d-9000-mil-2 operations manual
Contents
1. 261 SYN VS 6161 SVN STWS V N JUNO PN SIWJISAS UNINGI SHA je3n32n415 uoy pue Ajeng arvedsouay burjjejsur 14 WAYS OL4 buijjeysuir 97 L4 257 OSTI X WIN OL OSI SZL X WW 8 T LELZZ DELZE SW MIL SVN SAd 5 g azis lp uo je ruq2a1 10 63 1074 WOS O2 995 pnis 2215 200 585 pue e edsoJay pue eujsnpul sioquinu Jong enueui 99S 49T nup 59215 sy pesn WYA T T AC0006 G 9u ur jou SYN SW SUL LON Ajy Iqedeo 193uo Sh onp 000 14 uo posn 4V1 814 Jo3depy 81 4 Jo 3uouoduroo YIM uorounfuoo posn st 286 7814 941 ALON 000r Ld eIVI L8IA eIV L8 TI A 81 LS T INOS L8I 300174 18154 18154 eV LS8TICA LS 4 48154 L8TC 4 xXo orduiATO 8 88 4 1195 104 gXeJA A191 104 gXe ALKIIOQ 104 gXeJAKI2. DETAIL A WARRANTY Seller warrants the goods conform to applicable specifications and drawings and will be manufactured and inspected according to generally accepted practices of companies manufacturing industrial or aerospace fasteners In the event of any breach of the foregoing warranty Buyer s sole remedy shall be to return defective goods after receiving authorization from Seller for replacement or refund of the purchase price at the Seller s option Seller agrees to any freight costs in connection with the return of any defective goods but any costs relating to removal of the defective or nonconforming goods or installation of replacement goods shall be Buyer s responsibility SELLER S WARRANTY DOES NOT APPLY WHEN ANY PHYSICAL OR CHEMICAL CHANGE IN THE FORM OF THE PRODUCT IS MADE BY BUYER THE FOREGOING EXPRESS WARRANTY AND REMEDY ARE EXCLUSIVE AND AREIN LIEU OF ALL OTHER WARRANTIES AND REMEDIES ANY IMPLIED WARRANTY AS TO QUALITY FITNESS FOR PURPOSE OR MERCHANTABILITY IS HEREBY SPECIFICALLY DISCLAIMED AND EXCLUDED BY SELLER THIS WARRANTY IS VOID IF SELLER IS NOT NOTIFIED IN WRITING OF ANY REJECTION OF THE GOODS WITHIN ONE 1 YEAR AFTER INITIAL USE BY BUYER OF ANY POWER RIVETER OR NINETY 90 DAYS AFTER INITIAL USE OF ANY OTHER PRODUCT Seller shall not be liable under any circumstances for incidental special or consequential damages arising in whole or in part from any breach by Seller AND SUCH INCIDENTAL SPECIAL OR CONSEQUENTIA
3. Adjustable wrench a pair of pliers Bent hook for O ring removal Oil Pan large enough to contain fluid spills Hemove the foam handle by twisting and pulling it off if removal is not possible it may need to be cut off and replaced With the 5 32 hex wrench remove the side screw spring and ball 45 46 15 amp 16 place them in a clean area HYDRAULIC PUMP SERVICE Unthread and remove the front Adaptor 2 Unthread the hydraulic pump with a 9 16 deep socket wrench and pull it out carefully you may need to extract it with the help of a pair of pliers grab on the smaller diameter towards the front Place pump assembly in a vise and unthread item 16 use the socket wrench Push the stage piston 20 out so the O rings are accessible for replacement Unthread set screw 14 with the help of the 1 8 hex wrench and remove the spring and ball 15 amp 16 clean the ball and cavity carefully with a soft lint free piece of cloth Replace spring 15 re assemble with ball 16 and thread in the set screw 14 flush with the front surface of item 17 Replace O ring 18 PRESSURE RELIEF VALVE SERVICE With the help of the 1 16 hex wrench unthread the flat head screw 47 while holding the button 48 Pull button 48 out carefully Unthread the pressure relief valve 32 with a 9 16 deep socket wrench Unthread the adjustment plug 33 and remove the spring and poppet 25 amp 34 Replace the spring with a new one The seal
4. y TW 4 AM SWAISAS SNINGISHA pug pue en1 nujs Aeng sei Emang aseq 011295 sy uo abuey dup e sey uayo osje sip SJa ua 15 au Jo peal 55 P Ag a as x330 ie1u 40jeuBelw aui 51 uw we aljogouow OA LO TEAS AAA TENDOLUENH TINI SHLSAS INNTAS V SAI puljg EBJn35nJ1S UON PUB 5 Keno Eugsn THE Dep e s ove lt jeijnj2nis uow pue eimnujs o pma uoy S0902 0090Z SIN SIN SW jauseAA JaA IS HASWA UMANAS 0066 SVN S8BZIN XBW IV xvWaau jatjseM jeuicuou jein3anais 0065 SVN SSBZIN XINH xviWAusu ad AAA 1683 UR TC JORDY 66 1 861 SYN 2 968 WN zz zee elovoiduio epo JL N S 5 SW 1 5 25206 SIN JAoqixew puig
5. 1206 EAST MACARTHUR STREET SONOMA CA 95476 1372 10 32 PULL UP STUD NO 10 ANVIL 1 4 20 PULL UP STUD NO 1 4 TSN ANVIL 1 4 28 PULL UP STUD NO 1 4 ANVIL 5 16 18 PULL UP STUD NO 5 16 ANVIL 5 16 24 PULL UP STUD 3 8 16 PULL UP STUD 3 8 ANVIL 5MM PULL UP STUD 5 MM ANVIL 6 MM PULL UP STUD 6 MM ANVIL 8 MM PULL UP STUD 8 MM ANVIL 10 PULL UP STUD 10 MM ANVIL MASTERSHAFT TURN NUT ADAPTER SHAFT COMPENSATING ADAPTER SHAFT THROUGH HOLE ADAPTER SLEEVE ROTATING ADAPTER SLEEVE FLATS ADAPTER SHAFT MS STYLE EXT STR PULLING HD RIGHT ANGLE PULLING HD OFFSET PULLING HD SPARE PARTS CANISTER BLIND BOLT JAW HOLDER 2 PIECE CAST JAW SET 3 PIECE CAST JAW SET 3 PIECE JAW SET BB 5 32 3 PIECE JAW SET BB 3 16 JAW PUSHER BB D 700 JAW PUSHER PT 100 JAW PUSHER SPRING PT 100 1 4 JAW FOLLOWER JAW PUSHER SPRING RIVET NUT STROKE GAGE RIVET GRIP GAGE METAL WEATHER TIGHT CASE CD ROM USER MANUAL OPERATING INSTRUCTIONS LAMINATED TOOL ASSY CARDS ATTENTION TECHNICIA The D 9000 MIL 2 Blind Rivet Tool Kit is supplied with four riveters with 3 16 diameter nosepieces installed in their nose assemblies The D 28 Hand Riveter comes with 2 piece jaws All other riveters come with 3 piece jaws F123 which permit installation of most all rivets from 1 8 thru 1 4 simply by changing the nosepiece EXCEPT in the case of the 4000 Cordless Riveter which requires a larger jaw follower P N F3245 for 1 4
6. F187 2A C Sleeve Spring Right Angle Pulling F124 A Head F1075 4 Actuating Trigger Collet Assembly 729A25 701B29A Offset Pulling Head P F1076 Extended Straight Pulling Head ASSEMBLY INSTRUCTIONS F1074 1 Thread interior draw bolt of the Right Angle Pulling Head 1075 onto the Adapter Shaft F187 2A 3 turns 2 Push the Right Angle Pulling Head F1075 into the Adapter Sleeve F187 1A and mate thread Thread at least 5 full turns until rivet stem fits easily into nose piece Adjust nose piece in for larger diameters 3 Position head direction and set jamb nut Reverse for disassembly 4 Depress Actuating Trigger to install rivet see operating instructions OFFSET PULLING HEAD ASSEMBLY INSTRUCTIONS EN Open Offset Pulling Head F1076 1 4 as shown 2 Thread interior draw bolt of the Offset Pulling Head F1076 onto the Adapter Shaft F187 2A 4 turns Push the Offset Pulling Head F1076 into the Adapter Sleeve F187 1A and mate threads Thread in until 1 4 head gap 1s fully closed DON T GO BEYOND Position head direction COUNTERCLOCKWISE ONLY Set jamb nut Depress Actuating Trigger to install rivet Rivet stems will push out the back Reverse for disassembly EXTENDED STRAIGHT PULLING HEAD ASSEMBLY INSTRUCTIONS 1 palle Thread the Collet Assembly 749425 701 8294 onto the Adapter Shaft F187 2A Slide the Pulling Head Sleeve F1074 ov
7. For item and part numbers refer to the component list and exploded view on page 8 The stem of the fastener to be installed won t fit e Make sure the correct pulling head is used and that it is properly adjusted the jaws should free the broken stem when the side button is depressed Check for jammed stems inside the jaws press the side button to properly eject the stem The stems will not installation Check the jaws replace or clean them as necessary Make sure that the proper pulling head and optional components are used Check the fluid level replenish if low break to complete the Nothing happens when pump Check the fluid level fluid as needed Re adjust to increase output load Service or replace the pressure relief valve Disassemble and clean thoroughly the internal components debris or contamination in the fluid will cause the internal valves to malfunction MAINTENANCE AND REPAIR Too easy or too hard to pump it doesn t seem to shift Replace or service the stage piston 20 Output piston goes back and forth as pump e Make sure that the hollow set screw 14 is threaded in properly and has not backed off Unthread set screw 14 remove and inspect the compression spring 15 replace if damaged Clean the valve cavity before re assembling The lever bounces back forcefully preventing you to pump Disassemble and service the reservoir piston 44 F
8. Pressure relef E 1S SS Pu 77777 727220202022 Bleed AA E et AI SAN PEE 7 E mM 9 CONTACT Warani NoMa ON td puts BACK COVER DESCRIPTION D 700C is a lightweight ergonomic hand powered riveter providing means to install a wide variety of blind type fasteners in the absence of other power sources compressed air or electricity It combines the safe and smooth operation of well known pneumatic hydraulic riveters with the latest research in automatic systems It features an intelligent power optimization system that provides high installation loads at low hand effort Its durable all metal design makes this powerful and robust tool ideal for use in rugged repair facilities and field repair D 700C features a high strength steel mounting system compatible with the previous D 700A and D 100 7 5 5 9 5 1 SPECIFICATIONS Fastening Systems International Inc policy is one of continuous development Specifications shown in this document may be subject to change which may be introduced after publication For the latest information always consult FSI 0 750 Above 5000 Lbs F Hand Pum 30 3000 Lbs 1 96 Lbs p SAFET
9. diameter rivets Except for the D 28 Hand Riveter which comes with 2 piece jaws the riveters all will require the use of 2 piece jaws F122 A for 3 32 diameter rivet installation The 2 piece jaws F122 A are furnished in the spare parts canister 701 Common blind fasteners used throughout the U S military branches have been provided in a convenient chart form to help identify the proper nose assembly For information on any other blind riveting applications for ground and aircraft aerospace vehicles please con tact us at toll free 1 800 344 2393 or email us at sales fsirivet com USER GUIDE BLIND RIVET GRIP GAGE F269C3 BLIND RIVET GRIP GAGE The Blind Rivet Grip Gage F269C3 has been provided to permit the technician to properly select the rivet grip length required for the materials being joined Blind rivets are normally specified by their diameter in 1 32 increments and their grip in 1 16 increments hence a 3 16 diameter blind rivet with a 1 4 grip would have a suffix of 06 04 after the basic rivet manufacturer s part number or military specification number i e CR3213 06 04 nominal diameter CherryMax The numbers are often abbreviated to 6 4 You will notice that the grip gage has several holes in it They are to enable the rivet user to distinguish between the oversize 1 64 and nominal diameter sizes Once the sheets to be joined are brought tightly together a hole is then drilled and the grip gage
10. Pull trigger to move jaw mechanism about 200 to 400 inches and release trigger Check distance See Parts Drawing It must be 0 039 0 051 If distance gap 15 below 0 039 magnet holder 27 should be moved carefully to the right after loosening the to screws 28 in order to obtain 039 to 051 gap If distance A gap 1s larger that 0 051 magnet holder must be moved to the left accordingly After tightening the screws 28 repeat test and recheck distance Take battery 40 out of toll housing Finishing Lubricate gear teeth with lubricating grease 46 Insert suspension loop 30 Insert hand guard 31 Replace second half of tool housing Tighten both halves of tool housing 1 together with the five housing screws 33 and the three housing screws 32 using screw driver Torx T 20 Safety Notes The PT 4000 has been designed and manufactured in accordance with the applicable safety regulations If the PT 4000 is being used for the intended purpose in accordance with instruc tions and normal safety measures there is no danger involved during operation WARNING Never operate the PT 4000 without placing the blind rivet in proper hole of the work piece or material The rivet could be propelled from the tool Avoid pointing the tool at anyone during operation The spent mandrel container 39 must always be firmly screwed into place on the tool during operation Do not plug or cover ve
11. F502 F503 15 95460 Dyna Swivel PT 100M for use with CherryMax amp Huck Clinch NAS9300 M 7885 Pulling Heads C 42 UA F3187 Adapter Assembly F124 A F187 1 AF F187 3ACM Sleeve Spring F1075 Right Angle Pulling Head 1 F1074 15 95460 Extended Straight Dyna Swivel Pulling Head 5 Offset CHA RT L Pulling Head NOTE Pulling Heads are NOT included in the D 9000 MIL 1 Kit NSN 5180 01 470 6538 with MS amp NASI400A Offset Right Angle amp Side Ejection Heads RV872 Series bh AAS 2687 87 2 F124 A Sleeve Adapter Sleeve Spring sr FIZI ipe Jaws Note For 31 32 use 22 Jaws 3245 Jaw Follower ROTE Replace jaw follower F3621 with 23245 sec spare parts when installing 147 diameter You may alsc the E123 jaws for 187 thru 147 diameter blind rivets CHART N PT 4000 Blind Bolt Set Up for MS90353 54 S U amp Washer Anvil Drivers Single Action Styles Only F30 amp R1 A Spring Fi23 A 5 32 25050 5 32 F506 3 16 123 8 3 16 23245 Nosepieces Blind Bolt Jaws Jaw Follower CHART O 4000 Set Up for 19008 Type Single Action Blind Rivets F3621 Jaw Follower PT 4000 Juw Holder CHARTP F3621 Jaw Follower F126 F F3081 A Jaw Holder Spring NOTE Replace jaw follower F3621 with F3243 sec spare part can
12. OF 2 PAGES DESCRIPTION HAND HYDRAULIC RIVETER PRESSURE VALVE AIR HYDRAULIC RIVETER CORDLESS RIVETER HAND RIVETER BATTERY CHARGER SMART BATTERY PACK Ni MH 12v 3 2AH 3 32 1 8 NOSEPIECE 1 8 NOSEPIECE 1 8 3 16 NOSEPIECE 1 4 NOSEPIECE 3 16 MONOBOLT NOSEPIECE 1 4 MONOBOLT NOSEPIECE 3 16 MS NOSEPIECE 3 16 BULBTITE NOSEPIECE 1 4 BULBTITE NOSEPIECE 1 4 RIVET NOSEPIECE 3 32 NAS 1400A NOSEPIECE 1 8 NAS 1400A NOSEPIECE 5 32 NAS 1400A NOSEPIECE 3 16 NAS 1400A NOSEPIECE 1 8 NAS 1900S NOSEPIECE 5 32 NAS 1900S NOSEPIECE 3 16 NAS 1900S NOSEPIECE 5 32 MS90353 54 S U NOSEPIECE 3 16 MS90353 54 S U NOSEPIECE 6 32 PULL UP STUD NO 6 ANVIL 8 32 PULL UP STUD NO 8 ANVIL 10 24 PULL UP STUD NO 10 TSN ANVIL 2 D 9000 MIL 2 KIT CONTENTS EA 1 EA EA EA EA EA EA 2 EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA JEA EA SEA 3 EA EA EA EA EA 2 EA EA 2 EA EA EA EA EA EA EA SUPPLIER CAGE CODE 64878 FASTENING SYSTEMS INTERNATIONAL INC F362 F365 pnm F177 F363 F366 F374 F378 F377 F375 F379 F384 F365M F380 F366M F368 F378M F387 F379M F170 A F171 F187 3BCM F187 3ACM F187 1AR F687 1AF F687 2A F1074 F1075 F1076 F702 F128 F122 A F123 F123 A F123 B F758 F958 F990 F3245 F308 1 A F101 F269C3 F609A F701 D9 F754 D9000 F755 D9000
13. Pump the lever while holding the pressure relief button depressed the fluid level in the handle will decrease Re fill with fluid as needed Watch for air bubbles resurfacing in the fluid inside the handle while pumping keep pumping until there are no more air bubbles Release the pressure relief button and pump until the piston to full stroke Remove the side screw 46 and place thumb over the hole Push the reservoir piston 44 into the handle as far as it goes without threading it in allow excess fluid to leak out from under your thumb Re assemble the ball and spring 15 16 Thread in and tighten the side screw and seal 44 amp 45 Thread in the reservoir piston 44 and check the fluid level CHECKING THE FLUID LEVEL Turn the riveter upside down and observe the position of the indicator with respect to the silver grooves visible inside the handle e One indicator line is visible the tool is full of fluid The tool was filled and bled properly e Two indicator lines are visible the fluid level is OK for optimal function e Three indicator lines are visible the fluid level is dangerously low Inspect for leaks service and re fill as necessary FINAL STEP IN FILLING THE RIVETER Clean the riveter thoroughly and push the foam insulation 43 all the way over the handle This foam insulation is part of the service kit 800 5 and we recommend replacing it every time the tool is serviced REPLENISHING FLUID This operation i
14. Type Single Action EIU F187 1AR Adapter Sleeve F187 2A Puller Shaft F1076 Offset Pulling Head SU S amp CHERRY AEROSPACE e CHERRYMAX 7 486 21075 Right Angle Pulling Head 21074 Extended Straight Pulling Head CHART F D 700C Set up for MS amp NASI400A Pulling Heads F687 1AR Adapter Sleeve F687 2A Puller Shaft oe RV872 Offset Pulling Head F1060 Side Ejection Straight Pulling Head RV882 Series Right Angle Pulling Head CHART G D 700C Set up for Using the Stroke Gage PT 100M Standard Blind Riveting Set Up F123 Spe Jaws For VAT usc FIINA 1 dawa Nosepiece see tables 26 24 part numbers Jaw Holder Return Spring When installing 1 4 rivets we recommend use of F123 3pc jaws F15 95460 Dyna Swivel CHART H 100 Blind Bolt Configuration for MS90353 54 S U amp Washer Anvil Drivers Single Action Styles Only Fi23 A 5 32 BH F123 B 3 16 BB Blind Bolt Jaws F958 BB Jaw Follower 124 _ F990 BB Spring F505U 5 32 F128 F506 3 16 BB Jaw Return Nosepiece Holder Spring F15 95460 CHART I Dyna Swivel PT 100M Set Up for NASI400A F130 Nose Tube F126 Jaw Holder Replace 1233 jaws with FITILA 2 jaws When installiag 3 32 CHART J PT 100M Set Up for 5 19005 Type Single Action Blind Rivets i T F124 A Return Spring F501
15. actuate the Actuating Trigger and cause the nose tube to move forward thus allowing ease of nosepiece installation 3 Insert rivet into nosepiece being sure that the riveter 18 in the fully retracted position If nose tube is partially extended simply depress Releasing Trigger until the nose tube fully retracts to starting position Place rivet into properly prepared hole and hold riveter against materials being riveted using firm steady pressure Be sure to keep riveter as perpendicular to work surface as possible within 1 5 degrees from centerline Next depress Actuating Trigger being careful not to depress the Releasing Trigger at the same time If you do the tool will not actuate and the hydraulic fluid no 10 machine oil will just circulate through the by pass valve The riveter has maximum stroke of 625 and will set most blind fasteners 1n one stroke however if the tool reaches the end of its stroke before setting a fastener DO NOT CONTINUE TO DEPRESS THE ACTUATING TRIGGER Release the Actuating Trigger and depress the Releasing Trigger The riveter will then retract and you can re grip the fastener and reactivate the tool until you upset the fastener 4 After the rivet stem breaks you may depress the Releasing Trigger point the tool downward and the broken rivet stem will drop out of the nosepiece NOTE If the rivet stem sticks in the nose piece after the rivet 15 set lightly tap the end of the rivet stem on a hard surfa
16. as Lubriplate Tighten all components snuggly with a wrench QUANTITY E REFERENCE SINT NUMBER 272803 LEVER ARM www s emn Tama 010 s 010 7 9 mms wwmuown DESCRIPTION 7 3 4 4 2 N f a CETUR 7 f 5 1 9 S Jn A FA z 3 o 7777777277777 222722220772 LI XN pd mc
17. can be inserted into the hole The hook end of the gage should then catch on the back side of the hole and then the slide bar 15 brought down until it touches the top sheet The gage can then be removed and the grip measured Notice that the gage 15 scaled in 1 16 increments Most commercial and aerospace blind rivets have at least a 1 16 grip range with the dash number signifying the maximum thickness or grip range that the rivet may be used in If the measure ment falls right on the line then the user in the case of aerospace quality blind rivets can elect to use either the maximum grip of one rivet or the minimum grip of a longer rivet 1 e a 250 reading would allow the use of either a 4 grip rivet in its maximum grip or a 5 grip rivet in its minimum grip In normal circumstances users if they have the option will more likely select the rivet used in its maxi mum grip This helps minimize blind side protrusion and helps reduce unnecessary weight Several thousand rivets can add up to many extra pounds of weight the plane will have to carry over its lifetime which of course translates into fuel consumption CAUTION When gauging the material thickness it is always good to check at least two or more points around the hole This helps reduce the chance that a burr on the blind side is inadvertently hooked that could give you a false reading Of course any significant burrs or metal chips should be removed from between the sheets before
18. in front of the third guiding stud The electronic control unit 26 should be installed by putting it on the stud inside the tool housing and then fastened with the housing screw 32 Click magnet holder 27 the guid ing slot of the electronic control 26 Fasten other end of magnet holder 27 to ball screw drive 2 with magnet holder screws 28 together with two spring lock washers 29 using the hexagonal screw drive SW 2 5 For later stroke adjustment do not tighten the screws Plug the two blue connecting wires of motor 25 and electronic control until 26 together DO NOT CONNECT RED WIRE YET Stroke Adjustment Turn gear of pinion shaft until distance measures 0 118 See Parts Drawing Then insert battery 40 correctly in tool housing Attention Positive pole of battery 40 must be at top to avoid damage of electronic con trol unit 26 While trigger 1s pressed magnet holder 27 must be adjusted in slot of electronic control until red indicator light goes on After releasing trigger the two magnet holder screws 28 must be tightened NOW connect red wire to electronic control 26 Attention Both connecting wires must be places around guiding stud on electronic control 26 in such a way to keep slot free for movement of magnet holder 27 Preliminary Motor Test Motor 25 1s be carefully held down at both ends Make sure to al low room for magnet holder to move back and forth
19. pusher spring weak When trigger 1s pressed no function red indicator light shows No Spent Mandrel Discharge Causes Wrong nosepiece Nosepiece worn Mandrel jammed in jaws Head Dirty inside Spent mandrel container filled Passage clogged Red Light Indicated Faults A When trigger is pressed Causes Overheating of electronic control B While pulling the rivet Causes Overloading Overheating of electronic control Depleted battery charge C After releasing the trigger Causes Jaw mechanism 15 not reaching the front position Remedy Recharge if necessary replace Clean and lubricate or replace Tighten Replace Remedy Exchange according to page 2 Replace Loosen the mandrel clean and lubricate the jaws or replace Clean Remove and empty Remove clogged mandrels and check for free ejection Remedy Allow too to cool to ambient temperature Remedy Check working capacity Allow tool to cool to ambient temperature Recharge or replace Remedy Tighten jaw mechanism Maintenance Instructions General Notes Warranty repairs are carried out by the manufacturer only Repairs outside the warranty period should only be carried out by trained personnel The following instructions must be strictly ad hered to as assembly or adjustment errors may cause major damage to the 4000 Repair Tools amp Lubricant For repair of the PT 4000 the following should be available Screw Driver Torx T 20 Hex
20. 5 FS 1206 East MacArthur Street Sonoma CA 95476 ies ue Phone 707 935 1170 Fax 707 935 1828 Web www fsirivet com Email sales fsirivet com D 9000 MIL 2 NSN 5180 01 470 6539 Operations Manual D 9000 MIL 2 BLIND FASTENER INSTALLATION TOOL KIT Kit contains 86 separate pieces inside its carrying case Laminated Operating Instructions and Tool Selection Charts Grip Gage 28 Metric Studs Anvils D 700 VM Tool PT 100M Tool Ss 7 Sey P Adapters T dm 4 4 m 000 Too n a d 2 Battery Charger 4 7 spare Parts Canisters Pull Up Studs Anvils Nosepiece Bar Special CherryMax Pulling Heads Batteries found underneath PT 4000 EA EA EA EA EA 2 EA EA EA 4 EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA 1 EA EA EA EA EA EA SUPPLIER CAGE CODE 64878 D 9000 MIL 2 BLIND FASTENER INSTALLATION TOOL KIT NSN 5180 01 470 6539 KIT CONTENTS PART NUMBER D 700 VM PT 100M PT 4000 D 28 F 4000A F 3001A F156 2159 F143 F142 F168 F169 F580 F396 F398 F155 F390 F391 F392 F393 F501 F502 F503 F505U F506 F360 F367 F361 F364 F372 F176 FASTENING SYSTEMS INTERNATIONAL INC SONOMA CA 95476 1
21. CherryMax and Cherry thru 1 4 diameter in all materials and Blind Bolts and Maxibolts thru 3 16 diameter Equipment Accessories Nosepieces 3 32 thru 1 4 Wrench SW 12 covers nosepiece compartment Suspension Loop Flips open from housing Battery Quick Charge 12 Volt DC Technical Data Weight 4 85 Ibs with battery Stroke 787 Drive Unit 12 V direct current motor Traction Power 2 000 lbs Nosepiece Rivets Per Battery Table Charge Rivet Dia Rivet Body Material Rivets Per Charge Part No 3 32 Aluminum 1 900 F140 1 8 Aluminum 1 300 F159 1 8 Steel 1 100 F159 1 8 Stainless Steel 1 000 F159 5 32 Aluminum 1 000 F143 5 32 Steel 900 F143 5 32 Stainless Steel 800 F143 3 16 Aluminum 700 F143 3 16 Steel 500 F143 3 16 Stainless Steel 400 F143 1 4 Stainless Steel 90 F142 Rivets per battery charge based on Mil R 24243 style blind rivets in maximum grip condition Starting Procedure Install fully charged battery into housing Select proper nosepiece see page 2 and screw into head Attention Do not cover or stick anything into the vent holes Operating Procedure Pushing the trigger starts the operation When releasing the trigger the jaw mechanism returns to the start position automatically Eject the spent mandrel into the mandrel container by tilting the tool backward or through the nosepiece by tilting tool forward The riveting tool 15 equipped with o
22. IOQ 104 XLE W 104 104 2 VOOVISVN x 009025 9 peoH AAA PTT m P Meus WO8tE 814 dV L 28134 WOvE Z814 Assy BLES VOOt LSVN sX01 1duu AO v 420 AUaYD pue 50902 00907 SW nau pue buibbnjq J 25 OOEGSVN 588ZW j e3su spear 21995 10 sieidepy 91 894 894 ASS 894 D 700C Standard Blind Riveting Set Up F130 700C F122 A 2pc 21381 Spring Nose Tube Jaws a D 700C Set up for Blind Nut Installation F130 700C F170 A Nose Tube Master Shaft cv IBN See Anvil amp Studs Table for part numbers ATTENTION Female side of turn nut must face forward CHART B D 700C Standard Set Up NASI400A F130 700C F122 A 2pc 21381 Spring Nose Tube Jaws a mm rYVEWFVVYVVEWEE UY F700 041 Jaw Follower CHART C D 700C Standard Set Up for MS90353 54 S amp U amp Washer Anvil Driven Single Action Only F505U z 5 32 F506 3 16 E Arter we meum lt zm ETETETT F130 700C F123 A 5 32BB Jaws 23181 Spring amp F188A Nose Tube F123 B 3 16BB Jaws Adapter Bushing CHART D D 700C Standard Set Up for 5 19005
23. ISTON ROD 7 16 20UNF 1 1 re O RING oD 976 wor 2 12 F1061 BACK UP RING OD 9 16 W 05 2 13 _ Fi315 COMPRESSION SPRING 14 __ 1476 HOLLOWSET SCREW _ __ 1 15 _ 21473 _ COMPRESSION SPRING 16 F117 _ STEEL BALL 3 16 18 F269 O RING OD 15 16 W 07 POWER PISTON Feot O RING 0D 946 Wo7 SHIFT PISTON 21383 COMPRESSION SPRING F1475 27 1471 RING F800 007 POWER PISTON ROD ITEM PART NO DESCRIPTION 29 Fs00 005 CYLINDER 120 F383 O RING OD 7 16 W 07 F732 BACK UP RING OD 7 16 W 05 1 331 F800 021 ADJSTMENT PLUG EM 25 F1383 COMPRESSION SPRING 33 F800 020 VALVE 4 F701 O RING OD 5 8 W 07 F800 019 BODY PRESSURE RELIEF 37 F1474 O RING WHITE OD 9 16 W 07 293 O RING OD 5 16 W 07 F1472 BACK UP RING OD 5 16 W 05 F800 028 AEROSPACE LABEL ___1465 SETSCREW ___ 1 FOAM HANDLE O RING OD 5 8 W 07 STAT O SEAL 4 Must be ordered as a sub assembly No substitutions SUBASSEMBLY EXPLODED VIEWS STAGE PISTON item 20 26 EXPLODED VIEW 27 f 2B 25 em F 24 i n y R i i 5 PRESSURE RELIEF VALVE item 32 EXPLODED VIEW D 700C TOP ASSEMBLY EXPLODED VIEW SEE DETAIL A 43 Lj
24. L DAMAGES HEREBY EXPRESSLY EXCLUDED For more information please contact FSI Technical Services Department at Tel 707 935 1170 TM D 700C Rev Date 12 29 09 2009 Fastening Systems Int l Inc Supplier s Federal Identification Code 64878 CR 09 1506 D 26 OPERATION 1 2 Insert rivet into work with riveter Insert rivet stem into nosepiece piece held firmly and squarely against head of rivet 3 Squeeze the handles to install the rivet An additional stroke may be necessary depending on the rivet length and the thickness of the material being joined D 28 TROUBLESHOOTING 1 If rivet stem will not enter the pulling head with the handles fully extended the tool 15 probably contaminated with dirt or metal chips Dismantle pulling head parts 8 through 13 clean with a solvent examine jaw teeth for signs of wear and replace if worn 2 If rivet stem enters pulling head but is not gripped by jaws disassemble as in above and check for worn jaws or a weak jaw spring Jaw spring should not be less than 1 1 4 long 3 If rivet stem enters grips and sets rivet but does not release rivet disassemble as above check for dirt weak jaw spring or worn jaws 4 Pulling head components 8 through 13 should be clean and dry The only lubrication nec essary is on the outside of the jaws 10 to assure a sliding action between the collet taper and the backs of the jaws Use a clear grease such
25. Maxibolt Conversion When pulling Blind Bolts and Maxibolts you will need to use the following items For 5 32 or 3 16 Blind Bolts and Maxibolts Remove Nose Tube F130 F Thread off Jaw Holder F126 F and Jaws F122 A and set aside Be careful not to allow the spring and jaw follower to come out of the tool Next you will need the Blind Bolt Jaw Holder F128 Insert Jaw Set F123 A 5 32 size into holder keep rubber O Ring securely around the three piece jaws This is important because you must keep the jaws aligned at all times while pulling Blind Bolts or Maxibolts to prevent the stem from jamming and cracking the jaws Thread Jaw Holder F128 onto the Draw Bolt F3605 and thread nose tube back onto the tool Then use the 5 32 Maxibolt Nosepiece F505 MB for S Type Blind Bolts or the 5 32 Blind Bolt Nosepiece F505 for the U Type Blind Bolts Reverse the process to assemble tool for regular CherryMax riveting For 3 16 Blind Bolts and Maxibolts Remove Nose Tube F130 F Thread off Jaw Holder F126 F and Jaws F122 A and asset aside Be careful not to allow the spring and jaw follower to come out of the tool Next you will need the Blind Bolt Jaw Holder F128 Insert Jaw Set F123 B 3 16 size into holder keep rubber O Ring se curely around three piece jaws This is important because you must keep the jaws aligned at all times while pulling Blind Bolts or Maxibolts to prevent the stem from jamming and cracking the jaws Thread Jaw Hol
26. NDUCE VOMITING Inhalation No significant adverse health effects are expected to occur on short term exposure Hemove from contaminated area Apply artificial respiration if needed If unconscious consult physician ENVIRONMENT Waste Disposal In accordance with local state and federal regulations Spillage Prevent entry into drains sewers and water courses Soak up with diatomaceous earth or other inert material Store the spent fluid in appropriate containers for disposal HANDLING Eye protection required Protective gloves recommended Chemically resistant boots and apron recommended Use in well ventilated area COMBUSTIBILITY It is slightly combustible when heated above flash point It will release flammable vapors which can burn in open or be explosive in confined spaces if exposed to source of ignition FIRE Suitable extinguishing media CO2 dry powder foam or water fog DO NOT use water jets STORAGE Avoid storage near open flame or other sources of ignition PROPERTIES Specific gravity 0 863 Weight per gallon 7 18 lbs Open flash point gt 200 C 392 F PRIMING AND FILLING WITH FLUID e Perform as part of servicing the tool refer to the Parts List and Exploded Views on page 9 Use proper safety equipment per your 5 policy including rubber or latex gloves Step 1 To prepare the tool remove the handle insulation side screw spring and ball 43 amp 15 16 45 amp 46 and place them in a cl
27. Y WARNINGS Do not operate the tool when it is directed at any person and do not pull rivets in the air Do not pump beyond your hand strength capability use of two hands to complete an installation is OK Do not exceed a maximum output load adjustment of 5500 Lbs Do not throw drop or use the tool as a hammer Do not use the tool beyond its design intent Consult the tool manual before disassembly troubleshooting or repair It is advised that major repairs be undertaken by personnel trained by Fastening Systems Int l Inc FSI contact us with your training requirement Wear appropriate personal protection equipment when operating repairing or overhauling this tool Never use Loctite when mounting offset or right angle pulling heads No component substitutions are authorized any modification to the tool pulling heads accessories or FSI supplied components shall be at the customer s entire responsibility FSI will be pleased to advise on any proposed modification The tool must be maintained in a safe working condition at all times and examined at regular intervals For maintenance place the tool in an oil pan dispose of used fluid properly e Avoid excessive skin contact with the fluid Wash thoroughly after handling the fluid ERGONOMIC ADJUSTMENTS For item and part numbers refer to the component list and exploded views on page 8 Lever Span Tools necessary 5 32 hex wrench Adjust ho
28. agonal Wrench SW 2 5 mm Open End Wrench 27 mm Open End Wrench 17 mm Open End Wrench 14 mm Lubricating Grease 46 Dismantling the PT 4000 Remove battery 40 from the tool Unscrew spent mandrel container 39 Remove housing screw 3 pcs 32 amp 5 pcs of 33 with screw driver Torx T 20 Take off hand guard 31 Take off top of tool housing 1 and pull off the red and blue con necting wires from the electronic control 26 Unscrew electronic control 26 using screw driver Torx T 20 Unscrew magnet holder 27 using the hexagonal wrench SW 2 5mm Take out electronic control 26 and magnet holder 27 Take out motor 25 ATTENTION Reassembly Tip Note how connecting wires to the motor are laid out in the tool housing Take out drive system 42 Unscrew head 13 using open end wrench SW 27mm Un screw jaw housing 12 using open end wrench SW 17mm and take out jaws 11 jaw pusher 10 and jaw pusher spring 9 Unscrew jaw housing coupler 7 with scraper ring 8 using open end wrench SW 14mm Remove screws 4 of 6 using hexagonal wrench SW 2 5mm Pull off drive bearing 3 and pinion shaft 4 with snap ring 6 and bushing 20 Assembly amp Stroke Adjustment Assembly of Drive System 42 Slip drive bearing 3 over ball screw drive 2 and put pin ion shaft 4 together with snap ring 5 bearing place Attention Before screwing ball screw drive 2 and drive bearing 3 tog
29. catch spent stems The ventilation holes to the electric motor must not be obstructed Do not cover or place any thing over them Repairs should only be undertaken by skilled and trained repair technicians If unsure send the tool back to your dealer or the factory The PT 4000 and the battery charger unit must be kept away from moist wet surroundings and away from flammable liquids and gases Do not use in temperatures above 120 degrees F Socket Plug and Charger unit should be routinely inspected and if damaged replaced or re paired To charge batteries remove charger from steel case battery pack will only fit into charger socket in proper orientation and 15 installable with a minimum amount of insertion pressure When working on the PT 4000 1 replacing jaws jaw follower or spring be sure the battery pack 15 removed from the riveter Do not throw battery pack into water or fire as they can explode The battery pack should be recycled according to instruction manual Item Part No 1 QN 10 11 12 13 14 15 16 17 18 19 20 23014 23189 23185 23193 23753 23932 23605 23745 23081 23245 F123 F3126 F3130 F505 F506 F505 MB F506 MB F169 F143 F3893 Description Tool Housing complete Ball screw drive assembled Drive bearing complete Power transfer gear Snap ring Screw Draw Bolt Scraper ring Jaw pusher spring Jaw push
30. ce while holding the Releasing Trigger in the full depressed position This should then free the jaws and permit the tool to release the rivet stem If the rivet stem continues to bind or hang up in the nose assembly check the jaw holder by removing the nose tube to see if it is properly tightened into place If loose tighten and reassemble after checking the jaws to see that they are not severely worn Re place if necessary NOTE OF CAUTION If you cause the riveter to reach its maximum stroke you may cause the riveter to go into a by pass mode which causes a pressure relief valve to open this occurs when approximately 4 400 Ibs of pulling force is reached This condition will often cause the nor mal hand releasing pressure required to return the tool to its normal position to increase Simply increase pressure on the releasing trigger and the tool will release F157 ADAPTER FOR SPECIAL PULLING HEADS INSTRUCTIONS 1 Place the Adapter Shaft F187 2A into end of the Sleeve Spring F124 A 2 Place other end of the Sleeve Spring F124 A over the Puller Shaft and thread the 3 Adapter Shaft F187 2A onto the Puller Shaft hand tight against it so no threads showing Place the Adapter Sleeve F187 1A over assembly and hand tighten until threads disap pear Reverse for disassembly ASSEMBLY IS NOW READY FOR ANY OF THE SPECIAL PULLING HEADS 7 RIGHT ANGLE PULLING HEAD pesi Adapter Sleeve 187 1
31. der F128 onto the Draw Bolt 3605 and thread nose tube back onto the tool Then use the 5 32 Maxibolt nosepiece F506 MB for S Type Blind Bolts or the 5 32 Blind Bolt Nosepiece F506 for the U Type Blind Bolts Reverse the process to assemble the tool for regular CherryMax riveting FST FASTENING SYSTEMS INTERNATIONAL PT 100 PT 100M Riveter Operating Instructions 1206 East MacArthur Street Box 1372 Sonoma California 95476 Phone 707 935 1170 Toll Free 800 344 2393 Fax 707 935 1828 Email sales fsirivet com Website www fsirivet com MKT 02 inc WA FS PT 100 SERIES RIVETER FAS TENING SYSTEMS INTERNATIONAL NSN 5130 01 397 6805 ASSEMBLY DIAGRAM OPERATING INSTRUCTIONS Sleeve Spring Puller Shaft F124 A Two Piece Nose Tube de rii 7 Jaws a 4 2 4 i c D Reservoir Shield Actuating Trigger Adapter Shaft A Releasing Trigger F187 2A ordi Assembly Procedures 1 Place the Two Piece Jaws F122 A inside the Jaw Holder F126 2 Place the assembled item into one end of Sleeve Spring F124 A The flange on the Jaw Holder should bottom out on the Sleeve Spring These two items fit together firmly thus some pressure may be required 3 Next point the tool downward and place the open end of the Sleeve Spring F124 A over the Puller Shaft and thread the Jaw Holder onto the Puller Shaft until it bottoms out agai
32. e The valve is now completed retaining ring 5 Remove the internal O ring and back up ring 11 12 with a bent hook and replace them Apply O ring lubricant to all seal surfaces push piston rod 10 through the adaptor 2 Re assemble and tighten piston rod adaptor 49 use Loctite to secure in place Place the hydraulic pump inside the riveter body and thread it in with the help of the 9 16 deep socket wrench Make sure it there that the lever is pushed forward and there is no play after fully threading the hydraulic pump in Place spring 13 inside the riveter body over the hydraulic pump and thread in the piston and adaptor completed above use Loctite on the threads Tighten the adaptor securely Prime fill and bleed the riveter see next page FILL BLEED INSTRUCTIONS To fill and bleed you will need a 5 32 hex wrench a container with the recommended transmission fluid and an oil pan Make sure to place the tool over an oil pan to avoid and contain fluid spills FLUID USED Use automatic transmission fluid Type A no substitutes FSI recommends using Dexron ATF DEXRON OIL SAFETY DATA FIRST AID Skin Wash thoroughly with soap and water as soon as possible Casual contact requires no immediate attention If irritation develops consult a physician Eyes Flush with copious amounts of water If irritation develops consult a physician Ingestion Seek medical attention immediately DO NOT I
33. ean safe place Unthread and pull the reservoir piston assembly 44 out of the handle and set it aside Follow the below procedures select the one that pertains to you situation depending upon whether you are at a repair facility and a pressurized fluid source is available or not A At repair facility hydraulic pump or manual oil canister are available After step one above place the spring and ball 15 amp 16 back into the side port and thread in the hydraulic hose from the pressurized fluid source Turn the riveter up side so the inside of the handle is visible depress the pressure relief button and pump fluid through the system using the riveter s lever in some cases the fluid pressure may be enough to fill the tool without hand pumping The fluid level in the handle will increase until it overflows Watch for air bubbles and keep pumping until no more air bubbles are observed Remove the hydraulic hose and place thumb over the hole push the reservoir piston 44 into the handle as far as it goes without threading it in allow excess fluid to leak out from under your thumb Thread in and tighten the side screw and seal 45 amp 46 Thread in the reservoir piston 44 and check the fluid level B Field filling no pressurized fluid supply available After step 1 above thread screw and seal 45 amp 46 back in leave 15 amp 16 out Turn the riveter up side so the inside of the handle is visible and fill it with fluid
34. eep it from rotating Next take the straight pulling head s jam nut and back it off at least ten full turns from the end Now thread the adapter sleeve into place approximately six full turns Use the red marker on the jam nut to aid in counting Next engage battery pack into tool and fully retract the draw bolt haw holder assembly While keeping the jaw holder fully retracted insert desired rivet stem into nosepiece to set up for use with all sizes 3 16 oversize Now allow the jaw holder assembly to come forward If it easily accommodates the stem ie you can move it in and out freely you can now tighten the jam nut into place If however it does not readily accept or release the stem freely begin turning the outer sleeve clockwise in quarter turn increments until a proper setting 1s reached Offset Pulling Head F1076 Thread the internal threads of the offset pulling head s draw bolt onto the male thread of the adapter puller shaft Take two or three turns before engaging the male threads of the pulling head housing How thread both into place until there is no gap between the housing and the draw bolt Now tighten jam nut CAUTION If you tighten the outer sleeve too far down it will restrict the return of the draw bolt thereby causing an overload condition on the tool The red indicator light will come on Remove the battery immediately loosen outer sleeve and restart assembly procedure Failure to relieve For Blind Bolt and
35. er 1 4 Jaws 3 pc Jaw housing Nosetube Nosepiece 5 32 Blind Bolt Nosepiece 3 16 Blind Bolt Nosepiece 5 32 Maxibolt Nosepiece 3 16 Maxibolt Nosepiece 1 4 Monobolt Nosepiece 3 16 CherryMax Bushing Item 22 25 26 2 28 29 30 31 32 33 35 36 37 39 40 41 42 43 45 Part No 23761 23103 23850 23266 23990 23008 23559 23540 23032 23024 23030 23091 23834 23282 F 3001 F3555 F3197 F142 F 4000A Description Spent mandrel tube Motor complete Electronic control Magnet holder complete Magnet holder screw Spring lock washer Suspension loop Hand guard Housing screw Housing screw short Nosepiece bracket Nosepiece holder Nosepiece wrench Spent mandrel container Battery Lubricating grease Drive system pos 2 13 15 1 4 Nosepiece Battery Charger Wearing Parts 4000 optional Configurations F3605 Standard F130 F Draw Bolt Nose Tube F3621 Configuration B PT 4000 Pulling Head Configuration Extended Straight Pulling Head F1074 Right Angle Pulling Head F1075 F187 3BCM Adjustable Adapter Shaft Offset Pulling Head F1076 amp Rivets Configuration F3621 Jaw Follower Rivet Types Types of rivets ins
36. er the Collet Assembly 749425 70 8294 and into the Adapter Sleeve F187 1A and mate threads Thread on and bottom out against assembly DON T GO BEYOND Set jamb nut Reverse for disassembly Rivet may be forced in to open jaws initially Depress Actuating Trigger to install rivet ASSEMBLY DIAGRAM FOR OLYMPIC LOK PULLING HEADS Olympic Lok NAS1400 Code and the Cherry Lok use the same non shift tooling system One pulling head installs both flush and protruding head rivets in all grips No tool adjustment required with this system F657 ADAPTER FOR SPECIAL PULLING HEADS INSTRUCTIONS 1 Place the Adapter Shaft F687 2A into the end of the Sleeve Spring 124 2 Place other end of the Sleeve Spring F124 A over the Puller Shaft and thread the Adapter Shaft F687 2A onto the Puller Shaft hand tight against it 3 Place the Adapter Sleeve F687 1A over assembly and hand tighten threads should disap pear Reverse for disassembly ASSEMBLY IS NOW READY FOR ANY OF THE SPECIAL PULLING HEADS Adapter SI Adapter Shaft Sleeve Spring e ae 2 i Puller Shaft m Offset Pulling Hea V872 or RV887 Straight Extension Pulling Head RV812 OFFSET PULLING HEAD ASSEMBLY INSTRUCTIONS 1 Thread interior draw bolt of RV872 RV8872 onto the Adapter Shaft F687 2A approx 4 turns 2 Push RV872 RV8872 into the Adapter Sleeve F687 1A and mate threads Thread in until head gap is fu
37. ether make sure the locating marking of the bearing disk inside the ball screw drive 2 1s placed opposite the pinion shaft 4 See Parts Drawing Assemble this entire unit together with the 4 screws 6 using hexagonal wrench SW 2 5mm Screw jaw housing coupler 7 with scraper ring 8 onto ball screw using open end wrench SW 14mm Put jaw pusher spring 9 and jaw pusher 10 onto jaw housing coupler 7 Place the jaws 11 in jaw housing 12 and screw this onto jaw housing coupler 7 using open end wrench SW 17mm Screw head 13 on using open end wrench SW 27mm Assembly of the PT 4000 The sub assemblies and other parts should be put into tool housing half 1 containing the nosepiece bracket as follows To install drive system 42 slip the bushing 20 onto the shorter end of the pinion shaft 4 while ensuring that the snap ring 5 in pressed to the gear To insert the tube 22 the longer end of the tube must be inserted into the ball screw while the collar of the tube must be inserted into the provided recess of the tool housing To place the motor connecting wire the red wire should be bent downwards at the soldering tag towards the blue wire then bent again to be parallel with the blue wire To install motor 25 the two connecting wires are to be places side by aide around the first guiding stud of the tool housing and behind the middle guiding studs The wires should then be brought up
38. ister when installing 1 47 diameter rivets Replace 123 3 jaws with 122 2 jaws when installing 3 37 diameter rivets 187 1 rigz 3BCM oh pi Sleeve Adapter Shafi Righi Angle Hea _ Adiust jjustable CHART NOTE Pulling Heads are NOT included in the D 9000 MIL 1 Kit NSN 5180 01 470 6538 Aleeve component of 3187 adapter PT 4000 Set Up for CherryMax Riveting w H701B 465 Pulling Head FIX7T 3ACM Through Hole Puller Shaft 4000 F187 LAF Sleeve H701B 456 Assembly Straight Two Jaw Pulling Head 73621 F3081 A Jaw Follower Spring NOTE Insert spring and follower into PT 4000 BEFORE attaching the F187 2ACM CHART S component of F3187 adapter NOTE The H701B 456 is an OP TIONAL pulling Head which is sold separately PT 4000 with MS amp MASI400A Offset Right Angle amp Side Ejection Heads RV872 Series F728AR F728B4 Nose Tube 2 pc Jaws F728AS F728A7 Jaw Follower Jaw Holder ______ 2156 Nosepiece CHART U FSI FASTENING SYSTEMS INTERNATIONAL PT 4000 Operating Instructions 1206 East MacArthur Street Box 1372 Sonoma California 95476 Phone 707 935 11 70 Toll Free 800 344 2393 Fax 707 935 1828 Email sales fsirivet com Website www fsirivet com MKT 04 1 08 PT 4000 Rivet Capacity The PT 4000 pulls most all pull style blind rivets including
39. lly closed DON T GO BEYOND 3 Position head direction counterclockwise only Set jamb nut 4 Depress Actuating Trigger to install rivet Rivet stem will push out the back see operating instructions Reverse for disassembly STRAIGHT EXTENSION PULLING HEAD ASSEMBLY INSTRUCTIONS m Thread RV812 onto the Adapter Shaft F687 2A 2 Thread the sleeve of the RV812 over assembly and into the Adapter Sleeve F687 1A Thread on and bottom out against assembly DON T GO BEYOND Set jamb nut Reverse for disassembly Rivet may be forced in to open jaws initially 5 Depress Actuating Trigger to install rivet po OPERATING INSTRUCTIONS 700 Hand Powered Riveter PATENT PENDING 1206 E MacArthur Street Sonoma CA 95476 USA Tel 1 707 935 1170 Fax 1 707 935 1828 Fi AS ENING y 5 FL EMS WwW fsirivet com INTERNATIONAL TABLE OF CONTENTS BIS NEN EE DOES 3 3 Vy IN S erp 4 A A 4 ___ ___868_ 4 Hor T 4 Tool Operation Recommended Pulling 5 quaa Rudd 4 GUNS aet afe ater eom d id p EDD eben Cen n a s 5 aha 5 A 5 Ge UNG
40. luid traces that keep coming back even after wiping off the tool Fluid leaks are caused by worn seals Disassemble and replace the seals in the area where leaks are noticed o keep the tool in optimum operating condition we recommend inspecting and replacing all the seals as necessary see tool service page 6 This riveter was designed to be robust and require minimum troubleshooting and maintenance In order to keep it in optimum operating condition inspect routinely for leaks and damage and check the fluid level TOOL SERVICE For item and part numbers refer to the component list and exploded views on page 8 Tools needed F800KS maintenance kit Loctite amp 545 or comparable 1 16 1 8 and 5 32 hex wrenches e 2 deep socket hex wrench 9 16 size BEFORE TAKING THE TOOL APART Place the riveter over an oil pan to avoid and contain fluid spills clean up and dispose of used fluid properly Use care handling the internal components and valve cavities nicks or scratches may make components unusable Make sure that you have all the tools necessary before proceeding to service the tool Apply an O ring lubricant to all seals and mating surfaces When installing Back up Rings make sure the curved surface faces the O ring Use Loctite amp only where indicated use of Teflon tape is prohibited Handle with care and clean components thoroughly avoid contamination as it causes internal valve malfunction
41. measuring enable tach adardason ooordosoN N S vS S 06SIN ZE S SOO6ISVN ZE S VOOTISVN 91 6 VOOVISVN 8 1 15054 COSA adardason VOOVISVN N S 65 91 6 DN 9064 500615 91 6 2664 VOOVISVN Ct 2064 Hse 0664 606 me go01dason adardason PANELI 91 91 8 1 C 9654 8914 9614 BEES 92914950 yoqouopy a 3 1 9991dasoN 9 1 6914 SIN 9T t 214 6514 9664 0854 d Vd c HIN 0006 d 6ZtH Muy pnis 91 8 SLEA PMS Ze 4 8 4 PMS 81 91 5 PLEA Muy 9 14 pnis pc 01 CLE PMS pc 91 s Muy 644 Muy 8 4 pnjs 28641 pnjs 9864 spiiu y spnjs c TIIN 0006 G ez L4 swe od e yam gt d 7 a e daa pue N asn SIA p y zz L 4 smelad 7 YUM aae daJ ING N 1184 asn 000t Ld 941 buisn Sisal Jajaweip EP1sul 1211150215 OL SBEZW apopua 401eu6elA p mpnu s uow diic mnpnig CT feld epi ORC ze T
42. n with Weights 2 6 lbs Overcharge protection Capacity 1 4 amp hour Weight 1 4 Ibs Recharging Procedure Take charger out of steel case and connect to power line Make sure the voltage is in accordance with the label The battery must be installed correctly positive pole to positive pole with minimal force into the charger The quick recharging procedure is automatically started and indicated by red light After approximately 1 hour the charging procedure is finished and the charger switches to trickle charge indicate by a green light Place only cool batteries into the charger in order to obtain a full battery recharge Battery Handling The battery 15 rechargeable up to 1000 times and reaches its full power only after several re chargings Do not discharge the battery completely Recharge 15 not used for an extended pe riod Substantially reduced operating time of battery after a proper recharge indicates the battery must be replaced Keep battery in a cool and dry place with temperature not to exceed 122 F Environmental Protection If batteries have to be replaced the following instructions should be followed Return used batteries to your supplier or FSI for recycling Under no circumstances should nickel cadmium batteries be discarded as normal waste which might be burned or exposed to ground water Trouble Shooting Blind Rivet Cannot be Set Causes Depleted battery charge Jaws dirty or worn Jaw
43. nst Puller Shaft flange WARNING FAILURE TO BOTTOM OUT AGAINST THE FLANGE MAY DAMAGE THREAD AND OR CAUSE RIVETS TO JAM 4 Place the Nose Tube F130 over the complete assembly and hand tighten Threads on the outer sleeve should disappear and the Reservoir Shield should be stationary 5 Now select the proper nosepieces for the diameter and type of rivet being used and thread into the end of the Nose Tube until it bottoms out It may be necessary to extend the nose tube by actuating the trigger see operating instructions in order to thread the nosepiece completely into place CAUTION Nosepieces can loosen with use and may cause damage to the threads if not kept tight Check periodically and if no other nose pieces are going to be needed for the day tighten with a wrench 100 SERIES OPERATING INSTRUCTIONS 5 ya gt EA ae 1 Connect PT 100 riveter to air source Be sure to utilize clean dry compressed air over a 90 to 120 PSIG range If using a multi plane swivel be sure swivel 1s properly tightened into tool be fore installing air fitting into swivel 2 Select the proper nosepiece for installing the blind rivet being used and hand tighten it into the nose tube If frequent changing of the nosepiece is not required slight tightening with a wrench is recommended in order to prevent the nosepiece from backing out during riveting operation If rivet nosepiece will not easily install into nose tube simply
44. nt holes in tool housing an any time Repairs should be carried out by trained personnel only Otherwise return PT 4000 to supplier or to FSI Do not operate the PT 4000 and the Battery Charger in an environment allowing exposure to moisture combustible fluids or gases Safety Notes continued Avoid damage to cord and plug of charger Inspect regularly for any damage Ensure that the battery 1s properly secured in the tool housing Take the charger out of steel case when recharging the battery Place the battery 1n the correct position pole to pole and do not force it into the charger Always remove the battery before servicing repairing the 4000 Do not discard batteries into water or fire as danger of explosion exists Any used battery be disposed of in accordance with environmental regulations Do not use the 4000 for any function other than riveting especially not as a hammer Safety Precautions PT 4000 CORDLESS BLIND RIVETER The PT 4000 Blind Riveter has been designed with safety in mind and it conforms to all appli cable regulations governing cordless battery operated tooling If utilized 1n accordance with operating instructions danger free application of the tool 15 assured CAUTION Do not rivet without the rivet being installed into material The rivet body and a portion of the mandrel can shoot away from the tool which could cause injury Stem canister Item 39 should always be mounted on the tool to
45. s can now be removed using a bent hook make sure to remove the seals 38 amp 39 from inside the cavity Clean PISTON AND ADAPTOR Unthread adaptor 49 and push piston rod 10 out of the adaptor 2 Remove and replace seals 1 3 4 6 amp 7 Remove the retaining ring 5 and push piston 8 and rod 10 apart light tapping with a mallet is OK Replace O rng 9 and reassemble piston and rod 8 amp 10 by pressing them into each other and secure with the FINAL ASSEMBLY Place stage piston 20 in a vise unthread the cap 21 and clean it Inspect the edge of the hole facing the ball to make sure it is clean and in good condition free of nicks and scratches reassemble the stage piston 20 Replace the larger O ring and back up ring 11 4 12 Remove O rings and back up ring 9 30 and 31 from the power cylinder 29 and replace them Apply O ring lubricant to all the seal surfaces and push the stage piston 20 back into the power cylinder 29 Re assemble the rest of the components 17 amp 18 19 use Loctite on the threads and tighten securely The hydraulic pump is now completed and inspect the inside of the valve body and the poppet 34 amp 36 replace the seals Place the poppet and spring 34 25 back into the body 36 and thread in the adjustment plug 33 no Loctite amp on these threads Place a new O ring and back up ring 38 amp 39 onto the poppet stem protruding out of the pressure relief valv
46. s useful whenever you need to add some fluid in order to restore the fluid level It cannot be used after completed disassembly prime and fill with fluid in that case see previous page Tools needed 5 32 hex wrench and the 700A77 Bleeder Bottle with F1484 adaptor The Bleed Bottle should have at least 2 fl oz about 5 mL of fluid recommended fluid on page 7 e Remove the side screw spring and ball 15 16 45 amp 46 and place them in a clean place e Attach the bleed bottle to the side hole With the bottle up side down see picture unthread the reservoir piston 44 until fully disengaged do not pull the piston assembly out of the reservoir During this process fluid will be drawn into the reservoir Remove the bleed bottle and place the ball and spring 15 amp 16 back into the side port then tighten the screw and seal 45 amp 46 e Thread in and tighten the reservoir piston 44 check the fluid level e Ifthe fluid level is still low then tool needs to be primed and filled see page 6 D 700C PARTS LIST F 800 000 TOP ASSEMBLY 1 F701 O RING BLACK OD 5 8 W 07 2 Fa800 027 CHERRY HOUSING ADAPTOR 3 F1467 O RING WHITE OD 1 5 W 07 1 4 i479 SEAL BLACK OD 3 4 W 1 8 5 Fies EXTERNAL RETAINING RING 5 87 6 F299 O RING OD 1 39 W 14 BACK UP RING OD 1 39 W 14 8 800 013 WORK PISTON gf F721 O RING WHITE OD 3 4 W 07 10 __ 800 026 P
47. tallable with the PT 4000 include Note Replace Jaw Follower F3621 with F3245 see spare w parts canister when install ing 1 4 dia rivets You may mes but are not limited to vir 1 the F123 j F for 1 8 thru 1 47 diameter 130 F122 A tually all CherryMax blind rivets Nose Tube 2 pc Jaws M7885 Avdel or Cherry Monobolts PEE 25 Cherry Interlock amp Huck Jaw Follower MagnaLok and Pop type rivets The 4000 590353 54 U amp S Type Blind Bolt is also capable of Configuration installing both 5 32 and 3 16 Blind Bolts je F130 F Nose Tube wm MS90353 54 S U with the proper nosepieces provided in the Mlil 1 and 2 kits Jaw Follower BB Jaw Holder Aerospace and Industrial Sheet Metal eApplicationse Pulling Head Assembly Right Angle Pulling Head F1075 Thread the internal threads of the pulling head s draw bolt two or three turns onto the adapter puller shaft Next engage the threads of the pulling head housing and continue threading into place minimize stroke requirement and to set a particular rivet size simply adjust the nose tube of the right angle head by loosening the jam nut at its base Extended Straight F1074 Thread the extended straight pulling head s haw holder assembly onto the adapter puller shaft assembly Tighten by putting rivet stem into adapter puller shaft hole to k
48. verload protection In case if an overload the operation will be stopped and the red light goes on If that happens release the trigger and the mechanism will return to the start position The battery will deliver uniform power for tool operation until depleted to the last 2 3 rivets of charge capacity It is designed to have the jaw mechanism return to the starting position when the trigger has been released Maintenance The maintenance of the riveting tool is limited to the complete jaw mechanism and the included wearing parts Remove the battery 40 from the tool housing Unscrew the head 13 from the tool and clean it Unscrew the jaw housing 12 from the coupler Take the jaws 11 clean and lubricate or replace if worn Reassemble in reverse order and make sure that all parts tightened Warranty There is a 6 month warranty from the day of delivery on the PT 4000 Damages caused by com mon wearing overloading or improper usage or handling are excluded from the warranty Dam ages caused by material or manufacturing faults will be covered by this warranty and will be re paired or replaced at no cost Claims can only be accepted if the complete riveting tool fully as sembled 1s returned to the distributor or FSI Battery Charger Technical Data Charger Battery Input Voltage 110 V 60 Hz Rated Voltage 12 VDC Output Voltage 12 VDC Number of Cells 10 Pieces Recharge Time Approx hour Cell Constructio
49. w far the pump lever extends from the handle for a comfortable operation thread set screw 42 in to bring the lever closer thread out to increase lever distance see picture below Maximum output load Tools necessary 5 32 wrench This is a maximum output load adjustment if you need a more precise adjustment contact FSI hread out the adjustment screw 33 to lower the load thread in to increase it Cautions Do not thread out beyond flush with the pressure relief body 36 see picture below e Do not exceed a maximum output load adjustment of 5500 Lbs TOOL OPERATION Prior to using the hand riveter make sure that he piston is fully returned forward by depressing the side pressure relief button 48 he hand lever is properly adjusted for comfortable operation he correct pulling head is properly mounted see pulling head documentation for additional instructions Fastener Installation Insert the blind fastener into the structure and place the riveter onto the rivet stem Hand pump to complete installation after each pump allow the lever to fully return to its original position Short stroking is not recommended as it will increase the number of pumps Depress the pressure relief button and allow the broken stem to eject through the front RECOMMENDED PULLING HEADS Contact FSI at 1 800 344 2393 or 707 935 1170 by e mail at sales fsirivet com for recommendations TROUBLESHOOTING GUIDE
Download Pdf Manuals
Related Search