Emhart Teknologies POP ProSet 1600 Series Service Manual
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Emhart Teknologies POP ProSet 1600 Series Service Manual

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ProSet™ 1600 Series
Service Manual
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Summary of Contents for Emhart Teknologies POP ProSet 1600 Series

  • Page 1 Rivet Tool ProSet™ 1600 Series Service Manual...
  • Page 2 Page 2 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 3: Table Of Contents

    (*) Use FAN239-176 Jaw pusher set up. (†) Exclude MultiGrip ( ) Set air pressure at 90 psi (6.2 bar). Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 3...

  • Page 4: Safety Instructions

    16. Wash hands if exposed to hydraulic fluid or lubricant. 17. Keep hair, fingers and loose clothing away from moving parts of the tool. Page 4 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 5: Specifications

    PSA075508P [1 ¾ oz. (54 g)] Note: For best results and long service life, use dry, filtered air supply. (**) Note: See lubricant safety information. Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 5...

  • Page 6: Proset™ 1600 Tool Dimensions

    .682” (17.3 mm) 1.82” (46.3 mm) 1.83” (46.5 mm) 8.94” (227 mm) ProSet™ 1600 MCS 2.99” (76 mm) 3.27” (83 mm) Page 6 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 7: Common Nosepieces

    PRN534 PRN514* Included with the tool se FAN239-176 instead of DPN239-144 (installed) when using 3/32” (2.4mm) or smaller diameter rivets. Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 7...

  • Page 8: Chapter 1 - Upper And Lower Handle

    Sleeve Assy Handle Upper Assy Set an Upper Plate(50) on the Lower Handle Assembly. Upper Plate (50) Handle Lower Assy Page 8 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 9 Start a Sleeve Lock Nut (61). Tighten the Sleeve Lock Nut (61) with a 25mm closed wrench. Torque Values: 45±3Nm Sleeve Lock Nut (61) Page 9 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 10 At this time, the Upper and Lower Handle are in the same direction. Page 10 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 11: Chapter 2 - Hydraulic Piston

    Tighten the Housing Adapter Assembly to the Upper 22mm Handle Assembly (23). Hex Size: 22 mm Housing Adapter Assy Handle Upper (23) Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 11...
  • Page 12 Apply grease on the rod and seal part of the Hydraulic Piston Assembly. Hydraulic Piston Assy Insert the Hydraulic Piston Assembly into the Upper Handle Assembly. Hydraulic Piston Assy Page 12 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 13: Chapter 3 - Trigger Valve

    Connect Tube (80) S Valve Assy Insert the two Air Tubes of the S Valve Assembly to the Fittings. Fitting (70) Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 13...

  • Page 14: Chapter 4 - Pulling Head Adaptor

    Pulling Head Insert a Spring Receiver(12) into the Pulling Head(4). Spring Receiver (12) Assemble the Pulling Head(4) to the Hydraulic Piston(13). Page 14 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 15 Hydraulic Piston(13). Screw the Fill Screw Assembly by hand until the O- Ring appears a little. Space Fill Screw Assy Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 15...

  • Page 16: Chapter 5 - Ejector & Mcs Valve

    Apply Loctite242 to the thread part of an End Cap Adapter(28). End Cap Adapter (28) Set a MCS Cap(27) to the Upper Handle(23). MCS Cap (27) Handle Upper (23) Page 16 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 17 Apply grease on the Ejector Assembly. Ejector Assy Insert the Ejector Assembly. Be careful about the direction! Packing (44) Ejector Assy Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 17...

  • Page 18: Chapter 6 - Return Spring

    Insert the Slider Assembly. Slider Assy Apply grease on the thread part of the End Cap Assembly. End Cap Assy Page 18 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 19 Cap Screws(38). Socket Head Cap Screw This plate mounting is done only for (38) ProSet1600 MCS. End Cap Plate (39) Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 19...

  • Page 20: Chapter 7 - Jaws / Jaw Case

    Apply grease to inner circumference of a Jaw Guide(3). Grease: Three Bond 1901 Anti-seizing lubricant. Jaw Guide Insert Jaws(2) into the Jaw Guide(3). Jaws Jaw Guide Page 20 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 21 Screw the Jaw Guide(3) into Pulling Head two or three turns. Jaws Jaw Guide Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 21...

  • Page 22: Chapter 8 - Intensifier Chamber

    Air Piston Ram Pour Oil into the Lower Sleeve. Oil: Shell TELLUS OIL 68 Set the Air Piston Assembly. Air Piston Assy Page 22 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 23: Chapter 9 - Oil Filling Procedure

    Pull out the Air Piston, and pour oil into Lower Sleeve again. Set the Air Piston and, reciprocate the Air Piston three times. Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 23...
  • Page 24 Nose Housing Assy Wipe the over spilt oil out. When the oil is remained, it is ejected from outlet. Page 24 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 25 Remove the Nose Housing Assembly. Nose Housing Assy Loosen the Fill Screw Assembly and eject excess oil. Fill Screw Assy Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 25...
  • Page 26 Tighten the Jaw Guide(3). Jaw Guide Page 26 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 27: Chapter 10 - Shut Off Air Fitting

    Handle using 12mm wrench. The OS Joint Assembly and the Plug Assembly is interchangeable from right to left. OS Joint Assy Plug Assy Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 27...

  • Page 28: Chapter 11 - Grip Cover

    Set the R&L Handle to the tool body, and fasten them with Socket Head Cap Screws and Hexagon Nuts (2.5mm). 2.5mm Page 28 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 29 Socket Head Cap Screw (83) Hexagon Nut (84) Socket Head Cap Screw (85) Hexagon Nut (84) Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 29...

  • Page 30: Chapter 12A - Back End (Proset1600)

    Deflector Adapter Assembly. Socket Head Cap Screw (38) Set a Deflector(110) to the Deflector Adapter Assembly. Deflector Adapter Assy Deflector (110) Page 30 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 31: Chapter 12B - Back End (Proset1600Mcs)

    Chapter 12b – Back End (ProSet1600MCS) Set the Nose Housing Assembly. Nose Housing Assy Set the Collector Assembly. Collector Assy Finished Tool. Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 31...

  • Page 32: Proset™ 1600/1600Mcs Diagram

    These items require Loctite 242 adhesive. (†) These items have a specific tightening torque as indicated in the “Tool Assembly Torque Requirements” table. Page 32 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 33 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 33...

  • Page 34: Parts List

    PRN514 Nosepiece 5 size DPN900-011 O-Ring DPN239-139 HS Screw key - DPN900-012 O-Ring DPN239-068 J Valve Rod DPN239-069 EXT Silencer Page 34 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 35 PRT5250-99 Fitting for 4 size rivets ProSet™ 1600 MCS Retrofit Kit FAN239-177 Contains: DPN239-119 End Cap Plate FAN239-166 Collector Assembly Page 35 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 36: Safety Data

    Store in a cool, dry place with adequate information. These can be obtained from the point of purchase. ventilation. Keep away from open flames and high temperatures. Page 36 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

  • Page 37: Troubleshooting

    Clean or change Silencer. LOW VACUUM Collector is full of mandrels. Discard the mandrels. Insufficient air pressure. Adjust air supply pressure. Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 37...

  • Page 38: Ec Declaration Of Conformity

    Following the provisions of the Machine Directive 98/37/EEC which replaces Directive 89/392/EEC and its amending Directives 91/368/EEC, 93/44/EEC and 93/68/EEC. Signed: ____________________________________ Eymard Chitty, Vice President, R&D Birmingham . July 2006 Page 38 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...
  • Page 39 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 Page 39...
  • Page 40 Tel. +44 (0) 121 356-4811 Fax. +44 (0) 121 356-1598 Visit our website at http://www.emhart.com ©2006 Emhart Teknologies Form No. Pxx Rev. 1 (05/06) Page 40 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614...

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