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Pop ProSet PB2500 Service Manual Download Page 12

 

 

 

 

11 

 

2.4.

 

MAIN COMPONENTS LIST 

 

A 

Nose pieces 

L 

Manual 

B 

Nose housing 

M 

Charger lamp  

C 

Nose housing nut 

N 

Charger  

D 

Collector lock 

O 

Battery charger connection 

E 

Collector shutter 

P 

Jaw guide 

F 

Shutter guide sleeve 

Q 

Jaws 

G 

Motor housing 

R 

Jaw pusher 

H 

Exhaust vent 

S 

Spring 

I 

Handle 

T 

Pulling head 

J 

Switch 

U 

Front clutch 

K 

Battery pack 2.0 Ah 

W 

Collector space 

K2  Battery pack 4.0 Ah 

Y 

Rivet 

 

2.5.

 

OPTIONAL ACCESSORIES 

  WARNING: 

Since accessories, other than those offered by POP-Avdel® have not been tested with this 

product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only 

POP- Avdel® recommended accessories should be used with this product. 

Consult your dealer for further information on the appropriate accessories. 

WARNING: 

To reduce the risk of serious personal injury, disconnect battery pack before making any 

adjustments or removing/installing attachments or accessories. 

 

For a complete list of nose equipment and other accessories available for the PB Series, please visit our 

website 

http://www.stanleyengineeredfastening.com/resource-center/document-library 

 

 

 

Summary of Contents for ProSet PB2500

Page 1: ...Service Manual ...

Page 2: ...1 K O N M ...

Page 3: ...2 ...

Page 4: ...ties 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 trade marks CONTENT 1 Safety Definitions 4 1 1 GENERAL SAFETY 4 1 2 POWER TOOL USE AND CARE 4 1 3 IMPORTANT SAFETY INSTRUCTIONS FOR ALL BATTERY CHARGERS 5 1 4 IMPORTANT SAF...

Page 5: ...quipment When using power tools basic safety precautions must always be followed to reduce the risk of personal injury 1 1 GENERAL SAFETY WARNING Read all safety warnings and all instructions Failure to follow the warnings and instructions may result in electric shock fire and or serious injury SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE The term power tool in the warnings refers to yo...

Page 6: ...l with the nose housing removed Do not operate the tool or the charger in an explosive atmosphere or environment allowing exposure to combustible fluids or gasses Do not operate the tool or the charger in an environment allowing exposure to moisture or rain to avoid risk of electric shock Do not abuse the tool by dropping or using it as a hammer Keep dirt and foreign matter out of the air vents of...

Page 7: ...n dropped or otherwise damaged in any way Take it to an authorised service centre Do not disassemble charger take it to an authorised service centre when service or repair is required Incorrect reassembly may result in a risk of electric shock electrocution or fire Disconnect the charger from the outlet before attempting any cleaning This will reduce the risk of electric shock Removing the battery...

Page 8: ... created when lithium ion battery packs are burned 2 If battery contents come into contact with the skin immediately wash area with mild soap and water If battery liquid gets into the eye rinse water over the open eye for 15 minutes or until irritation ceases If medical attention is needed the battery electrolyte is composed of a mixture of liquid organic carbonates and lithium salts 3 Contents of...

Page 9: ...DeWALT POP Avdel charger may make them burst or lead to other dangerous situations Have defective cords replaced immediately Risk of electric shock STANLEY Engineered Fastening policy is one of continuous product development and improvement and we reserve the right to change the specification of any product without prior notice 2 SPECIFICATIONS 2 1 TECHNICAL DATA 2 1 1 ProSet PB2500 Voltage V 18 n...

Page 10: ...e Mains voltage VAC 120 100 230 Input frequency Hz 60 50 60 50 Weight kg 0 50 0 50 0 50 Fuses Europe 230 V tools 10 Amperes mains U K Ireland 230 V tools 3 Amperes in plugs PB Series tools are compatible with DEWALT POP Avdel 18V nom 20V max Li Ion slide type batteries Charging duration is based on the DCB115 DEWALT Charging units 2 1 4 Nom Rivet Dia Mm in Battery 2 0Ah Battery 4 0Ah Ø 2 4 3 32 1 ...

Page 11: ...APK Klamp Tite BAPKTR VGrip Note For details on the nose equipment please refer to the accessories manual 2 3 PACKAGE CONTENTS This package contains 1 Cordless Installation Tool 1 Charger 1 Lithium Ion battery pack 1 set Nose Equipment Accessories 3 2mm 4 0mm 4 8mm 1 Kit Box 1 Instruction Manual If the Model Number purchased is a bare tool then only the Cordless Installation Tool will be supplied ...

Page 12: ...than those offered by POP Avdel have not been tested with this product use of such accessories with this tool could be hazardous To reduce the risk of injury only POP Avdel recommended accessories should be used with this product Consult your dealer for further information on the appropriate accessories WARNING To reduce the risk of serious personal injury disconnect battery pack before making any...

Page 13: ...ord should not be used unless absolutely necessary Use an approved extension cable suitable for the power input of your charger see Technical Data The minimum conductor size is 1 mm2 the maximum length is 30 m When using a cable reel always unwind the cable completely Before Use Select relevant size nose equipment and install Ensure that the battery is fully charged Insert Battery Pack into the to...

Page 14: ...eated in the charger The red charging light will blink continuously indicating that the charging process has started The completion of charge will be indicated by the red light remaining ON continuously The pack is fully charged and may be used at this time or left in the charger NOTE To ensure maximum performance and life of Li Ion battery packs charge the battery pack fully before first use Char...

Page 15: ...st results make sure your battery pack is fully charged The tool will shut off without warning when the battery is fully discharged TO INSTALL THE BATTERY PACK INTO THE HANDLE Align the battery pack K with the rails inside the tool s handle fig 3 Slide it into the handle until the battery pack is firmly seated in the tool and ensure that it does not disengage TO REMOVE THE BATTERY PACK FROM TO THE...

Page 16: ... been set completely repeat the previous steps Reset function fig 9 If the tool does not move to its initial position after releasing the switch or stops during the setting stroke reset the tool to home by quickly pulling and releasing the switch J If this does not resolve the issue remove the battery re insert and then repeat the prior step If the issue persists contact your local service represe...

Page 17: ...d in these parts Use a cloth dampened only with water and mild soap Never let any liquid get inside the tool never immerse any part of the tool into a liquid Cleaning the Nose Equipment fig 4 5 Loosen the nose housing nut C Remove the nose housing B Press the front clutch U and loosen the jaw guide P Release the front clutch U Remove the jaws Q and the jaw pusher R Remove the spring S Clean the in...

Page 18: ...ll be recycled or disposed of properly 6 5 Protecting the Environment Separate collection This product must not be disposed of with normal household waste Should you find one day that your POP Avdel product needs replacement or if it is of no further use to you do not dispose of it with household waste Make this product available for separate collection Separate collection of used products and pac...

Page 19: ... JP TP154 500 1 NA QW GB XE XD JAW PUSHER ASSEMBLY 5 TP124 548 1 JP TP154 505 1 NA QW GB XE XD JAW PUSHER ASSEMBLY 4 TP124 635 1 JP TP154 502 1 NA QW GB XE XD JAW PUSHER SPRING TP114 652 1 See BOM page for option Apply grease to the inside of the Jaw Guide Grease recommended Molybdenum disulfide grease Jaw Guide Grease Apply grease SA Jaw Pusher 4 Jaw Guide SA Jaw Pusher 6 Jaws Jaw Pusher Spring S...

Page 20: ...e Jaw Guide as shown so that the teeth are on the inside After inserting the Jaws check that they are set correctly Put the Jaw Pusher Spring into the Pulling Head Jaw Guide Jaws Jaw Guide Jaws Jaw Pusher Spring Pulling Head ...

Page 21: ...Jaw Guide with Jaws to the Pulling Head with pulling Jaw Case Lock by hand until it stops Turn back a little until the rotation is locked by the boss of the Jaw Case Lock Jaw Pusher Spring SA Jaw Pusher Jaw Guide Pulling Head Jaw Case Lock Jaw Guide Lock Jaw Case Lock ...

Page 22: ...k the tool operates correctly by pulling and releasing the trigger Check for Pulling operation Return operation Reset operation Full stroke Stroke end clutch operation Return to home position Front end clutch operation Remove the battery after checking Battery ...

Page 23: ...TP124 541 1 SA NOSEPIECE 4 TP124 540 1 See BOM page for option Insert the SA Nosepiece on to the SA Nose Housing and screw on by hand Tighten up the SA Nosepiece securely with spanners see adjacent picture Width across flats 14mm and 23mm SA Nosepiece SA Nose Housing SA Nose Housing SA Nosepiece SA Nose Housing Spanner 14mm Spanner 23mm SA Nosepiece ...

Page 24: ...Nut see adjacent picture Insert the SA Nose Housing on to the Mast Housing of the tool Tighten the SA Nose Housing on to the thread of the Mast Housing by hand SA Nose Hosuing Mast Hosuing Nose Hosuing Nut Apply grease SA Nose Hosuing Mast Hosuing ...

Page 25: ... stroke There is no protruding mandrels There is no abnormal noise The next rivet introduced to the front of the tool is inserted smoothly The jaws do not bite The waste mandrel is ejected to the Collector The collector shutter operates normally Open Close Appearance check Any scratches on the housings Loose components and screws Any oil spots on the housings Peeling of the outer mold Rubber grip ...

Page 26: ...umber PB2500 NA203 BATTERY PACK DCB203 NA 1PC CHARGER DCB115 NA SA NOSEPIECE 4 TP124 540 SA NOSEPIECE 5 TP124 541 JAW PUSHER ASSEMBLY 4 TP154 502 JAW PUSHER ASSEMBLY 5 TP154 505 FOAM SPACER TRM00194 1PC INSTRUCTION MANUAL TRM00203 QW EUROPE Model number PB2500 QW183 STANDARD PB2500 QW183A EASTERN EUROPE BATTERY PACK DCB183 QW 1PC CHARGER DCB115 QW SA NOSEPIECE 4 TP124 540 SA NOSEPIECE 5 TP124 541 ...

Page 27: ...CTION MANUAL TRM00201 XE AUSTRALIA Model number PB2500 XE B KIT SA NOSEPIECE 4 TP124 540 SA NOSEPIECE 5 TP124 541 JAW PUSHER ASSEMBLY 4 TP154 502 JAW PUSHER ASSEMBLY 5 TP154 505 FOAM SPACER TRM00194 1PC INSTRUCTION MANUAL TRM00201 XD MALAYSIA Model number PB2500 XD B KIT SA NOSEPIECE 4 TP124 540 SA NOSEPIECE 5 TP124 541 JAW PUSHER ASSEMBLY 4 TP154 502 JAW PUSHER ASSEMBLY 5 TP154 505 FOAM SPACER TR...

Page 28: ...11 Exploded View 61 65 13 56 60 11 50 1 21 55 62 33 2 4 27 3 9 12 35 13 14 15 16 10 18 20 17 22 24 41 26 36 38 28 40 34 39 25 37 40 41 42 23 19 41 41 42 41 41 30 31 32 34 29 59 67 4 52 51 70 63 64 13 66 68 ...

Page 29: ...g 1 27 TP113 646 Spur gear 1 28 TP114 678 Snap ring 1 TP124 539 SA Nosepiece 314 1 TP123 551 SA Second shaft 1 TP124 544 SA Nosepiece 424 1 TP123 550 SA Planetary carrier 1 TP124 615 SA Nosepiece 434 1 N112877 Ring gear 1 TP124 545 SA Nosepiece 524 1 TP124 511 O ring 1 TP124 546 SA Nosepiece 624 1 TP152 552 Motor and Module assembly 1 TP124 543 SA Nosepiece 6K 1 TP114 628 Pipe bridge 1 TP124 638 J...

Page 30: ... TP124 558 Thrust race 1 TP124 539 SA Nosepiece 314 1 26 TP123 552 SA Gear housing 1 TP124 544 SA Nosepiece 424 1 27 TP113 646 Spur gear 1 TP124 615 SA Nosepiece 434 1 28 TP114 678 Snap ring 1 TP124 545 SA Nosepiece 524 1 TP123 551 SA Second shaft 1 TP124 546 SA Nosepiece 624 1 TP123 550 SA Planetary carrier 1 TP124 543 SA Nosepiece 6K 1 N112877 Ring gear 1 TP124 638 Jaw pusher assembly 4 for PRG5...

Page 31: ... TP124 539 SA Nosepiece 314 1 26 TP123 552 SA Gear housing 1 TP124 544 SA Nosepiece 424 1 27 TP113 646 Spur gear 1 TP124 615 SA Nosepiece 434 1 28 TP114 678 Snap ring 1 TP124 545 SA Nosepiece 524 1 TP123 551 SA Second shaft 1 TP124 546 SA Nosepiece 624 1 TP123 550 SA Planetary carrier 1 TP124 543 SA Nosepiece 6K 1 N112877 Ring gear 1 TP124 638 Jaw pusher assembly 4 for PRG540 46B 1 TP124 511 O rin...

Page 32: ... TP124 558 Thrust race 1 TP124 539 SA Nosepiece 314 1 26 TP123 552 SA Gear housing 1 TP124 544 SA Nosepiece 424 1 27 TP113 646 Spur gear 1 TP124 615 SA Nosepiece 434 1 28 TP114 678 Snap ring 1 TP124 545 SA Nosepiece 524 1 TP123 551 SA Second shaft 1 TP124 546 SA Nosepiece 624 1 TP123 550 SA Planetary carrier 1 TP124 543 SA Nosepiece 6K 1 N112877 Ring gear 1 TP124 638 Jaw pusher assembly 4 for PRG5...

Page 33: ... TP124 558 Thrust race 1 TP124 539 SA Nosepiece 314 1 26 TP123 552 SA Gear housing 1 TP124 544 SA Nosepiece 424 1 27 TP113 646 Spur gear 1 TP124 615 SA Nosepiece 434 1 28 TP114 678 Snap ring 1 TP124 545 SA Nosepiece 524 1 TP123 551 SA Second shaft 1 TP124 546 SA Nosepiece 624 1 TP123 550 SA Planetary carrier 1 TP124 543 SA Nosepiece 6K 1 N112877 Ring gear 1 TP124 638 Jaw pusher assembly 4 for PRG5...

Page 34: ... TP124 558 Thrust race 1 TP124 539 SA Nosepiece 314 1 26 TP123 552 SA Gear housing 1 TP124 544 SA Nosepiece 424 1 27 TP113 646 Spur gear 1 TP124 615 SA Nosepiece 434 1 28 TP114 678 Snap ring 1 TP124 545 SA Nosepiece 524 1 TP123 551 SA Second shaft 1 TP124 546 SA Nosepiece 624 1 TP123 550 SA Planetary carrier 1 TP124 543 SA Nosepiece 6K 1 N112877 Ring gear 1 TP124 638 Jaw pusher assembly 4 for PRG5...

Page 35: ...uipment Service and clean Nose Assembly More than one operation of the trigger needed to place rivet Buildup of debris inside the Nose Equipment Service and clean Nose Assembly Worn or broken Jaws Fit new Jaws Improper rivet being used for application grip thickness Review application details and verify fastener requirement Jaw Guide or Pulling Head Adapter not seated correctly Correctly assemble ...

Page 36: ... Debris in Nose Piece Service and clean Nose Assembly Rivet stem does not break Battery is low voltage Charge battery Setting load of rivet is beyond tool capacity Reset tool to home remove rivet use appropriate tool to set rivet Incorrect Nose Equipment for rivet Refer to Accessories Manual Select and install correct nose equipment Nose Equipment and Stem Collector full of stems Empty Stem Collec...

Page 37: ...36 TRM00791 0 ...

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