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Emhart Teknologies - 50 Shelton Technology Center, Shelton CT 06484 - Tel. (203) 924-9341 - Fax (800) 225-5614 

 

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. 

 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for 1600MCS

Page 1: ...Rivet Tool ProSet 1600 Series Maintenance Manual ...

Page 2: ...e 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 9 9 9 Al St SS 9 9 9 St St 9 9 9 Open End MultiGrip SS SS Mo St S...

Page 3: ...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...

Page 4: ... 9 9 1 Operating Instructions 9 9 P449 1 Maintenance Manual 9 9 P513 1 Nosepiece for 3 size open end rivets 9 9 PRN314 1 Nosepiece for 4 size open end rivets Installed Installed PRN414 1 Nosepiece for 5 size open end rivets 9 9 PRN514 1 Jaw Pusher Assy for 3 32 rivets 9 9 FAN239 176 1 Air Line Assembly 9 9 FAN239 157 1 4 mm Hex Socket Screw Key 9 9 DPN239 139 1 Warranty Card 9 9 FG2184 Tool Requir...

Page 5: ...4 9341 Fax 800 225 5614 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: ...S 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...

Page 7: ...al 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 ...

Page 8: ...ce 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 f...

Page 9: ...nto 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 Nu...

Page 10: ...nter Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 ProSet 1600 1600MCS 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 3 size rivets ...

Page 11: ...Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 11 ...

Page 12: ...on Assembly 1 1 60 DPN900 010 O Ring 1 1 61 DPN239 063 Sleeve Lock Nut 1 1 62 DPN239 064 Bottom Plate 1 1 63 DPN239 065 J Valve Cap 1 1 Item Part No Description 1600 1600 MCS 64 DPN900 011 O Ring 2 2 65 DPN900 012 O Ring 1 1 66 DPN239 068 J Valve Rod 1 1 67 DPN239 069 EXT Silencer 1 1 68 DPN900 013 O Ring 3 3 69 DPN239 071 Valve Stopper 1 1 70 DPN239 120 Fitting 4 4 71 DPN239 121 Air Tube 2 2 72 F...

Page 13: ... Joint 1 FAN239 172 Jaw Pusher Assembly 1 FAN239 175 ProSet 1600 1600MCS Seal Kit Contains 7 DPN900 001 O Ring 1 15 DPN900 002 O Ring 1 18 DPN900 003 O Ring 2 22 DPN900 004 O Ring 1 25 DPN900 005 O Ring 2 Part No Description 37 DPN900 006 O Ring 2 46 DPN900 007 O Ring 1 60 DPN900 010 O Ring 1 68 DPN900 013 O Ring 2 94 DPN900 017 O Ring 2 17 DPN908 001 Scraper 1 19 DPN908 002 B U Ring 1 20 DPN908 0...

Page 14: ... Lower 51 to the level of the Backup Ring white part 53 Fig 4 9 Push Air Piston Assembly 57 into Sleeve Lower 51 to half way point so that dirty hydraulic oil and air bubbles will come out from the loosened Fill Screw 45 Hold Air Piston Assembly until no more oil or bubbles come out Fig 5 10 Loosely tighten Fill Screw 45 and pull out Air Piston Assembly 57 11 Pour more hydraulic oil into Sleeve Lo...

Page 15: ...l Screw 45 approximately 3 3 full turns or a 0 14 3 6mm gap to allow excess hydraulic oil and bubbles to escape When no more oil comes out tighten the Fill Screw Fig 7 17 Wipe off any dirt and oil on the tool 18 Replace the Nose Housing 6 and Collector 96 Maintenance Preventative Maintenance Schedule Item Action Frequency Clean and lubricate Front End of tool See Front End Service 1 x per day or 5...

Page 16: ...be made to burn Use water spray regular foam dry chemical or carbon dioxide Environment WASTE DISPOSAL Do not flush to drain or storm sewer Contract authorized disposal service SPILLAGE Contain Spill Absorb onto inert material Shovel sweep or vacuum spill Handling Storage NFPA Class IIIB Storage Avoid prolonged breathing of mist or vapor Avoid prolonged or repeated contact with skin Avoid contact ...

Page 17: ...e Housing loose Excess hydraulic oil in tool Perform Front End Service and clean inside of Nose Housing Tighten Nose Housing Service tool by qualified service personnel MANDREL STICKING IN JAWS Jaws dirty or need lubrication Perform Front End Service to clean and lubricate Jaws RIVET FAILS TO INSERT INTO NOSEPIECE Incorrect nosepiece Shear ring stuck in hole of nosepiece Install correct nosepiece ...

Page 18: ...Set 1600 ProSet 1600 MCS Conforms to the following standards EN ISO 12100 part 1 and part 2 ISO prEN 15744 ISO 3744 EN 28662 1 ISO prEN 792 part 1 EN 12096 EN ISO 4871 Following the provisions of the Machine Directive 98 37 EEC which replaces Directive 89 392 EEC and its amending Directives 91 368 EEC 93 44 EEC and 93 68 EEC Signed ____________________________________ Eymard Chitty Vice President ...

Page 19: ...Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 19 Notes ...

Page 20: ... Marne France Tel 33 1 5671 2424 Fax 33 1 5671 2434 Norway Postboks 153 Leirdal 1009 Oslo Norway Tel 47 2290 9990 Fax 47 2290 9980 Spain Carretera M 300 Km 29 700 28802 Alcalá de Henares Madrid Spain Tel 34 91 887 1470 Fax 34 91 882 3602 Sweden Skjutbanevägen 6 SE 701 44 Örebro Sweden Tel 46 19 2058000 Fax 46 19 260038 United Kingdom 177 Walsall Road Perry Barr Birmingham B42 1BP United Kingdom Te...

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