Emhart ProSet 2500 Series Specifications
Contents
1. i 1 1 22 DP203 263 COLLECTOR BOTTLE MCS S A 1 1 23 DP203 265 LEAK FILTER i 1 1 24 DP203 272 MCS FILTER 1 25 DP203 276 MCS MUFFLER 1 26 203 287 VALVE STEM RETAINING BUSHING 1 27 DP900 005 O RING ADAPTOR 1 1 1 28 DP900 006 O RING COLLAR FD 2100 1 29 DP900 007 O RING COLLAR RD 2101 1 1 30 DP900 008 O RING MH2BH i 1 31 DP900 009 O RING SWITCH RING i i 1 32 DP900 010 O RING FILTER COVER 2 2 33 DP900 011 O RING COLLECTOR BOTTLE 2 1 34 DP903 001 SCREW FHSCS 6 32 X 0 500 i 3 3 35 DP904 001 SET SCREW 5 16 18 X 5 32 HOLLOW 1 36 DP906 002 SCREW 4 40 X 3 16 BHCS s 2 1 1 37 DP907 001 SCREW 6 32 X 1 1 4 SHCS 3 3 38 DP908 001 SEALING WASHER 2 PC ASSEMBLY i 1 1 39 DP909 001 3 FLAT WASHER ORIFICE 1 1 40 FA203 194 PULLING HEAD ADAPTOR ASSEMBLY 2100 1 1 41 FA203 200 PULLING HEAD ADAPTOR ASSEMBLY 2101 1 1 42 FA203 277 MIDDLE HOUSING ASSEMBLY 1 1 43 FA203 281 FILTER COVER ASSEMBLY 1 1 44 MCS500 22 O RING TRANSDUCER 2 2 45 MCS5200 13 O RING 5 A 1 1 46 MCS5200 18 O RING i 1 1 47 MCS5200 19 RETAINER TRANSDUCER 1 1 48 MCS5200 20 TRANSDUCER ASSEMBLY 1 1 49 MCS5200 21 O RING 3 3 50 MCS5200 3 SPRING VALVE STEM e S 1 1 51 MCS5200 7 VALVE GUIDE E 1 1 52 PRG402 8A JAW 2 i 2 53 PRG510 107 O RING 1 1 54 PRG510 123 SPRING JAW PUSHER 1 1 1 1 Page 12 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 T2. for rivet break loads of 1 000 Ibs max Packaged Accessories Qty Item 2100 2101 Part No 1 ProSet Rivet Tool Y 1 Operating Instructions P449 1 Maintenance Manual P442 1 Nosepiece for 4 size open end rivets Installed PRN414 1 Nosepiece for 5 size open end rivets v v PRN514 1 Nosepiece for 6 size open end rivets Installed PRN614 1 Jaw Pusher PRG520 33 1 Air Hose Assembly Y PRT5200 220 1 Warranty Card Y Y FG2184 Tool Requirements Air supply 6 scfm 150 l min Minimum Recommended Operating Pressure 72 5 90 PSI 5 0 6 2 Bar dry filtered Maximum Operating Pressure 100 PSI 6 9 Bar dry filtered Hydraulic Oil POP p n PRG540 130 1 qt 945 ml Mobil DTE 26 Jaw Lubricant POP p n PRG510 130 6 oz 177 ml Seal Lubricant Lubriplate 130 AA Note For best results and long service life use only a dry filtered air supply Note See lubricant safety information Lubriplate is a register mark of Fiske Brothers Refining Company kk Page 4 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Tool Dimensions 953 24 2 mm 11 14 283 mm 689 17 5 mm 10 53 267 5 mm E o por 11 07 281 2 mm 10 85 275 6 mm ProSet 21 00 3 8 96 5 mm amp ProSet 2101 Dimensions
3. 0 P N PA203 001 ProSet 2100 MCS P N PA203 003 ProSet 2101 P N PA203 002 ProSet 2101 MCS P N PA203 004 0 953 24 2 mm Max 3 32 to 3 16 2 4 to 4 8 mm 0 689 17 5mm Max ProSet 2001 models are recommended for rivet break loads of 1 000 Ibs max Page 2 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 A Safety Instructions INSURE PROPER FUNCTIONING AND SAFE OPERATION READ THIS MANUAL CAREFULLY BEFORE SETTING UP OR OPERATING THE ProSet 2100 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 the tool both the operator and any person s in the vicinity are required to wear eye protection to protect against injury 3 Inspect tool for damage before connecting to air supply 4 Trained personnel must perform tool repair and or maintenance at the prescribed intervals for damage and functionality 5 Disconnect the air supply when adjusting servicing or removing any part of the tool 6 Keep your fingers off of the trigger when connecting the air supply 7 Keep your fingers away from the front of the tool when connecting the air supply or setting rivets 8 DO NOT point the tool at any person s or the operator 9 DO NOT operate tool with nose housing removed 10 DO NOT operate tool without deflector
4. 4 Tel 203 924 9341 Fax 800 225 5614 LUBRIPLATE 130 AA Manufactured by Fiske Brothers Refining Co Phone 419 691 2491 First Aid SKIN Remove any contaminated clothing and wash with soap and warm water If injected by high pressure under skin regardless of the appearance of its size contact a physician IMMEDIATELY Delay may cause loss of affected part of body INGESTION Call a physician immediately Do not induce vomiting EYES Flush with clear water for 15 minutes or until irritation subsides If irritation persists consult a physician Fire FLASH POINT COC 400 F Cool exposed containers with water Use foam dry chemical carbon dioxide or water spray Environment WASTE DISPOSAL Assure conformity with applicable disposal regulations Dispose of absorbed material at an approved waste disposal facility or site SPILLAGE Scrape up grease wash remainder with suitable petroleum solvent or add absorbent Handling Storage Keep containers closed when not in use Do not handle or store near heat sparks flame or strong oxidants Safety Data JAW LUBE P N PRG510 130 Distributed By Emhart Teknologies Phone 203 924 9341 First Aid SKIN Wash with soap and water until no odor remains If redness or swelling develops obtain medical assistance Wash cloths before reuse INGESTION Do not induce vomiting Do not give liquids Obtain emergency medical atten
5. 484 6212 Finland Hyttm stargr nden 4 FIN 02780 Esbo Finland Tel 358 9 8190060 Fax 358 9 812428 France ZA des Petits Carreaux B timent Haute Technologie No 8 Lot B 2 bis Avenue des Coquelicots 94385 Bonneuil Sur 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 Alcal de Henares Madrid Spain Tel 34 91 887 1470 Fax 34 91 882 3602 Sweden Skjutbanev gen 6 SE 701 44 rebro Sweden Tel 46 19 2058000 Fax 46 19 260038 United Kingdom 177 Walsall Road Perry Barr Birmingham B42 1BP United Kingdom Tel 44 0 121 356 4811 Fax 44 0 121 356 1598 Form No P442 Rev 3 07 05 ASIA PACIFIC Japan Shuwa Kioicho Park Building 302 3 6 Kioicho Chiyoda Ku Tokyo 102 0094 Japan Tel 81 03 3265 7291 Fax 81 03 3265 7298 Korea Rm 609 Seorin Bldg 45 15 Yeoido Dong Yeongdeungpo Ku Seoul 150 891 R O Korea Tel 82 2 783 9226 Fax 82 2 783 9228 P R China 488 Jiatang Road Jiading District Shanghai 201807 People s Republic of China Tel 86 21 5954 8626 Fax 86 21 5954 8775 Emhart Teknologies A BLACKS DECKER COMPANY
6. LIPPING ON MANDRELS Jaws dirty or need lubrication Jaws worn Clean and lube jaws Replace jaws JAWS FAIL TO OPEN Insufficient air pressure Nose housing loose Excess hydraulic oil in tool Adjust air supply pressure Tighten nose housing Service tool by qualified service personnel MANDREL STICKING IN JAWS Jaws dirty or need lubrication Clean and lube jaws RIVET FAILS TO INSERT INTO NOSEPIECE Incorrect nosepiece Shear ring stuck in hole of nosepiece Install correct nosepiece Remove shear ring RIVET MANDREL DOES NOT BREAK Rivet not fully set Mandrel break load requirement too high Insufficient air pressure Repeat stroke required or change rivet Upgrade tool Adjust air supply pressure MCS NOT WORKING Tool not connected to air supply MCS switch ring in off position Collector bottle not tight or missing Collector bottle seal damaged or missing Low flow adjusted to off position Mandrel path blocked Connect to recommended air supply source Rotate MCS switch ring to ON position Check collector bottle Replace seal Adjust low flow valve Activate trigger to check Clear mandrel path Collector bottle not tight Check collector bottle LOW VACUUM Dirty filter Clean or change filter Collector bottle seal damaged or missing Replace seal Insufficient air pressure Adjust air supply pressure Page 18 Emhart Teknologies 50 She
7. POP five Tool ProSet 2100 Series Maintenance Manual Emhart Teknologi es INtFOGUCTION MC Cm 2 Safety Instructions amp Precautions Specifications See SCH E EE ee Made d 4 Packaged Accessories Tool Requirements Tool Dimensions Common Nosepieces Basic Tool Operation tamaai eae ee PE NEG Re pee a 6 Front End Service Mandrel Collector System MCS Adjusting Low Flow Vacuum Cleaning the MCS Filter Exploded View Of Tool od sere ex lee candice Soe alin thy Wek ee eee RU 10 Parts EISi e ee AER teen SE E ea a eee ee EAA 12 Tool Cross Sectlon e MR Ren Ge AE eae le ee Gee eee te RE 14 Hydraulic Oil Charging Procedure 15 Maintenance Schedule 16 Safety Data scsi eshte payaa mere NEE ee wa ECH 17 Troubleshooting apne eee eee eee 18 EC Declaration of Conformity 19 Introduction Thank you for choosing the Emhart Teknologies ProSet 2100 Series Rivet Tool ProSet tools are recommended to be used with genuine POP Brand Rivets Models Diameter Rivet Size Nose Housing Diameter ProSet 210
8. VE PLUG 1 1 1 1 83 PRT5200 37 SCREW END CAP 3 3 84 PRT5200 46 RAM SLEEVE 1 1 1 1 85 PRT5200 47 RESTRICTOR SEAT 1 1 1 1 86 PRT5200 48 RETAINER PLATE RAM SLEEVE 1 1 1 1 87 PRT5200 50 PRESSURE REGULATOR ASSEMBLY 1 1 1 1 88 PRT5200 59 O RING RAM SLEEVE 1 1 1 1 89 PRT5200 62 SCREW CLAMP FRONT 1 1 90 PRT5200 63 SCREW CLAMP BACK 1 1 91 PRT5200 8 ROD SEAL 1 1 92 PRT5200 84 RAM SEAL 1 1 93 PRT5300 26 GROMMET 1 1 94 PRT5500 113 CLAMP NUT 2 2 2 2 95 PRT5200 55 AIR VALVE ASSEMBLY 1 1 96 PRG540 39 AIR LINE 1 1 97 PRG540 40 HOSE FEMALE FITTING 1 1 98 PRG540 45 AIRLINE O CLAMP 2 2 2 2 99 PRT5200 90 AIR LINE FITTING 1 1 1 1 100 FA203 279 BOTTOM HOUSING ASSEMBLY 1 101 FA203 092 NOSE HOUSING ASSEMBLY 2100 1 102 FA203 097 NOSE HOUSING ASSEMBLY 2101 1 1 107 FA203 405 COLLECTOR BOTTLE ASSEMBLY 1 108 FA203 402 MANDREL COLLECTION SYSTEM 1 109 FA203 404 NOSE HOUSING NUT ASSEMBLY 1 1 1 110 FA203 406 END CAP ASSEMBLY 1 FD Denotes Full Diameter option 2100 RD Denotes Reduce Diameter option 2101 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 13 Optional Kits are also available separately Part No Description FA203 400 ProSet 2100 Seal Kit FA203 401 ProSet 2100MCS Seal Kit FA203 403 Reduced Diameter Front End Kit 2100 to 2101 conversion FA203 408 ProSet 2100 Adaptor Kit for MCS5000 remote MCS FA203 2102K Red
9. acuum setting if necessary e See Adjusting low flow vacuum page 8 Q Insert rivet into nosepiece Q Position rivet in work piece Q Pull trigger to set rivet e When turned on the MCS vacuum will automatically switch to high flow mode and transfer the mandrel into the collector bottle Q Release trigger e MCS low flow will begin to time out Approx 5 to 18 seconds Page 6 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Front End Service Adapter Nose Housing Assembly Collar teeth 12 teeth To remove ONLY Jaw Guide Tooth For optimal tool performance Front End maintenance should be performed regularly per the Preventative Maintenance Schedule 1 REMOVE NOSE HOUSING 4 REASSEMBLY OF INTERNAL PARTS AND JAW GUIDE Remove Nose Housing Assembly by grasping the Nose Housing Nut by hand and rotate the entire Apply Lubriplate to jaws and to conical area of the jaw assembly counterclockwise until the threads are guide and Jaw Pusher Place the Jaws and Jaw fully disengaged Tools are not required however Pusher into the Jaw Guide and slide the Jaw Pusher flats are provided as back up Spring into the Pulling Head Adaptor Slide Nose Housing Assembly off the tool Apply a slight amount of Lubriplate 130 AA to the Pulling Head Adaptor threads and Collar teeth Screw 2 REMOVE JAW GUIDE TO ACCESS JAWS the Jaw Guide onto the Pulli
10. atches Reinstall the intensifier chamber and sleeve 78 amp 79 and O ring 93 amp 58 Install the Clamp assemblies 11 12 89 90 and 94 Be sure lt that the orientation of the clamps is correct Tighten both Clamp Nuts 94 to 8 10 in lbs NOTE The orientation of the words Made U S A of the clamps should be the same as the words POP the Handle 4 and located opposite the air inlet port of the Handle 180 GAP SETTING NOTE 23 Reinstall the Nose Housing Assembly 101 102 Maintenance Preventative Maintenance Schedule Item Action Frequency Clean and lube Front End pd 1 x per day or of tool S e on 580468 5 000 rivet settings Look for broken jaws and During Front End service Inspect jaws damage or wear on jaw 9 When jaws slip mandrel gripping teeth When the quantity of stored spent mandrels begin to interfere with Empty Collector Bottle mandrels entering the collector bottle Storage quantity depends on rivet size MCS Collector Unit and application Clean MCS Filter Once a day or when MCS vacuum will not pull rivet into collector bottle 2 months or 250 000 rivet settings Clean MCS Muffler Note Only use Emhart specified greases and lubricants Page 16 Emhart Teknologies 50 Shelton Technology Center Shelton CT 0648
11. chnology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 7 Mandrel Collection System MCS For ProSet 2100MCS amp ProSet 2101MCS The MCS suction on the ProSet model tools is switched ON and OFF by turning the red Switch Ring 21 to one of the three ON positions The MCS features an automatic timer and switch that reduces air flow to a Low Flow mode if the tool is left idle Air Flow Modes With the Switch Ring in the ON position air will flow through the MCS system If the trigger has not been pressed the air flow will be in the Low Flow mode Pressing the trigger will activate the Full Flow mode for 15 20 seconds After 15 20 seconds if the trigger has not been pressed again the tool will automatically return to the Low Flow mode Adjusting Low Flow Vacuum D 2 SO n Remove Collector Bottle 22 from tool Remove Filter Cover Assembly 43 Remove Filter 24 Optional Connect tool to air supply Turn on MCS unit by rotating the Switch Ring 21 to one of the three on positions e Activate Trigger 5 while rotating Switch Ring 21 to on position Using a small screwdriver rotate Low flow adjustment screw e Clockwise reduce vacuum in low flow mode If screw is fully in there won t be vacuum during the low flow mode e Counter clockwise increase vacuum in low flow mode If screw is fully back vacuum during the low flow mode will continue at full flow DO NOT a
12. el 203 924 9341 Fax 800 225 5614 Parts List e v e N N 9 E O 5 95 ITEM Part DESCRIPTION e 81 a 55 PRG510 56 DEFLECTOR 1 1 56 PRG520 100 SCREWS RETAINER PLATE 3 3 3 3 57 PRG520 101 RETAINING RING SEAL SLEEVE 1 1 1 1 58 PRG520 106 O RING POT 1 1 1 1 59 PRG520 45 RESTRICTOR 1 1 1 1 60 PRG520 47 O RING SS WIPER 1 1 1 1 61 PRG520 49 O RING END CAP OUTSIDE 1 1 1 1 62 PRG520 89 O RING SS OUTSIDE 1 1 1 1 63 PRG540 102 WASHER FILL SCREW 1 1 1 1 64 PRG540 117 O RING VALVE 4 4 3 3 65 PRG540 118 O RING END CAP INSIDE 1 2 2 66 PRG540 120 LOCK WASHER 3 3 3 3 67 PRG540 122 FILL SCREW 1 1 68 PRG540 4 O RING NH 1 1 69 PRN 414 NOSEPIECE 4 SIZE 1 1 70 PRN 614 NOSEPIECE 6 SIZE 71 PRT5200 4 JAW PUSHER ASSEMBLY 1 1 72 PRT5200 15 PISTON SEAL 2 PC ASSEMBLY 1 1 73 PRT5200 19 WASHER SS 1 1 74 PRT5200 20 RETAINING RING SS 1 1 75 PRT5200 220 AIR LINE ASSEMBLY COMPLETE 1 1 76 PRT5200 26 INTENSIFIER ASSEMBLY 1 1 77 PRT5200 28 SEAL AIR PISTON 1 1 1 1 78 PRT5200 29 INTENSIFIER CHAMBER 1 1 1 1 79 PRT5200 30 INTENSIFIER CHAMBER SLEEVE 1 1 1 1 80 PRT5200 33 SPRING PIN TRIGGER 1 1 1 1 81 PRT5200 34 JAW PUSHER CONICAL 1 1 82 PRT5200 35 VAL
13. eve 16 Slowly move the pulling head back until the oil level in the ram sleeve drops to approximately inch for top of seal sleeve 17 Add hydraulic fluid until level with the top of the ram sleeve 18 Install the intensifier assembly 76 into the ram sleeve Push in until itis about 1 3 down 19 Reposition this assembly to the upright position as shown on view E2 20 Let the tool stand for approximately 2 minutes so that any air in the ram sleeve rises to the top Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 15 21 22 23 24 25 26 27 28 29 Move the intensifier item 76 up approximately inch more This will force air trapped at the top of the ram sleeve into the upper bore chamber of the handle in front of the hydraulic piston Let the tool stand for approximately 2 minutes so that any air in the upper bore chamber rises towards the fill screw Move the intensifier up so that the pulling head is in the full back position Apply pressure to the bottom of the air piston and loosen the fill screw until oil seeps by the threads of the fill screw Continue until the piston gap setting is 180 4 6mm See gap setting Tighten fill screw to 60 65 in Ibs Wipe away any excess oil from the handle GAP SETTING Inspect Ram Seal 92 for cuts and defects Inspect inside surface of the Ram Sleeve 84 for marks and scr
14. lton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 EC Declaration of Conformity We Emhart Teknologies Tucker Fasteners Limited Birmingham B42 1BP United Kingdom Declare that ProSet 2100 MCS ProSet 2101 MCS Conforms to the following standards EN 292 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 gen Eymard Chitty Vice President R amp D Signed Birmingham 17 November 2003 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 19 E Ol United States 50 Shelton Technology Center P O Box 859 Shelton CT 06484 USA Tel 203 924 9341 Fax 800 225 5614 Canada 9870 boul du Golf Anjou Quebec H1J 2Y7 Canada Tel 514 351 0330 Fax 514 351 0458 Brazil Rua Ricardo Cavatton 226 LAPA CEP 05038 110 Sao Paulo SP Brazil Tel 55 11 3871 6460 Fax 55 11 3611 3508 M xico Bosque de Radiatas No 42 Bosques de las Lomas 05120 M xico D F Tel 52 555 326 7100 Fax 52 555 326 7141 Visit our website at http www emhart com 2005 Emhart Industries Inc EUROPE Denmark Farverland 1B DK 2600 Glostrup Denmark Tel 45 4484 1100 Fax 45 4
15. ng Head Adaptor until the INTERNAL PARTS teeth on the Collar causes the Jaw Guide to stop rotating Pull back the Collar to disengage the Collar teeth Do not pull the collar back and fully tighten jaw from the Jaw Guide teeth guide onto the pulling head adaptor Once the teeth are disengaged unscrew the Jaw Apply jaw lube to the jaw area by submerging the Guide from the Pulling Head Adaptor assembled jaw guide into jaw lube about 1 in 25mm Remove jaws jaw pusher and jaw pusher spring for Make sure the MCS unit is turned off servicing Tools are not required 5 REINSTALL NOSE HOUSING ASSEMBLY 3 CLEAN PARTS Slide the Nose Housing Assembly over the Pulling Clean jaws jaw guide jaw pusher spring and Head Adaptor Hand tighten the Nose Housing Nut thread area of the pulling head adaptor Also be onto the Adaptor so that it squeezes snuggly against sure to clean the inside of the Nose Housing the Nose Housing Seal Assembly A long narrow wire may be needed to Do not use a wrench to tighten the nose housing loosen debris at the inside front surface onto the tool The wrench flats are only to assist removal of the nose housing when necessary Check to make sure that there is sufficient squeeze on the Nose Housing Seal There may be a loss of vacuum if the Nose Housing Seal is not fully engaged Note Turn off MCS unit while servicing tool to avoid sucking any oils or other fluids into the MCS unit Emhart Teknologies 50 Shelton Te
16. or MCS options 11 DO NOT modify the tool in any way In addition to voiding any applicable warranties unauthorized modifications can result in damage to the tool or physical injury to the user 12 DO NOT lock into the tool from the front or the back during use Rivets or expended mandrels may be ejected resulting in injury 13 The operating pressure shall not exceed 100 psi 6 9 bar 14 DO NOT direct tool exhaust towards anyone 15 If there is excessive contact with hydraulic fluid or lubricants care should be taken to wash thoroughly 16 Take care to keep hair fingers and loose clothing away from moving parts of the tool to avoid entanglement and or physical injury Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 3 Specifications ProSet 2100 ProSet 2101 MCS w MCS MCS w MCS Weight 3 31 Ibs 1 5 kg 3 70 Ibs 1 68 kg 3 13 Ibs 1 4 kg 3 50 Ibs 1 59 kg Length 11 14 283 0 mm 12 32 312 9 10 53 267 5 mm 11 71 297 4 mm Height 11 07 281 2 mm 10 85 275 6 mm Tool stroke 669 17 mm 629 16 mm Pulling force 1900 Ibs 85 PSI 8452N 5 9 bar 1900 Ibs 85 PSI 8452N 5 9 bar Air consumption 011 cu ft 0 to 2 scfm 011 cu ft 0 to 2 scfm per rivet 31 liters rivet adjustable 31 liters rivet adjustable ProSet 2001 models are recommended
17. shown in square brackets Y 3 45 87 6 mm 12 32 312 9 mm 11 71 297 4 mm 953 24 2 mm 689 17 5 mm 11 07 281 2 mm 10 85 275 6 mm La 3 8 96 5 mm ProSet 2100 MCS amp ProSet 2101 MCS Dimensions shown in square brackets 3 45 87 6 mm 8 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 5 Common Nosepieces Ge ClosedEnd End HR Rivets Mandrel Mandrel Body Body 3 32 2 4 mm PRN314 1 8 3 2 mm or e 2 8 mm PRN414 PRN424 PRN434 i PRN414 PRN4H 5 32 4 0 mm PRN514 PRN524 PRN534 mro PRN514 PRN5H 3 16 4 8 mm PRN614 PRN624 PRN634 PRN625 PRN614 EN Included with the tool Before operating the tool check the following 0 Inspect tool for damage or leaking oil e Do not use tool if damaged or leaking oil Check to see that correct nosepiece is installed into the nose housing e Tighten nosepieces to 60 65 in lbs of torque Be sure that the nose housing nut 9 is tight e Hand tighten only Q Connect tool to air supply e See air supply requirements page 4 Turn on MCS by rotating switch ring to one of the three ON positions e MCS style only Q Adjust low flow v
18. sted However get medical attention EYES Flush with water If irritation occurs get medical attention Fire FLASH POINT 390 F 198 9 C Material will float and can be re ignited on the surface of water Use water fog alcohol foam dry chemical or carbon dioxide gt to extinguish flames Do not use a direct stream of water Environment WASTE DISPOSAL SPILLAGE Soak up residue with an absorbent such as clay sand or other suitable material Place in a non leaking container and seal tightly for proper disposal Handling Wash with soap and water before eating drinking smoking applying cosmetics or using toilet Properly dispose of leather articles such as shoes or belts that cannot be decontaminated Use in a well ventilated area Storage Store in a cool dry place with adequate ventilation Keep away from open flames and high temperatures Page 17 Troubleshooting Symptom Probable Cause Remedy TOOL FAILS TO OPERATE Tool not connected to air supply Insufficient air pressure Air pressure too high Tool low on hydraulic fluid Connect to recommended air supply source Adjust air supply pressure Adjust air supply pressure Service tool by qualified service personnel TOOL NOT RETURNING Insufficient air pressure Adjust air supply pressure TOOL LOSING STROKE Tool low on hydraulic fluid Service tool by qualified service personnel JAWS S
19. tch or score the inside of the Ram Sleeve surface 84 7 Turn the tool right side up over a pan that can capture the hydraulic oil as it is drained from the tool The oil will exit the tool out of the Ram Sleeve 84 8 Remove or loosen the fill screw Assembly 67 amp 63 Allow oil to drain for a minute or two 9 Invert the handle pulling head down view E1 in a soft jawed vise Grip the tool gently on the aluminum casting in the middle of the tool handle grip area 10 If fill screw 67 and fill screw washer 63 have been removed during dismantling reinstall these before proceeding and tighten hand tight approximately 15 in Ibs 11 Move the pulling head 40 or 41 to the full forward position Note VIEW E2 rotating the pulling head adaptor while moving it will reduce sudden UPRIGHT POSITION uncontrolled movement 67 TRE Nox 63 12 Fill ram sleeve 84 with hydraulic oil until level with the top of the Spe CD ram sleeve 13 Slowly move the pulling head back about 7 inch Then slowly return the pulling head to the full forward position Note rotating the pulling head adaptor while moving it will reduce sudden uncontrolled movement 14 Refill ram sleeve 84 with hydraulic oil until level with the top of the ram sleeve Repeat above procedure a second time 15 With the pulling head in full forward position refill ram sleeve if needed with hydraulic fluid until level with the top of the ram sle
20. tion Small amounts that accidentally enter mouth should be rinsed out until taste of it is gone EYES Flush with water Fire FLASH POINT Greater than 200 F Can 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 with eyes Wash thoroughly after handling Please refer to the actual MSDS for complete safety and handling information These can be obtained from the point of purchase Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 MOBIL DTE 26 P N PRG540 130 Distributed By Emhart Teknologies Phone 203 924 9341 Manufactured By ExxonMobil Corporation Emergency Phone 609 737 4411 MSDS Fax on Demand 613 228 1467 MSDS 602649 00 First Aid SKIN Remove contaminated clothing and shoes and wipe excess from skin Flush skin with water then wash with soap and water If irritation occurs get medical attention Do not reuse clothing until cleaned INGESTION Do not induce vomiting In general no treatment is necessary unless large quantities of product are inge
21. tle 22 w O Ring 33 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Page 9 REDUCED DIAMETER OPTION ProSet 2101 PRT OPTION _ 2 42 0 DY z o o z Page 11 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Parts List 5 5 5 5 IA z 8 DESCRIPTION 5 55 N o 9 o 1 13300 JAW 3 STYLE 3 i 3 2 2 7 072 O RING 2 1 3 DP203 011 SEAL SLEEVE 1 1 1 4 DP203 031 HANDLE 1 1 1 5 DP203 032 TRIGGER 1 1 1 6 DP203 037 END CAP POP OFF STYLE 1 1 7 203 086 HYDRAULIC PISTON 1 1 1 8 DP203 090 NOSE HOUSING FD 2100 1 9 203 091 NOSE HOUSING NUT 1 1 1 10 DP203 096 NOSE HOUSING RD 2101 1 1 11 DP203 120 CLAMP LEFT 1 1 1 12 DP203 121 CLAMP RIGHT 1 1 1 1 13 DP203 172 JAW GUIDE RD 2101 1 1 14 DP203 181 JAW GUIDE FD 2100 1 1 15 203 191 ADAPTOR 1 1 1 1 16 DP203 210 ORIFICE MCS 1 1 17 DP203 236 BOTTOM HOUSING MCS i 2 1 1 18 DP203 245 MCS VALVE STEM 2 1 1 19 DP203 250 MCS VALVE STEM SEAL 2 1 1 20 DP203 260 TOP HOUSING 5 1 1 21 DP203 261 SWITCH RING MCS
22. ttempt to remove Low Flow Adjustment Screw A flange on the blind side prevents removal and the assembly will be damaged if removal is attempted Replace filter 24 e sure that filter does not cover both Low flow adjustment and vacuum holes Replace Filter Cover Assembly 43 Replace Collector Bottle 22 Page 8 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Cleaning the MCS Filter For optimal performance the MCS filter should be cleaned at regular intervals per the Preventative Maintenance Schedule Note Turn off MCS unit AND UNPLUG AIR SUPPLY while servicing MCS to avoid INJURY 1 CLEAN THE MANDREL COLLECTION UNIT e Remove and empty the Collector Bottle 22 by unscrewing counterclockwise e Remove the Filter Cover Assembly 43 by taking hold of the center stem and pulling the assembly out e Remove the Filter 24 e Remove debris from the back of the MCS taking care not to let debris fall into the piston shaft area 2 RE ASSEMBLE THE MANDREL COLLECTION UNIT e Place the Filter 24 back into the MCS unit ensuring that the oval slot in the filter exposes the two holes in the back of the MCS e Insert the Filter Cover Assembly 43 into the recess in the back of the unit O rings first e Screw on the Collector Bottle 22 hand tight so that the O ring 33 seal squeezes tightly against the back of the MCS unit Collector Bot
23. uced Diameter Front End Extension Kit 6 length FA203 2103K Reduced Diameter Front End Extension Kit 8 length FA203 2104K Standard Diameter Front End Extension Kit 6 length FA203 2105K Standard Diameter Front End Extension Kit 8 length Tool Cross Section 21 42 13 14 37 69170 33 69 1 1 52 Double balloons indicate 2100 2101 equivalents MCS version shown Page 14 Emhart Teknologies 50 Shelton Technology Center Shelton CT 06484 Tel 203 924 9341 Fax 800 225 5614 Hydraulic Oil Charging Procedure IMPORTANT TOOL MUST BE DISCONNECTED FROM THE AIR SUPPLY USE ONLY APPROVED HYDRAULIC OIL SPECIFIED IN THIS MANUAL VIEW E1 1 Disconnect tool from air supply INVERTED POSITION Remove Nose Housing Assembly 101 or 102 Loosen fill screw 67 together with fill screw washer 63 74 turn Ici SS Remove clamp screws 89 amp 90 clamp nuts 94 right and left clamps 11 amp 12 Note the orientation of Clamp lettering Made In U S A 5 Remove intensifier chamber and sleeve 78 amp 79 Remove O ring 93 amp 58 To avoid spilling hydraulic oil DO NOT remove Intensifier Assembly 76 at this time 6 Turn tool upside down as shown in View E1 Slowly withdraw the intensifier assembly 76 being careful not to scra
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