Pop ProSet 2500 Series User manual

Rivet
Tool
ProSet®2500 Series
Maintenance Manual

Contents
Introduction...............................................................................................................................................2
Safety Instructions....................................................................................................................................3
Specifications ...........................................................................................................................................4
Packaged Accessories..........................................................................................................................4
Tool Requirements................................................................................................................................4
®2500 Tool Dimensions.............................................................................................................5ProSet
Common Nosepieces............................................................................................................................6
Basic Tool Operation ................................................................................................................................6
Front End Service.................................................................................................................................7
®2500 MCS .....................................................................8Mandrel Collection System (MCS) – ProSet
Cleaning the Collector Silencer.............................................................................................................8
Tool Assembly Torque Requirements....................................................................................................9
®2500/2500MCS Diagram ..........................................................................................................10ProSet
Parts List ................................................................................................................................................12
Hydraulic Oil Charging Procedure..........................................................................................................14
Maintenance...........................................................................................................................................15
Safety Data.............................................................................................................................................16
Troubleshooting......................................................................................................................................17
EC Declaration of Conformity.................................................................................................................18
Introduction
®
POP®ProSet 2500 tools are light weight Air/Hydraulic rivet setting tools recommended for use with genuine
POP Brand Rivets per following chart:
Rivet Diameter
Material
(Body – Mandrel)
Rivet Type 1/8”(*)
[3.2 mm] 5/32”(*) [4.0 mm] 3/16”(**) [4.8 mm]
Al – Al 999
Al – St / SS 999
St – St 999
Open End & MultiGrip
9(†) SS – SS; Mo – St /SS 99
Al – Al 999
Al – St / SS; Cu – St 999
St – St 999
Closed End
SS – SS 999
LSR Rivets Al – Al 999
HR™ Rivets St – St 99(**) 9
T - Rivet Al – St 999
Self Plugger St – St 999
UltraGrip Al-Al , St- St, SS-SS - - 9
Al: Aluminum, St: Steel, SS: Stainless Steel, Cu: Cooper, Mo: Monel
(*) Use FAN275-028 Jaw pusher set up. (**) Use DPN275-027 Jaw pusher set up.
(†) Exclude MultiGrip™
Page 2 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]

Safety Instructions
TO INSURE PROPER FUNCTIONING AND SAFE OPERATION READ THIS MANUAL
CAREFULLY BEFORE SETTING UP OR OPERATING THE POP®ProSet™ 2500 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.
Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 3

Specifications
® ®
ProSet ProSet
Packaged Accessories
Qty Item PROSET 2500 PROSET 2500MCS Part No.
1 ProSet®2500 Rivet Tool 99-
1 Operating Instructions 99P449
1 Maintenance Manual 99P534
1 Nosepiece for 4 size open end rivets 99PRN414
1 Nosepiece for 5 size open end rivets 99PRN514
1 Nosepiece for 6 size open end rivets Installed Installed PRN614
1 Jaw Pusher (Assy.) for 1/8,5/32” rivets 99FAN275-028
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 (5.0-6.2 Bar) dry, filtered
Maximum Operating Pressure 100 PSI (6.9 Bar) 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)]
2500 2500MCS
2.65 lbs. (1.20 kg) 2.89 lbs. (1.31 kg)
Weight
Length 11.42” (290 mm) 11.97” (304 mm)
Height 10.20” (259 mm) 10.20” (259 mm)
0.71” (18 mm) 0.71” (18 mm)
Tool stroke
Pulling force 2110 lbs @ 90 PSI (9400 N @ 6.2 bar) 2110 lbs @ 90 PSI (9400 N @ 6.2 bar)
Air consumption 0.076 cu. ft. per rivet
(2.15 liters per rivet)
2.47 scfm (MAX)
(70 ℓ/min (MAX))
(*) Note: For best results and long service life, use dry, filtered air supply.
(**) Note: See lubricant safety information.
Page 4 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]

ProSet®2500 Tool Dimensions
.811” (20.6 mm)
11.97” (304 mm)
10.20” (259 mm)
3.46” (88 mm)
1.85” (47 mm)
3.54” (90 mm)
2.15” (54.5 mm)
3.11” (79 mm) ProSet®2500 MCS
ProSet®2500
3.11” (79 mm)
11.42” (290 mm)
3.54” (90 mm)
.811” (20.6 mm)
10.20” (259 mm)
3.46” (88 mm)
2.15” (54.5 mm)
1.85” (47 mm)
Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 5

Common Nosepieces
Closed End HR Rivets
Rivet Diameter Open End Jaw Pusher
Steel
Mandrel Aluminum Mandrel Aluminum Body Steel Body
1/8” (3.2 mm) or
7/64” (2.8 mm) PRN414* PRN424 PRN434 PRN414* PRN4K FAN275-028*
PRN514* PRN524 PRN534 PRN514* -
5/32” (4.0 mm) - - - - PRN5K
DPN275-027*
3/16” (4.8 mm) PRN614* PRN624 PRN634 PRN614* PRN6K
* Included with the tool
Use FAN275-028 instead of DPN275-027 (installed) when using 7/64” (2.8mm) - 5/32” (4.0mm).
Use N-406 nosepiece when using 3/16” (4.8mm) UltraGrip® ®
rivets; use N-410 for Monobolt 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™ 2500 has an OS (Open-Shut) Valve for switching the air supply ON and OFF to
save air when the tool is not in use.
Air Supply ON
: Open OS Valve
by sliding OS Slider in the
direction shown (up).
A
ir Supply OFF: Close OS Valve
by sliding OS Slider in the
direction shown (down).
OS Slide
r
Page 6 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]

®
ProSet 2500 Front End Service
For optimum tool performance, Front-End maintenance should be performed regularly as per the “Preventative
Maintenance Schedule”.
!Note: UNPLUG AIR SUPPLY while servicing front-end to avoid INJURY.
Jaw Guide
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 Lube 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 Pulling Head
Jaw Guide Lock
Housing Adapter
Wrench Flat
Jaw Guide Lock motion
O-Ring
Pulling Head Locking Teeth.
Jaw Guide teeth
Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 7

®
Mandrel Collection System (MCS) – ProSet 2500 MCS
For safety purposes, removing the Collector from the tool automatically turns the MCS suction OFF. Refitting
the Collector turns the MCS suction ON.
MCS suction ON MCS suction OFF
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)
Page 8 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]

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).
Screwdriver
Tool Assembly Torque Requirements
Item Part No. Description Torque Value
1
119
120
PRN614
PRN414
PRN514
Nosepiece 6 size
Nosepiece 4 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
Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone] Page 9

ProSet®2500/2500MCS Diagram
(*) These items require Loctite®242 adhesive.
(†) These items have a specific tightening torque as indicated in the “Tool Assembly Torque Requirements” table.
Use with 4 or 5 size rivets
Page 10 Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. [phone] - Fax [phone]