TKR Group VAS 6790/2 Setup And Installation Manual
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TKR Group VAS 6790/2 Setup And Installation Manual

Pneumatic/hydraulic blind riveting tool
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VAS 6790/2
VAS 6792
VAS 6792/1
VAS 6792/2
Pneumatic/hydraulic
blind riveting tool
BA3
Setup – Installation: Blind riveting tool
Additional information to the instruction manual
BA1 (VAS 6790/2, VAS 6792, VAS 6792/1, VAS 6792/2)
ATTENTION
This supplementary sheet serves as a supplement to the instruction manual BA1
(VAS 6790/2, VAS 6792, VAS 6792/1, VAS 6792/2) and may only be used in
conjunction with it.
Translation of original instruction manual

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  • Page 1 BA1 (VAS 6790/2, VAS 6792, VAS 6792/1, VAS 6792/2) ATTENTION This supplementary sheet serves as a supplement to the instruction manual BA1 (VAS 6790/2, VAS 6792, VAS 6792/1, VAS 6792/2) and may only be used in conjunction with it. Translation of original instruction manual...
  • Page 2 Zusatzinformation zur Betriebsanleitung BA1 (VAS 6790/2, VAS 6792, VAS 6792/1, VAS 6792/2) ACHTUNG Diese Montageanleitung dient als Ergänzung zur Betriebsanleitung BA1 (VAS 6790/2, VAS 6792, VAS 6792/1, VAS 6792/2) und darf nur im Zusammenhang mit dieser verwendet werden. Originalbetriebsanleitung Owner‘s manual 1.

  • Page 3: Table Of Contents

    Chapter Page Safety Designations Scope of supply Scope of Supply and Accessories Technical specifications Working with the blind riveting tool - basic principles 10 Maintenance Technical data Technical data Device components Connecting the high-pressure coupling to the Compact Booster Connecting the blind riveting tool and the Compact Booster VAS 6792/2, VAS 6792/24: Screwing the extension onto the blind riveting tool...
  • Page 4 Using the blind riveting tool 4.10 Replacing the rivet head 4.11 Fitting the ejector 4.12 Using with the operating unit 4.13 Emptying the mandrel collector 4.14 Maintenance and cleaning 4.15 Spare parts 4.16 Troubleshooting Maintenance / Service Disposal BA1, 60 Warranty BA1, 61 Declaration of Conformity...

  • Page 5: Designations

    Designations Markings on the blind riveting tool 1.1.1 Manufacturer‘s identification Serial number Production date Warnings (for complete view see Fig. 1.1.3) 1.1.2 1.1.3...

  • Page 6: Scope Of Supply And Accessories

    Scope of Supply and Accessories VAS 6790/2 VAS 6792 VAS 6792/1 VAS 6792/2 Pneumatisch hydraulisches Blindniet-Werkzeug Bedienungsanleitung Originalbetriebsanleitung Nietmatrix VAS 6792/11 VAS 6792/14 VAS 6792/13 VAS 6792/10 VAS 6792/12 VAS 6792/27 Ø 2,0 mm Ø 2,6 mm Ø 3,0 mm Ø...
  • Page 7 Item VAS 6792 VAS 6790/2 • • 1 Case • • 1 Blind riveting tool • 1 Spiral hose assembly 1 Ejector • • 1 Compact Booster • • 1 High-pressure coupling • • 1 Assembly wrench 1 Assembly aid •...
  • Page 8 Scope of Supply and Accessories Accessories set, optional VAS 6792/1 Item VAS 6792/1 • Extension, 160 mm Carrying strap • • Hose assembly • Operating unit • Plug connector Pneumatic hose • • Supporting belt • Cardboard box...

  • Page 9: Technical Specifications

    Technical specifications Travel 20 mm Setting force 24500 N at 6 bar Weight 0.8 kg (without hose and operating unit) Hydraulic operating pressure max. 600 bar Pneumatic operating pressure 6 bar Ambient temperature 5 – 50 °C/41 – 122 °F Protective gloves, eye protection, long-sleeved Prescribed safety clothing working clothes, close fitting at the neck...

  • Page 10: Working With The Blind Riveting Tool - Basic Principles

    Working with the blind riveting tool - basic principles Risk of injury Route all supply lines in a manner that prevents people from tripping over them. Correctly route and attach the compressed air hose. If a compressed air hose whips around wildly, it could cause severe bodily injury.

  • Page 11: Maintenance

    Maintenance The tool‘s hydraulic system, pneumatic control systems, hoses and couplings must all be kept free of dirt and other contamination. Foreign bodies in the hydraulic fluid or in the control air will cause the tool system to malfunction. All maintenance and service work on the blind riveting tool must only be per- formed with the pressure generator disconnected.

  • Page 12: Technical Data

    Technical data Blind riveting tool with mandrel collector 3.1.1 Overall length 179 mm Length of mandrel collector 87 mm Height 58 mm Width 35 mm Ø Mandrel collector 34 mm Ø Rivet head 28 mm...
  • Page 13 Blind riveting tool with ejector 3.1.2 Overall length 109 mm Length of ejector 17 mm Width 35 mm Height 58 mm Ø Ejector 38 mm Ø Rivet head 28 mm...
  • Page 14 Technical data Blind riveting tool with mandrel collector and extension 3.1.3 VAS 6792/24 260.2 260.2 VAS 6792/2 VAS 6792/24 VAS 6792/2 Overall length 360 mm 260.2 mm Height 58 mm 58 mm Ø Rivet head 20 mm 20 mm Width 35 mm 35 mm Length of straight housing...
  • Page 15 High-pressure coupling 3.1.4 Length 125 mm Ø Coupling 58 mm Ø Connection 27 mm...

  • Page 16: Device Components

    Device components 3.2.1...
  • Page 17 Title Blind riveting tool Front ejector Assembly wrench Assembly aid High-pressure coupling Spiral hose Compact Booster Hose adapter Blind rivet set Protection cover Protection cover Extension rod Rivet head Extension casing Mandrel collector Conical grip Ejector Plug connector Extension 160 mm Hose package Operating unit Pneumatic hose...

  • Page 18: Compact Booster

    Connect the high-pressure coupling to the Compact Booster 4.1.1 4.1.2 4.1.3 4.1.1 – 4.1.3 Press the lever on the Compact Booster to turn the locking mechanism clockwise.
  • Page 19 4.1.4 4.1.5 4.1.6 4.1.7 4.1.4 – 4.1.7 Insert the high-pressure coupling straight into the seating on the Compact Booster and turn the locking mechanism counterclockwise until it engages.

  • Page 20: Connecting The Blind Riveting Tool And The Compact Booster

    Connecting the blind riveting tool and the Compact Booster 4.2.1 4.2.2 4.2.1/4.2.2 Remove the protective caps from the high-pressure coupling and the blind riveting tool.
  • Page 21 4.2.3 4.2.4 4.2.5 4.2.3 – 4.2.5 Use the high-pressure coupling to connect the blind riveting tool and the Compact Booster, ensuring they engage audibly.

  • Page 22: Vas 6792/2, Vas 6792/24: Screwing The Extension Onto The Blind Riveting Tool

    VAS 6792/2, VAS 6792/24: Screwing the extension onto the blind riveting tool 4.3.1 4.3.1 Remove the mandrel collector from the blind riveting tool. 4.3.2 4.3.2/4.3.3 Remove the conical grip from the blind rive- ting tool. The extension is set up as shown in Fig.
  • Page 23 4.3.4 4.3.5 4.3.4 – 4.3.6 4.3.6 Unscrew the yellow protective cover from the extension. Remove the extension sleeve from the housing. Then remove the extensi- on rod from the extension sleeve.
  • Page 24 VAS 6792/2, VAS 6792/24: Screwing the extension onto the blind riveting tool 4.3.7 4.3.7/4.3.8 Insert the appropriate conical grip into the extension rod. Ensure that the conical side of the conical grip is facing the extension rod. 4.3.8 Only for VAS6792/2: Before setting up, al- VAS 6792/2 ways position the conical grip in the tool correctly, using the assembly aid.
  • Page 25 4.3.10 4.3.11 4.3.10/4.3.11 Remove the rivet head from the blind riveting tool before fully securing the extension sleeve up to the stop with the assembly wrench. Take extra care over this, ensuring that the assembly wrench is positioned in the notches provided in the blind riveting tool to allow the extension sleeve to be detached.
  • Page 26 VAS 6792/2, VAS 6792/24: Screwing the extension onto the blind riveting tool 4.3.12 4.3.13 4.3.12 – 4.3.14 Fit the extension casing over the extension sleeve and secure it to the blind riveting tool. Hand-tighten the casing with the assembly wrench. Then fit the mandrel collector.

  • Page 27: Replacing The Rivet Head Extension

    Replacing the extension rivet head 4.4.1 4.4.2 4.4.1 – 4.4.2 When changing the rivet head on the extension, note that it must be hand-tightened using the assembly wrench.

  • Page 28: Removing The Extension

    Removing the extension 4.5.1 4.5.1 To remove the extension sleeve from the blind riveting tool, the mandrel collector must first be removed. 4.5.2 4.5.2 Then fit the assembly wrench to the blind riveting tool at the back. Take particular care to ensure that the assembly wrench is posi- tioned in the notches provided in the blind riveting tool to allow the extension sleeve to...

  • Page 29: Replacing The Conical Grip

    Replacing the conical grip 4.6.1 4.6.2 4.6.1/4.6.2 4.6.3 Unscrew the rivet head with the assembly wrench and remove. 4.6.3 Position the conical grips at the point of the assembly aid. Ensure that the conical side faces...
  • Page 30 Replacing the conical grip 4.6.4 4.6.5 Nietmatrix VAS 6792/11 VAS 6792/14 VAS 6792/13 VAS 6792/10 VAS 6792/12 VAS 6792/27 Ø 2,0 mm Ø 2,6 mm Ø 3,0 mm Ø 3,4 mm Ø 4,0 mm Ø 4,0 – 4,2 mm VAS 6792/15 VAS 6792/16 VAS 6792/17 VAS 6792/18...
  • Page 31 4.6.6 4.6.7 4.6.6 - 4.6.8 4.6.8 Once the conical grip has been inserted into the blind riveting tool, the mandrel collector must be fitted.

  • Page 32: Connecting The Spiral Hose To The Compact Booster And Hose Adapter

    Connecting the spiral hose to the Compact Booster and hose adapter 4.7.1 4.7.2 4.7.3 4.7.4 4.7.1/4.7.2 Connect the spiral hose to the Compact Booster. 4.7.3/4.7.4 Connect the plug on the hose to the hose adapter. The hose adapter can now be connected up to the workshop‘s air supply.

  • Page 33: Connecting The Pneumatic Hose To The Compact Booster And The Spiral Hose

    Connecting the pneumatic hose to the Compact Booster and the spiral hose 4.8.1 4.8.2 4.8.3 4.8.1 – 4.8.3 Connect the spiral hose with the hose adapter and the black pneumatic hose. Then secure the pneumatic hose to the Compact Booster.

  • Page 34: Using The Blind Riveting Tool

    Using the blind riveting tool 4.9.1 4.9.2 4.9.3 4.9.4 4.9.1/4.9.2 Insert the blind rivet, centered in the tool's rivet guide. 4.9.3/4.9.4 Position the blind riveting tool and insert it into the hole provided as far as the contact surface.
  • Page 35 4.9.5 4.9.6 4.9.5/4.9.6 Start the riveting operation by pressing the lever on the Compact Booster. Draw the mandrel into the tool. The projecting part of the mandrel breaks at the front side at the intended breaking point. This causes the rivet material to spread out around the rivet head on the opposite side.

  • Page 36: Replacing The Rivet Head

    4.10 Replacing the rivet head 4.10.1 4.10.2 4.10.1/4.10.2 When changing the rivet head, the replacement rivet head must be hand-tightened with the assembly wrench.

  • Page 37: Fitting The Ejector

    4.11 Fitting the front ejector 4.11.1 4.11.2 4.11.1/4.11.2 Turn the mandrel collector counterclockwise. The compressed air supply MUST be switched off. When opening the blind riveting tool, hold it angled slightly forward because the conical grip can fall out.
  • Page 38 4.11 Fitting the front ejector 4.11.3 4.11.4 4.11.5 4.11.6 4.11.3/4.11.4 Insert the front ejector and tighten clockwise until the contact surface is reached. 4.11.5/4.11.6 Tighten by hand using the large opening of the assembly wrench. When not in use, keep the front ejector in the protective cover provided for this purpose.

  • Page 39: Using With The Operating Unit

    4.12 Using with the operating unit 4.12.1 4.12.2 4.12.1 – 4.12.3 4.12.3 Remove the protective cap on the hose as- sembly and connect the coupling to the high-pressure coupling on the Compact Booster.
  • Page 40 4.12 Using with the operating unit 4.12.4 4.12.4 Lead the blue and black hoses through the opening in the locking mechanism so they are out of the way during use. 4.12.5 4.12.5 Connect the blue hose to the hose assembly to the Compact Booster.
  • Page 41 4.12.6 4.12.7 4.12.6 – 4.12.8 4.12.8 Secure the support belt around the depres- sed lever on the Compact Booster because rivet setting is controlled by the operating unit.
  • Page 42 4.12 Using with the operating unit 4.12.9 4.12.9 Connect the black hose to the plug connector. Always ensure that the plug con- nector symbol is pointing toward the black hose. 4.12.10 4.12.10 Then connect the spiral hose to the other side of the plug connector.
  • Page 43 4.12.12 4.12.13 4.12.14 4.12.15 4.12.12 – 4.12.15 Now connect the hose assembly to the operating unit. Then connect the blue and black hoses to the operating unit. Note that the hoses must be inserted in accordance with the lettering.
  • Page 44 4.12 Using with the operating unit 4.12.16 4.12.16 Remove the front protective cap on the ope- rating unit and the protective cap on the blind riveting tool. 4.12.17 4.12.17/4.12.18 The blind riveting tool can now be connected to the operating unit. 4.12.18...
  • Page 45 4.12.19 4.12.19 The blind riveting tool must be used as shown in the illustration, by a professi- onal operator trained in its use.

  • Page 46: Emptying The Mandrel Collector

    4.13 Emptying the mandrel collector 4.13.1 4.13.2 4.13.3 4.13.4 4.13.1 Press the mandrel collector towards the blind riveting tool, as shown in the laser engraving. 4.13.2 – 4.13.4 Turn the mandrel collector to open the recovery aperture to allow the mandrels to be removed.

  • Page 47: Maintenance And Cleaning

    4.14 Maintenance and cleaning 4.13.5 4.14.1 4.14.2 4.14.3 4.13.5 To close, press the mandrel collector towards the riveting tool, as shown in the laser engraving. Turn the mandrel collector to close the recovery aperture. 4.14.1 – 4.14.3 Disconnect the blind riveting tool from the operating unit and/or the high-pressure coupling. Remove the high-pressure coupling from the Compact Booster.
  • Page 48 4.14 Maintenance and cleaning 4.14.4 4.14.4 Remove the conical grip from the housing. If a cone is left behind the piston and the seal, both the tool and cone will be damaged.
  • Page 49 Clean and check the gripper teeth on the conical grip. Replace the conical grip if it is blunt. Rounded teeth can cause faulty operation or damage to the tool. Never use compressed air to clean the tool casing. This will result in dirt being blown into the seals.

  • Page 50: Spare Parts

    4.15 Spare parts 4.15.1...
  • Page 51 Overview Artikelnr. Designation VAS 6790/56 Carrying strap VAS 6790/60 Supporting belt VAS 6792/7 High-pressure coupling VAS 6792/26 Hose package VAS 6790/55 Spiral hose VAS 6792/25 Operating unit VAS 6792/23 Pneumatic hose black Ø 6 mm VAS 6792/3 Blind riveting toolbox VAS 6790/20 Compact Booster VAS 6792/22...
  • Page 52 4.15 Spare parts 4.15.2 VAS 6792/16 VAS 6792/18 VAS 6792/19 Ø 2,6 mm Ø 3,4 mm Ø 4,0 mm VAS 6792/20 VAS 6792/17 VAS 6792/15 Ø 4,0 – 4,2 mm Ø 3,0 mm Ø 2,0 mm...
  • Page 53 Overview Artikelnr. Designation VAS 6792/14 Rivet holder for 2.6 mandrel VAS 6792/10 Rivet head for 3.4 mandrel VAS 6792/12 Rivet head for 4.0 mandrel VAS 6792/19 Conical grip, welding mandrel VAS 6792/16 Conical grip, 2.6 mandrel VAS 6792/13 Rivet holder for 3.0 mandrel VAS 6792/18 Conical grip, 3.4 mandrel VAS 6792/11...

  • Page 54: Troubleshooting

    4.16 Troubleshooting Problem Cause Compressed air supply not connected Control lines (black and blue hoses) incorrectly connected Control lines (black and blue hoses) not connected Blind riveting tool not working Insufficient air pressure Hydraulic hose assembly not coupled Compact Booster defective Control lines (black and blue hoses) incorrectly connected Control lines (black and blue hoses) not connected...
  • Page 55 Remedy Chapter Connect compressed air see BA1 Connect control lines (black and blue hoses) correctly, ensuring they are 4.12 properly seated. Connect control lines (black and blue hoses) correctly, ensuring they are 4.12 properly seated. Check air supply at pressure intensifier see BA1 Connect hydraulic hose assembly in accordance with Operating Instructions 4.7,4.8...
  • Page 56 4.16 Troubleshooting Problem Cause Conical grips dirty Blind rivet not being gripped, conical Gripper teeth on conical grips worn grips slipping on mandrel Incorrect conical grips Insufficient quantity of oil (pressure intensifier) Gripper teeth on conical grips worn Blind riveting process not completed, rivet shaft is not separated from rivet head Compact Booster defective Insufficient air pressure...
  • Page 57 Remedy Chapter Carefully clean conical grips Replace worn conical grips with new Check and replace conical grips Check oil level and fill if necessary see BA1 Replace worn conical grips with new. Arrange for repair by manufacturer/service partner see BA1 Check air supply at pressure intensifier see BA1 Replace hydraulic hose assembly...
  • Page 58 4.16 Troubleshooting Problem Cause Conical grips in piston adapter (3-part) sitting in different positions Mandrel collector overfilled - broken off mandrels can Blind rivet cannot be inserted no longer be carried back Incorrect conical grips...
  • Page 59 Remedy Chapter Unscrew rivet guide and gently push conical grips back 2-5 mm with a blunt implement until they are evenly positioned. Empty the collector. Use a blunt implement to push back any mandrels left in 4.13 the casing. Check and replace conical grips...
  • Page 60 Disposal Tools and machinery and components of idem and machinery must be dispo- sed of in accordance with the laws, regulations and other stipulations of the country in which they are located. We recommend that disposal be undertaken by licensed professional operators. Hydraulic oils and lubricants can be dangerous because they can contamina- te groundwater.

  • Page 61: Warranty Ba1

    Warranty There is a warranty period of 24 on all TKR Spezialwerkzeuge GmbH stamping and riveting tools that covers manufacturing or material defects. Otherwise, the statutory conditions go- verning warranty periods and our General Terms and Conditions of Sale and Supply apply. This does not cover those parts subject to wear and tear (rivet mandrels, rivet dies, screw needles, extension) or hydraulic oil.

  • Page 62: Declaration Of Conformity

    EU Declaration of Conformity In accordance with EU Machinery Directive 2006/42/EC Manufacturer: TKR Spezialwerkzeuge GmbH Am Waldesrand 9-11 58285 Gevelsberg, Germany Person authorised to compile the technical documentation: Thorsten Weyland Tool type: Pneumatic/hydraulic stamping and riveting tool Model designation: CB 1.0 Developed and manufactured in accordance with the standards and guidelines listed below by...
  • Page 64 Am Waldesrand 9–11 D-58285 Gevelsberg (Germany) Phone: +4923 32 666 07 - 0 Fax: +4923 32 666 07 - 941 E-mail: info@tkrgroup.com Web: www.tkrgroup.com...

This manual is also suitable for:

Vas 6792Vas 6792/1Vas 6792/2

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