Stanley 78200-010040 Troubleshooting guide

INSTRUCTION AND
SERVICE MANUAL
ORIGINAL INSTRUCTION
78200-010040 Mini MBS Workstation for Speed Rivets
Hydro-Pneumatic Power Tool
EN
Hydro-Pneumatic PowerTool
DE
Hydropneumatisches Setzgerät

©2022 STANLEY Black & Decker
All rights reserved.
The information provided may not be reproduced and/or made public in any way and through any means (electronically
or mechanically) without prior explicit and written permission from 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. Therefore, STANLEY Engineered
Fastening cannot be held liable for any damage resulting from deviations from the original specications of the product.
The information available has been composed with the utmost care. However, STANLEY Engineered Fastening will not
accept any liability with respect to any faults in the information nor for the consequences thereof. STANLEY Engineered
Fastening will not accept any liability for damage resulting from activities carried out by third parties. The working names,
trade names, registered trademarks, etc. used by STANLEY Engineered Fastening should not be considered as being free,
pursuant to the legislation with respect to the protection of trademarks.
CONTENT
1. SAFETY DEFINITIONS 4
1.1 GENERAL SAFETY RULES 4
1.2 PROJECTILE HAZARDS 5
1.3 OPERATING HAZARDS 5
1.4 REPETITIVE MOTIONS HAZARDS 5
1.5 ACCESSORY HAZARDS 5
1.6 WORKPLACE HAZARDS 5
1.7 NOISE HAZARDS 6
1.8 ADDITIONAL SAFETY INSTRUCTIONS FOR PNEUMATIC & HYDRAULIC POWER TOOLS 6
1.9 OPERATING COMPANY’S DUE DILIGENCE 6
1.10 PERSONNEL REQUIREMENTS 7
2. SPECIFICATION 8
2.1 78200010040 WORKSTATION SPECIFICATION 8
2.2 7050002000 MODULE SPECIFICATION 9
2.3 RIVETING EQUIPMENT 9
2.4 PRESSURE INTENSIFIER 9
2.3 PNEUMATIC CONTROL 10
3. INTENT OF USE 11
3.1 LAYOUT OF THE FASTENER RIVETING STATION MINIMBS 11
3.2 ARRANGEMENT OF CONTROL ELEMENTS 13
4. PUTTING INTO SERVICE 14
4.1 AIR SUPPLY 14
4.1.1 HOW TO CONNECT THE COMPRESSED AIR SUPPLY 14
4.1.2 HOW TO CONNECT THE PNEUMATIC HOSES 14
4.1.3 HOW TO CONNECT THE HYDRAULIC SYSTEM 15
4.2 SETUP 15
4.2.1 PRESSURE INTENSIFIER 16
4.2.2 CHECKING THE OIL LEVEL ON THE PRESSURE INTENSIFIER 16
4.3 PRESSURE SETTINGS 17
4.3.1 SETTING THE INPUT PRESSURE 17
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ENGLISH ORIGINAL INSTRUCTION

4.3.2 SETTING THE WORKING PRESSURE 17
4.3.3 ADJUSTING THE RETURN STROKE AT THE PRESSURE INTENSIFIER 17
4.4 LOADING THE SPEED FASTENER MODULES 18
4.4.1 CURSOR 18
4.4.2 LOADING THE MANDREL 18
4.4.3 LOADING THE SPEED FASTENER MODULE 18
4.5 OPERATING PROCEDURE 19
4.6 PLACING EQUIPMENT 20
4.7 STORAGE AND TRANSPORT 20
5. SERVICING THE TOOL 21
5.1 MAINTENANCE INTERVAL 21
5.2 MOLY LITHIUM GREASE EP 3753  SAFETY DATA 21
6. MAINTENANCE 23
6.1 DISMANTLING 7050002000 23
6.2 RECOMMENDED SPARE PARTS 23
6.3 PROTECTING THE ENVIRONMENT 23
7. PRIMING 24
7.1 OIL DETAILS 24
7.2 PRIMING PROCEDURE 24
8. FAULT DIAGNOSIS 25
9. DISPOSAL 26
9.1 DISPOSAL 26
10. EC DECLARATION OF CONFORMITY 27
11. UK DECLARATION OF CONFORMITY 28
12. PROTECT YOUR INVESTMENT! 29
13. THIRDPARTY DOCUMENTATION 30
13.1 PRESSURE INTENSIFIER 30
14. MINI MBS WORKSTATION DRAWINGS 32
14.1 MINI MBS WORKSTATION GENERAL ASSEMBLY DRAWING 32
14.2 PNEUMATIC CIRCUIT DIAGRAM 34
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ORIGINAL INSTRUCTION ENGLISH

This instruction manual must be read by any person installing or operating this tool with particular attention to the
following safety warnings and instructions.
Always wear impact-resistant eye protection during operation of the tool. The grade of protection required should
be assessed for each use.
Use of the tool can expose the operator’shands to hazards, including crushing, impacts, cuts and abrasions and
heat. Wear suitable gloves to protect hands.
Use hearing protection in accordance with employer’sinstructions and as required by occupational health and
safety regulations.
1. SAFETY DEFINITIONS
The denitions below describe the severity for each signal word. Please read the manual and pay attention to these symbols.
DANGER:Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING:Indicates apotentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION: Indicates apotentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION: Used without safety alert symbol indicates apotentially hazardous situation which, if not avoided, may result
in property damage.
Improper operation or maintenance of this product could result in serious injury and property damage.
Read and understand all warnings and operating instructions before using this equipment. When using
power tools, basic safety precautions must always be followed to reduce the risk of personal injury.
When the tool is operated it must not be held in the hand or be in contact with any part of the body. There is
apossibility of ashear injury when the piston retracts.
NOTE: The Mini MBS Workstation for Speed Rivets may only be operated by appropriately trained and instructed personnel.
Observe all relevant accident prevention regulations!
NOTE: Alegible copy of these operating instructions must at all times be stored at the place of use of the Mini MBS
Workstation for Speed Rivets and kept accessible to the operating personnel.
NOTE: The Mini MBS Workstation for Speed Rivets may only be used for the intended purpose.
NOTE: Should you have any questions concerning plant and operator safety, please contact STANLEY Engineered Fastening.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
1.1 GENERAL SAFETY RULES
• For multiple hazards, read and understand the safety instructions before installing, operating, repairing, maintaining,
changing accessories on, or working near the tool. Failure to do so can result in serious bodily injury.
• Only qualied and trained operators must install, adjust or use the tool.
• DO NOT use outside the design intent of placing STANLEY Engineered Fastening Blind Rivets.
• Use only parts, fasteners, and accessories recommended by the manufacturer.
• DO NOT modify the tool. Modications can reduce the eectiveness of safety measures and increase the risks to the
operator. Any modication to the tool undertaken by the customer will be the customer’sentire responsibility and void
any applicable warranties.
• Do not discard the safety instructions; give them to the operator.
• Do not use the tool if it has been damaged.
• Prior to use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that aects
the tool’soperation. If damaged, have the tool serviced before using. Remove any adjusting key or wrench before use.
• Tools shall be inspected periodically to verify that the ratings and markings required by this part of ISO 11148 are
legibly marked on the tool. The employer/user shall contact the manufacturer to obtain replacement marking labels
when necessary.
• The tool must be maintained in asafe working condition at all times and examined at regular intervals for damage
and function by trained personnel. Any dismantling procedure will be undertaken only by trained personnel. Do not
dismantle this tool without prior reference to the maintenance instructions.
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ENGLISH ORIGINAL INSTRUCTION

1.2 PROJECTILE HAZARDS
• Disconnect the tool from the pneumatic supply before performing any maintenance, attempting to adjust, t or
remove anose assembly or accessories.
• Be aware that failure of the workpiece or accessories, or even of the inserted tool itself can generate high-velocity
projectiles.
• Always wear impact-resistant eye protection during operation of the tool. The grade of protection required should be
assessed for each use.
• The risks to others should also be assessed at this time.
• Ensure that the workpiece is securely xed.
• Check that the means of protection from ejection of fastener and/or mandrel is in place and is operative.
• Warn against the possible forcible ejection of mandrels from the front of the tool.
• DO NOT operate atool that is directed towards any person(s).
1.3 OPERATING HAZARDS
• Use of the tool can expose the operator’shands to hazards, including crushing, impacts, cuts and abrasions and heat.
Wear suitable gloves to protect hands.
• Keep tool handles dry, clean, and free from oil and grease.
• Maintain abalanced body position and secure footing when operating the tool.
• Release the start-and-stop device in the case of an interruption of the hydraulic supply.
• Use only lubricants recommended by the manufacturer.
• Contact with hydraulic uid should be avoided. To minimise the possibility of rashes, care should be taken to wash
thoroughly if contact occurs.
• Material Safety Data Sheets for all hydraulic oils and lubricants is available on request from your tool supplier.
• Avoid unsuitable postures as it is likely for these positions not to allow counteracting of normal or unexpected
movement of the tool.
• If the tool is xed to asuspension device, make sure that the xation is secure.
• Beware of the risk of crushing or pinching if nose equipment is not tted.
• DO NOT operate tool with the nose equipment removed.
• Adequate clearance is required for the tool operator’shands before proceeding.
• Care should be taken to ensure that spent mandrels do not create ahazard.
• The mandrel collector must be emptied when approximately half full.
1.4 REPETITIVE MOTIONS HAZARDS
• When using the tool, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of the
body.
• While using the tool, the operator should adopt acomfortable posture whilst maintaining asecure footing and
avoiding awkward or o -balance postures. The operator should change posture during extended tasks; this can help
avoid discomfort and fatigue.
• If the operator experiences symptoms such as persistent or recurring discomfort, pain, throbbing, aching, tingling,
numbness, burning sensations or sti ness, these warning signs should not be ignored. The operator should tell the
employer and consult aqualied health professional.
1.5 ACCESSORY HAZARDS
• Disconnect the tool from the pneumatic supply before tting or removing the nose assembly or accessory.
• Use only sizes and types of accessories and consumables that are recommended by the manufacturer of the tool; do
not use other types or sizes of accessories or consumables.
1.6 WORKPLACE HAZARDS
• Slips, trips and falls are major causes of workplace injury. Be aware of slippery surfaces caused by use of the tool and
also of trip hazards caused by the air line or hydraulic hose.
• Proceed with care in unfamiliar surroundings. There can be hidden hazards, such as electricity or other utility lines.
• The tool is not intended for use in potentially explosive atmospheres and is not insulated against contact with electric
power.
• Ensure that there are no electrical cables, gas pipes, etc., which can cause ahazard if damaged by use of the tool.
• Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts.
Loose clothes, jewellery or long hair can be caught in moving parts.
• Care should be taken to ensure that spent mandrels do not create ahazard.
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ORIGINAL INSTRUCTION ENGLISH

1.7 NOISE HAZARDS
• Exposure to high noise levels can cause permanent, disabling hearing loss and other problems, such as tinnitus
(ringing, buzzing, whistling or humming in the ears). Therefore, risk assessment and the implementation of appropriate
controls for these hazards are essential.
• Appropriate controls to reduce the risk may include actions such as damping materials to prevent workpieces from
“ringing”.
• Use hearing protection in accordance with employer’sinstructions and as required by occupational health and safety
regulations.
• Operate and maintain the tool as recommended in the instruction manual, to prevent an unnecessary increase in the
noise level.
• Ensure that the silence within the mandrel collector is in place and in good working order when the tool is being
operated.
1.8 ADDITIONAL SAFETY INSTRUCTIONS FOR PNEUMATIC & HYDRAULIC POWER TOOLS
• The operating supply air must not exceed 6 bar (87 PSI).
• Air under pressure can cause severe injury.
• Never leave operating tool unattended. Disconnect air hose when tool is not in use, before changing accessories or
when making repairs.
• DO NOT let air exhaust opening on the mandrel collector face in the direction of the operator or other persons. Never
direct air at yourself or anyone else.
• Whipping hoses can cause severe injury. Always check for damaged or loose hoses and ttings.
• Prior to use, inspect airlines for damage, all connections must be secure. Do not drop heavy objects on hoses. Asharp
impact may cause internal damage and lead to premature hose failure.
• Cold air shall be directed away from hands.
• Whenever universal twist couplings (claw couplings) are used, lock pins shall be installed and whipcheck safety cables
shall be used to safeguard against possible hose-to-tool or hose-to-hose connection failure.
• DO NOT lift the placing module by the hose. Always use the placing tool handle.
• Vent holes must not become blocked or covered.
• Keep dirt and foreign matter out of the hydraulic system of the tool as this will cause the tool to malfunction.
• Oil under pressure can cause severe injury.
• Prior to use, inspect hydraulic hoses for damage. All hydraulic connections must be clean, fully engaged and tight
before operation. Do not drop heavy objects on hoses. Asharp impact may cause internal damage and lead to
premature hose failure.
• DO NOT pull or move the intensier unit using the hoses. Always use the unit handle.
• Use only clean oil and lling equipment.
• Only recommended hydraulic uids may be used.
• Maximum temperature of the hydraulic uid at the inlet is 100°C (212°F).
1.9 OPERATING COMPANY’SDUE DILIGENCE
The fastener riveting station Mini-MBS complies with the state-of-the art and guarantees the highest level of safety.
However, during practical operation, this safety level can only be achieved if all necessary measures for this are taken. It is
subject to the due diligence of the company operating the machine to plan these measures and to check their execution.
The operating company must ensure that
• The fastener riveting station Mini-MBS is only used in accordance with its intended purpose.
• The fastener riveting station Mini-MBS is only operated in afaultless, functional state and that
• The mechanical safety equipment is existent.
• The necessary personal protective clothing is made available to and used by the operating, maintenance and repair
personnel.
• The operating instructions and any equally applicable documents are always available at the place of use of the
fastener riveting station Mini-MBS in acomplete and legible state. It must be ensured that any persons who have to
carry out tasks at the fastener riveting station Mini-MBS are able to look at the operating instructions at all times.
• The fastener riveting station Mini-MBS is only serviced and repaired by suciently qualied and authorised personnel.
• This personnel is regularly instructed with regard to all relevant questions pertaining to occupational safety and
protection of the environment and knows the operating instructions and in particular the safety instructions contained
therein.
• None of the safety instructions and warnings attached to the product are removed and any labels remain legible.
• All national accident prevention regulations and internal rules are observed.
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ENGLISH ORIGINAL INSTRUCTION

1.10 PERSONNEL REQUIREMENTS
During any activity at the fastener riveting station Mini-MBS the following safety instructions must be heeded without
fail - this avoids potentially lethal bodily injuries, machine damage and other damage to property as well as environmental
damage.
The personnel must ensure that
• Personnel to be trained at rst only works at the fastener riveting station Mini-MBS under the supervision of an
experienced person.
• Any persons who service the fastener riveting station Mini-MBS read the operating instructions and conrm with their
signature that they have understood the operating instructions.
• No unauthorised persons stay in the range of the fastener riveting station Mini-MBS.
• In addition to the operating instructions, the working instructions as dened by the Occupational Safety and Health Act
and the Work Equipment Ordinance are observed.
• In the event of amalfunction, the operating company or the supervisory sta are notied.
• Damages to the fastener riveting station Mini-MBS are reported without delay and that the fastener riveting station
Mini-MBS is immediately shut down in case of imminent danger.
• The necessary personal protective clothing is used.
The following work described in the operating instructions may only be carried out by qualied personnel:
• Assembly
• Commissioning
• Operation
• Repair
STANLEY Engineered Fastening policy is one of continuous product development and improvement and we reserve
the right to change the specication of any product without prior notice.
WARNING: While asmall amount of wear and marking will naturally occur through normal and correct use of
mandrels, they must be regularly examined for excessive wear and marking, with particular attention to the
head diameter, the tail jaw gripping area of the shank or heavy pitting of the shank and any mandrel distortion.
Mandrels which fail during use could forcibly exit the tool. It is the customer’sresponsibility to ensure that
mandrels are replaced before any excessive levels of wear and always before the maximum recommended
number of placings. Contact your STANLEY Engineered Fastening representative who will let you know what
that gure is by measuring the broach load of your application with our calibrated measuring tool.
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ORIGINAL INSTRUCTION ENGLISH

2. SPECIFICATION
2.1 78200010040 WORKSTATION SPECIFICATION
Air Pressure Minimum – Maximum 5-6 bar (70-87 lbf/in2)
Hydraulic Pressure Maximum 120 bar (1741 lbf/in2)
Hydraulic Fluid Specication Castrol Hyspin VG32
Hydraulic Fluid Volume Approximately 1.5 litres (0.05 ft3)
Cycle Time Approximately 1 second
Weight 51 kg (112 lb)
Noise values determined according to noise test code ISO 15744 and ISO 3744
A-weighted sound power level dB(A), LWA Uncertainty noise: kWA = 2.3 dB(A) 71.3 dB(A)
A-weighted emission sound pressure level at the workstation dB(A), LpA Uncertainty noise: kpA = 2.3 dB(A) 60.3 dB(A)
C-weighted peak emission sound pressure level dB(C), LpC, peak Uncertainty noise: kpC = 2.5 dB(C) 94 dB(C)
2
1
1
3
4
5
WIDTH
400 MM
DEPTH
305 MM
HEIGHT
1090 MM
For the bill of materials refer to the drawing and parts list on page 30.
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ENGLISH ORIGINAL INSTRUCTION

ITEM PART NUMBER DESCRIPTION
1 70500-02000 70500 SPEED FASTENER MODULE
2 REFER TO ASSEMBLY DRAWING PROTECTIVE COVER
3 78201-010073 PC PNEUMATIC CONTROL
4 DU100/22 H65 RS PRESSURE INTENSIFIER
5 REFER TO ASSEMBLY DRAWING FOOT ACTIVATION PEDAL (RIVETING)
2.2 7050002000 MODULE SPECIFICATION
Pull Force At stated pressure 3.0 kN (674 lbf)
Hydraulic Pressure Maximum 140 bar (2030 lbf/in2)
Stroke Piston Stroke 30.0 mm (1.18 in)
Cycle Time Approximately 1 second
Weight Without nose equipment 1 kg (2.2 lb)
For the operating instructions, bill of materials, service and maintenance details on the 70500-02000 module, refer to
Instruction Manual 07900-09704.
2.3 RIVETING EQUIPMENT
IMPORTANT - Any use other than that described in Section 3.0 is considered contrary to the intended use.
The riveting equipment consists of the following items:
ITEM PART NUMBER DESCRIPTION
1CUSTOMER SPECIFIC PN NOSE JAWS
2CUSTOMER SPECIFIC PN MANDREL
3CUSTOMER SPECIFIC PN MANDREL SPRING
The riveting equipment is exclusively intended for place Ø2.4 to Ø6.4 STANLEY Engineered Fastening speed fasteners and
should only be used for this purpose.
Only Riveting Equipment manufactured by STANLEY Engineered Fastening must be used.
2.4 PRESSURE INTENSIFIER
Part Number - DU100/22 H65 RS
Pneumatic Pressure Inlet 6 bar (87 lbf/in2)
Operating Pressure Max. Hydraulic 120 bar (1741 lbf/in2)
Intensication Ratio - 1:20
Hydraulic Fluid Specication Castrol Hyspin VG32
Hydraulic Fluid Volume Approximately 24.5 cm3(1.5 in3)
Pneumatic Connection - G1/4”
Hydraulic Connection - G1/4”
For the full bill of materials, service and maintenance details refer to the third-party documentation on page 30.
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ORIGINAL INSTRUCTION ENGLISH

2.3 PNEUMATIC CONTROL
Part Number - 78200-010073 PC
Circuit Diagram Refer to drawing 78200-010073 PC
Pneumatic Pressure Inlet 6 bar (87 lbf/in2)
For the pneumatic circuit diagram refer to the drawing on page 34.
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ENGLISH ORIGINAL INSTRUCTION