FSI PT-4000-1 User manual

PT-4000-1
Operating Instructions
MKT-02 1/13

PT-4000-1 Rivet Capacity
The PT-4000-1 pulls most all pull style blind rivets including CherryMax and Cherry “A” Max
thru 1/4” diameter in all materials and Blind Bolts and Maxibolts thru 3/16” diameter.
Equipment/Accessories
Nosepieces: 3/32 thru 1/4
Wrench: SW 12 (covers nosepiece compartment)
Suspension Loop: Flips open from housing
Battery: Quick Charge/ 12 Volt DC
Technical
Data
Weight: 4.85 lbs (with battery)
Stroke: 0.787”
Drive Unit: 14.4 V direct current motor
Traction Power: 4,000 lbs.
Nosepiece Table
Rivet Diameter Rivet Body Material *Rivets Per Charge Nosepiece Part No.
3/32” Aluminum 1,900 F140
1/8” Aluminum 1,300 F159
1/8” Steel 1,100 F159
1/8” Stainless Steel 1,000 F159
5/32” Aluminum 1,000 F143
5/32” Steel 900 F143
5/32” Stainless Steel 800 F143
3/16” Aluminum 700 F143
3/16” Steel 500 F143
3/16” Stainless Steel 400 F143
1/4” Stainless Steel 90 F142
* Rivets per battery charge based on Mil-R-24243 style blind rivets in maximum grip condition
1.

Attention: Do not cover or stick anything into the vent holes.
Starting Procedure
Install fully charged battery into housing. Select proper nosepiece (see page 2) and screw into
head.
Operating Procedure
Pushing the trigger starts the operation. When releasing the trigger, the jaw mechanism returns to
the start position automatically.
Eject the spent mandrel into the mandrel container by tilting the tool backward, or through the
nosepiece by tilting tool forward.
The riveting tool is equipped with overload protection. In case if an overload, the operation will
be stopped and the red light goes on. If that happens, release the trigger and the mechanism will
return to the start position.
The battery will deliver uniform power for tool operation until depleted to the last 2-3 rivets of
charge capacity. It is designed to have the jaw mechanism return to the starting position when the
trigger has been released.
Maintenance
The maintenance of the riveting tool is limited to the complete jaw mechanism and the included
wearing parts.
Remove the battery (#40) from the tool housing. Unscrew the head (#13) from the tool and clean
it. Unscrew the jaw housing (#12) from the coupler. Take out the jaws (#11), clean and lubricate
or replace if worn. Reassemble in reverse order and make sure that all parts are tightened!
Warranty
There is a 12 month warranty from the day of delivery on the PT-4000-1. Damages caused by
common wearing, overloading or improper usage or handling are excluded from the warranty.
Damages caused by material or manufacturing faults will be covered by this warranty and will be
repaired or replaced at no cost. Claims can only be accepted if the complete riveting tool, fully
assembled, is returned to the distributor or FSI.
2.

Charger Battery
Input Voltage: 110 V/60 Hz Rated Voltage: 12 VDC
Output Voltage: 12 VDC Number of Cells: 10 Pieces
Recharge Time: Approx. 1 hour Cell Construction: Nickel-Metal with
Weights: 2.6 lbs. Overcharge protection
Capacity: 3.2 amp hour
Weight: 1.4 lbs
Recharging Procedure
Take charger out of steel case and connect to power line.
Make sure the voltage is in accordance with the label!
The battery must be installed correctly (positive pole to positive pole) with minimal force into
the charger. The quick recharging procedure is automatically started and indicated by red light.
After approximately 1 hour the charging procedure is finished and the charger switches to
trickle charge, indicate by a green light.
Place only cool batteries into the charger in order to obtain a full battery recharge.
Battery Handling
The battery is rechargeable up to 1000 times and reaches its full power only after several
recharging's. Do not discharge the battery completely. Recharge is not used for an extended
period.
Substantially reduced operating time of battery after a proper recharge indicates the battery
must be replaced. Keep battery in a cool and dry place, with temperature not to exceed (122 F).
Environmental Protection
If batteries have to be replaced, the following instructions should be followed:
Return used batteries to your supplier or FSI for recycling. Under no circumstances should
nickel-cadmium batteries be discarded as normal waste which might be burned or exposed to
ground water.
3.
Battery / Charger Technical Data

Blind Rivet Cannot be Set
Causes Remedy
Depleted battery charge Recharge, if necessary replace
Jaws dirty or worn Clean and lubricate or replace
Jaw pusher spring weak Tighten
When trigger is pressed, no function Replace
(red indicator light shows)
Troubleshooting
No Spent Mandrel Discharge
Causes Remedy
Wrong nosepiece Exchange according to page 2
Nosepiece worn Replace
Mandrel jammed in jaws Loosen the mandrel, clean and lubricate the
jaws or replace
Head Dirty inside Clean
Spent mandrel container filled Remove and empty
Passage clogged Remove clogged mandrels and check for free
ejection
Red Light Indicated Faults
A) When trigger is pressed
Causes Remedy
Overheating of electronic control Allow too to cool to ambient temperature
B) While pulling the rivet
Causes Remedy
Overloading Check working capacity
Overheating of electronic control Allow tool to cool to ambient temperature
Depleted battery charge Recharge or replace
C) After releasing the trigger
Causes Remedy
Jaw mechanism is not reaching the front Tighten jaw mechanism
position 4.

Maintenance Instructions
General Notes
Warranty repairs are carried out by the manufacturer only. Repairs outside the warranty period
should only be carried out by trained personnel. The following instructions must be strictly
adhered to, as assembly or adjustment errors may cause major damage to the PT-4000-1.
Repair Tools & Lubricant
For repair of the PT-4000-1, the following should be available:
Screw Driver Torx T 20
Hexagonal Wrench SW 2.5 mm
Open End Wrench 27 mm
Open End Wrench 17 mm
Open End Wrench 14 mm
Lubricating Grease (#46)
Dismantling the PT-4000-1
Remove battery (#40) from the tool. Unscrew spent mandrel container (#39). Remove housing
screw (3 pcs. #32 & 5 pcs. of #33) with screw driver Torx T 20.
Take off hand guard (#31). Take off top of tool housing (#1) and pull off the red and blue
connecting wires from the electronic control (#26). Unscrew electronic control (#26) using
screw driver Torx T 20.
Unscrew magnet holder (#27) using the hexagonal wrench SW 2.5mm. Take out electronic
control (#26) and magnet holder (#27). Take out motor (#25).
ATTENTION: Reassembly Tip: Note how connecting wires to the motor are
laid out in the tool housing!
Take out drive system (#42). Unscrew head (#13) using open end wrench SW 27mm.
Unscrew jaw housing (#12) using open end wrench SW 17mm and take out jaws (#11), jaw
pusher (#10) and jaw pusher spring (#9).
Unscrew jaw housing coupler (#7) with scraper ring (#8) using open end wrench SW 14mm.
Remove screws (4 of #6) using hexagonal wrench SW 2.5mm. Pull off drive bearing (#3) and
pinion shaft (#4) with snap ring (#6) and bushing (#20).
5.

Assembly & Stroke Adjustment
Assembly of Drive System (#42) Slip drive bearing (#3) over ball screw drive (#2) and put
pinion shaft (#4) together with snap ring (#5) in bearing place.
Attention: Before screwing ball screw drive (#2) and drive bearing (#3) together, make sure
the locating marking “B” of the bearing disk inside the ball screw drive (#2) is placed opposite
the pinion shaft (#4). See Parts Drawing.
Assemble this entire unit together with the 4 screws (#6) using hexagonal wrench SW 2.5mm.
Screw jaw housing coupler (#7) with scraper ring (#8) onto ball screw using open end wrench
SW 14mm.
Put jaw pusher spring (#9) and jaw pusher (#10) onto jaw housing coupler (#7). Place the jaws
(#11) in jaw housing (#12) and screw this onto jaw housing coupler (#7) using open end wrench
SW 17mm.
Screw head (#13) on using open end wrench SW 27mm.
Assembly of the PT-4000-1
The sub-assemblies and other parts should be put into tool housing half (#1) containing the
nosepiece bracket as follows:
To install drive system (#42), slip the bushing (#20) onto the shorter end of the pinion shaft (#4)
while ensuring that the snap ring (#5) in pressed to the gear.
To insert the tube (#22), the longer end of the tube must be inserted into the ball screw, while
the collar of the tube must be inserted into the provided recess of the tool housing.
To place the motor connecting wire, the red wire should be bent downwards at the soldering tag
towards the blue wire, then bent again to be parallel with the blue wire.
To install motor (#25), the two connecting wires are to be places side by aide around the first
guiding stud of the tool housing and behind the middle guiding studs. The wires should then be
brought up in front of the third guiding stud.
The electronic control unit (#26) should be installed by putting it on the stud inside the tool
housing and then fastened with the housing screw (#32). Click magnet holder (#27) in the
guiding slot of the electronic control (#26).
Fasten other end of magnet holder (#27) to ball screw drive (#2) with magnet holder screws
(#28) together with two spring lock washers (#29) using the hexagonal screw drive SW 2.5.
For later stroke adjustment, do not tighten the screws. Plug the two blue connecting wires of
motor (#25) and electronic control until (#26) together.
DO NOT CONNECT RED WIRE YET!!
6.

Stroke Adjustment
Turn gear of pinion shaft until distance “A” measures 0.118” -See Parts Drawing. Then insert
battery (#40) correctly in tool housing.
ATTENTION: Positive pole of battery (#40) must be at top to avoid dam-
age of electronic control unit (#26).
While trigger is pressed, magnet holder (#27) must be adjusted in slot of electronic control until
red indicator light goes on. After releasing trigger, the two magnet holder screws (#28) must be
tightened. NOW connect red wire to electronic control (#26).
ATTENTION: Both connecting wires must be places around guiding stud on
electronic control (#26) in such a way to keep slot free
for movement of magnet holder (#27).
Preliminary Motor Test: Motor (#25) is be carefully held down at both ends. Make sure to
allow room for magnet holder to move back and forth. Pull trigger to move jaw mechanism
about .200 to .400 inches, and release trigger.
Check distance “A” (See Parts Drawing). It must be 0.039” - 0.051”
If distance “A” gap is below 0.039”, magnet holder (#27) should be moved carefully to
the right after loosening the to screws (#28) in order to obtain .039 to .051 gap.
If distance “A” gap is larger that 0.051”, magnet holder must be moved to the left
accordingly. After tightening the screws (#28), repeat test and recheck distance “A”.
Take battery (#40) out of toll housing.
Finishing
Lubricate gear teeth with lubricating grease (#46). Insert suspension loop (#30). Insert hand
guard (#31). Replace second half of tool housing.
Tighten both halves of tool housing (#1) together with the five housing screws (#33) and the
three housing screws (#32) using screw driver Torx T 20.
7.

Safety Notes
The PT-4000-1 has been designed and manufactured in accordance with the applicable safety
regulations. If the PT-4000-1 is being used for the intended purpose in accordance with
instructions and normal safety measures, there is no danger involved during operation.
WARNING!
Never operate the PT-4000-1 without placing the blind rivet
in proper hole of the work piece or material.
The rivet could be propelled from the tool.
Avoid pointing the tool at anyone during operation.
The spent mandrel container (#39) must always be firmly screwed into place on the tool
during operation. Do not plug or cover vent holes in tool housing an any time.
Repairs should be carried out by trained personnel only. Otherwise, return PT-4000-1 to
supplier or to FSI.
Do not operate the PT-4000-1 and the Battery Charger in an environment allowing exposure
to moisture, combustible fluids or gases.
Avoid damage to cord and plug of charger. Inspect regularly for any damage. Ensure that the
battery is properly secured in the tool housing.
Take the charger out of steel case when recharging the battery. Place the battery in the correct
position (+pole to +pole) and do not force it into the charger.
Always remove the battery before servicing / repairing the PT-4000-1.
Do not discard batteries into water or fire as danger of explosion exists. Any used battery be
disposed of in accordance with environmental regulations.
Do not use the PT-4000-1 for any function other than riveting, especially not as a hammer.
8.

Safety Precautions
The PT-4000-1 Blind Riveter has been designed with safety in mind and it conforms to all
applicable regulations governing cordless battery operated tooling. If utilized in accordance
with operating instructions, danger free application of the tool is assured.
CAUTION: Do not rivet without the rivet being installed into material.
The rivet body and a portion of the mandrel can shoot away
from the tool which could cause injury.
Stem canister (Item #39) should always be mounted on the tool to catch spent stems.
The ventilation holes to the electric motor must not be obstructed. Do not cover or place
anything over them.
Repairs should only be undertaken by skilled and trained repair technicians. If unsure, send the
tool back to your dealer or the factory.
The PT-4000-1 and the battery charger unit must be kept away from moist / wet surroundings
and away from flammable liquids and gases. Do not use in temperatures above 120 degrees F.
Socket, Plug and Charger unit should be routinely inspected, and if damaged, replaced or
repaired.
To charge batteries, remove charger from steel case. The battery pack will only fit into charger
socket in proper orientation and is installable with a minimum amount of insertion pressure.
When working on the PT-4000-1 (i.e., replacing jaws, jaw follower or spring) be sure the
battery pack is removed from the riveter.
Do not throw battery pack into water or fire as they can explode. The battery pack should be
recycled according to instruction manual.
9.

Item Part No. Description Item Part No. Description
1F3014 Tool Housing, complete 22 F3761 Spent mandrel tube
2F3189 Ball screw drive, assembled 25 F3103 Motor, complete
3F3185 Drive bearing, complete 26 F3850-1Electronic control
4F3193 Power transfer gear 27 F3266 Magnet holder, complete
5F3753 Snap ring 28 F3990 Magnet holder screw
6F3932 Screw 29 F3008 Spring lock washer
7F3605 Draw Bolt 30 F3559-1Suspension loop
8F3745 Scraper ring 31 F3540 Hand guard
9* F3081 Jaw pusher spring 32 F3032 Housing screw
10* F3245 Jaw pusher, 1/4” 33 F3024 Housing screw, short
11* F123 Jaws (3 pc) 35 F3030 Nosepiece bracket
12 F126-FJaw housing 36 F3091 Nosepiece holder
13 F130-FNosetube 37 F3834 Nosepiece wrench
14 F505U Nosepiece, 5/32” Blind Bolt 39 F3282 Spent mandrel container
15 F506 Nosepiece, 3/16” Blind Bolt 40 F-3001A Battery Pack
16 F505-MB Nosepiece, 5/32” Maxibolt 41 F3555 Lubricating grease
17 F506-MB Nosepiece, 3/16” Maxibolt 42 F3197 Drive system (pos. 2-13,15)
18 F169 Nosepiece, 1/4” Monobolt 43 F142 1/4” Nosepiece
19 F143 Nosepiece, 3/16 CherryMax 45 F-4000A Battery Charger
20 F3893 Bushing * Wearing Parts
10.

11.
*F3245
Jaw Follower
Right Angle Pulling Head
F1075
Extended Straight
Pulling Head F1074
Offset Pulling Head
F1076
F126-F
Jaw Holder F123
3 pc Jaws
F3621
Jaw Follower
F3093
Spring
Nosepiece
Standard
Configuration
CherryMax® Pulling
Head Configuration
F187-3BCM
Adjustable Adapter
Shaft
F187-1AR
Sleeve
F122-A
2 pc Jaws
*Note: Replace Jaw Follower
F3621 with F3245 (see spare
parts canister) when in-
stalling 1/4” dia. rivets. You
may also use the F123 (3pc)
jaws for 1/8” thru 1/4” diam-
eter blind rivets.
1/4” Rivets
PT-4000-1 (optional) Configurations
Rivet Types:
Types of rivets installable
with the PT-4000-1 in-
clude, but are not limited
to, virtually all Cherry-
Max® (M7885), Avdel®,
or Cherry Monobolts®,
Cherry Interlock®, Huck
MagnaLok®, and Pop
type rivets. The PT-4000
-1 is also capable of
installing both 5/32” and
3/16” Blind Bolts
(MS90353/54-S/U) with
the proper nosepieces
(provided in the Mil-1
and MIL-2 kits).
Aerospace and Industrial
Sheet Metal Applications
*
CherryMax® &
Pop® Rivets
Configuration
F3245
Jaw Follower
Nosepiece
F130-F
Nose Tube
F123-A or
F123-B
BB Jaws
F128
BB Jaw Holder
F3081
Spring
F130-F
Nose Tube
MS90353/54 “U” &
“S” Type Blind Bolt
Configuration
F3081
Spring
F3081
Spring
F3605
Draw Bolt

Pulling Head Assembly
Right Angle Pulling Head (F1075): Thread the internal threads of the pulling head’s
draw bolt two or three turns onto the adapter puller shaft. Next, engage the threads of the
pulling head housing and continue threading into place. To minimize stroke requirement
and to set a particular rivet size, simply adjust the nose tube of the right angle head by loos-
ening the jam nut at its base.
Extended Straight (F1074): Thr ead the extended straight pulling head’s haw holder
assembly onto the adapter puller shaft assembly. (Tighten by putting rivet stem into
adapter puller shaft hole to keep it from rotating.) Next, take the straight pulling head’s
jam nut and back it off at least ten full turns from the end. Now thread the adapter sleeve
into place, approximately six full turns. Use the red marker on the jam nut to aid in
counting. Next, engage battery pack into tool and fully retract the draw bolt / haw holder
assembly. While keeping the jaw holder fully retracted, insert desired rivet stem into
nosepiece (to set up for use with all sizes 3/16 oversize). Now allow the jaw holder
assembly to come forward. If it easily accommodates the stem (i.e., you can move it in and
out freely), you can now tighten the jam nut into place. If, however, it does not readily
accept or release the stem freely, begin turning the outer sleeve clockwise in quarter turn
increments until a proper setting is reached.
Offset Pulling Head (F1076): Thr ead the internal thr eads of the offset pulling head’s
draw bolt onto the male thread of the adapter puller shaft. Take two or three turns before
engaging the male threads of the pulling head housing. How thread both into place until
there is no gap between the housing and the draw bolt. Now tighten jam nut.
CAUTION: If you tighten the outer sleeve too far down, it will restrict the return of the
draw bolt, thereby causing an overload condition on the tool. The red indicator light
will come on. Remove the battery immediately, loosen outer sleeve, and restart as-
sembly procedure. Failure to relieve condition can damage the tool.
12.

PT-4000-1
Operating Instructions For Blind Bolt and Maxibolt Conversion
When pulling Blind Bolts and Maxibolts you will need to use the following items:
For 5/32 or 3/16 Blind Bolts and Maxibolts:
Remove Nose Tube (F130-F). Thr ead off Jaw Holder (F126-F) and Jaws (F122-A) and
set aside. Be careful not to allow the spring and jaw follower to come out of the tool. Next,
you will need the Blind Bolt Jaw Holder (F128). Insert Jaw Set (F123-A) 5/32 size into
holder, keep rubber O-Ring securely around the three piece jaws. This is important because
you must keep the jaws aligned at all times while pulling Blind Bolts or Maxibolts to pre-
vent the stem from jamming and cracking the jaws. Thread Jaw Holder (F128) onto the
Draw Bolt (F3605) and thr ead nose tube back onto the tool. Then use the 5/32 Maxi-
bolt Nosepiece (F505-MB) for S-Type Blind Bolts or the 5/32 Blind Bolt Nosepiece
(F505U) for the U & S Type Blind Bolts. Reverse the process to assemble tool for r eg-
ular CherryMax riveting.
For 3/16 Blind Bolts and Maxibolts:
Remove Nose Tube (F130-F). Thr ead off Jaw Holder (F126-F) and Jaws (F122-A) and
asset aside. Be careful not to allow the spring and jaw follower to come out of the tool.
Next, you will need the Blind Bolt Jaw Holder (F128). Insert Jaw Set (F123-B) 3/16 size
into holder, keep rubber O-Ring securely around three piece jaws. This is important be-
cause you must keep the jaws aligned at all times while pulling Blind Bolts or Maxibolts to
prevent the stem from jamming and cracking the jaws. Thread Jaw Holder (F128) onto the
Draw Bolt (3605) and thread nose tube back onto the tool. Then use the 5/32 Maxibolt
nosepiece (F506-MB) for S-Type Blind Bolts or the 5/32 Blind Bolt Nosepiece (F506) for
the U & S Type Blind Bolts. Reverse the process to assemble the tool for regular Cherry-
Max riveting.
13.