Pop PRT5400 Installation instructions

5400 Series Rivet Tools
PRT5400 / PRT5400LS / MCS5400 / MCS5400LS
Operator and Maintenance Manual

IMPORTANT
READ THE FOLLOWING SAFETY INSTRUCTIONS CAREFULLY.
DISCONNECT TOOL FROM AIR SUPPLY BEFORE ATTEMPTING SERVICE.
SERVICE SHOULD ONLY BE PERFORMED BY TRAINED PERSONNEL.
WARNING: SERVICE PROCEDURES SHOULD BE PERFORMED ONLY BY
TRAINED SERVICE PERSONNEL.
INSTRUCTION MANUAL
Page 2 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com

SAFETY INSTRUCTIONS
1. Always wear eye protection when operating the tool.
2. To avoid injury
do not point the tool at anyone.
3. Do not exceed recommended maximum air pressure (100 psi max.).
4.
Disconnect the tool from the air supply when not in use for an extended period of time
or before proceeding with any maintenance procedures. Take care to control air hoses when dis-
connecting to prevent whipping.
5. Do not attempt to operate the tool with the Nose Housing removed. This exposes potential
pinch points and could result in injury.
6.
Do not tamper with the Clamp Screws or Fill Screw. Loosened screws may result in
malfunction or injury due to air or hydraulic pressure.
7.
Do not operate the tool without either the deflector (PRT Option) or the collector (MCS
Option) installed on the tool.
Spent rivet mandrels may be forcefully ejected.
8.
Always clear the tool of spent rivet mandrels before setting a new fastener. Failure to do so may
result in tool jams or forceful ejection of spent mandrels.
9.
Use caution when holding the tool at an angle since compressed air is released through
the Intensifier Chamber and may be directed toward the operator. Do not direct exhaust towards
anyone.
10. Inspect the tool at regular intervals for damage and proper function.
Replace damaged parts
immediately. Do not connect a damaged tool to an air supply.
11. Use only genuine Pop
®
brand replacement parts.
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 3
DESCRIPTION AND MODEL IDENTIFICATION
The 5400 Series tools are lightweight air-hydraulic Rivet Tools capable of setting all commercial blind
rivets up to and including 1/4" (6.4mm) diameter in all materials. Four models are available.
PRT5400 Standard model without mandrel collector.
MCS5400 Standard model with automatic vacuum mandrel collector attached.
PRT5400LS Long stroke version without mandrel collector.
MCS5400LS Long stroke version with automatic vacuum mandrel collector attached.
To determine model check length and height specifications or shipping carton label. Models PRT5400 and
MCS5400 are shipped set up for 3/16" (4.8 mm) and smaller diameter rivets. A simple front end parts change
is required to for setting larger diameter rivets. Refer to Service Procedures, Section 1 of this manual for more
information. All the necessary parts are included in the carton. Models PRT5400LS and MCS5400LS are
shipped set up for 1/4" (6.4 mm) diameter rivets. Parts to convert for smaller rivets are included in the carton.

Page 4 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com
PACKED IN CARTON - MODELS PRT5400 and MCS5400
Part Number Part Name Data
Model 5400 Rivet Tool Assembled with air line
PRG540-56 Deflector Safety device - PRT5400 (LS) only
MCS5400-8 Collector bottle MCS5400(LS) only
PRT5500-8 Jaw Pusher 1/4" (6.4mm) diameter rivets
PRG540-44 Jaws 1/4" (6.4mm) diameter rivets
PRN414 Nosepiece 1/8" (3.2mm) open end rivets
PRN514 Nosepiece 5/32" (4.0mm) open end rivets
PRN811 Nosepiece 1/4" (6.4mm) open end rivets
PRG540-127 Screw Use for Hydraulic oil replacement
P342 Operator's Instructions
P343 Instruction Manual
PACKED IN CARTON - MODELS PRT5400LS and MCS5400LS
Part Number Part Name Data
Model 5400 Rivet Tool Assembled with air line
PRG540-56 Deflector Safety device - PRT5400 (LS) only
MCS5400-8 Collector bottle MCS5400(LS) only
PRT5500-6 Jaw Pusher 3/16" (4.8mm) and smaller dia. rivets
PRG540-46 Jaws 3/16" (4.8mm) and smaller dia. rivets
PRG540-43 Mandrel Guide Tube 3/16" (4.8mm) and smaller dia. rivets
PRN414 Nosepiece 1/8" (3.2mm) open end rivets
PRN514 Nosepiece 5/32" (4.0mm) open end rivets
PRN614 Nosepiece 3/16" (4.8mm) open end rivets
PRG540-127 Screw Use for Hydraulic oil replacement
P342 Operator's Instructions
P343 Instruction Manual

SPECIFICATIONS
PRT5400 MCS5400
Weight: 2.1 Kg (4.63 lbs.) 2.25 Kg (4.96 lbs.)
Length: 296.75mm (11.68 in.) 322.10mm (12.66 in.)
Height: 306.23mm (12.13 in.) 306.23mm (12.13 in.)
Stroke: 18mm (.708 in.) 18mm (.708 in.)
Pulling Force: 15.1 kN (3400 lbs.) 15.1 kN (3400 lbs.)
Operating Pressure: 5.8 bar (85 psi.) 5.8 bar (85 psi.)
Air Consumption: .57 litres/rivet (.02 cu.ft.) .57 litres/rivet (.02 cu.ft.)
+.057 cu.m/min. (2 scfm)
PRT5400LS MCS5400LS
Weight: 2.15 Kg (4.74 lbs.) 2.3 Kg (5.07 lbs.)
Length: 304.75mm (12.00 in.) 326.49mm (12.93 in.)
Height: 336.59mm (13.25 in.) 336.59mm (13.25 in.)
Stroke: 26mm (1.02 in.) 26mm (1.02 in.)
Pulling Force: 15.1 kN (3400 lbs.) 15.1 kN (3400 lbs.)
Operating Pressure: 5.8 bar (85 psi.) 5.8 bar (85 psi.)
Air Consumption: .78 litres/rivet (.028 cu.ft.) .78 litres/rivet (.028 cu.ft.)
+.057 cu.m/min. (2 scfm)
THEORY OF OPERATION
When the tool is connected to an air supply and the Trigger is operated, pressurized air pushes the air
piston which acts on the Hydraulic Ram Assembly. The Hydraulic Ram Assembly forces hydraulic fluid from the
reservoir in the handle into the main hydraulic bore where it moves the hydraulic piston together with the
attached pulling mechanism rearward. As the pulling Jaws move rearward they close on and grip the rivet man-
drel and set the rivet.
When the trigger is released air at line pressure forces the hydraulic piston forward to the starting position. As
the hydraulic piston moves forward the hydraulic fluid is also forced back returning the hydraulic fluid and the
Ram Assembly and air piston to the starting position. The compressed air used to set the rivet is quietly exhaust-
ed through the base of the Intensifier Chamber. When the hydraulic piston is fully returned the broken rivet man-
drel is released as the Jaws are forced open again by the Nosepiece.
If the tool is equipped with a Mandrel Collection System (MCS models) the mandrel will be drawn out of the tool
and deposited in the Collector Bottle.
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 5

Note: Numbers in bold type refer to call out numbers in illustration.
Page 6 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com
PREPARATION FOR OPERATION
CAUTION:
Do not connect to air supply until all tool parts are properly installed.
Wear eye protection when operating this tool.
AIR SUPPLY REQUIREMENTS
1. Use a dry, filtered air supply regulated to 75
- 85 psig (5 - 6 bar). A minimum of 3.0 scfm
(85.0 liters / min.) is recommended. It is not nec-
essary and undesirable to lubricate the air sup-
ply. Excess oil, water or debris in the air supply
will necessitate more frequent tool service and
significantly reduce the operating efficiency of
the Mandrel Collection System. If the recom-
mended operating pressure is exceeded the
tool may not function because there is a built in
pressure limiter.
2. For optimum performance connect the tool air
line to an air supply line at least as large in
diameter as the air line supplied with the tool -
6.35mm (1/4 in.) minimum.
3. A lightweight, 6' (1.83 m) air line is supplied
attached to the tool to minimize operator
fatigue. Attaching an air line coupler at the tool
adds weight and changes the balance of the
tool.
PRT5400 / MCS5400
1. Select and attach the appropriate Nosepiece
(12-A, 12-B, 12-C) based on the rivet size /
mandrel diameter. The PRT5400 and MCS5400
Models arrive assembled with Nosepiece 12-C
suitable for 3/16" (4.8mm) diameter open end
rivets. To convert for smaller size rivets it is only
necessary to change the Nosepiece.
2. To set up the tool for 1/4" (6.4mm) diameter open end rivets attach Nosepiece 12-D, install Jaws 3-B, and
Jaw Pusher 22-B and remove Mandrel Guide Tube 71. Refer to SERVICE PROCEDURES. A wide variety
of Nosepieces are available from your POP distributor for special rivets and special applications or to
improve access problems.
3. Attach Deflector 47 or Collector 58 before operating tool.
PRT5400LS / MCS5400LS
1. Select and attach the appropriate Nosepiece (12-A, 12-B, 12-C, 12-D) based on the rivet size /
mandrel diameter. The PRT5400LS and MCS5400LS Models arrive assembled with Nosepiece 12-D suit-
able for 1/4" (6.4mm) diameter open end rivets.
2. To convert for smaller size rivets attach the appropriate Nosepiece (12-A, 12-B, 12-C) and install Jaws 3-A,
Jaw Pusher 22-A and Mandrel Guide Tube 71. Refer to SERVICE PROCEDURES.
3. Attach Deflector 47 or Collector 58 before operating tool.
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OPERATION
1. Attach Air Line 72 to air supply.
2. If so equipped, turn on the Mandrel Collection System by rotating the Switch/Deflector Ring 67 on the
Mandrel collector until one of the indicators is aligned with the arrow on the top of the tool. There are three
ON positions so that the air exhaust may be directed away from the operator.
3. Insert a rivet mandrel into the Nosepiece 14. If the tool is equipped with a Mandrel Collection System (MCS
Models) the rivet will be held in the tool by vacuum.
4. Guide the tool until contact is made between the face of the rivet head and the outer surface of the piece to
be riveted.
5. Squeeze the trigger 13 to set the rivet. Once the rivet is set, release the trigger. If using a PRT5400 or
PRT5400LS be sure to clear the mandrel from the tool by tipping the tool to let the mandrel slide either out
the front or out the back of the tool. If using the MCS5400 or MCS5400LS the mandrel will be automatical-
ly propelled into the mandrel Collector Bottle.
SERVICE PROCEDURES
CHANGING TOOL SET UP FOR DIFFERENT RIVET SIZES
To prevent mandrel jams from occurring and to maximize jaw life it is important to install the correct Nosepiece,
Jaws, Jaw Pusher and Mandrel Guide tube.
For 3/16" (4.8mm) diameter or smaller rivets use the following parts:
Item 3Jaws, Part No. PRG540-46
Item 22 Jaw Pusher, Part No. PRT5500-6
Item 71 Mandrel Guide Tube, Part No. PRG540-43
Item 12 Nosepiece - PRN414 for 1/8" (3.2mm) diameter rivets
PRN524 for 5/32" (4.0mm) diameter rivets
PRN614 for 3/16" (4.8mm) diameter rivets
For 1/4" (6.4mm) diameter rivets use the following parts:
Item 3Jaws, Part No. PRG540-44
Item 22 Jaw Pusher, Part No, PRT5500-8
Item 12 Nosepiece - PRN811 for 1/4" (6.4mm) diameter rivets
(no Mandrel Guide Tube is required)
Equipment Needed: 7/16" (11mm) O.E. Wrench
Two adjustable wrenches 1" (26mm) or larger
Soft-jawed vise
Procedure
1. Place the tool in a soft-jawed vise, gripping the tool in the center of the handle.
2. Remove the Nosepiece 12.
3. Remove the Nose Housing 44.
4. Remove the Jaw Guide 11, Jaws 3and Jaw Pusher 22.
5. Insert (or remove) the Mandrel Guide Tube 71 into the Jaw Pusher Spring 5.
6. Install the correct Jaw Pusher 22.
7. Install the correct Jaws 3.
8. Re-install the Jaw Guide 11 and tighten to torque specifications in Table 1.
9. Replace the Nose Housing 44 and tighten to torque specifications in Table 1.
10. Install correct Nosepiece 12 and tighten to torque specifications in Table 1.
Caution:
Read the Operator Instruction Leaflet before operating the tool.
Note: Numbers in bold type refer to call out numbers in illustration.
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 7

Page 8 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com
Note: Numbers in bold type refer to call out numbers in illustration.
SERVICING THE JAWS, JAW PUSHER AND JAW PUSHER SPRING
Regularly cleaning the Jaws and front end parts will prevent mandrels sticking in the Jaws and extend the life
of the Jaws.
1. Disassemble the tool front end as described above. Clean Jaws 3using a brush and solvent. If jaw teeth
show significant wear replace both jaws.
2. Check Jaw Pusher Spring 5for fatigue. A new spring measures 2-1/8" (54mm) in length. Replace spring if
shorter than 1-7/8" (46mm).
3. Thoroughly clean the inside of the Jaw Guide 11, Nose Housing 44, the Jaw Pusher 22 and wipe out or blow
out debris from around other exposed parts.
4. Lightly oil Jaws 3and Jaw pusher 22 before reassembling.
5. Reassemble parts in reverse order tightening Jaw Guide 11, Nose Housing 44 and Nosepiece 12 to torque
specifications in Table 1.
REPLENISHMENT OF HYDRAULIC FLUID
A shortened stroke indicates minor hydraulic fluid loss. Small amounts of fluid can be replaced without
disassembling the tool.
Equipment Needed: Oil Replacement Screw, 3/8" - 24 Socket Head Cap Screw
Large slotted screwdriver
Hydraulic Fluid
Soft jawed vise
7/16" (11mm) open end wrench
Procedure
1. Place the tool in a soft-jaw vise, making sure the Fill Screw 10 is point-
ing up.
2. Remove the Nosepiece 12, the Fill Screw 10 and Seal Washer 4.
3. Screw the Oil Replacement Screw into the Nose Housing where the
Nosepiece 12 was removed. Tighten only until resistance is felt.
4. To properly add fluid, the Hydraulic Piston 26 must be pushed back. To
do this,
simultaneously turn the Oil Replacement Screw into the Nose
Housing (approximately 8-10 turns of the screw) while adding the oil
one drop at a time through the Fill Screw opening.
Do not tighten the
Oil Replacement Screw since internal tool damage may result.
5. Allow bubbles to rise out of the oil and top off if necessary.
6. Reinstall Fill Screw 10 and Seal Washer 4. Tighten securely. For torque
specifications see Table 1.
7. Remove the Oil Replacement Screw. Replace the Nosepiece 12 and
tighten securely.
8. Reconnect the air supply.
9. Loosen Fill Screw 10 very slightly, allowing excess oil to be forced out.
10. Wipe tool clean and tighten Fill Screw 10 to torque specifications in Table 1.
If oil loss is rapid or excessive, refer to the service manual for seal replacement procedures.
Caution: The tool must be disconnected from the air supply before attempting
to replenish hydraulic fluid.
Caution: Do not depress the trigger when Fill Screw 10 is loose. This will
cause oil to be forced out under great pressure.
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PRT5400, MCS5400, PRT5400LS, MCS5400LS
DISASSEMBLY & ASSEMBLY INSTRUCTIONS
SERVICE NOTES
All disassembly procedures should be performed in a clean, well lighted work area. O-rings, seals and sealing
surfaces should be lightly lubricated with a white mineral oil based grease such as Lubriplate 130-AA or equiv-
alent prior to assembly. Do not use solvents other than approved hydraulic fluid to clean O-rings or seals.
Numbers in bold type in this manual refer to item numbers in illustrations.
RECOMMENDED TOOLS AND EQUIPMENT
Soft jawed vice Small wire brush for jaws
Cross recess screw driver Set of adjustable open end wrenches
Large slotted screw driver 19mm (3/4 inch) deep socket wrench
Small slotted screwdriver 2mm (.080 inch) pin punch
Torque wrench Torque screwdriver
Small machinist's hammer Internal retaining ring pliers
Narrow nose pliers Slip joint pliers
Hydraulic fluid Lubriplate 130-AA or equivalent
Clean soft rags
FRONT END ASSEMBLY
1. Place the tool in a soft jawed vise with the Nose Housing 44 pointing upward. Grip the tool gently on the
aluminum casting in the middle of the handle grip area.
2. Remove Nosepiece 12.
3. Remove Nose Housing 44.
4. Remove Jaw Guide 11.
5. Remove Jaws 3and Jaw Pusher 22.
6. Remove Mandrel Guide Tube 71 if so equipped.
7. Remove Jaw Pusher Spring 5.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Clean all parts including the serrated teeth of the Jaws, the inside of the Jaw Guide, between the Pulling
Head Adaptor 28 and the Wiper Retainer Washer 24 and the inside of the Nose Housing. Replace any worn
or damaged parts before reassembling.
2. Check to see if the Jaw Pusher Spring 5has been shortened by use. Replace spring if shorter than 48mm
(1-7/8 inches).
3. Lubricate Jaws 3and Jaw Pusher 22 before reassembling.
4. Tighten Jaw Guide 11, Nose Housing 44 and Nosepiece 12 to torque specifications in Table 1.
IMPORTANT
READ SAFETY INSTRUCTIONS ON PAGE 2 OF INSTRUCTION MANUAL.
DISCONNECT TOOL FROM AIR SUPPLY BEFORE ATTEMPTING SERVICE.
SERVICE SHOULD BE PERFORMED BY TRAINED PERSONNEL ONLY.
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 9
Note: Numbers in bold type refer to call out numbers in illustration.

Page 10 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com
Note: Numbers in bold type refer to call out numbers in illustration.
HANDLE CAP ASSEMBLY (PRT OPTION)
1. Remove Deflector 47.
2. Remove Handle Cap Screws 48.
3. Pull off Handle Cap 49.
4. Remove O-rings 8and 35.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Lubricate O-rings prior to installation.
2. Tighten Handle Cap Screws 48 to torque specification in
Table 1.
INTENSIFIER ASSEMBLY (PNEUMATIC PISTON)
1. Loosen the Fill Screw 10.
2. Place the tool in a soft jawed vise with the Intensifier Chamber 45
up. Grip the tool gently on the aluminum casting in the middle of the
handle grip area.
3. Remove Clamp Screws 37 and 38, Clamp Nuts 23, Right Clamp 42
and Left Clamp 43.
4. Remove Intensifier Chamber 45, Intensifier Chamber Sleeve 46
and O-ring 8. Pull out the Intensifier Chamber Sleeve 46 and
remove Grommet 21.
5. Slowly withdraw the Intensifier Assembly 29 by pulling up on the air
piston.
6. Remove the Ram Seal 40 from the Ram using a plastic or wooden
wedge to push the seal off the end of the Ram. Take care not to
damage the sealing surfaces of the Ram stem.
7. Remove Air Piston Seal 30.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Lubricate all O-rings and seals prior to installation.
2. Lubricate the inside of the Intensifier Chamber Sleeve
46 prior to assembly.
3. Fill tool with hydraulic fluid prior to installation of
Intensifier Assembly 29. Refer to HYDRAULIC FLUID
CHARGING PROCEDURE in this manual.
4. Tighten Fill Screw 10 and Clamp Screws and Nuts 37,
38 and 23 to torque specifications in Table 1.
35
8
49
48
47
40
30
29
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PULLING HEAD ASSEMBLY (HYDRAULIC PISTON)
1. Remove Nose Housing 44 (steps 1-7 in the FRONT END ASSEMBLY section of this manual), Intensifier
Chamber 45 and Intensifier Assembly 29 (steps 1-3 in the INTENSIFIER ASSEMBLY section of this
manual).
2. Remove Handle Cap Assembly 49 (PRT Option - see HANDLE CAP ASSEMBLY section of this manual) or
Mandrel Collection System Assembly (MCS Option - see MANDREL COLLECTION SYSTEM ASSEMBLY
section of this manual).
3. Loosen but do not remove the Fill Screw 10. Remove the tool from the vise. Invert the tool over a container
to drain hydraulic fluid from the Ram Sleeve 32. Then remove Fill Screw 10 and Fill Screw Washer 4. Allow
hydraulic fluid to drain out before continuing disassembly of the tool.
4. Using internal retaining ring pliers remove Sleeve Retaining Ring 18.
5. Position the rear end of the Hydraulic Piston Rod 26 on a flat work surface and push down on the tool Handle
31 to push the Pulling Head Assembly out of the front of the Handle.
6. Firmly grasp the Pulling Head Adaptor 28 and gently but firmly pull the entire Pulling Head Assembly the rest
of the way out of the Handle 31.
7. Using a 19mm (3/4") deep socket wrench on Hydraulic Piston Rod 26 loosen and remove Pulling Head
Adaptor 28 and slide Seal Sleeve assembly 25 off the Hydraulic Piston Rod.
8. To disassemble the Seal Sleeve 25, remove Seal Snap Ring 20 using
internal retaining ring pliers. Remove Seal Retainer Washer 19, Rod
Seal 17, O-ring 41 and Piston Rod Seal 6. Take care not to damage seal-
ing surfaces on the Seal Sleeve.
9. Using narrow nose pliers squeeze and pull to remove Piston Seal 27.
Note: this is a two part seal - be sure to also remove the inner seal ener-
gizer ring. Do not reuse old seal or energizing ring. Take care not to
scratch the sealing surfaces of the Hydraulic Piston Rod 26.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Lubricate all O-rings and seals prior to installation.
2. Refer to torque specifications in Table 1 when tighten Pulling Head
Adaptor 28 to Piston Rod 26 and when installing Fill Screw 10.
Before reinstalling the Pulling Head Assembly into the tool lubricate the
bore chamfer. Take care not to cut or damage Piston Seal 18.
3. Do not force the Seal Sleeve 25 into final position. To seat the Seal
Sleeve, screw in the Nose Housing 44 to gently and slowly push the Seal
Sleeve into position then remove the Nose Housing and install the
Sleeve Retaining Ring 18.
20
19
17
6
25
41
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 11
Note: Numbers in bold type refer to call out numbers in illustration.

Page 12 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com
Note: Numbers in bold type refer to call out numbers in illustration.
RAM SLEEVE ASSEMBLY
1. Remove Intensifier Assembly 29 (steps 1-4 in the INTENSI-
FIER ASSEMBLY section of this manual).
2. Drain hydraulic oil (step 3 in PULLING HEAD ASSEMBLY
section of this manual).
3. Remove Retainer Plate Screws 1and Lock Washers 9.
4. Remove Ram Sleeve Retainer Plate 34.
5. Invert tool and using a pair of pliers gently grasp the outside
of the Ram Sleeve 32 and pull to remove. Take care not to
grasp the inner surface of the Ram Sleeve or crush the Ram
Sleeve.
6. Remove the Restrictor 2and Restrictor Seat 33 from the end
of the Ram Sleeve 32. If the Restrictor and Restrictor Seat
remain in the tool, they can be dislodged by blowing com-
pressed air into the Fill Screw hole while covering the other
end of the casting to catch the parts.
7. Remove O-ring 36.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Lubricate all O-rings and seals prior to installation.
2. Before installing the Ram Sleeve Assembly place Restrictor
2in the upper recess of the Ram Sleeve 32, then using a
spot of lubricant adhere the Restrictor Seat 33 on the top rim
of the Ram Sleeve. Carefully insert the entire assembly
upward into the inverted tool Handle 31. When resistance is
felt carefully push on the end of the Ram Sleeve to seat O-
ring 36.
3. Tighten Retainer Plate Screws 1to torque specifications in
Table 1.

AIR VALVE AND PRESSURE REGULATOR ASSEMBLY
1. Remove Trigger 13 by driving out Trigger Pin 14 using 2mm (0.080") pin punch.
2. Remove Ram Sleeve Retainer Plate 34 (steps 1-4 in RAM SLEEVE ASSEMBLY section of this
manual).
3. Using the pin punch or a screwdriver through the Trigger opening gently push out the Pressure Regulator
39, the Air Valve Assembly 16, and the Valve Plug 15.
4. Remove O-rings 7.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Lubricate all O-rings and seals prior to installation.
2. Be sure to properly position the trigger slot in Pressure Regulator 39 so that the low side is forward toward
the trigger.
3. Install the Air Valve Assembly 16 so that the holes are parallel to the Nose Housing 44.
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 13
Note: Numbers in bold type refer to call out numbers in illustration.

MANDREL COLLECTION SYSTEM ASSEMBLY (MCS OPTION)
1. Remove Collector 58 and Collector Gasket 55.
2. Remove Vacuum Cap Screws 65, Filter Cover 59 and Filter 61.
3. Pull the Entire MCS Assembly from the Handle 31.
4. Grasp the Switch Deflector Ring 67 and the Vacuum Cap Body Assembly 63 and twist to remove
the Vacuum Cap Body Assembly. Take care not to lose O-rings 54 and 56 positioned between the two sec-
tions.
5. Remove the Muffler 62, the Air Block 68 and the Switch Deflector Ring 67.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Lubricate all O-rings and seals prior to installation.
2. Take care not to wrinkle or cut O-rings during assembly.
VACUUM CAP BODY SUB-ASSEMBLY
1. Note: It is normally not necessary to disassemble the
Vacuum Cap Body for cleaning. Blowing compressed air
into the various openings will usually clean out any debris.
2. Remove O-ring 47.
3. Using a small, pointed pick remove Pump Retainer 52.
4. Remove Vacuum Pump Assembly 53 consisting of two
brass turnings.
5. Remove two O-rings 70.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Lubricate all O-rings and seals prior to installation.
2. Take care not to wrinkle or cut O-rings during assembly.
VALVE HOUSING SUB-ASSEMBLY
1. Remove O-rings 8and 35.
2. Remove Valve Body Ring 69.
3. To remove the Valve Body 60 from the Valve Housing 66 blow compressed air into the smallest hole at the
front (tool end) of the Valve Housing 66 while covering the Valve Body 60 with a rag to catch the small parts
as they are dislodged.
4. Remove Valve Stem 64, Valve Guide 49, Spring 48 and O-rings 51 and 57.
ASSEMBLE IN REVERSE ORDER
Assembly Notes:
1. Lubricate all O-rings and seals prior to installation.
2. Take care not to wrinkle or cut O-rings during assembly.
3. Position Valve Body 60 so that outside curve matches curve of Valve Housing 66.
Page 14 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com
Note: Numbers in bold type refer to call out numbers in illustration.

HYDRAULIC FLUID CHARGING PROCEDURE
APPROVED HYDRAULIC FLUIDS
MOBIL - DTE26*
EXXON - NUTO H-68
SHELL - TELLUS 68
TEXACO - RANDO HD-68
*Available in .945mL (1 qt.) containers part no. PRG540-130
Note: If recharging a completely assembled tool cycling the tool a couple of times before disconnecting from
the air source will free up the seals.
IMPORTANT
TOOL MUST BE DISCONNECTED FROM THE AIR SUPPLY.
All procedures must be performed in a clean environment.
Use only approved hydraulic fluids specified in this manual.
Use hydraulic fluid that is clean and free from air bubbles.
Take care to prevent foreign matter from entering the tool.
CAUTION:
Disconnect the tool from the air supply before proceeding.
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 15

Page 16 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com
Note: Numbers in bold type refer to call out numbers in illustration.
PROCEDURE
1. Loosen Fill Screw 10.
2. Place the tool upside down in a soft jawed vise. Grip the tool gently on the aluminum casting in the middle
of the tool handle grip area.
3. Remove Clamp Screws 37 and 38, Clamp Nuts 23, Right Clamp 42 and Left Clamp 43.
4. Remove Intensifier Chamber 45, together with Intensifier Chamber Sleeve 46. Take care not to loosen
O-ring 8when removing these parts. Remove O-ring 8.
5. Slowly withdraw the Intensifier Assembly 29 by pulling up on the air piston.
6. If Fill Screw 10 and Fill Screw Washer 4have been removed during dismantling reinstall these before
proceeding and tighten hand tight.
7. Remove Nose Housing 44.
8. Pull out on the Pulling Head Adaptor 28 (or push on the rear of the Hydraulic Piston Rod 26) to ensure that
the Pulling Head Assembly (Hydraulic Piston) is fully forward.
9. Very slowly fill Ram Sleeve 32 with hydraulic fluid to the bottom of the chamfer. Take care to prevent
aeration of the hydraulic fluid.
10. Position Ram Assembly 29 over Ram Sleeve 32 and tilt slightly to immerse one edge of Ram Seal 40 into
the fluid, then straighten to fully immerse the seal without entrapping air. Push the Ram Assembly in as far
as it will go. The Hydraulic Piston Rod 28 will move rearward.
11. Remove Ram Assembly 29 and repeat steps 8, 9 and 10 above.
12. Remove the tool from the vise and stand it on the Air Piston on a flat surface.
13. Allow a few seconds for any entrapped air to rise in the tool before proceeding.
14. Place a spacer approximately 6mm (1/4 inch) thick between the Air Piston and the Handle 31 then slightly
loosen the Fill Screw 10 and slowly push down on the tool Handle expelling excess hydraulic fluid and
entrapped air from the Fill Screw hole. Continue pushing down until the Handle rests on the spacer.
15. Tighten Fill Screw 10 to torque specifications in Table 1, wipe Handle dry.
16. Lubricate the inside of Intensifier Chamber Sleeve 46 and the outside edge of the Air Piston Seal 30.
17. Reassemble Intensifier Chamber 45 and Clamps 42 and 43. Install Clamp Screws 37 and 38 and Clamp
Nuts 23 and tighten to torque specifications in Table 1.
18. Replace Nose Housing 44 and tighten to torque specification in Table 1.
19. Connect air supply to tool and check tool function and stroke length.

MAINTENANCE SCHEDULE
DAILY
1. Inspect tool and air supply hose for damage. Replace damaged parts immediately.
2. Purge air supply filters to eliminate accumulated dirt, oil and water.
3. Check to see that pressure regulator is properly set at 5 bar (85 psi).
4. Check tightness of Clamp Screws and Clamp Nuts 37, 38 and 23.
5. Check tightness of Fill Screw 10, Nosepiece 12 and Nose Housing 44.
6. Lubricate Jaws 3, with light oil or Jaw Lube (Part No. PRG510-130).
WEEKLY OR EVERY 15,000 CYCLES
1. Dismantle Front End Assembly, thoroughly clean all parts, check Jaws 3, Jaw Pusher 22 and Jaw Pusher
Spring 5for wear and replace as needed.
2. Lightly lubricate all parts before reassembling.
ANNUALLY OR EVERY 500,000 CYCLES
1. Dismantle tool and replace all seals and O-rings. Inspect all parts for wear or damage and replace as needed.
2. Lightly lubricate all seals, O-rings and front end parts before reassembling.
Table 1 – TORQUE SPECIFICATIONS
Torque in Torque in Torque in
Item Description Newton-Meters Inch-Pounds Foot-Pounds
12 Nosepiece 6.8 - 7.3 60 - 65 5.0 - 5.4
44 Nose Housing 52.0 - 54.2 460 - 480 38.3 - 40.0
11 Jaw Guide 20.3 - 24.9 180 - 220 15.0 - 18.3
28 Pulling Head Adaptor 61.0 - 63.3 540 - 560 45.0 - 46.7
10 Fill Screw 6.9 - 7.3 60 - 65 5.0 - 5.4
48 Handle Cap Screw 1.4 - 1.6 12 - 14 1.0 - 1.2
65 Vacuum Cap Screw 1.4 - 1.6 12 - 14 1.0 - 1.2
1 Retainer Plate Screw 0.9 - 1.1 8 - 10 0.7 - 0.8
37 Clamp Screw - Front 0.9 - 1.1 8 - 10 0.7 - 0.8
38 Clamp Screw - Rear 0.9 - 1.1 8 - 10 0.7 - 0.8
72 Air Line Assembly 3.4 - 4.5 30 - 40 2.5 - 3.3
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 17
Note: Numbers in bold type refer to call out numbers in illustration.

5400 SERIES PARTS LIST
ITEM PART NO. DESCRIPTION QTY.
1 PRG540-100 RETAINER PLATE SCREW 3
2 PRT5400-2 RESTRICTOR 1
3-A PRG540-46 JAWS (1/8
" -3/16 " , 3.2mm-4.8mm) PRT5400 & MCS5400 2
3-B PRG540-44 JAWS (1/4
" , 6.4mm) PRT5400LS & MCS5400LS 2
4 PRG540-102 FILL SCREW WASHER 1
5 PRG540-105 JAW PUSHER SPRING 1
6 PRG510-114 PISTON ROD SEAL 1
7 PRG540-117 O-RING 3
8 PRG540-118 O-RING 2
9 PRG540-120 LOCK WASHER 3
10 PRG540-122 FILL SCREW 1
11 PRH850-11 JAW GUIDE 1
12-A PRN414 NOSEPIECE (1/8
" , 3.2mm) 1
12-B PRN514 NOSEPIECE (5/32
" , 4.0mm) 1
12-C PRN614 NOSEPIECE (3/16
" , 4.8mm) PRT5400 & MCS5400 1
12-D PRN811 NOSEPIECE (1/4
" , 6.4mm) PRT5400LS & MCS5400LS 1
13 PRT5200-32 TRIGGER 1
14 PRT5200-33 TRIGGER PIN 1
15 PRT5200-35 VALVE PLUG 1
16 PRT5200-55 AIR VALVE ASSEMBLY 1
17 PRT5300-8 ROD SEAL 1
18 PRT5300-11 SLEEVE RETAINING RING 1
19 PRT5300-19 SEAL RETAINER WASHER 1
20 PRT5300-20 SEAL SNAP RING 1
21 PRT5400-26 GROMMET 1
22-A PRT5400-6 JAW PUSHER (1/8
" -3/16 " , 3.2mm-4.8mm) PRT/MCS5400 1
22-B PRT5400-8 JAW PUSHER (1/4
" , 6.4mm) PRT/MCS5400LS 1
23 PRT5400-113 CLAMP NUT 2
ITEM PART NO. DESCRIPTION QTY.
24 PRT5400-9 WIPER RETAINER WASHER 1
25 PRT5400-10 SEAL SLEEVE 1
26 PRT5400-14 HYDRAULIC PISTON ROD 1
27 PRT5400-15 PISTON SEAL 1
28 PRT5400-21 PULLING HEAD ADAPTOR 1
29 PRT5400-25 INTENSIFIER ASSEMBLY 1
30 PRT5400-28 AIR PISTON SEAL 1
31 PRT5400-31 HANDLE 1
32 PRT5400-46 RAM SLEEVE 1
33 PRT5400-47 RESTRICTOR SEAT 1
34 PRT5400-48 RETAINER PLATE 1
35 PRT5400-49 O-RING 1
36 PRT5400-59 O-RING 1
37 PRT5200-62 CLAMP SCREW - FRONT 1
38 PRT5200-63 CLAMP SCREW - REAR 1
39 PRT5400-50 PRESSURE REGULATOR 1
40 PRT5400-84 RAM SEAL 1
41 PRT5400-89 O-RING 1
42 PRT5400-42 RIGHT CLAMP 1
43 PRT5400-43 LEFT CLAMP 1
44-A PRT5400-22 NOSE HOUSING (PRT/MCS5400) 1
44-B PRT5400-72 NOSE HOUSING (PRT/MCS5400LS) 1
45-A PRT5400-29 INTENSIFIER CHAMBER (PRT/MCS5400) 1
45-B PRT5400-79 INTENSIFIER CHAMBER (PRT/MCS5400LS) 1
46-A PRT5400-30 INTENSIFIER CHAMBER SLEEVE (PRT/MCS5400) 1
46-B PRT5400-70 INTENSIFIER CHAMBER SLEEVE (PRT/MCS5400LS) 1
71 PRG540-43 MANDREL GUIDE (Installed on PRT5400 & MCS5400) 1
72 PRT5200-220* AIR LINE ASSEMBLY 1
ITEM PART NO. DESCRIPTION QTY.
47 MCS500-10* O-RING (CAP BODY-VALVE BODY) 1
48 MCS5200-3* SPRING 1
49 MCS5200-7* VALVE GUIDE 1
50 MCS5200-13* O-RING 1
51 MCS5200-18* O-RING 1
52 MCS5200-19* PUMP RETAINER 1
53 MCS5400-20* VACUUM PUMP (Assembly) 1
54 MCS5200-21 O-RING 1
55 MCS5500-16 COLLECTOR GASKET 1
56 PRG520-47 O-RING 1
57 PRG520-106* O-RING 1
58 MCS5400-8 COLLECTOR 1
59 MCS5400-2 FILTER COVER 1
60 MCS5400-4* VALVE BODY 1
61 MCS5400-5 FILTER 1
62 MCS5400-6 MUFFLER 1
63 MCS5400-9* VACUUM CAP BODY 1
64 MCS5400-10* VALVE STEM 1
65 MCS5400-11 VACUUM CAP SCREW 4
66 MCS5400-14* VALVE HOUSING 1
67 MCS5400-12 SWITCH/DEFLECTOR RING 1
68 MCS5400-16 AIR BLOCK 1
69 MCS5400-13* VALVE BODY RING 1
70 MCS500-22* O-RING 2
ITEM PART NO. DESCRIPTION QTY.
47 PRG510-56 DEFLECTOR 1
48 PRT5200-37 HANDLE CAP SCREWS 4
49 PRT5400-36 HANDLE CAP 1
MCS OPTION PRT OPTION
1. AIR LINE ASSEMBLY PRT5200-220 CONSISTS OF:
PRG540-39 AIR LINE 1
PRG540-40 AIR LINE FITTING, FEMALE 1
PRG540-45 O-CLAMP (Connects to air supply) 2
PRT5200-90 AIR LINE FITTING, MALE (Connects to tool) 1
2. ITEMS 48, 49, 50, 51, 57, 60, 64, 66 & 69 AVAILABLE AS AN ASSEMBLY -
MCS5400-30 VALVE HOUSING ASSEMBLY
3. ITEMS 47, 52, 53, 63 & 70 AVAILABLE AS AN ASSEMBLY -
MCS5400-40 VACUUM CAP BODY ASSEMBLY
NOTES:
Page 18 EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com

PRT Option
35
66
54
56
49
48
64
60
57
50
51 62
63
61
58
55
65
59
MCS Option
26
23
40
29
30
46
21
45
70
42
33
2
36
32
39
16
7
15
37
43
38
34
9
1
13
14
8
31
625 41
17 19
20
10
4
18
28
5
22-A
24
27
M
A
D
E
I
N
U
.
S
.
A
.
35 849
48
47
47
52
53
68
67
69
8
12-B
44
11
3-A
71
3-B
12-A
12-C12-D
22-B
72
EMHART TEKNOLOGIES • 50 Shelton Technology Center, Shelton, CT 06484 • Tel. (877) EMHART1 • Fax: [phone] • www.emhart.com Page 19

©2006 Emhart Industries, Inc.
Visit our Web Site at http://www.emhart.com P343 Rev. 1 (11/06)
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