Pop ProSet 1600 Series User manual

Rivet
Tool
ProSet®1600 Series
Maintenance Manual

Page 2 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Contents
Introduction...............................................................................................................................................2
Safety Instructions....................................................................................................................................3
Specifications ...........................................................................................................................................4
Packaged Accessories..........................................................................................................................4
Tool Requirements................................................................................................................................4
ProSet®1600 Tool Dimensions.............................................................................................................5
Common Nosepieces............................................................................................................................6
Basic Tool Operation ................................................................................................................................6
Front End Service.................................................................................................................................7
Mandrel Collection System (MCS) – ProSet®1600 MCS .....................................................................8
Cleaning the Collector Silencer.............................................................................................................8
Tool Assembly Torque Requirements....................................................................................................9
ProSet®1600/1600MCS Diagram..........................................................................................................10
Parts List ................................................................................................................................................12
Hydraulic Oil Charging Procedure..........................................................................................................14
Maintenance...........................................................................................................................................15
Safety Data.............................................................................................................................................16
Troubleshooting......................................................................................................................................17
EC Declaration of Conformity.................................................................................................................18
Introduction
POP®ProSet®1600 tools are light weight Air/Hydraulic rivet setting tools recommended for use with genuine
POP®Brand Rivets per following chart:
Rivet Diameter
Rivet Type Material
(Body – Mandrel) 3/32” (*)
[2.4 mm] 1/8” [3.0 - 3.2 mm] 5/32” [4.0 mm]
Al – Al 999
Al – St / SS 999
St – St 999(†)
Open End & MultiGrip
SS – SS; Mo – St /SS 99
Al – Al 999
Al – St / SS; Cu – St 999()
St – St 99
Closed End
SS – SS 99
LSR Rivets Al – Al 999
HR™ Rivets St – St 99
T - Rivet Al – St 999
Self Plugger St – St 99
Al: Aluminum, St: Steel, SS: Stainless Steel, Cu: Cooper, Mo: Monel
(*) 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. [phone] - Fax [phone] Page 3
Safety Instructions
TO INSURE PROPER FUNCTIONING AND SAFE OPERATION READ THIS MANUAL
CAREFULLY BEFORE SETTING UP OR OPERATING THE POP®ProSet™ 1600 SERIES TOOLS
1. DO NOT use this tool in a manner other than that recommended by Emhart Teknologies.
2. Always wear eye protection when using or when near a tool that is in use.
3. This tool is NOT designed for use in explosive atmospheres.
4. Inspect tool for damage before connecting to air supply including all air connections.
5. Trained personnel must perform tool repair and/or maintenance at the prescribed intervals.
6. Disconnect the air supply when adjusting, servicing or removing any part of the tool.
7. Keep fingers off the trigger when connecting the air supply or if the air supply fails.
8. Keep fingers away from the front of the tool when connecting the air supply or setting rivets.
9. DO NOT point the tool at anyone.
10. DO NOT operate tool with the nose housing removed.
11. DO NOT operate tool without the Deflector or Collector.
12. DO NOT modify the tool in any way. Modification will make void any applicable warranties
and could result in damage to the tool or physical injury to the user.
13. DO NOT look into the tool from the front or the back during use or when connected to air
supply.
14. The operating pressure must not exceed 100 psi (6.9 bar).
15. DO NOT direct tool exhaust towards anyone.
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. [phone] - Fax [phone]
Specifications
ProSet®1600 ProSet®1600MCS
Weight 2.15 lbs. (0.98 kg) 2.30 lbs. (1.05 kg)
Length 10.83” (275 mm) 10.71” (272 mm)
Height 8.94” (227 mm) 8.94” (227 mm)
Stroke 0.71” (18 mm) 0.71” 18 mm)
Air Consumption 0.043 cu. ft. per rivet
(1.22 lper rivet) 2.47 scfm (max.)
(70 l/min (max.))
Pulling Force 1090 lbs. @ 90 psi (4850 N @ 0.62 MPa)
Noise Level LAeq,T = 80.2 dB(A), LWA = 85.0 dB(A), LPeak = 110.4 dB(C)
Vibration Level 0.54 m/s2, Time to 2.5 m/s2> 24hrs (EAV)
Packaged Accessories
Qty Item PROSET1600 PROSET1600MCS Part No.
1 ProSet®1600 Rivet Tool 99-
1 Operating Instructions 99P449
1 Maintenance Manual 99P513
1 Nosepiece for 3 size open end rivets 99PRN314
1 Nosepiece for 4 size open end rivets Installed Installed PRN414
1 Nosepiece for 5 size open end rivets 99PRN514
1 Jaw Pusher (Assy.) for 3/32” rivets 99FAN239-176
1 Air Line Assembly 99FAN239-157
1 4 mm Hex. Socket Screw Key 99DPN239-139
1 Warranty Card 99FG2184
Tool Requirements
Air supply * 6 scfm (150 l/min) Minimum
Recommended Operating Pressure 72.5-90 psi (0.5-0.62 MPa) dry, filtered
Maximum Operating Pressure 100 psi (0.69 MPa) dry, filtered
Hydraulic Oil ** POP®p/n: PRG540-130 [1 qt. (.945 ml)]
Jaw Lubricant ** POP®p/n: PRG510-130 [6 oz. (177 ml)]
Seal Lubricant ** POP® p/n: 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. [phone] - Fax [phone] Page 5
ProSet®1600 Tool Dimensions
.682” (17.3 mm)
10.83” (275 mm)
8.94” (227 mm)
2.99” (76 mm)
3.27” (83 mm)
ProSet
®
1600
1.83” (46.5 mm)
3.3” (82 mm)
1.82” (46.3 mm)
10.71” (272 mm)
3.27” (83 mm)
2.99” (76 mm)
.682” (17.3 mm)
8.94” (227 mm)
ProSet
®
1600 MCS
1.83” (46.5 mm)
1.82” (46.3 mm)
3.23” (82 mm)

Page 6 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Common Nosepieces
* Included with the tool
Use FAN239-176 instead of DPN239-144 (installed) when using 3/32” (2.4mm) or smaller diameter
rivets.
Basic Tool Operation
Before operating the tool check the following:
Inspect tool for damage or leaking oil – do not use tool if it is damaged or leaking oil.
Check that correct nosepiece is fitted and tightened to 60 - 65 in-lbs [6.8 – 7.3 N-m] torque.
Check that the nose housing nut (8) is tight – hand tighten only.
Connect tool to air supply – see air supply requirements (page 4).
Fit Mandrel Collector (96) – (MCS tool only).
Open air supply valve by Sliding red OS Sleeve (93) on side of tool (see note below).
Insert rivet into nosepiece.
Position rivet in work piece.
Pull trigger to set rivet.
Release trigger – if equipped, MCS suction will draw mandrel into the collector.
!Note: The ProSet®1600 has an OS (Open-Shut) Valve for switching the air supply ON and OFF to
save air when the tool is not in use.
Closed End HR Rivets
Rivet Diameter Open End Steel Mandrel Aluminum
Mandrel Aluminum Body Steel Body Jaw Pusher
2.0 mm PRN214 - - - -
FAN239-176*
(PRG402-02 - JAWS)
3/32” (2.4 mm) PRN314* - - - - FAN239-176*
1/8” (3.2 mm) or
7/64” (2.8 mm) PRN414* PRN424 PRN434 PRN414* PRN4K
5/32” (4.0 mm) PRN514* PRN524 PRN534 PRN514* - DPN239-144*
Air Supply ON: Open OS Valve
by sliding OS Sleeve in the
direction shown (up).
A
ir Supply OFF: Close OS Valve
by sliding OS Sleeve in the
direction shown (down).
OS Sleeve

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 7
Front End Service
For optimum tool performance, Front-End Service should be performed regularly as per the “Preventative Maintenance
Schedule”.
!Note: UNPLUG AIR SUPPLY while servicing front-end to avoid INJURY.
1. REMOVE NOSE HOUSING:
Unscrew the Nose Housing Nut by hand and
slide Nose Housing off the tool.
2. REMOVE JAW GUIDE TO ACCESS JAWS
AND INTERNAL PARTS:
Pull back the Jaw Guide Lock to disengage the
Jaw Guide Lock Teeth and unscrew and remove
the Jaw Guide.
Remove Jaws, Jaw Pusher, and Jaw Pusher
Spring for servicing.
3. CLEAN PARTS:
Clean Jaws, Jaw Guide, Jaw Pusher, Spring
and thread area of the Pulling Head.
Apply Seal Lube to outside surface of Jaws and
inside surface of the Jaw Guide.
4. REASSEMBLY OF INTERNAL PARTS AND JAW
GUIDE:
Place the Jaws into the Jaw Guide and slide the Jaw
Pusher Spring and Jaw Pusher into the Pulling Head.
Apply a small amount of Seal lubricant to the Pulling
Head threads and Jaw Guide Lock teeth. Screw the Jaw
Guide onto the Pulling Head until the teeth on the Jaw
Guide Lock stop the Jaw Guide rotating.
Apply Jaw lubricant to the Jaw area by submerging the
assembled Jaw Guide into Jaw lube about 1 in. (25mm).
Clean off excess Jaw Lube from the outside of the Jaw
Guide.
5. REINSTALL NOSE HOUSING ASSEMBLY:
Refit the Nose Housing and Hand-tighten the Nose
Housing Nut securely against the O-Ring. If the Nut is
not tightened sufficiently against the O-Ring there may
be a loss of suction.
Nose Housing
Nose Housing Nut
Wrench Flat
Jaw Guide
Pulling Head
Jaw Guide Lock
Housing Adapter
O-Ring
Jaw Guide Lock motion

Page 8 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
Mandrel Collection System (MCS) – ProSet®1600 MCS
For safety purposes, removing the Collector from the tool automatically turns the MCS suction OFF. Refitting
the Collector turns the MCS suction ON.
Cleaning the Collector Silencer
For optimum performance, the Collector Silencer should be cleaned at regular intervals as per the
“Preventative Maintenance Schedule”.
!Note: UNPLUG AIR SUPPLY while servicing Collector to avoid INJURY.
1. CLEAN THE COLLECTOR :
•Remove and empty the Collector (96) by turning counterclockwise.
•Remove the Collector End Nut (106) (17mm wrench) and remove the Collector End Cap (105).
•Remove the Collector Silencer (103).
•Clean and remove debris from all components.
Collector Silencer (103)
Collector End (104)
Collector End Cap (105)
Collector End Nut (106)
Collector Body (101)
MCS suction ON MCS suction OFF

Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 9
2. RE-ASSEMBLE THE COLLECTOR :
•Secure Collector End (104) to Collector Body (101). Use a screwdriver or similar tool to hold the
Collector End in place during re-assembly (see picture below).
•Place the Collector Silencer (103) onto the Collector End (104).
•Place Collector End Cap (105) on Collector Body End (104).
•Install and tighten Collector End Nut (106) on Collector End (104).
Tool Assembly Torque Requirements
Item Part No. Description Torque Value
1
119
120
PRN414
PRN314
PRN514
Nosepiece 4 size
Nosepiece 3 size
Nosepiece 5 size
60 – 65 in-lbs (6.8 – 7.3 N-m)
51 DPN239-053 Sleeve Lower 35 - 39 ft-lbs (47 - 53 N-m)
61 DPN239-063 Sleeve Lock Nut 31 - 35 ft-lbs (42 - 48 N-m)
88 DPN907-003 Socket Head Cap Screw 46 - 51 in-lbs (5.2 – 5.8 N-m)
See exploded Tool Diagram
Screwdriver

Page 10 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]
ProSet®1600/1600MCS Diagram
(*) These items require Loctite®242 adhesive.
(†) These items have a specific tightening torque as indicated in the “ToolAssembly Torque Requirements” table.
Use with 3 size rivets