Stanley POP PB2500 Service Manual
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Stanley POP PB2500 Service Manual

Battery powered blind rivet tool
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Summary of Contents for Stanley POP PB2500

  • Page 1 Service Manual...

  • Page 4: Table Of Contents

    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.

  • Page 5: Safety Definitions

    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.

  • Page 6: Important Safety Instructions For All Battery Chargers

    • 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.

  • Page 7: Important Safety Instructions For All Battery Packs

    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.

  • Page 8: Specific Safety Instructions For Lithium-Ion (Li-Ion)

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

  • Page 9: Specifications

    DeWALT/POP-Avdel charger may make them Risk of electric shock. burst or lead to other dangerous situations. STANLEY Engineered Fastening policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice.
  • Page 10 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.

  • Page 11: Placing Specifications

    2.2. PLACING SPECIFICATIONS 2.4mm 3.2mm 4.0mm 4.8mm Rivet Type 3.0mm 4.3mm 5.0mm 6.0mm 7.0mm [3/32´´] [1/8´´] [5/32´´] [3/16´´] OPEN END ● ● ● ● ● CLOSED END ● ● ● HR (except SSHR) ● ● ● SSD SSHR ● ● ●...

  • Page 12: Main Components List

    2.4. MAIN COMPONENTS LIST Nose pieces Manual Nose housing Charger lamp Nose housing nut Charger Collector lock Battery charger connection Collector shutter Jaw guide Shutter guide sleeve Jaws Motor housing Jaw pusher Exhaust vent Spring Handle Pulling head Switch Front clutch Battery pack 2.0 Ah Collector space Battery pack 4.0 Ah...

  • Page 13: Tool Use & Set Up

    3. Tool Use & Set up The PB Series of tools are designed for installation of STANLEY Engineered Fastening Blind Fasteners. DO NOT use under wet conditions or in presence of flammable liquids or gases. READ ALL SAFETY WARNINGS AND INSTRUCTIONS BEFORE PUTTING TOOL INTO SERVICE.

  • Page 14: Chargers

    Mounting the jaw pusher (fig. 4 & 5) • Select the correct jaw pusher or jaw pusher assembly (R) that matches the Nose Piece selected. Ref. the Accessories Manual for appropriate nose equipment • Insert jaw pusher (R) into jaw pusher spring (S). •...

  • Page 15: Battery Packs

    Lithium-Ion Battery Packs only STANLEY Engineered Fastening PB Series Li-Ion tools are designed with an Electronic Protection System that will protect the battery against overloading, overheating or deep discharge.

  • Page 16: Proper Hand Position

    WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand position. WARNING: To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction. 5.1. Proper Hand Position Proper hand position requires one hand on the main handle (I) fig. 1. 5.2.

  • Page 17: Servicing The Tool

    6. Servicing the tool 6.1. Maintenance frequency Item Frequency General Tool Inspection Daily Clean & lubricate Nose Equipment 5,000 rivets Clean & grease Ball Screw and Thrust Bearing 50,000 rivets* *Recommend contacting authorized service centre 6.2. Cleaning ALWAYS wear approved eye protection at all times when cleaning equipment Tool Exterior Keep the brushless motor exhaust vent openings (H) free from dust and dirt.

  • Page 18: Spare Parts - Tools

    Charger Cleaning Instructions WARNING: Shock hazard. Disconnect the charger from the AC outlet before cleaning. Dirt and grease may be removed from the exterior of the charger using a cloth or soft non-metallic brush. DO NOT use water or any cleaning solutions. 6.3.

  • Page 19: Jaws, Jaw Guide, Jaw Pusher And Jaw Pusher Spring

    7. Jaws, Jaw Guide, Jaw Pusher and Jaw Pusher Spring SA Jaw Pusher, 6 SA Jaw Pusher, 4 Jaw Guide Jaws Jaw Pusher Spring SA Jaw Pusher, 5 BOM for Jaws, Jaw Guide, SA Jaw pusher and Jaw Pusher Spring 13300 1set JAWS...
  • Page 20 Jaw Guide Jaws Put the Jaws into the Jaw Guide (as shown) so that the teeth are on the inside. Jaw Guide Jaws After inserting the Jaws, check that they are set correctly. Pulling Head Jaw Pusher Spring Put the Jaw Pusher Spring into the Pulling Head.
  • Page 21 Jaw Pusher Spring Put the SA Jaw Pusher through the Jaw Pusher Spring. SA Jaw Pusher Jaw Guide Tighten the Jaw Guide, with Jaws, to the Pulling Head, with pulling Jaw Case Lock, by hand until it stops. Jaw Case Lock Pulling Head Jaw Guide Turn back a little until the rotation is locked by...
  • Page 22 Set a battery on to the tool to check the operation. Battery Check the tool operates correctly by pulling and releasing the trigger. Check for: ⚫ Pulling operation ⚫ Return operation ⚫ Reset operation ⚫ Full stroke → Stroke end clutch operation → Return to home position →...

  • Page 23: Sa Nose Housing And Sa Nose Piece

    8. SA Nose Housing and SA Nose Piece SA Nose Housing SA Nosepiece BOM for SA Nose Housing and SA Nosepiece SA NOSE HOUSING TP133-570 SA NOSEPIECE, 6 TRM00825 SA NOSEPIECE, 5 TRM00824 SA NOSEPIECE, 4 TRM00823 *See BOM page for option SA Nosepiece Insert the SA Nosepiece on to the SA Nose Housing and screw on by hand.
  • Page 24 Nose Housing Nut Apply grease to the inside of Nose Housing Nut (see adjacent picture). Apply grease Mast Housing SA Nose Housing Insert the SA Nose Housing on to the Mast Housing of the tool. Mast Housing SA Nose Housing Tighten the SA Nose Housing on to the thread of the Mast Housing by hand.

  • Page 25: Operation Test And Appearance Check

    9. Operation Test and Appearance check Operation Check Set 20 rivets of 4.8mm(3/16”) SSD-6*-BS and 10 rivets of 4.8mm(3/16”) AD-6*-ABS to check followings: ⚫ The tool does not slip ⚫ Rivet setting is done in one stroke ⚫ There is no protruding mandrels ⚫...

  • Page 26: Accessories

    10. Accessories JP (JAPAN) Model number PB2500-JP183 BATTERY PACK DCB183-JP(1PC) CHARGER DCB115-JP SA NOSEPIECE, 4 TRM00823 SA NOSEPIECE, 5 TRM00824 JAW PUSHER ASSEMBLY, 4 TP124-635 JAW PUSHER ASSEMBLY, 5 TP124-548 FOAM SPACER TRM00194(1PC) INSTRUCTION MANUAL TRM00622 BRIEF INSTRUCTION TRM00623 MANUAL NA (NORTH AMERICA) Model number PB2500-NA203...
  • Page 27 GB (GREAT BRITAIN) Model number PB2500-GB183 BATTERY PACK DCB183-QW(1PC) CHARGER DCB115-GB SA NOSEPIECE, 4 TRM00823 SA NOSEPIECE, 5 TRM00824 JAW PUSHER ASSEMBLY, 4 TP154-502 JAW PUSHER ASSEMBLY, 5 TP154-505 FOAM SPACER TRM00194(1PC) INSTRUCTION MANUAL TRM00201 XE (AUSTRALIA) PB2500-XE-B-KIT Model number SA NOSEPIECE, 4 TRM00823 SA NOSEPIECE, 5...
  • Page 28 KR (SOUTH KOREA) Model number PB2500-KR-B-KIT SA NOSEPIECE, 4 TRM00823 SA NOSEPIECE, 5 TRM00824 JAW PUSHER ASSEMBLY, 4 TP154-502 JAW PUSHER ASSEMBLY, 5 TP154-505 FOAM SPACER TRM00194(1PC) INSTRUCTION MANUAL TRM00201 A9 (CHINA) PB2500-A9-B-KIT Model number SA NOSEPIECE, 4 TRM00823 SA NOSEPIECE, 5 TRM00824 JAW PUSHER ASSEMBLY, 4 TP154-502...

  • Page 29: Exploded View

    11. Exploded View...

  • Page 30: Bom

    12. BOM PB2500-JP Part number Description Part number Description Accessories TRM00825 Sa Nosepiece, 614 DPN900-021 O ring TRM00823 SA, Nosepiece, 414 TRM00394 Nosepiece, 614 DPN900-013 O ring TP144-645 TRM00820 Nosepiece, 414 PRS2500-01 Jaw guide TP144-645 13300 1set TRM00824 SA, Nosepiece, 514 TP124-549 SA Jaw pusher, 6 DPN900-013...
  • Page 31 PB2500-NA Part number Description Part number Description Accessories TRM00825 Sa Nosepiece, 614 DPN900-021 O ring TRM00823 SA, Nosepiece, 414 TRM00394 Nosepiece, 614 DPN900-013 O ring TP144-645 TRM00820 Nosepiece, 414 PRS2500-01 Jaw guide TP144-645 71210-15001 Jaws 1set TRM00824 SA, Nosepiece, 514 TP154-500 SA Jaw pusher, 6 DPN900-013...
  • Page 32 PB2500-QW Part number Description Part number Description Accessories TRM00825 Sa Nosepiece, 614 DPN900-021 O ring TRM00823 SA, Nosepiece, 414 TRM00394 Nosepiece, 614 DPN900-013 O ring TP144-645 TRM00820 Nosepiece, 414 PRS2500-01 Jaw guide TP144-645 71210-15001 Jaws 1set TRM00824 SA, Nosepiece, 514 TP154-500 SA Jaw pusher, 6 DPN900-013...
  • Page 33 PB2500-GB Part number Description Part number Description Accessories TRM00825 Sa Nosepiece, 614 DPN900-021 O ring TRM00823 SA, Nosepiece, 414 TRM00394 Nosepiece, 614 DPN900-013 O ring TP144-645 TRM00820 Nosepiece, 414 PRS2500-01 Jaw guide TP144-645 71210-15001 Jaws 1set TRM00824 SA, Nosepiece, 514 TP154-500 SA Jaw pusher, 6 DPN900-013...
  • Page 34 PB2500-XE Part number Description Part number Description Accessories TRM00825 Sa Nosepiece, 614 DPN900-021 O ring TRM00823 SA, Nosepiece, 414 TRM00394 Nosepiece, 614 DPN900-013 O ring TP144-645 TRM00820 Nosepiece, 414 PRS2500-01 Jaw guide TP144-645 71210-15001 Jaws 1set TRM00824 SA, Nosepiece, 514 TP154-500 SA Jaw pusher, 6 DPN900-013...
  • Page 35 PB2500-XD Part number Description Part number Description Accessories TRM00825 Sa Nosepiece, 614 DPN900-021 O ring TRM00823 SA, Nosepiece, 414 TRM00394 Nosepiece, 614 DPN900-013 O ring TP144-645 TRM00820 Nosepiece, 414 PRS2500-01 Jaw guide TP144-645 71210-15001 Jaws 1set TRM00824 SA, Nosepiece, 514 TP154-500 SA Jaw pusher, 6 DPN900-013...
  • Page 36 PB2500-KR Part number Description Part number Description Accessories TRM00825 Sa Nosepiece, 614 DPN900-021 O ring TRM00823 SA, Nosepiece, 414 TRM00394 Nosepiece, 614 DPN900-013 O ring TP144-645 TRM00820 Nosepiece, 414 PRS2500-01 Jaw guide TP144-645 71210-15001 Jaws 1set TRM00824 SA, Nosepiece, 514 TP154-500 SA Jaw pusher, 6 DPN900-013...
  • Page 37 PB2500-A9 Part number Description Part number Description Accessories TRM00825 Sa Nosepiece, 614 DPN900-021 O ring TRM00823 SA, Nosepiece, 414 TRM00394 Nosepiece, 614 DPN900-013 O ring TP144-645 TRM00820 Nosepiece, 414 PRS2500-01 Jaw guide TP144-645 71210-15001 Jaws 1set TRM00824 SA, Nosepiece, 514 TP154-500 SA Jaw pusher, 6 DPN900-013...

  • Page 38: Troubleshooting Guide

    Troubleshooting Guide Symptom Cause Remedy Tool does not operate when switch Battery is defective Replace battery is pressed. Battery is not fully charged Charge battery Battery is not fully seated Remove battery and re-insert. Reset tool to home. Battery pack has reached operating Remove battery &...
  • Page 39 Broken rivet stems jammed in Nose Service and clean Nose Assembly. Equipment. Refer to Accessories Manual. Check Nose Equipment is correct for rivet Broken rivet stems jammed in Pulling Empty Stem Collector and clear Head Assembly. Pulling Head Assembly. Debris in Nose Piece. Service and clean Nose Assembly.
  • Page 40 TRM00791 211210-1...

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