Stanley ProSet XT2 Rivet Tool

Introduction

This document is the instruction manual for the Stanley ProSet XT2 rivet tool, designed for pop rivet fastening. Please read this manual carefully before use to ensure correct and safe operation. Keep this manual in a location where users can easily access it at any time.

Table of Contents Overview

This manual covers the following topics:

• Safety Precautions
• Parts Identification
• Overview and Specifications
• Preparation for Use
• Precautions for Use
• Operating Instructions
• Maintenance and Inspection
• Troubleshooting
• Options
• Parts List
• Exploded View
• Wear Parts List
• AVSEAL® II Parts
• Free Repair Conditions
• Warranty Certificate

Safety Precautions

[Warning] Ignoring these instructions and handling the product incorrectly may lead to death or serious injury.

[Caution] Ignoring these instructions and handling the product incorrectly may lead to injury or property damage.

Please read all safety precautions thoroughly before use and follow the instructions in this manual.

General Safety Guidelines

• Keep this manual accessible for users at all times.
• Use this tool only for fastening pop/avdel rivets. Refer to the pop/avdel rivet catalog for rivet selection.
• Warning: Use with a compressed air pressure of 0.5-0.6 MPa. Exceeding this pressure may cause tool damage, accidents, or injuries.
• Do not point the tool at people or look into the front or rear of the tool during operation. Rivets and broken mandrels may fly out, causing injury (including blindness). Wear safety glasses (JIS T8147 standard compliant) during operation.
• Ensure the collector bottle is securely attached to the tool. Failure to do so may result in broken mandrels flying out and causing injury.
• Before use, check all parts for damage. If any damage is found, stop using the tool and send it for repair. Using a damaged tool can lead to accidents or injuries.
• Ensure the compressed air supply connection is secure. Loose or insufficient thread engagement can cause the coupler or hose to detach, leading to accidents or injuries.
• Do not use the tool fixed to jigs or fixtures. This tool is designed for manual operation, and fixing it may cause accidents or injuries depending on the situation.
• Caution: When disassembling or assembling the tool for maintenance or parts replacement, always disconnect the compressed air supply by separating the coupler. Failure to do so may result in parts flying out, oil leakage, or unexpected movement, causing accidents or injuries.
• Ensure the bleed screw is tightened securely during use. A loose or detached bleed screw can cause oil leakage and potential injury.
• Do not operate the tool with the nose housing removed. This can cause finger pinching or other injuries.
• Use only parts supplied by or recommended by the company. Using non-recommended parts may result in poor performance, abnormal operation, accidents, or injuries.
• Do not modify the tool without authorization. Unauthorized modifications can lead to abnormal operation, accidents, or injuries.
• Maintenance should only be performed by qualified personnel who understand the tool's function and mechanism, following the instructions in this manual. Improper maintenance by untrained individuals may lead to poor performance, accidents, or injuries.
• For repairs, contact the place of purchase or the company. Untrained individuals performing repairs may lead to poor performance, accidents, or injuries.
• Keep the handle grip clean and dry. Oil or grease on the handle can cause it to slip, leading to the tool being dropped.
• Do not leave broken mandrels scattered on the floor. Broken mandrels are sharp and can cause injury. Stepping on them can cause slipping and falls.
• Avoid contact of the collector bottle (polycarbonate material) with organic solvents, as this can cause deformation or damage. Clean with a mild detergent.
• Be aware of the exhaust from the exhaust port. High-velocity air may be discharged, potentially causing eye irritation. Avoid directing the exhaust towards people or sensitive equipment. The exhaust may also contain oil mist and water, which can stain nearby objects.

1. Parts Identification

The following diagram identifies the main components of the ProSet XT2 rivet tool:

• Mandrel Guide
• Urethane Washer
• Jaw
• Jaw Guide Lock
• Jaw Pusher Spring
• Jaw Pusher
• Jaw Guide
• Nose Housing
• Nose Piece
• Nose Housing Nut (attached)
• Bleed Screw
• Collector Bottle
• Exhaust Port
• ON-OFF Valve
• Compressed Air Supply Port (NPT1/8)
• Coupler (Plug)
• Chamber
• Chamber Protector
• Mandrel Body
• Rivet
• Trigger
• Handle
• Warning Label

(Refer to Page 3 for detailed part names and diagram.)

2. Overview

The ProSet XT2 is a compact and lightweight hydraulic-pneumatic rivet tool. It features the MCS (Mandrel Collection System), which collects broken mandrels into the collector bottle after fastening.

2-1. Rivet Compatibility and Parts List

Use parts compatible with the rivet model. Using incorrect nose pieces, jaw pushers, or mandrel guides can lead to improper rivet fastening or tool malfunction.

Table 2-1: Rivet Compatibility

Notes:

• 1: For 3.2 mm rivet diameter with 1.6 mm mandrel diameter, use Jaw 13300 (See Page 22).
• 2: Use Jaw: PRG540-46B, Jaw Pusher: TP144-181.
• 3: TLrivets®, BULBEX®, MONOBOLT®, INTERLOCK® may not complete fastening in a single operation depending on usage conditions.
• 4: Requires 0.60 MPa compressed air pressure.
• 5: Requires dedicated Jaw Pusher Spring (TRM00480).

If mandrel slippage occurs, optional jaws with higher grip strength are available. These are recommended for stainless steel mandrels or those with surface treatments like Geomet. (See Page 22).

Table 2-2 & 2-3: Parts Compatibility

Detailed parts compatibility tables are provided on pages 9 and 10 of the original document.

3. Specifications (Dimensional Diagram)

The ProSet XT2 rivet tool has the following specifications:

The dimensional diagram (Figure 3-1) shows the tool with various measurements, including overall length, height, and specific component dimensions.

4. Preparation for Use

1. Check Installed Parts: Ensure the correct nose piece, jaw pusher, and mandrel guide are installed for your rivet type. The tool is shipped with PRN614US, TP144-050, and TP144-052 installed. If incompatible parts are installed, replace them with the correct ones (refer to Tables 2-1, 2-2, 2-3 on pages 5-7). Refer to pages 14 and 15 for replacement procedures.
2. Connect Air Supply: Attach a coupler (plug) to the tool's compressed air supply port. Connect the tool to a compressor via an air filter and regulator. Set the supply air pressure to 0.5-0.6 MPa. Ensure the hose used is rated for the operating temperature and pressure (minimum 0.7MPa at normal temperature). Refer to hose manufacturer's catalog for details.
3. Attach Collector Bottle: Ensure the collector bottle is securely attached by turning it clockwise. The ON-OFF valve should be in the ON position. If the collector bottle is not properly attached, the mandrel collection air will not function.
4. ON-OFF Valve: The tool is equipped with an ON-OFF valve to stop compressed air consumption when not in use. To supply air, push the valve (ON). To stop air supply, pull the valve (OFF).
5. Nose Housing Nut: An included nose housing nut can be used to easily attach or detach the nose housing, depending on your usage environment.

5. Precautions for Use

• Air Pressure: Use compressed air at 0.5-0.6 MPa. Using higher pressure may damage the tool and cause injury. Using lower pressure may prevent rivet fastening. Use a regulator to adjust air pressure.
• Air Filter: Use an air filter to remove moisture and debris from the compressed air, which can affect the tool's lifespan.
• Nose Pieces, Jaw Pusher, Mandrel Guide: Use parts compatible with the rivet being fastened. Incorrect parts can lead to improper fastening. Refer to pages 5-7 and 14-15 for replacement.
• Hydraulic Oil: Use only wear-resistant hydraulic oil ISO VG32. Using other oils can cause malfunctions. Examples of suitable oils are listed in Table 5-1.
• Mandrel Disposal: Dispose of collected mandrels from the collector bottle within its capacity (refer to Table 6-1 on page 13). Overfilling can prevent continued operation, damage the MCS, or cause mandrel jams.
• Collector Bottle Care: The collector bottle is made of polycarbonate. Avoid contact with organic solvents, which can cause degradation or damage. Clean with mild detergent.

6. Operating Instructions

6-1. Fastening Operation

Ensure the collector bottle is attached before starting fastening operations (See Figure 4-2 on page 9).

1. Install Mandrel and Rivet: Insert the mandrel into the nose piece, install the rivet, and then insert the rivet body into the hole in the base material. The rivet will be held by the nose piece via the MCS. Alternatively, insert the rivet body into the base material hole, then bring the tool to the rivet and insert the mandrel into the nose piece.
2. Fasten Rivet: Press the tool perpendicular to the base material, ensuring the rivet flange and nose piece are flush with the material. Pull the trigger. The mandrel will break, and the rivet will be fastened.
3. Release Trigger: After fastening, release the trigger. The broken mandrel will be collected in the collector bottle.
4. Check Mandrel Collection: Confirm mandrel collection before proceeding to the next fastening.

Refer to the pop/avdel rivet catalog for rivet selection and base material hole size specifications.

6-2. Mandrel Disposal

Dispose of mandrels collected in the collector bottle when it reaches capacity (refer to Table 6-1). The capacity varies by rivet diameter and mandrel diameter.

Usage Method:

• To remove the collector bottle, turn it counter-clockwise. Dispose of mandrels through the opening. The mandrel collection air will stop automatically when the ON-OFF valve is open.
• When fastening rivets, turn the collector bottle clockwise to attach it securely. The mandrel collection air will start automatically when the ON-OFF valve is open and the bottle is attached.

7. Maintenance and Inspection

Regular maintenance ensures optimal performance and longevity of the tool.

Table 7-1: Maintenance Schedule and Items

7-1. Cleaning and Greasing of Jaws and Tip Parts

Clean and grease the jaws and other tip parts approximately every 3,000 fastenings. For rivets with special surface treatments (e.g., Geomet), maintenance frequency may need to be increased. Metal powder can adhere to tip parts, causing reduced movement or jaw slippage, which shortens jaw life. Poor lubrication can also cause jamming and premature wear of jaws and jaw guides.

Procedure:

1. Disconnect compressed air supply (e.g., by separating the coupler).
2. Manually remove the nose housing. If it cannot be loosened by hand, use the included nose housing nut or a wrench/spanner.
3. Release the jaw guide lock by hand and remove the jaw guide from the spring head (See Figure 7-1).
4. The parts that come off are shown in Figure 7-2. Clean these parts and the inside of the nose housing and spring head using a brush and degreasing solvent.
5. Apply grease generously to the inside of the jaw guide (the surface that contacts the jaws). Molybdenum disulfide grease is recommended.
6. Tighten the jaw guide by hand until it stops, then back it off one notch (See Figure 7-1).
7. Manually tighten the nose housing. It is not necessary to use a wrench to tighten the nose housing.

7-2. Nose Piece Replacement

If the nose piece is damaged, replace it with a new one. If changing rivet types, replace it with the specified nose piece (refer to Tables 2-2 and 2-3 on pages 6-7).

Procedure:

1. Remove the nose piece from the nose housing using a wrench and spanner (See Figure 7-4).
2. Securely tighten the specified nose piece into the nose housing.

7-3. Jaw Pusher Replacement

If the jaw pusher is damaged, replace it with a new one. If changing rivet types, replace it with the specified jaw pusher (refer to Table 2-2 on pages 6-7).

Procedure:

1. Remove and replace the jaw pusher as described in Section 7-1 (Page 14).

7-4. Jaw Replacement

If the jaws are damaged or slip easily even after cleaning (due to worn teeth), replace them with new jaws.

Procedure:

1. Remove and replace the jaws as described in Section 7-1 (Page 14).
2. Before reassembly, clean and grease the tip parts (See Figure 7-3 on Page 15).

7-5. Jaw Pusher Spring Replacement

Replace the jaw pusher spring if its length is less than 28mm (new length is 33mm) or if it is broken.

Procedure:

1. Remove and replace the jaw pusher spring as described in Section 7-1 (Page 14).

7-6. Nose Housing Cleaning

The inside of the nose housing also requires cleaning. If metal powder accumulates inside, the jaws may not open fully, preventing rivet insertion (See Figure 7-5). For rivets with surface treatments like Geomet, maintenance frequency may need to be increased.

Procedure:

1. Remove the nose housing as described in Section 7-1 (Page 14).
2. Use a flat-head screwdriver or similar tool to remove accumulated metal powder from the inside of the nose housing (See Figure 7-6).

7-7. Collector Bottle Cleaning

If the collector bottle's silencer becomes clogged, mandrels are not collected, or suction power decreases, clean the unit. For rivets with surface treatments like Geomet, which can cause debris buildup, cleaning frequency may need to be increased.

Procedure:

1. Remove the collector bottle from the tool.
2. Use an air duster gun to blow high-pressure air into the air deflector exhaust port to clean it (See Figure 7-7).
3. Remove debris from the slits in the collector bottle (See Figure 7-8).
4. Avoid contact of the collector bottle (polycarbonate) with organic solvents.

7-8. Schrader Valve Replacement

Procedure:

1. Using a 2.0 mm pin or pin punch and hammer, tap out the trigger pin from the right side of the tool (See Figure 7-9). Refer to Pin Punch (Page 21, 9-6).
2. Remove the trigger.
3. Using the optional Trigger Valve Extractor, turn the Schrader valve counter-clockwise to remove it (See Figure 7-10). Refer to Trigger Valve Extractor (Page 21, 9-7).
4. Replace the Schrader valve and tighten it clockwise using the Trigger Valve Extractor (See Figure 7-11).
5. Reinstall the trigger. Align the trigger pin with the serration and gently tap it in from the left side of the tool with a hammer (See Figure 7-12).

7-9. Hydraulic Oil Replacement

While oil replacement by the customer is generally not required, an optional Oil Filler Kit is available for easier oil changes. Follow the instructions provided with the kit. If stroke issues persist after oil replacement, it may indicate seal wear, requiring complete disassembly and repair.

7-10. Disassembly and Repair

Disassembly and repair are recommended every 1 million operations or annually (whichever comes first). Disassembly or repair by untrained personnel is strictly prohibited. For repair services, download the repair request form from the company website and submit it along with the product to your dealer or the company. Visit http://www.popnpr.co.jp/ for details.

8. Troubleshooting

If problems persist after checking the following, contact your dealer or the company for repair.

9. Options

9-1. TRM00475 / Tube Ejection Kit

This kit is for ejecting mandrels through a tube.

(Diagram shows components of the tube ejection kit.)

9-2. TRM00332 / Extension Kit

This kit extends the nose housing by 50 mm.

(Diagram shows components of the extension kit.)

9-3. PCH-M / Corner Head

Enables fastening in confined spaces. Applicable rivet sizes are 4-6. Refer to the Corner Head Instruction Manual for details.

(Diagram shows dimensions of the corner head.)

9-4. TRM00477 / Corner Head PCH-M Adapter Kit

This kit is for attaching the Corner Head PCH-M. Please read the included instruction manual before use.

(Diagram shows components of the adapter kit.)

9-5. TRM00478 / Oil Filler Kit

This kit allows for easy oil changes. Please read the included instruction manual before use.

9-6. 07900-00158 / Pin Punch

A specialized tool used for tapping out the trigger pin when replacing the Schrader valve. Refer to Section 7-8 (Page 17) for usage.

9-7. 07900-00692 / Trigger Valve Extractor

A special tool for removing the Schrader valve. Refer to Section 7-8 (Page 17) for usage.

9-8. XT Oil / ISO VG32

Hydraulic oil for ProSet XT, viscosity grade 32. Capacity is 1,000ml.

9-9. Mandrel Slip Prevention Jaws

Recommended jaws and jaw pushers for rivets with special surface treatments like stainless steel mandrels or Geomet.

4.5 Size

Note: For SSD, SSK-5*-SSHR rivets, use the 6-size parts listed below.

6 Size

9-10. Mandrel Diameter 1.6 Jaw

4.5 Size

9-11. For ProSet2500A Jaws

4.5 Size

6 Size

(Images show the external appearance of various jaws.)

10. Parts List

A comprehensive list of parts with their numbers, names, and quantities is provided. This list includes standard parts, optional parts, and accessories.

(The full parts list is extensive and detailed, covering numbered components from 1 to 92, plus accessories.)

11. Exploded View

The exploded view diagram visually represents all components of the ProSet XT2 rivet tool, numbered for easy reference with the parts list.

(The diagram shows all parts disassembled and laid out, with numbers corresponding to the parts list.)

12. Wear Parts List

This section lists parts subject to wear and their approximate durability. Durability may vary based on rivet type, usage environment, and maintenance.

Standard Parts

Mandrel Slip Prevention Jaws (Durability for Stainless Steel Mandrel Fastening)

ProSet2500A Jaws

13. AVSEAL® II Parts

This section details parts for the AVSEAL® II system, used with the ProSet XT2.

1. Work Hole Size:

• Enlarging the work hole can reduce contact between the sealing plug and the hole, potentially decreasing pressure resistance and shortening the body length.
• When using Avseal® II sealing plugs with the minimum or intermediate hole size, standard types or types with protruding tips can be used.
• When using Avseal® II sealing plugs with intermediate or maximum hole sizes, types with protruding tips are recommended.

2. Work Hole Surface Roughness: Recommended surface roughness is 1.3 ~ 6.3 µm Ra.

3. Hole Depth (Specific Nose Pieces): Nose pieces with protruding tips can be used depending on the required hole depth. Types include Flat, 2mm protrusion, and 8mm protrusion. For hole depths not exceeding 1.5 times the hole diameter, short-type Avseal® II sealing plugs are recommended.

4. Sealing Effect by Material: The effectiveness of Avseal® II sealing plugs varies by material; testing is required for each material.

Warranty Information

Free Repair Conditions:

1. Free repair will be provided for malfunctions occurring within the warranty period, provided the product was used according to the instruction manual and labels.
2. To request free repair, present the product with the warranty certificate to the dealer or agent. If you cannot contact the dealer/agent, contact POP RIVETS AND FASTENERS LTD.
3. For transfers of ownership, consult the dealer/agent or POP RIVETS AND FASTENERS LTD. for repair requests.
4. For gifts or when free repair is unavailable from the dealer/agent, contact POP RIVETS AND FASTENERS LTD.
5. Repairs may be charged under the following conditions, even within the warranty period:
   • Malfunctions or damage due to incorrect use, unauthorized repair, or modification.
   • Malfunctions or damage due to relocation, transportation, drops, etc., after purchase.
   • Malfunctions or damage due to fire, earthquake, flood, lightning, natural disasters, pollution, salt damage, voltage fluctuations, or use with non-specified power sources.
   • Malfunctions or damage occurring when installed in vehicles, ships, etc.
   • Failure to present this document.
   • Missing or altered warranty certificate information (date of purchase, customer name, dealer name).
   • Shipping costs for direct repairs to the service center are the customer's responsibility. On-site service charges will also apply.
6. This warranty is valid only in Japan.
7. This warranty certificate will not be reissued; please keep it safe.

Contact Information:

POP RIVETS AND FASTENERS LTD.

Head Office: 3-6 Kioicho, Chiyoda-ku, Tokyo 102-0094, Japan. TEL: (03)3265-7291

Toyohashi Plant: Toyohashi, Aichi 441-8540, Japan. TEL: (0532)25-1126

For repair requests, download the repair request form from the website (http://www.popnpr.co.jp/) and submit it with the product to your dealer or the company. For warranty period repairs, return the product with the warranty certificate. The warranty period is 6 months from the date of purchase (consumables are subject to charge even within the warranty period). Repairs after the warranty period are available upon request if feasible, with charges for labor, parts, and travel.

Warranty Card

Please fill in the following details: