricate all parts before reassembly.

ANNUALLY OR EVERY 500,000 CYCLES 1. Dismantle tool and replace all seals and O-rings. Inspect all parts for wear or damage and replace as necessary. 2. Lightly lubricate all seals, O-rings and front end parts before reassembly.

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PRT / MCS 4000 PARTS DIAGRAM

MANDREL COLLECTION SYSTEM

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PARTS LIST No.

Description

Qty

No.

Article No

07 08 09 10 11 12 13 14

15800 15790 16216 17595 15791 16212 16210 15792 15793 15794 15782 15795 15796 15797 15798 15799 15804 15805

PRT 4000 Setting Tool MCS 4000 Setting Tool PRN414 Nosepiece-3.2mmØ Rivets PRN314 Nosepiece-2.4mmØ Rivets PRT4000-01 Nose Housing PRH820-11A Jaw Guide PRG402-8A Jaws PRT4000-02 Jaw Pusher PRT4000-02-1 SUS Pipe 3.0x2.4 PRT4000-02-2 Jaw Pusher Head PRG510-123 Jaw Pusher Spring PRT4000-03A Hydraulic Piston Assy PRT4000-04A Handle C-Ring PTW22 O-Ring P18(1B) PRT4000-05 Seal Sleeve O-Ring P12(1B) Backup Ring PSL600CJ-13

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

15836 15837 15838 15839 15840 15841 15842 15843 15844 15845 15846 15847 15848 15849 15850 15851

15 16 17 18 19 20 21

15806 15807 15808 15809 15810 15811 15812

Pentaseal PSL600CJ-14 PRT4000-06 Fill Screw PRT4000-07 Fill Washer O-Ring P22(1B) Backup Ring T2P22 PRT4000-08 Return Spring O-Ring S26(1A)

1 1 1 2 1 1 1

Article No

15813

PRT4000-09 Tool Hanger

Article No

23 24 25 26 27 28 29

15814 15815 15816 15817 15818 15819 15820

E-Ring 10 PRT4000-10 End Cap Set Screw SS-M6*5 PRM530-40 Spring Pin PRT4000-11 Trigger Spring Pin SPIN-3*8AW PRT4000-12 Trigger Rod

1 1 1 1 1 2 1

16213 15801 15802 15803

No.

Article No

Description

Qty

30 31 32 33 34 35 36 37

15821 15822 15823 15824 15825 15826 16309 15827

PRT4000-13 Trigger Lever Cap Spring Pin SPIN-3*14AW PRT4000-14 Trigger Lever O-Ring P16(1A) PRT4000-15 Cap Assembly Set Screw SS-M4*5 PRG510-56 Deflector O-Ring PRL600-10

1 1 1 1 1 1 1 3

100 101 102 103 104 105 106 107

15856 15857 15858 15859 15789 15788 15787 15786

Complete MCS Kit MCS4000-01 MCS Cap Assembly O-Ring P7A(1A) Hexagon Thin Nut M10 T5 MCS4000A-09 MCS Nozzle MCS4000A-06 Collector Lock Nut MCS4000A-07 Collector O-Ring 1033(1A)

1 1 1

38 39 40 41 42 43 44 45

15828 15829 15830 15831 15832 15833 15834 15835

O-Ring P4(1A) Pentaseal PS15 Backup Ring T2P15 O-Ring P15(1B) PRT4000-17 Lock Nut PRT4000-18A Ram Toothed Lock Washer TLW-A8 PRT4000-20A Rubber Cushion

1 1 1 1 1 1 1 1

108 109 110 33 37 23

15785 15784 15783 15824 15827 15814

MCS4000A-07-1 Collector Body MCS4000A-07-2 Collector Cover MCS4000A-07-3 Collector End O-Ring P16(1A) O-Ring PRL600-10 E-Ring 10

01 02 03 04 05 06

Article No

Description O-Ring P9(1A) O-Ring P58(1A) PRT4000-21 Ram Washer PRT4000-22 Air Piston Washer Nut M8-T5 PRT4000-24 Air Piston PRT4000-25 Chamber PRT4000-26 Air Chamber Cap O-Ring G65 O-Ring AN500A-51-6 PRT4000-27 Valve Cap PRT4000-28 Valve Pusher PRT4000-29 Valve Spring PRT4000-30 Copper Washer PRT4000-31 Valve PRT4000-32 Spring

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

ACCESSORY PARTS 15852 15853 15854 15855

Description PRN530-49 Hex Wrench PRT4000-33 Spanner PRT4000-34 Cap Spanner AN500-72 Coupler

OPTIONAL PARTS Description PRN424 Nosepiece-3.2mm Ø Closed End PRN214 Nosepiece-2.0mm Ø Rivets PRT4000-50 Jaw Pusher –2.0mm Ø Rivets PRG402-02 Jaws-2.0mm Ø Rivets

Qty 1 1 1 1

MCS PARTS LIST

1 1 1 1 1 1 1 1 1 1 1

Emhart Fastening Teknologies Walsall Road, Birmingham B41 1BP, UK Tel: +44 (0)121 356 4811 Fax: +44 (0)121 356 1598

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